JLG 450AJ Operator Manual

Operators and Safety Manual

Model

450A

450AJ

3120868

April 24, 2002

FOREWORD

f

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion o
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER­ATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS.

THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAU­TION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these

areas. They are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR
DEATH.]

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE
PRACTICES

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
OR DEATH.

IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES
ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOL­LOWED, MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
MACHINE.

JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM­PLETED ON THE AFFECTED JLG PRODUCT

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notifica­tion. Contact JLG Industries, Inc. for updated information.

3120868 – JLG Lift – a

FOREWORD

This page left blank intentionally.

b – JLG Lift – 3120868

FOREWORD

All procedures herein are based on the use of the
machine under proper operating conditions, with no
deviations from original design intent... as per OSHA
regulations.

READ & HEED!

The ownership, use, service, and/or maintenance of
this machine is subject to various governmental and
local laws and regulations. It is the responsibility of
the owner/user to be knowledgeable of these laws
and regulations and to comply with them. The most
prevalent regulations of this type in the United States
are the Federal OSHA Safety Regulations*. Listed
below, in abbreviated form are some of the require­ments of Federal OSHA regulations in effect as of the
date of publication of this handbook.

The listing of these requirements shall not relieve
the owner/user of the responsibility and obligation
to determine all applicable laws and regulations and
their exact wording and requirements, and to com­ply with the requirements. Nor shall the listing of
these requirements constitute an assumption of
responsibility of liability on the part of JLG Indus­tries, Inc.

1. Only trained and authorized operators shall be
permitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until
repaired.

3. The controls shall be plainly marked as to their
function.

4. The controls shall be tested each day prior to
use to determine that they are in safe operating
condition.

5. All personnel in the platform shall, at all times,
wear approved fall protection devices and
other safety gear as required.

6. Load limits specified by the manufacturer shall
not be exceeded.

7. Instruction and warning placards must be legi­ble.

8. Aerial lifts may be field modified for uses other
than those intended by the manufacturer only if
certified in writing by the manufacturer to be in
conformity to JLG requirements and to be at
least as safe as it was prior to modification.

9. Aerial lifts shall not be used near electric power
lines unless the lines have been de energized
or adequate clearance is maintained.

10. Employees using aerial lifts shall be instructed
on how to recognize and avoid unsafe condi­tions and hazards.

11. Ground controls shall not be operated unless
permission has been obtained from personnel
in the platform, except in case of an emer­gency.

12. Regular inspection of the job site and aerial lift
shall be performed by competent persons.

13. Personnel shall always stand on the floor of the
platform, not on boxes, planks, railing or other
devices, for a work position.

*Applicable Federal OSHA regulations for the
United States, as of the date of publication of this
manual, include, but are not limited to, 29 CFR

1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR

1926.28, and 29 CFR 1926.453.

3120868 – JLG Lift – c

FOREWORD

REVISON LOG

Original Issue - May, 1998
Revised - August 1, 1999
2-12 and 2-13 - Updated 11-2-99
5-3 - Updated 2-16-00
3-6 - Updated 9-19-00
3-10 - Updated 4-24-02

d – JLG Lift – 3120868

TABLE OF CONTENTS

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

SECTION - FOREWORD

SECTION 1 - SAFETY PRECAUTIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.4 Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

SECTION 2 - PREPARATION AND INSPECTION

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2.6 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.4 Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.5 Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

SECTION 4 - MACHINE OPERATION

4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.6 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.7 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.8 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9 Lift Up and Platform Level Down Disable Switch Functional Check . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.10 Shut Down and Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.11 Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.12 Oscillating Axle Lockout Test (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.13 Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

SECTION 5 - OPTIONAL EQUIPMENT

5.1 Dual Fuel System (Gas Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 Platform W/soft Touch Proximity System Bumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.4 Four Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.5 Cold Weather Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.6 Travel Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.7 Electric Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.8 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.9 Cylinder Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.10 Boom Wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.11 Hostile Environment Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.12 Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

3120868 – JLG Lift – i

TABLE OF CONTENTS (Continued)

TABLE OF CONTENTS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

5.13 Semi-Track . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

SECTION 6 - EMERGENCY PROCEDURES

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Machine Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-5. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-6. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

3-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Position of Least Backward Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-4. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-5. Platform Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-6. Danger and Warning Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-7. Control Panel Symbols - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-8. Control Panel Symbols - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-2. Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-3. Machine Tie Down - A Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-4. Machine Tie Down - AJ Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-5. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-6. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated)

power lines and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

ii – JLG Lift – 3120868

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section prescribes the proper and safe practices for
major areas of machine usage. In order to promote proper
usage of the machine, it is mandatory that a daily routine
be established based on instructions given in this section.
A maintenance program must also be established by a
qualified person and must be followed to ensure that the
machine is safe to operate.

The owner/user/operator of the machine should not
accept operating responsibility until this manual has been
read and understood, and operation of the machine,
under the supervision of an experienced and qualified per­son, has been completed. If there is a question on appli­cation and/or operation, JLG Industries Inc., should be
consulted.

MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF
THE MANUFACTURER.

1.2 DRIVING/TOWING

Before driving the machine, the user must be familiar with
the drive, steer and stopping characteristics. This is espe­cially important when driving in close quarters.

The user should be familiar with the driving surface before
driving. The surface should be firm and level and grades
should not exceed the allowable grade for the machine.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

The machine is not equipped with provisions for towing.
Refer to Section 6 for emergency towing procedures.

SPECIAL NOTE:

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION AND ON THE MACHINE COULD RESULT IN
MACHINE DAMAGE, PERSONNEL INJURY OR DEATH, AND IS A
SAFETY VIOLATION.

3120868 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

Table 1-1.Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V to 50 KV 3

Over 50KV to 200 KV 5

Over 200 KV to 350 KV 6

Over 350 KV to 500 KV 8

Over 500 KV to 750 KV 11

Over 750 KV to 1000 KV 14

DANGER: DO NOT maneuver machine or personnel inside PROHIBITED ZONE. ASSUME all electric al parts and wiring
are ENERGIZED unless known othe rwise.

1.3 ELECTROCUTION HAZARD

MINIMUM SAFE APPROACH DISTANCE

in Meters

FROM CONTACT WITH OR PROXIMITY TO AN ELEC­TRICALLY CHARGED CONDUCTOR.

• MAINTAIN A CLEARANCE OF AT LEAST 3 M (10
FEET) BETWEEN ANY PART OF THE MACHINE OR
ITS LOAD AND ANY ELECTRICAL LINE OR APPARA­TUS CARRYING UP TO 50,000 VOLTS. 30.5 cm ADDI­TIONAL CLEARANCE IS REQUIRED FOR EVERY
ADDITIONAL 30,000 VOLTS OR LESS.

1.4 PRE-OPERATIONAL

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

• MAINTAIN SAFE CLEARANCE FROM ELECTRICAL
LINES AND APPARATUS. ALLOW FOR BOOM SWAY,
ROCK OR SAG AND ELECTRICAL LINE SWAYING.
THE MACHINE DOES NOT PROVIDE PROTECTION

• ALLOW ONLY AUTHORIZED AND QUALIFIED PER­SONNEL TO OPERATE MACHINE WHO HAVE DEM­ONSTRATED THAT THEY UNDERSTAND SAFE AND
PROPER OPERATION AND MAINTENANCE OF THE
UNIT.

1-2 – JLG Lift – 3120868

SECTION 1 - SAFETY PRECAUTIONS

• AN OPERATOR MUST NOT ACCEPT OPERATING
RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS
BEEN GIVEN BY COMPETENT AND AUTHORIZED
PERSONS.

• BEFORE OPERATION, CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES, MACHINE TRAFFIC
SUCH AS BRIDGE CRANES, HIGHWAY, RAILWAY AND
CONSTRUCTION EQUIPMENT.

• NEVER DISABLE OR MODIFY THE FOOTSWITCH OR
ANY OTHER SAFETY DEVICE. UNAUTHORIZED MOD­IFICATION OF THE MACHINE IS A SAFETY VIOLA­TION.

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN
THE WORK AREA MUST BE TAKEN BY THE OPERA­TOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS
BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.

• ENSURE DAILY INSPECTION AND FUNCTION CHECK
IS PERFORMED PRIOR TO PLACING MACHINE INTO
OPERATION.

• DO NOT OPERATE MACHINE WHEN WIND CONDI­TIONS EXCEED 12.5 M/S (30MPH).

• NEVER OPERATE BOOM FUNCTIONS (TELE, SWING,
LIFT) WHEN MACHINE IS ON A TRUCK, OTHER VEHI­CLE, OR ABOVE GROUND STRUCTURE.

• THIS MACHINE CAN BE OPERATED IN NOMINAL
AMBIENT TEMPERATURES OF -20° C TO 40° C (0° F

TO 104° F). CONSULT FACTORY TO OPTIMIZE
OPERATION OUTSIDE THIS RANGE.

• APPROVED HEAD GEAR MUST BE WORN BY ALL
OPERATING AND GROUND PERSONNEL.

3120868 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

.

• READ AND OBEY ALL DANGERS, WARNINGS, CAU­TIONS AND OPERATING INSTRUCTIONS ON
MACHINE AND IN THIS MANUAL.

• BE FAMILIAR WITH LOCATION AND OPERATION OF
GROUND STATION CONTROLS.

• ALWAYS POSITION BOOM OVER REAR (DRIVE) AXLE
IN LINE WITH DIRECTION OF TRAVEL. REMEMBER,
IF BOOM IS OVER FRONT (STEER) AXLE, DIRECTION
OF STEER AND DRIVE MOVEMENT WILL BE OPPO­SITE FROM NORMAL OPERATION.

• ALWAYS USE THREE POINT CONTACT WHEN
ENTERING OR EXITING THE MACHINE. FACE THE
MACHINE WHEN YOU ENTER OR LEAVE. THREE
POINT CONTACT MEANS THAT TWO HANDS AND
ONE FOOT OR ONE HAND AND TWO FEET ARE IN
CONTACT WITH THE MACHINE AT ALL TIMES DUR­ING MOUNT AND DISMOUNT.

1.5 DRIVING

• WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN DRIVING.

• DO NOT USE DRIVE FUNCTION TO POSITION PLAT­FORM CLOSE TO OBSTACLES. USE BOOM FUNC­TION INSTEAD.

• WHEN DRIVING IN HIGH SPEED, SWITCH TO LOW
SPEED BEFORE STOPPING. TRAVEL GRADES IN
LOW DRIVE, HIGH ENGINE ONLY.

• DO NOT USE HIGH SPEED DRIVE WHEN IN
RESTRICTED OR CLOSE QUARTERS, OR WHEN
DRIVING IN REVERSE.

• BE AWARE OF STOPPING DISTANCES WHEN TRAV­ELING IN HIGH AND LOW SPEEDS.

• ALWAYS POST A LOOKOUT AND SOUND HORN
WHEN DRIVING IN AREAS WHERE VISION IS
OBSTRUCTED.

• KEEP NON-OPERATING PERSONNEL AT LEAST 2 M
(6 FEET) AWAY FROM MACHINE DURING DRIVING
OPERATIONS.

1-4 – JLG Lift – 3120868

SECTION 1 - SAFETY PRECAUTIONS

1.6 OPERATION.

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

• CHECK TRAVEL PATH FOR PERSONS, DEPRES­SIONS, HOLES, BUMPS, DROP-OFFS, OBSTRUC­TIONS, DEBRIS, AND COVERINGS WHICH MAY
CONCEAL HOLES AND OTHER HAZARDS.

• TRAVEL IS PERMITTED ON GRADES NO GREATER
THAN THOSE INDICATED ON THE SERIAL NUMBER
PLATE.

• DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5°.

• DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES,

AS TIPPING WILL OCCUR.

• DO NOT DRIVE MACHINE NEAR PITS, LOADING
DOCKS OR OTHER DROP-OFFS.

• PRIOR TO ENTERING AND EXITING PLATFORM AT
GROUND LEVEL, FULLY LOWER THE BOOM.
EXTEND BOOM UNTIL END OF FLY BOOM CON­TACTS GROUND. WITH BOOM LIFT IN THIS CONFIG­URATION, ENTER AND/OR EXIT PLATFORM
THROUGH GATE OPENING.

• JLG RECOMMENDS ALL PERSONS IN THE PLAT­FORM TO WEAR LANYARDS WITH AN APPROVED
FALL PROTECTION DEVICE. SECURE LANYARD TO
DESIGNATED LANYARD ATTACH POINT ON PLAT­FORM. KEEP GATE CLOSED AT ALL TIMES.

• TO AVOID FALLING - USE EXTREME CAUTION WHEN
ENTERING OR LEAVING PLATFORM ABOVE
GROUND. ENTER OR EXIT THRU GATE ONLY. PLAT­FORM FLOOR MUST BE WITHIN 30CM (1 FOOT) OF
ADJACENT - SAFE AND SECURE - STRUCTURE.
ALLOW FOR PLATFORM VERTICAL MOVEMENT AS
WEIGHT IS TRANSFERRED TO OR FROM PLAT­FORM.

3120868 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• TRANSFERS BETWEEN A STRUCTURE AND THE
AERIAL PLATFORM EXPOSE OPERATORS TO FALL
HAZARDS. THIS PRACTICE SHOULD BE DISCOUR­AGED WHEREVER POSSIBLE. WHERE TRANSFER
MUST BE ACCOMPLISHED TO PERFORM THE JOB
TWO LANYARDS WITH AN APPROVED FALL PRO­TECTION DEVICE WILL BE USED. ONE LANYARD
SHOULD BE ATTACHED TO THE AERIAL PLATFORM.
THE OTHER TO THE STRUCTURE. THE LANYARD
THAT IS ATTACHED TO THE AERIAL PLATFORM
SHOULD NOT BE DISCONNECTED UNTIL SUCH
TIME AS THE TRANSFER TO THE STRUCTURE IS
COMPLETE. OTHERWISE, DO NOT STEP OUTSIDE
OF PLATFORM.

• DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS
TO THE PLATFORM. ADDITION OF SUCH ITEMS
INCREASES THE EXPOSED WIND AREA OF THE
MACHINE.

• NEVER POSITION LADDERS, STEPS, OR SIMILAR
ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE.

• WHEN RIDING IN OR WORKING FROM PLATFORM,
BOTH FEET MUST BE FIRMLY POSITIONED ON THE
FLOOR.

• KEEP OIL, MUD AND SLIPPERY SUBSTANCES
CLEANED FROM FOOTWEAR AND PLATFORM
FLOOR.

• NEVER "WALK" THE BOOM TO GAIN ACCESS TO OR
LEAVE PLATFORM.

• NEVER PLACE HANDS OR ARMS IN TOWER BOOM
OR UPRIGHT MECHANISM.

• KEEP ALL NON-OPERATING PERSONNEL AT LEAST
2 METERS (6 FEET) AWAY FROM THE MACHINE AT
ALL TIMES.

• IF PLATFORM OR BOOM IS CAUGHT SO THAT ONE
OR MORE WHEELS ARE OFF THE FLOOR, ALL PER­SONNEL MUST BE REMOVED FROM PLATFORM
BEFORE ATTEMPTING TO FREE MACHINE. USE
CRANES, FORKLIFT TRUCKS OR OTHER EQUIP­MENT TO REMOVE PERSONNEL AND STABILIZE
MACHINE MOTION, IF NECESSARY.

• THE OPERATOR IS RESPONSIBLE TO AVOID OPER­ATING MACHINE OVER GROUND PERSONNEL AND
TO WARN THEM NOT TO WORK, WALK OR STAND
UNDER A RAISED BOOM OR PLATFORM. POSITION
BARRICADES ON FLOOR IF NECESSARY.

1-6 – JLG Lift – 3120868

SECTION 1 - SAFETY PRECAUTIONS

.

• ENSURE MACHINE IS POSITIONED ON A FIRM,
LEVEL AND UNIFORM SUPPORTING SURFACE
BEFORE RAISING OR EXTENDING BOOM.

• CHECK CLEARANCES ABOVE, ON SIDES AND BOT­TOM OF PLATFORM WHEN RAISING, LOWERING,
SWINGING, AND TELESCOPING BOOM.

• EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER-

FERING WITH OPERATING CONTROLS AND PER­SONS IN PLATFORM.

• ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR MACHINES ARE AWARE OF THE AERIAL
PLATFORMS PRESENCE. DISCONNECT POWER TO
OVERHEAD CRANES. POSITION BARRICADES ON
FLOOR IF NECESSARY.

• NEVER "SLAM" A CONTROL SWITCH OR LEVER
THROUGH NEUTRAL TO THE OPPOSITE DIRECTION.
ALWAYS RETURN SWITCH TO NEUTRAL AND STOP;
THEN MOVE SWITCH TO THE DESIRED POSITION.
OPERATE LEVERS WITH SLOW, EVEN PRESSURE.

• DO NOT CARRY MATERIALS ON PLATFORM RAILING
UNLESS APPROVED BY JLG INDUSTRIES INC.

• NEVER PUSH OR PULL THE MACHINE OR OTHER
OBJECTS BY TELESCOPING THE BOOM.

• NEVER USE BOOM FOR ANY PURPOSE OTHER
THAN POSITIONING PERSONNEL, THEIR TOOLS
AND EQUIPMENT.

• NEVER EXCEED MANUFACTURERS RATED PLAT­FORM CAPACITY - REFER TO CAPACITY DECAL ON
MACHINE. DISTRIBUTE LOADS EVENLY ON PLAT­FORM FLOOR.

• NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE, RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.

• DO NOT REMOVE, MODIFY, OR DISABLE FOOT­SWITCH BY BLOCKING OR ANY OTHER MEANS.

• DO NOT ASSIST A STUCK OR DISABLED MACHINE
BY PUSHING OR PULLING EXCEPT BY PULLING AT
CHASSIS TIE-DOWN LUGS.

• NEVER ATTEMPT USING BOOM AS A CRANE.
STRUCTURAL DAMAGE OR TIPPING MAY OCCUR.

• STOW BOOM AND SHUT OFF ALL POWER BEFORE
LEAVING MACHINE.

• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.

3120868 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• NEVER ATTEMPT TO FREE A MACHINE STUCK IN
SOFT GROUND OR ASSIST A MACHINE UP A STEEP
HILL OR RAMP BY USING BOOM "LIFT", "TELE­SCOPE", OR "SWING" FUNCTIONS.

• NEVER ATTACH WIRE, CABLE, OR ANY SIMILAR
ITEMS TO PLATFORM.

• DO NOT PLACE BOOM OR PLATFORM AGAINST ANY
STRUCTURE TO STEADY PLATFORM OR SUPPORT
STRUCTURES.

• DO NOT USE THE LIFT, SWING, OR TELESCOPE
FUNCTIONS FOR THE BOOM, TO MOVE EITHER THE
MACHINE OR OTHER OBJECTS.

• HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT
FULLY EXTENDED OR RETRACTED FOR ANY
LENGTH OF TIME. ALWAYS "BUMP" CONTROL IN
OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION
BEING USED REACHES END OF TRAVEL. THIS
APPLIES TO MACHINES IN OPERATION OR IN
STOWED MODE.

• DO NOT OPERATE ANY MACHINE ON WHICH DAN­GER, WARNING, CAUTION OR INSTRUCTION PLAC­ARDS OR DECALS ARE MISSING OR ILLEGIBLE.

• MACHINE MUST ALWAYS BE SHUT DOWN WHEN
REFUELING. NO SMOKING IS MANDATORY. NEVER
REFUEL DURING AN ELECTRICAL STORM. ENSURE
THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.

1.7 TOWING AND HAULING

• DO NOT TOW A MACHINE EXCEPT IN AN EMER­GENCY. SEE SECTION 6 FOR EMERGENCY TOWING
PROCEDURES.

• LOCK TURNTABLE BEFORE TRAVELING LONG DIS­TANCES OR BEFORE HAULING MACHINE ON A
TRUCK OR TRAILER.

1-8 – JLG Lift – 3120868

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtaining maxi­mum service life and safe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE

Before a new machine is put into operation it must be
carefully inspected for any evidence of damage resulting
from shipment and inspected periodically thereafter, as
outlined in Delivery and Frequent Inspection (see section
2-3). During initial start-up and run, the unit should be
thoroughly checked for hydraulic leaks. A check of all
components should be made to assure their security.

All preparation necessary to place the machine in opera­tion readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate prop­erly) coupled with a series of visual inspections. The man­datory requirements are given in the Daily Walk Around
Inspection (see section 2-4).

It should be assured that the items appearing in the Deliv­ery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.

2.3 DELIVERY AND FREQUENT INSPECTION

NOTE: This machine requires periodic safety and mainte-

nance inspections by an authorized JLG Dealer.

NOTE: An annual inspection shall be performed on the

aerial platform no later than thirteen (13) months
from the date of the prior annual inspection. The
inspection shall be performed by person(s) qualified
as a mechanic on the specific make and model of
the aerial platform.

The following checklist provides a systematic inspection
to assist in detecting defective, damaged, or improperly
installed parts. The checklist denotes the items to be
inspected and conditions to examine.

Frequent inspection shall be performed every 3 months or
150 hours whichever comes first, or more often when
required by environment, severity, and frequency of
usage.

This inspection checklist is also applicable and must be
followed for all machines that have been in storage or for
all machines that will be exposed to harsh or changing cli­mates.

These checks are also to be performed after maintenance
has been performed on the machine.

Chassis

1. Check front tires and wheel assemblies for loose or
worn spindles, components and hardware for secu­rity, tires for wear and damage.

2. Check steering assembly for loose or bent tie rod,
cylinder and hydraulic lines for leaks and security,
and hardware for proper installation.

3. If equipped with 4WD, check drive hubs, hydraulic
motors, brakes and hydraulic lines for damage and
leaks.

4. Check rear tires and wheel assemblies for security,
tires for wear and damage.

5. Check drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.

6. Check oil level in drive hub by removing pipe plug
on side and feeling for oil level. (Contact Service
Personnel for assistance if needed).

NOTE: Torque hubs should be one-half full of lubricant.

7. Check oscillating axle (if equipped) for loose, miss­ing and worn parts, pivot pin and lockout cylinder
pins for security, lockout cylinders and hydraulic
hoses for damage and leaks.

3120868 – JLG Lift – 2-1

SECTION 2 - PREPARATION AND INSPECTION

Turnt abl e

1. Check turntable for damage, loose or missing parts,
and security. Check swing drive and brake for dam­age, loose or missing parts, hydraulic lines and
component housings for evidence of leakage; worm
gear for proper mesh with swing gear.

2. Check swing bearing for damage, wear, lubrication
and loose or missing bearing bolts.

3. Check solenoid valves and hydraulic lines for dam­age, leakage, security and electrical connections for
tightness and evidence of corrosion.

4. Check ground controls for damage, loose or miss­ing parts, security, electrical connections for evi­dence of corrosion and tightness and wiring for
insulation damage. Assure that all switches function
properly.

5. Check battery for damage, loose or missing vent
caps, electrical connections for tightness, and evi­dence of corrosion, hold-down brackets for tight­ness, and electrolyte for proper water level. Add only
clean distilled water to battery.

6. Check engine tray pivot assembly for damage, loose
or missing parts, and security.

7. Check engine and accessories for damage, loose or
missing parts, leakage and security. Check throttle
solenoid and linkage for damage, electrical connec­tions for tightness, and evidence of corrosion and
wiring for insulation damage.

8. Check fuel lines for damage, leakage and security.

9. Check all access doors for damage, proper opera­tion of latches, props and security.

10. Check fuel tank for damage, leakage and filler cap
for security.

11. Check hydraulic reservoir and hydraulic lines for
damage, leakage and security.

NOTE: JLG recommends replacing the hydraulic filter ele-

ment after the first 50 hours of operation and then
every 300 hours thereafter, unless system indicator
require earlier replacement.

12. Check all pin and shaft retaining hardware for secu­rity and wear.

13. Check all electrical cables for defects, damage,
loose or corroded connections.

Boom

1. Check Lower Boom and leveling link for damage,
missing parts and security.

2. Check all pin and shaft retaining hardware for secu­rity and wear.

3. Check hydraulic lines and electrical cable for dam­age, missing parts and security.

4. Check limit switch connections and plunger for cor­rosion and security.

5. Check Lower Upright, cross pins and hydraulic lines
for damage, wear, lubrication, leakage and security.

6. Check Lower Upright for damage, wear, lubrication
and security.

7. Check hydraulic lines mounted on upright for dam­age, leakage and security.

8. Check boom pivot bushings for wear.

9. Check boom lift cylinder and hydraulic lines for dam­age, leakage and security. Check lift cylinder cross
pins for damage, wear and security.

10. Check all pin and shaft retaining hardware for secu­rity and wear.

11. Check Upper Upright, cross pins and hydraulic lines
for damage, wear, lubrication, leakage and security.

12. Check Upper Upright for damage, wear, lubrication
and security.

13. Check hydraulic lines mounted on upright for dam­age, leakage and security.

14. Check Upper Boom Lift Cylinder and cross pins and
hydraulic lines for damage, wear, lubrication, leak­age and security.

2-2 – JLG Lift – 3120868

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Machine Nomenclature

3120868 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

15. Check Upper Boom pivot pin for damage, wear,
lubrication and security.

16. Check Upper Boom for damage, missing parts and
security.

17. Check Upper Boom wear pads for damage, missing
parts and security.

18. Check Upper Boom telescope cylinder, cross pins
and hydraulic lines for damage, wear, lubrication,
leakage and security.

19. Check Platform Leveling Cylinder, cross pins and
hydraulic lines for damage, wear, lubrication, leak­age and security.

Platform

1. Check platform and control console for damage,
loose or missing parts, and security.

2. Check control switches and levers for damage,
loose or missing parts and security. Assure that
levers function properly.

3. Check control switches, levers and electrical con­nections for tightness and evidence of corrosion,
and wiring for defects and chafing damage. Assure
that switches function properly.

4. Check access gate hinges, stop, and latch for
proper operation, damage and security.

5. Check platform rotator mechanism for proper opera­tion, damage, security. Check hydraulic lines for
leakage, damage and security.

NOTE: Check all DANGER, WARNING, CAUTION and

INSTRUCTION placards for legibility and security on
the entire machine.

Tor q ue R e q u i r e m e n t s

The Torque Chart (Figure 2-6.) consists of standard torque
values based on bolt diameter and grade, also specifying
dry and wet torque values in accordance with recom­mended shop practices. This chart is provided as an aid
to the operator in the event he/she notices a condition that
requires prompt attention during the walk-around inspec­tion or during operation, until the proper service personnel
can be notified. The Service and Maintenance manual
provides specific torque values and periodic maintenance
procedures with a listing of individual components. Utiliz­ing this Torque Chart in conjunction with the preventive
maintenance section in the Service and Maintenance
manual will enhance safety, reliability, and performance of
the machine.

2-4 – JLG Lift – 3120868

SECTION 2 - PREPARATION AND INSPECTION

2.4 DAILY WALK-AROUND INSPECTION

It is the operators responsibility to inspect the machine
before the start of each workday. It is recommended that
each operator inspect the machine before operation, even
if the machine has already been put into service under
another operator. This Daily Walk-Around Inspection is the
preferred method of inspection.

These checks are also to be performed after maintenance
has been performed on the machine.

In addition to the Daily Walk-Around Inspection, be sure to
include the following as part of the daily inspection:

1. Overall cleanliness.

Check all standing surfaces for oil, fuel and hydrau­lic oil spillage and foreign objects. Ensure overall
cleanliness.

2. Placards.

Keep all information and operating placards clean
and unobstructed. Cover when spray painting or
shot blasting to protect legibility.

3. Operator’s and Safety Manual.

Ensure a copy of this manual and the ANSI A92.5­1992 Responsibilities, are enclosed in the manual
storage box.

4. Machine Log.

Ensure a machine operating record or log is kept,
check to see that it is current and that no entries

have been left uncleared, leaving machine in an
unsafe condition for operation.

5. Start each day with a full fuel tank.

TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS
"OFF" DURING WALK-AROUND INSPECTION.

NOTE: Check boom limit switches on upright for proper

operation and security, both visually and manually.
The lower switch cuts out drive speed when the
lower boom is above horizontal. The upper switch
cuts out drive speed when the upper boom is above
horizontal. Only creep drive speed will continue to
function.

6. Check platform footswitch for proper operation.
Switch must be released to start engine and
depressed to operate machine.

7. Check that drive brakes hold when machine is
driven up a grade not greater than specified on the
serial number placard and stopped.

NOTE: On new machines, those recently overhauled, or

after changing hydraulic oil, operate all systems a
minimum of two complete cycles and recheck oil
level in reservoir.

8. Assure that all items requiring lubrication are ser­viced. Refer to Figure 2-5., Lubrication Diagram for
specific requirements.

3120868 – JLG Lift – 2-5