JLG 600A-AJ Operator Manual

Operation and Safety Manual

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

Boom Lift Models 600A 600AJ

ANSI

3121204

April 30, 2012

A Machine that incorporates ADE (Advanced Design Electronics) can be outwardly identified by the analyzer connection at the base of the platform control box as shown by the arrow.

ADE Identification

All 600A and 600AJ machines from S/N 64249 incorporate ADE. The following machine serial numbers prior to S/N 64249 also utilize ADE: 63908, 63912, 63932, 63936, 63938, 63954, 63959, and 63963.

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.

3121204 – 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 DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

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 – 3121204

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.

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

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.

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:

3121204 – JLG Lift – c

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

FOREWORD

REVISION LOG

Original Issue - April 1, 2005

Revised - October 6, 2005

Revised - February 27, 2006

Revised - May 8, 2006

Revised - February 22, 2008

Revised - January 1, 2009

Revised - September 17, 2009

Revised - November 25, 2009

Revised - July 22, 2010

Revised - August 25, 2010

Revised - September 27, 2011

Revised - April 30, 2012

d – JLG Lift – 3121204

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE 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 PREPARATION, AND INSPECTION

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

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

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

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

2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . 2-5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

Platform Control . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Platform Control Indicator Panel . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING 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 . . . . . . . . . . . . . 4-6

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-6

3121204 – JLG Lift – i

TABLE OF CONTENTS

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

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8

Raising and Lowering the Tower Boom . . . . . . 4-9

Raising and Lowering the Main Boom . . . . . . 4-10

Telescoping the Main Boom . . . . . . . . . . . . . . 4-10

4.8 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-10

4.9 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.10 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . 4-13

4.11 TOWING (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . 4-13

4.12 AUXILIARY POWER - NON ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Activating from the Platform Control Station . . 4-17 Activating from the Ground Control Station . . 4-17

4.13 AUXILIARY POWER - ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Activating from the Platform Control Station . . 4-18 Activating from the Ground Control Station . . 4-18

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-19

Changing From Gasoline to LP Gas . . . . . . . . 4-19

Changing From LP Gas to Gasoline . . . . . . . . 4-19

4.15 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER4-19

Level Override Valve . . . . . . . . . . . . . . . . . . . . 4-19

4.16 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-20

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1

Operator Unable to Control Machine . . . . . . . . . 5-1

Platform or Boom Caught Overhead . . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2

5.5 MANUAL DESCENT (MACHINES PRIOR TO

S/N 70975) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Torque Requirements. . . . . . . . . . . . . . . . . . . . . 6-9

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

Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-12

Serial Number Locations . . . . . . . . . . . . . . . . . 6-12

ii – JLG Lift – 3121204

TABLE OF CONTENTS

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-23

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-33

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-34

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.5 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

6.6 DRAINING OIL BUILD UP FROM THE PROPANE REG-

ULATOR (PRIOR TO S/N 0300132529) . . . . . . . .6-38

6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-39

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-41

6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-42

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Machine Nomenclature - 600AJ . . . . . . . . . . . . . . . 2-9

2-2. Machine Nomenclature - 600A . . . . . . . . . . . . . . . 2-10

2-3. Daily Walk-Around Inspection Diagram . . . . . . . . 2-11

2-4. Daily Walk-Around Inspection Points -

Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-5. Daily Walk-Around Inspection Points -

Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-6. Daily Walk-Around Inspection Points -

Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

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

3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . . 3-7

3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . . 3-8

3-4. Malfunction Indicator Light and Test Button . . . . . 3-9

3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-11

3-6. Platform Control Console - w/Drive Orientation . . 3-12

3-7. Platform Control Indicator Panel . . . . . . . . . . . . . 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 Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-4. Boom Upright Positioning - Sheet 1 of 2 . . . . . . . 4-11

4-5. Boom Upright Positioning - Sheet 2 of 2 . . . . . . . 4-12

4-6. Towbar Connecting Points - Prior to S/N 81836 . 4-14

3121204 – JLG Lift – iii

TABLE OF CONTENTS

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

4-7. Towbar Connecting Points - S/N 81836

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-8. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . 4-16

4-9. Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-10. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-11. 600A & 600AJ Decal Installation - Sheet 1 of 4. . . 4-23 4-12. 600A & 600AJ Decal Installation - Sheet 2 of 4. . . 4-24 4-13. 600A & 600AJ Decal Installation - Sheet 3 of 4. . . 4-25 4-14. 600A & 600AJ Decal Installation - Sheet 4 of 4. . . 4-26

6-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . 6-12

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. Lubrication and Maintenance Point Location . . . . 6-22

6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . .6-40

iv – JLG Lift – 3121204

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE 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 600A Decal Legend - Prior to S/N 0300140401 . . 4-27 4-2 600A Decal Legend - S/N 0300140401 to Present 4-31 4-3 600AJ Decal Legend - Prior to S/N 0300140401 . 4-35 4-4 600AJ Decal Legend - S/N 0300140401 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39

6-1 Operating Specifications - Prior to

S/N 0300140401 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Operating Specifications - S/N 0300140401

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-3 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-4 Continental TMD27 Specifications . . . . . . . . . . . . . 6-4

6-5 Ford LRG-423 Specifications . . . . . . . . . . . . . . . . . 6-5

6-6 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-5

6-7 Deutz F4M1011F/F4M2011 Specifications . . . . . . 6-6

6-8 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . 6-6

6-9 Caterpillar 3044C / 3.4 . . . . . . . . . . . . . . . . . . . . . . 6-7

6-10 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-11 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-12 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-13 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . 6-9

6-14 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . 6-9

6-15 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-10

6-16 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . 6-10

6-17 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . 6-11

6-18 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-19 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . 6-12

6-20 Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-23

6-21 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-36

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

3121204 – JLG Lift – v

TABLE OF CONTENTS

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

This page left blank intentionally.

vi – JLG Lift – 3121204

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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.

1.2 PRE-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.

3121204 – 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.

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.

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.

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 – 3121204

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

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.

• 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.

3121204 – 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 – 3121204

SECTION 1 - SAFETY PRECAUTIONS

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

• 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-

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

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.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3121204 – 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 must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

1-6 – JLG Lift – 3121204

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.

3121204 – 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.

1.4 TOWING, 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 – 3121204

SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL 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.

3121204 – 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

Number

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 ru stle

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.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t 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.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121204

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, drop-offs.

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.

3121204 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, 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 PRODUCT MODEL.

2-2 – JLG Lift – 3121204

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection (See Note)

Frequent Inspection In ser vice for 3 months or 150 hours, whichever

Annual Machine Inspection

Preventative Maintenance

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

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG

comes first;

Out of service for a period of more than 3 months;

Purchased used.

Annually, no later than 13 months from the date of prior inspection.

At intervals as specified in the Service and Maintenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Qualified

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Service Technician

Mechanic

Reference

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

3121204 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pare nt Metal C rack Weld Crack

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. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. 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.

4. 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.

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

6. Battery – Charge as required.

7. Fuel (Combustion Engine Powered Machines) – Add the

proper fuel as necessary.

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

9. 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 – 3121204

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 all limiting and cut-

out switches;

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 cut-

out 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 opera-

tion.

2.3 LIMIT SWITCH FUNCTIONAL CHECK

TO AVOID MACHINE UPSET DO NOT USE MACHINE IF TOWER BOOM SWITCHING IS OUT OF SEQUENCE.

IF THE TOWER BOOM LIFTS ‘DOWN’ WITH THE TOWER BOOM TELESCOPED ‘OUT’, SHUT DOWN MACHINE AND CONTACT A CERTIFIED JLG TECHNICIAN.

IF THE TOWER BOOM ‘TELESCOPES’ WITH THE TOWER BOOM LESS THAN FULLY ELEVATED ‘UP’, SHUT DOWN MACHINE AND CONTACT QUALIFIED JLG TECHNICIAN.

TO AVOID UPSET IF TOWER BOOM SWITCHING MALFUNCTIONS:

— LOWER THE PLATFORM TO GROUND VIA MAIN BOOM LIFT AND TELESCOPE FUNCTIONS.

— HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE.

3121204 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

6. Place TOWER TELESCOPE to ‘in’ position and fully retract the TOWER BOOM. Place TOWER BOOM to

TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE.

1. Check hydraulic boom sequence cam valves. Raise, extend, retract and lower tower boom. Check for smooth and proper operation.

NOTE: Perform checks from ground controls first, then from plat-

form controls.

2. Operate machine from ground control.

3. Move TOWER TELESCOPE to ‘out’ position. Tower

should not telescope with TOWER BOOM less than fully elevated ‘up’. (Must be approximately 13 degrees from vertical to move TOWER TELESCOPE ‘out’.)

4. Move TOWER BOOM to ‘up’ position and hold until the TOWER BOOM is completely elevated. Move TOWER TELESCOPE to ‘out’ position and hold until the TOWER BOOM is fully extended.

5. With TOWER BOOM completely extended, place TOWER LIFT in ‘down’ position. Tower boom should not LIFT ‘down’ unless the TOWER BOOM is fully retracted.

TO AVOID TIPPING OVER DO NOT USE MACHINE IF TOWER BOOM SWITCHING IS OUT OF SEQUENCE.

NOTE: For adjustments see Service Manual - Limit Switch Adjust-

NOTE: Angle indicator should be placed between the main boom

‘down’ and fully lower the TOWER BOOM. Upright in vertical position. If Tower Boom does not rest on stop with machine in the stowed position, this indicates upright is out of plumb. See Section 4, Boom Synchronizing Procedure, in Service Manual.

ments.

7. Check elevation limit switch as follows:

Main Boom Angle Limit Switch.

a. Lift boom up to 5 degrees above horizontal. Limit

switch should activate at this point.

b. Lift main boom down until limit switch resets. This

should be 4 degrees to 9 degrees below horizontal.

pivot pin and the main boom lift cylinder attach point on the base boom. On machines not equipped with ADE, the main boom angle limit switch activation may be checked

2-6 – JLG Lift – 3121204

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

by using test light in terminal # 24 in the main terminal box. Tower angle switch must be reset before main boom angle switch can be activated.

Tower Boom Angle Limit Switch.

a. Place machine on level surface.

b. Using the bottom of the upright and the ground as a

reference, lift the tower boom 40" to 42" (101.6 to

106.6 cm) from the stowed position. The tower boom angle limit switch should activate at this point.

c. Lower the tower boom 25" to 30" (63.5 to 76.2 cm)

from where the switch activated. This switch should reset at this point.

NOTE: On machines not equipped with ADE, the tower boom

angle limit switch activation may be checked by using a test light in terminal #43 on the main terminal box.

NOTE: Step 8 is only applicable for 600A ANSI market machines.

8. Check capacity limit switch as follows:

Main Boom Length Switch.

a. Lift main boom to approximately horizontal.

b. Telescope boom out until 500 lb. (227 kg for ANSI

markets and 230 kg for CE and Australia markets) light comes on (may need to used auxiliary power to position boom correctly).

c. Mark the wear pad location on the main fly boom.

d. Telescope the main boom to full extension.

e. Measure from the mark on the fly boom to the wear

pad. The dimension should be 125" to 127" (317.5 to 322.6 cm).

Main Boom Angle Switch.

a. Lift main boom to approximately horizontal.

b. Telescope boom out until 500 lb. (227 kg for ANSI

markets and 230 kg for CE and Australia markets) light comes on (may need to used auxiliary power to position boom correctly).

c. Lift main boom up until 1000 lb. (454 kg for ANSI

markets and 450 kg for CE and Australia markets) light comes on. The boom angle at this point should be 55 degrees to 60 degrees.

d. Lift main boom down until 500 lb. (227 kg for ANSI

markets and 230 kg for CE and Australia markets) light comes on. The boom angle at this point should be 45 degrees to 50 degrees.

3121204 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTE: If limit switch settings need to be changed, you will need

to recheck that the 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia markets) light comes on at 45 degrees to 50 degrees when lifting down.

9. Raise, extend, retract and lower main boom. Check for smooth operation.

10. Swing turntable to LEFT and RIGHT a minimum of 45 degrees. Check for smooth motion.

NOTE: Step 11 is only applicable for machines with an external

tilt sensor.

11. With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform control console, manually activate the indicator light by compressing any one of the three tilt indicator mounting springs. If the light does not illuminate, shut down machine and contact a qualified service technician before continuing operation.

NOTE: Step 12 is applicable for machines with an internal tilt sen-

sor.

12. Check the chassis out of level indicator located on the platform control console by driving, with the machine in level position, up a suitable ramp of at least 5° slope. Check the out of level indicator, with the machine on the ramp. If the light does not illuminate, return the machine to a level surface, shut down the machine, and contact a qualified technician before resuming operation.

2-8 – JLG Lift – 3121204

+ 118 hidden pages