JLG 510AJ Operator Manual

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models 450A Series II 450AJ Series II 510AJ

ANSI											3121179
											May 8, 2012
								®

FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

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.

3121179

– JLG Lift –

a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

b

– JLG Lift –

3121179

FOREWORD

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

	• Accident Reporting	• Standards and Regulations
	• Product Safety Publica-	Compliance Information
	tions	• Questions Regarding Spe-
	• Current Owner Updates	cial Product Applications
	• Questions Regarding	• Questions Regarding Prod-
		uct Modifications
	Product Safety

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: [phone]

Fax: [phone]

E-mail: [e-mail]

3121179

– JLG Lift –

c

FOREWORD

	REVISION LOG
Original Issue	- January 1, 2003
Revised	- April 24, 2003
Revised	- August 26, 2003
Revised	- June 15, 2004
Revised	- May 4, 2005
Revised	- February 8, 2006
Revised	- May 22, 2006
Revised	- August 2, 2007
Revised	- January 11, 2008
Revised	- October 29, 2009
Revised	- November 25, 2009
Revised	- July 30, 2010
Revised	- September 8, 2011
Revised	- March 5, 2012
Revised	- May 8, 2012

d

– JLG Lift –

3121179

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

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

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-

RATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION - PARAGRAPH, SUBJECT

PAGE

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Indicator Panel . . . . . . . . . . . . . 3-5

Platform Control Station . . . . . . . . . . . . . . . . . . . 3-9

Platform Control Indicator Panel . . . . . . . . . . . . 3-14

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward and Reverse . . . . . . . . . . . . . 4-7

3121179

– JLG Lift –

i

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7 Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7 4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8 Raising and Lowering the Lower and Mid Boom 4-8 Raising and Lowering the Main (Upper) Boom. 4-8 Telescoping the Main Boom . . . . . . . . . . . . . . . 4-8

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-9 4.9 AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.10 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-10 4.12 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-10 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.13 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 Prior to Towing. . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-13 Changing From Gasoline to LP Gas . . . . . . . . 4-13 Changing From LP Gas to Gasoline . . . . . . . . 4-13

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-2 Operator Unable to Control Machine . . . . . . . . . 5-2 Platform or Boom Caught Overhead . . . . . . . . . 5-2 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2OPERATING SPECIFICATIONS AND PERFORMANCE

DATA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Reach Specifications . . . . . . . . . . . . . . . . . . . . . 6-3

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Major Component Weights. . . . . . . . . . . . . . . . . 6-9

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

Serial Number Location . . . . . . . . . . . . . . . . . . 6-13

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-25

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-37

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

ii

– JLG Lift –

3121179

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-37

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-38

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-38

6.5DRAINING OIL BUILD UP FROM THE PROPANE REG-

ULATOR (PRIOR TO S/N 0300137808) . . . . . . . .6-40 6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-41 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41 Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-43

6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-44

SECTION - 7 - INSPECTION AND REPAIR LOG

SECTION - PARAGRAPH, SUBJECT

PAGE

LIST OF FIGURES

2-1. Basic Nomenclature - Sheet 1 of 2. . . . . . . . . . . . . 2-6 2-2. Basic Nomenclature - Sheet 2 of 2. . . . . . . . . . . . . 2-7 2-3. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . 2-8 2-4. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . 2-9 2-5. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . 2-10 3-1. Ground Control Station - A Models . . . . . . . . . . . . 3-2 3-1. Ground Control Station - AJ Models . . . . . . . . . . . 3-3 3-2. Ground Control Indicator Panel - Sheet 1 of 2. . . . 3-6 3-3. Ground Control Indicator Panel - Sheet 2 of 2. . . . 3-7 3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-10 3-5. Platform Control Console - w/Drive Orientation . . 3-11 3-6. Platform Control Indicator Panel - Sheet 1 of 2 . . 3-16 3-7. Platform Control Indicator Panel - Sheet 2 of 2 . . 3-17 3-8. Platform Control Indicator Panel - w/Drive

Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 4-1. Position of Least Forward Stability . . . . . . . . . . . . . 4-4 4-2. Position of Least Backward Stability . . . . . . . . . . . 4-5 4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . 4-6 4-4. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-11 4-5. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-12 4-6. Decal Installation - Sheet 1 of 6 . . . . . . . . . . . . . . 4-14 4-7. Decal Installation - Sheet 2 of 6 . . . . . . . . . . . . . . 4-15 4-8. Decal Installation - Sheet 3 of 6 . . . . . . . . . . . . . . 4-16 4-9. Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . 4-17

3121179

– JLG Lift –

iii

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE

4-10. Decal Installation - Sheet 5 of 6. . . . . . . . . . . . . . . 4-18

4-11. Decal Installation - Sheet 6 of 6. . . . . . . . . . . . . . . 4-19

6-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . 6-13

6-2. Engine Operating Temperature Specifications - Deutz

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-3. Engine Operating Temperature Specifications - Deutz

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-4. Engine Operating Temperature Specifications - Ford -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-5. Engine Operating Temperature Specifications - Ford -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-6. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18

6-7. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19

6-8. Engine Operating Temperature Specifications - GM -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-9. Engine Operating Temperature Specifications - GM -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-10. Engine Operating Temperature Specifications -

Perkins - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . 6-22

6-11. Engine Operating Temperature Specifications -

Perkins - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . 6-23

6-12. Operator Maintenance and Lubrication Diagram . 6-24

6-13. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-42

SECTION - PARAGRAPH, SUBJECT

PAGE

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5 1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10 2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3 4-1 Decal Legend - Prior to S/N 0300141424 . . . . . . 4-20 4-2 Decal Legend - S/N 0300141424 to Present . . . . 4-23 6-1 Operating Specifications - 450A/450AJ - Prior

to S/N 0300141424. . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-2 Operating Specifications - 450A/450AJ - S/N

0300141424 to Present . . . . . . . . . . . . . . . . . . . . . 6-2 6-3 Operating Specifications - 510AJ. . . . . . . . . . . . . . 6-3 6-4 Reach Specifications - 450. . . . . . . . . . . . . . . . . . . 6-3 6-5 Reach Specifications - 510. . . . . . . . . . . . . . . . . . . 6-3 6-6 Dimensional Data - 450 . . . . . . . . . . . . . . . . . . . . . 6-4 6-7 Dimensional Data - 510 . . . . . . . . . . . . . . . . . . . . . 6-4 6-8 Chassis Specifications - 450 . . . . . . . . . . . . . . . . . 6-4 6-9 Chassis Specifications - 510 . . . . . . . . . . . . . . . . . 6-5 6-10 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-11 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 6-12 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-6 6-13 Deutz F3M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 6-14 Deutz F3M2011F/D2011L03. . . . . . . . . . . . . . . . . . 6-7 6-15 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . 6-7 6-16 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 6-17 Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

iv

– JLG Lift –

3121179

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT

PAGE SECTION - PARAGRAPH, SUBJECT

PAGE

6-18 Component Weights - 450 . . . . . . . . . . . . . . . . . . . 6-9

6-19 Component Weights - 510 . . . . . . . . . . . . . . . . . . . 6-9

6-20 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-21 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . 6-10

6-22 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . 6-10

6-23 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-11

6-24 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . 6-11

6-25 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-12

6-26 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-27 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-25

6-28 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-39

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

3121179

– JLG Lift –

v

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT	PAGE		SECTION - PARAGRAPH, SUBJECT	PAGE

This page left blank intentionally.

vi

– JLG Lift –

3121179

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1GENERAL

This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should not operate the machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2PRE-OPERATION

Operator Training and Knowledge

•Read and understand this manual before operating the machine.

•Do not operate this machine until complete training is performed by authorized persons.

•Only authorized and qualified personnel can operate the machine.

3121179

– JLG Lift –

1-1

SECTION 1 - SAFETY PRECAUTIONS

•Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.

•Use the machine in a manner which is within the scope of its intended application set by JLG.

•All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

•Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to operation of the machine.

Machine Inspection

•Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.

•Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.

•Be sure the footswitch and all other safety devices are operating properly. Modification of these devices is a safety violation.

Workplace Inspection

•The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.

•Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.

•Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

•Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.

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

•Do not operate any machine on which safety or instruction placards or decals are missing or illegible.

•Avoid any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1-2

– JLG Lift –

3121179

SECTION 1 - SAFETY PRECAUTIONS

1.3OPERATION

General

•Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.

•Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine.

•Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

•Hydraulic cylinders should never be left fully extended or fully retracted before shutdown or for long periods of time.

•Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.

•Do not carry materials directly on platform railing. Contact JLG for approved material handling accessories.

•When two or more persons are in the platform, the operator shall be responsible for all machine operations.

•Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

•Supplies or tools which extend outside the platform are prohibited unless approved by JLG.

•When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed.

•Do not assist a stuck or disabled machine by pushing, pulling, or by using boom functions. Only pull the unit from the tie-down lugs on the chassis.

•Do not place boom or platform against any structure to steady the platform or to support the structure.

•Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

3121179

– JLG Lift –

1-3

SECTION 1 - SAFETY PRECAUTIONS

•Before operating the machine, make sure all gates are closed and fastened in their proper position.

•Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach.

•Never use the boom assembly to enter or leave the platform.

•Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the ground for entry/exit. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.

Electrocution Hazards

•This machine is not insulated and does not provide protection from contact or proximity to electrical current.

1-4

– JLG Lift –

3121179

SECTION 1 - SAFETY PRECAUTIONS

•Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1- 1.

•Allow for machine movement and electrical line swaying.

Table 1-1. Minimum Approach Distances (M.A.D.)

Voltage Range	MINIMUM APPROACH DISTANCE
(Phase to Phase)	in Feet (Meters)
0 to 50 KV	10 (3)
Over 50KV to 200 KV	15 (5)
Over 200 KV to 350 KV	20 (6)
Over 350 KV to 500 KV	25 (8)
Over 500 KV to 750 KV	35 (11)
Over 750 KV to 1000 KV	45 (14)

NOTE: This requirement shall apply except where employer, local or governmental regulations are more stringent.

•Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

3121179

– JLG Lift –

1-5

SECTION 1 - SAFETY PRECAUTIONS

•The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

•The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

1-6

– JLG Lift –

3121179

SECTION 1 - SAFETY PRECAUTIONS

•Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface.

•Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

•Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.

•Do not raise the platform or drive from an elevated position unless the machine is on firm, level and smooth surfaces.

•Keep the chassis of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards on the floor/surface.

•Do not push or pull any object with the boom.

•Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure.

•Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

•Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

•Do not increase the platform size with unauthorized deck extensions or attachments.

•If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine.

Crushing and Collision Hazards

•Approved head gear must be worn by all operating and ground personnel.

•Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.

•During operation, keep all body parts inside platform railing.

3121179

– JLG Lift –

1-7

SECTION 1 - SAFETY PRECAUTIONS

•Use the boom functions, not the drive function, to position the platform close to obstacles.

•Always post a lookout when driving in areas where vision is obstructed.

•Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations.

•Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel.

•Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.

•Do not use high speed drive in restricted or close quarters or when driving in reverse.

•Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

•Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

•Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1.4TOWING, LIFTING, AND HAULING

•Never allow personnel in platform while towing, lifting, or hauling.

•This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

•Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

•When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

•Refer to the Machine Operation section of this manual for lifting information.

1-8

– JLG Lift –

3121179

SECTION 1 - SAFETY PRECAUTIONS

1.5ADDITIONAL HAZARDS / SAFETY

•Do not use machine as a ground for welding.

•When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter.

•Do not refuel the machine with the engine running.

•Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.

•Charge batteries only in a well ventilated area.

3121179

– JLG Lift –

1-9

SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28

MPH (12.5 M/S).

			Table 1-2. Beaufort Scale (For Reference Only)
Beaufort	Wind Speed			Description	Land Conditions
Number
	mph	m/s
0	0	0-0.2		Calm	Calm. Smoke rises vertically
1	1-3	0.3-1.5		Light air	Wind motion visible in smoke
2	4-7	1.6-3.3		Light breeze	Wind felt on exposed skin. Leaves rustle
3	8-12	3.4-5.4		Gentle breeze	Leaves and smaller twigs in constant motion
4	13-18	5.5-7.9		Moderate breeze	Dust and loose paper raised. Small branches begin to move.
5	19-24	8.0-10.7		Fresh breeze	Smaller trees sway.
6	25-31	10.8-13.8		Strong breeze	Large branches in motion. Whistling heard in overhead wires.
					Umbrella use becomes difficult.
7	32-38	13.9-17.1		Near Gale/Moderate Gale	Whole trees in motion. Effort needed to walk against the wind.
8	39-46	17.2-20.7		Fresh Gale	Twigs broken from trees. Cars veer on road.
9	47-54	20.8-24.4		Strong Gale	Light structure damage.

1-10

– JLG Lift –

3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.

Operator Training

Operator training must cover:

1.Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2.Control labels, instructions, and warnings on the machine.

3.Rules of the employer and government regulations.

4.Use of approved fall protection device.

5.Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.

6.The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, dropoffs.

7.Means to avoid the hazards of unprotected electrical conductors.

8.Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

3121179

– JLG Lift –

2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED

THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD-

UCT MODEL.

2-2

– JLG Lift –

3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

	Type	Frequency	Primary	Service	Reference
			Responsibility	Qualification
	Pre-Start Inspection	Before using each day; or	User or Operator	User or Operator	Operator and Safety Manual
		whenever there’s an Operator change.
	Pre-Delivery Inspection	Before each sale, lease, or rental delivery.	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	(See Note)			Mechanic	Manual and applicable JLG
					inspection form
	Frequent Inspection	In service for 3 months or 150 hours, whichever	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
	(See Note)	comes first; or		Mechanic	Manual and applicable JLG
		Out of service for a period of more than 3 months;			inspection form
		or
		Purchased used.
	Annual Machine Inspection	Annually, no later than 13 months from the date of	Owner, Dealer, or User	Factory-Qualified	Service and Maintenance
	(See Note)	prior inspection.		Service Technician	Manual and applicable JLG
				(Recommended)	inspection form
	Preventative Maintenance	At intervals as specified in the Service and Main-	Owner, Dealer, or User	Qualified JLG	Service and Maintenance
		tenance Manual.		Mechanic	Manual

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

3121179

– JLG Lift –

2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

1.Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2.Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

3.Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container.

4.“Walk-Around” Inspection – Refer to Figure 2-3. and Figure 2-4.

5.Battery – Charge as required.

6.Fuel (Combustion Engine Powered Machines) – Add the proper fuel as necessary.

7.Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.

8.Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

9.Accessories/Attachments - Reference the Operator and Safety Manual of each attachment for accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

10.Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE

MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER

MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL

IT IS DECLARED SAFE FOR OPERATION.

2-4

– JLG Lift –

3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Perform the Function Check as follows:

1.From the ground control panel with no load in the platform:

a.Check that all guards protecting the switches or locks are in place;

b.Operate all functions and check boom limit switches; drive speed should switch to creep mode if lower boom is elevated or main boom is above horizontal.

c.Check auxiliary power (or manual descent);

d.Ensure that all machine functions are disabled when the Emergency Stop Button is activated.

2.From the platform control console:

a.Ensure that the control console is firmly secured in the proper location;

b.Check that all guards protecting the switches or locks are in place;

c.Operate all functions and check all limiting and cutout switches;

d.Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in.

3.With the platform in the transport (stowed) position:

a.Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold;

b.Check the tilt sensor alarm to ensure proper operation.

3121179

– JLG Lift –

2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature - Sheet 1 of 2

2-6

– JLG Lift –

3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1.Steer Wheels

2.Drive Wheels

3.Lower Lift Cylinder

4.Lower Upright

5.Mid Boom

6.Upper Lift Cylinder

7.Main Boom Assembly

8.Power Track

9.Level Cylinder

10.Jib Cylinder

11.Platform

12.Platform Console

13.Jib

14.Fly Boom

15.Base Boom

16.Master Cylinder

17.Tower or Lower Boom

18.Turntable

19.Frame

20.Tower Link

Figure 2-2. Basic Nomenclature - Sheet 2 of 2

3121179

– JLG Lift –

2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-8

– JLG Lift –

3121179