JLG 601S Operator Manual

Operation and Safety Manual

Keep this manual with the machine at all times.

Boom Lift Models 601S

ANSI

3121218

June 22, 2006

ADE Identification

All machines after S/N 60444 incorporate ADE (Advanced Design Electronics). The following machine serial numbers prior to S/N 60444 also utilize ADE: 58993, 58998, 59222, 59223, 59275, 59281, 59315, 59319, 59352, 59358, 59361, 59769, 60253, 60254, 60286, and 60242.

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

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.

3121218 – 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.

b – JLG Lift – 3121218

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.

IMPORTANT

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.

IMPORTANT

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

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233

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: 717-485-5161 E-mail: ProductSafety@JLG.com

FOREWORD

3121218 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - June 24, 2005

Revised - June 22, 2006

d – JLG Lift – 3121218

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 . . . . . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-2

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Platform Control Indicator Panel . . . . . . . . . . . . 3-10

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 . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-5

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

Traveling Forward or Reverse . . . . . . . . . . . . . . . 4-7

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . 4-8

4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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TABLE OF CONTENTS

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

Loading From Ground Level . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . 4-8

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-10

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

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

4.9 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-10

Changing From Gasoline to LP Gas . . . . . . . . 4-11

Changing From LP Gas to Gasoline . . . . . . . . 4-11

4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-11

4.11 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

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

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-12

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-19

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-19

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-20

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-20

6.5 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . .6-22

6.6 OSCILLATING AXLE LOCKOUT TEST. . . . . . . . . .6-22

SECTION - 7 - INSPECTION AND REPAIR LOG

ii – JLG Lift – 3121218

TABLE OF CONTENTS

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

LIST OF FIGURES

2-1. Machine Nomenclature . . . . . . . . . . . . . . . . . . . . . .2-8

2-2. Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . .2-9

2-3. Daily Walk-Around Inspection - Sheet 2 of 4 . . . . .2-10

2-4. Daily Walk-Around Inspection - Sheet 3 of 4 . . . . .2-11

2-5. Daily Walk-Around Inspection - Sheet 4 of 4 . . . . .2-12

3-1. Ground Control Panel . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Ground Control Indicator Panel. . . . . . . . . . . . . . . .3-5

3-3. Malfunction Indicator Light and Test Button . . . . . .3-6

3-4. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-8

3-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-10

4-1. Position of Least Backward Stability . . . . . . . . . . . .4-2

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

4-3. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-4. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-5. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-6. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . .4-15

4-7. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . .4-16

4-8. Decal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . .4-17

4-9. Decal Installation - Sheet 3 of 4 . . . . . . . . . . . . . . .4-18

4-10. Decal Installation - Sheet 4 of 4 . . . . . . . . . . . . . . .4-19

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

6-2. Engine Operating Temperature Specifications -

Deutz - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . .6-7

6-3. Engine Operating Temperature Specifications -

Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-8

6-4. Engine Operating Temperature Specifications -

Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-5. Engine Operating Temperature Specifications -

Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-10

6-6. Lubrication and Maintenance Diagram . . . . . . . . 6-11

3121218 – JLG Lift – iii

TABLE OF CONTENTS

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3

4-1 601S Decal Legend . . . . . . . . . . . . . . . . . . . . . . . .4-20

4-2 601SS Decal Legend. . . . . . . . . . . . . . . . . . . . . . . 4-24

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Ford LRG-425 Specifications. . . . . . . . . . . . . . . . . . 6-2

6-4 Deutz F4M1011F/F4M2011 Specifications . . . . . . . 6-3

6-5 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

6-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-9 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . .6-5

6-10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-12

6-12 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . 6-21

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

iv – JLG Lift – 3121218

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.

3121218 – 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.

• This machine can be operated in temperatures of 0

F (-20o C to 40o C). Consult JLG for operation out-

104 side this range.

F to

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 – 3121218

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.

• 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 unless approved by JLG.

• 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.

3121218 – 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 – 3121218

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)

3121218 – 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 – 3121218

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).

• 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 and remove personnel.

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.

3121218 – 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 – 3121218

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.

SECTION 1 - SAFETY PRECAUTIONS

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SECTION 1 - SAFETY PRECAUTIONS

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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.

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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.

IMPORTANT

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

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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 (See Note)

Annual Machine Inspection (See Note)

Preventative Maintenance At inter vals as specified in the Service and Main-

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

In service for 3 months or 15 0 hours, whichever comes first; or Out of service for a period of more than 3 months; or Purchased used.

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

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Cer tified

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Service Technician (Recommended)

Mechanic

Reference

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

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

Parent Metal Crack Weld Crack

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 2-2. thru Figure 2-5.

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.

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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 indicator light to ensure proper

operation.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 LIMIT SWITCH FUNCTIONAL CHECK

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.

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

ments.

1. Check elevation limit and boom angle switches as follows:

a. Make sure the boom is fully lowered and retracted.

b. Verify the capacity indicator starts with the 1000 lb

(450 kg) light on. Raise the boom and verify the capacity indicator changes to the 500 lb (230 kg) light.

2. Check capacity limit and boom length switches as follows:

a. Make sure the boom is fully lowered and retracted.

b. Raise boom to horizontal.

c. Verify the capacity indicator starts with the 1000 lb

(450 kg) light on. Telescope the boom out and verify the capacity indicator changes to the 500 lb (230 kg) light.

d. Retract the boom and verify the capacity indicator

changes to 1000 lb (450 kg) capacity.

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.

3. Raise main boom, extend and retract telescope. Check for delayed movement of fly section, indicating loose cables.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

NOTE: Step 5 is only applicable for machines with an external tilt

sensor.

5. 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 6 is applicable for machines with an internal tilt sen-

sor.

6. 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.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1. Platform Control Box 2 . P l a tf o rm 3 . F o ot s wi t c h

4. Slave Level Cylinder 5 . L i f t Cy l in d er 6 . S w i ng B ea r in g

7. Drive Wheels 8 . F r am e

9. Steer Wheels

10. Turntable

11. Ground Control Box

12. Telescope Cylinder (Inside)

13. Boom Assembly

14. Base Boom

15. Mid Boom

16. Fly Boom

17. Rotator

Figure 2-1. Machine Nomenclature

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 4

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.

1. Platform Assembly and Gate - Lockbolts in place. Footswitch works properly, not modified, disabled or blocked. Latch, stop, and hinges in working condition.

2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legible, control markings legible.

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

3. Rotator - See Inspection Note.

4. Rotator Motion Control Valve - See Inspection Note.

5. Dual Capacity Limit Switch - See Inspection Note.

6. Power Track - See Inspection Note.

7. Drive Motor and Brake - See Inspection Note.

8. Drive Hub, Right Rear - See Inspection Note.

9. Wheel/Tire Assemblies - Properly secured, no miss-

ing lug nuts, proper inflation (pneumatic).

10. Turntable Lock - Operable; See Inspection Note.

11. Auxiliary Power Pump - See Inspection Note.

12. Swing Drive Motor and Brake - See Inspection Note.

13. Control Valve (Tank Compartment) - See Inspection

Note.

14. Turntable Bearing and Pinion - See Inspection Note. No evidence of loose bolts or looseness between bearing and structure.

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