JLG 740AJ Operator Manual

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Operation and Safety Manual

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

Boom Lift Models 740AJ

S/N 0300185828 to Present

3121654

June 10, 2014

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.

3121654 – 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 – 3121654

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED 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

• Product Safety Publications

• Current Owner Updates

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

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

3121654 – JLG Lift – c

FOREWORD

Original Issue - March 31, 2014

Revised - April 30, 2014

Revised - June 10, 2014

REVISION LOG

d – JLG Lift – 3121654

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

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

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

Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2.3 FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

From the Ground Control Station with No Load in the

Platform: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

From the Platform Control Station: . . . . . . . . . . . . . . . 2-12

2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-15

2.5 INSPECTION AND USE OF FALL ARREST SYSTEM. . . . . . 2-16

Prior to Use Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Inspecting Cable Tension and Slip Indicator . . . . . . 2-17

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-7

Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Platform Console Indicator Panel. . . . . . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

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

4.2 BOOM OPERATING CHARACTERISTICS AND

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

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

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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TABLE OF CONTENTS

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

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-6

4.4 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-10

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-12

Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12

Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12

4.8 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.9 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

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

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-15

4.11 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.12 TOW BAR (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.13 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-17

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-18

Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-18

4.14 RE-SYNCHRONIZE UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Releveling Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.15 AIR COMPRESSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Normal Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . 4-20

Normal Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-20

Daily Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Boom Movement Prevented By Boom Control

System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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TABLE OF CONTENTS

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

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . 6-14

6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-23

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

6.5 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 6-26

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26

6.6 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 6-27

6.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-28

SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

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

LIST OF FIGURES

2-1. Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

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

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

2-5. Boom Upright Positioning - Correct . . . . . . . . . . . . . . . . . 2-10

2-6. Boom Upright Positioning - Incorrect. . . . . . . . . . . . . . . . 2-11

2-7. Fall Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

3-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

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

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

3-4. Platform Console Indicator Panel. . . . . . . . . . . . . . . . . . . . 3-17

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

4-2. Positions of Least Backward Stability (Sheet 1 of 2). . . . 4-3

4-3. Positions of Least Backward Stability (Sheet 2 of 2). . . . 4-4

4-4. Grade and Sideslopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-6. Tow Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-7. Releveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-8. Decal Installation - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . 4-21

4-9. Decal Installation - Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . 4-22

4-10. Decal Installation - Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . 4-23

4-11. Decal Installation - Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . 4-24

4-12. Decal Installation - Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . 4-25

6-1. Engine Operating Temperature Specifications - Deutz -

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

6-2. Engine Operating Temperature Specifications - Deutz -

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

6-3. Engine Operating Temperature Specifications - GM -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-4. Engine Operating Temperature Specifications - GM -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-5. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . 6-13

6-6. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-7. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6

1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9

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

4-1 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

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

6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Deutz TD 2.9 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-6 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-7 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

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

6-11 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-12 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-13 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-14 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .6-14

6-15 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-25

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

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

This page left blank intentionally.

vi – JLG Lift – 3121654

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage. 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 must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility 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.

This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. 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

• The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

3121654 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.

• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.

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

• Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined 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 your utilization and application of the machine.

Workplace Inspection

• Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.

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

• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.

• Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

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

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.

1-2 – JLG Lift – 3121654

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.

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

• Ensure all 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 PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

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

• Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.

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

1.3 OPERATION

General

• Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.

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

• Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.

• Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

• 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.

3121654 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• 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 or pulling except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leaving machine.

• Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.

• 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.

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..

• Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

1-4 – JLG Lift – 3121654

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 position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.

• Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

• Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. Refer to Section

2.5 for additional information on the proper use of the Fall Arrest System. 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.

3121654 – JLG Lift – 1-5

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 1-1.

• 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)

1-6 – JLG Lift – 3121654

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.

• Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.

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

3121654 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

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

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

• 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.

1-8 – JLG Lift – 3121654

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ S).

Table 1-2. Beaufort Scale (For Reference Only)

SECTION 1 - SAFETY PRECAUTIONS

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 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. Flags waving near horizontal. Umbrella use

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 fro m 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

becomes difficult.

3121654 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

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.

• 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.

• Under all travel conditions, the operator must 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.

1-10 – JLG Lift – 3121654

SECTION 1 - SAFETY PRECAUTIONS

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.

1.5 MAINTENANCE

This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.

• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.

3121654 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

• Ensure replacement parts or components are identical or equivalent to original parts or components.

• Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.

• 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.

• Use only approved non-flammable cleaning solvents.

• Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.

• Refer to the Service and Maintenance Manual for the weights of critical stability items.

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

1-12 – JLG Lift – 3121654

Battery Hazards

SECTION 1 - SAFETY PRECAUTIONS

• Always disconnect batteries when servicing electrical components or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery during charging or servicing.

• Do not contact tools or other metal objects across the battery terminals.

• Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.

3121654 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121654

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, or drop-offs exist.

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.

3121654 – 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 required 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-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

2-2 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Typ e 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 intervals as specified in the Service and 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 J LG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of mo re than 3 months; or Purchase d used.

An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f p r i or inspection.

Manual.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Service

Qualification

Service Technician (Recommended)

Reference

and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

3121654 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack 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 2-2. and Figure 2-3.

6. Battery – Charge as required.

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

proper fuel as necessary.

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

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

10. Function Check - Once the "Walk-Around" Inspection is complete, perform a functional check of all systems in accordance with Section 2.3 in an area free of overhead and ground level obstructions. Refer to Sections 3 and 4 for more specific machine operating 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 – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Chassis

2. Ground Console

3. Tower Lift Cylinder

4. Upright Level Cylinder

5. Upright

6. Main Boom Lift Cylinder

7. Master Cylinder

8. Main Boom Base Section

9. Main Boom Fly Section

10. Jib

11. Rotator

12. Platform Control Console

13. Footswitch

14. Platform

15. Jib Lift Cylinder

16. Slave Cylinder

17. Tower Boom

18. Turntable

3121654 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-6 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF.

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 - Footswitch works properly, not modified, disabled or blocked. Latch and hinges in working condition.

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

3. Rotator -

See Inspection Note.

4. Jib - See Inspection Note.

5. Dual Capacity Limit Switch (ANSI, Australia, if equipped);

Transport Position Limit Switch (CE) - Properly secured, no damage to the switch, arm free to move, and free from dirt and grease.

6. Power Track -

See Inspection Note.

7. All Hydraulic Cylinders - See Inspection Note.

8. Drive Motor, Brake, and Hub - See Inspection Note.

9. Wheel/Tire Assemblies - Properly secured, no missing lug

nuts. Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

10. Main Control Valve - See Inspection Note.

11. Turntable Bearing - Evidence of proper lubrication. No evi-

dence of loose bolts or looseness between bearing and structure.

12. Manual Descent -

See Inspection Note. (if equipped)

Figure 2-3. Daily Walk-Around Inspection (Sheet 2 of 3)

3121654 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

13. Fuel Tank - See Inspection Note.

14. Swing Drive Motor and Brake -

See Inspection Note.

15. Door and Latches - Hood door and latches in working condition, properly secured, no loose or missing parts.

16. Tie Rod and Steering Linkage -

See Inspection Note.

17. Dual Capacity and Horizontal Cutout Limit Switches if equipped - Properly secured, no damage to the switches, arm free to move, and free from dirt and grease.

18. Battery - Proper electrolyte levels; cables tight, no visible damage or corrosion.

19. Hydraulic Pumps -

See Inspection Note.

20. Tower Boom - No visible damage; wear pads secure. All cylinders - rod end pins and barrel-end pins properly secured.

21. Frame -

See Inspection Note.

22. Main Boom Sections - No visible damage; wear pads secure. All cylinders - rod end shafts and barrel-end shafts properly secured.

23. Upright - In vertical position, relative to the chassis. Refer to Figure 2-5. and Figure 2-6. If out of alignment, do not use machine until the upright has been synchronized in accordance with Section 4.16.

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

2-8 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 FUNCTION CHECK

Perform a function check of all systems, once the walk-around inspection is complete, in an area free of overhead and ground level obstructions.

A MACHINE MALFUNCTION COULD CAUSE DEATH OR SERIOUS INJURY. IF ANY MALFUNCTIONS OCCUR DURING THE FUNCTION TEST, DISCONTINUE OPERATION AND CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE.

From the Ground Control Station with No Load in the Platform:

1. Check that all guards protecting the function switches or locks are in place. Ensure that all function controls and switches return to the "off" or neutral position when released.

DO NOT OPERATE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION

2. Raise the tower base boom to approximately 40 degrees, then lower the tower boom back to the below horizontal

position. While raising and lowering the tower boom assembly, observe the position of the upright. Ensure that the upright remains vertical relative to the chassis. Refer to Figure 2-5. and Figure 2-6.

3. Check that all machine functions are disabled when the Emergency Stop Button is pushed in.

4. Check for proper operation of the auxiliary power and manual descent system (if equipped). Operate each function control to ensure proper operation.

3121654 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

90°

Figure 2-5. Boom Upright Positioning - Correct

UPRIGHT MUST BE 90° (VERTICAL) RELATIVE TO THE

CHASSIS.

CORRECT

2-10 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

90°

Figure 2-6. Boom Upright Positioning - Incorrect

TO AVOID TIPPING IF THIS OCCURS:

-LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT

AND TELESCOPE FUNCTIONS. HAVE CONDITION COR-

RECTED BY A TRAINED JLG SERVICE TECHNICIAN BEFORE

CONTINUING USE OF MACHINE.

INCORRECT

3121654 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

From the Platform Control Station:

1. Check that the control console is secure and all guards protecting the function switches or locks are in place. Ensure that all function controls and switches return to the "off " or neutral position when released.

DO NOT OPERATE MACHINE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION

2. Check the footswitch adjustment and operation as follows:

a. With engine power shut down, attempt to start engine.

Engine should not attempt to start when footswitch is activated.

b. Start engine. Activate hydraulic system by depressing

footswitch. Activate a boom function. Continue to activate the function and remove foot from footswitch. The motion should stop.

DISCONTINUE OPERATION IF THE FOOTSWITCH DOES NOT OPERATE PROPERLY.

c. Check adjustment of footswitch. Footswitch must be

adjusted so that functions will operate when pedal is approximately at its center of travel. If the footswitch operates within last 1/4" of travel, top or bottom, it should be adjusted.

NOTE: Footswitch has a 7 second delay timer. If a function is not acti-

vated within 7 seconds after depressing the footswitch, reset the footswitch.

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

4. Check auxiliary power for proper operation. Operate each function control switch to ensure proper operation of the auxiliary power system.

2-12 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

5. Drive forward and reverse; check for proper operation.

6. Steer left and right; check for proper operation.

7. Check the high-drive cutout for the tower boom assembly as

follows:

a. Place machine on level surface with booms retracted

and lowered.

b. From the platform control, position Drive Speed/Torque

Select switch to Fast (Forward Position).

c. Using extreme caution, partially position the DRIVE

control to Forward just enough to cause the machine to move.

d. Raise the Tower Boom until the drive speed shifts from

high speed to slow or creep speed. The bottom of the upright should NOT be above the hood level of the machine.

8. Check the high-drive cutout for the main boom assembly as follows:

a. Place machine on level surface with booms retracted

and lowered.

b. From the platform control, position Drive Speed/Torque

Select switch to Fast (Forward Position).

c. Raise the main boom above horizontal.

d. Using extreme caution, partially position the Drive con-

trol to Forward just enough to cause the machine to move. The drive speed should be in slow or creep mode.

9. Swing turntable to Left and Right a minimum of 45 degrees. Check for smooth motion.

NOTE: Ensure the turntable lock is disengaged. To disengage lock, pull

snap pin from lock pin, lift lock pin up to unlock turntable. Return snap pin to lock pin to hold lock pin in the disengaged position. Reverse procedure to engage turntable lock.

3121654 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

10. Check the Tilt Alarm and Warning System as follows:

IF THE TILT ALARM AND WARNING SYSTEM DOES NOT OPERATE PROPERLY, DISCONTINUE OPERATION. CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE.

With the platform in the transport position (tower base boom lowered, main fly boom retracted, and main base boom below horizontal) drive up a suitable ramp of at least 5° slope. The tilt indicator light on the platform control console should illuminate.

11. Check that the platform automatically levels properly during raising and lowering of the boom.

12. Check that the platform level override operates properly.

13. Check platform rotator for smooth operation and assure

platform will rotate 90 degrees in both directions from centerline of boom.

14. If equipped with 4-wheel steer, check rear steer left and right for proper operation.

15. If equipped, raise and lower the articulating jib boom. Check for smooth operation.

16. If equipped with Auxiliary Power, operate each function control switch to assure that they function in both directions using auxiliary power instead of engine power.

17. Ground Controls - Place Ground/Platform Select switch to Ground. Start engine. Platform controls should not operate.

2-14 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and centered between

drive wheels prior to beginning lockout cylinder test.

1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control station, start engine.

3. Position Drive Speed/Torque Select switch to Slow.

4. Place Drive control lever to Forward position and carefully

drive machine up ascension ramp until left front wheel is on top of block.

5. Carefully activate Swing control lever and position boom over Right side of machine.

6. With boom over right side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

7. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground.

8. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders.

9. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel.

10. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block.

11. Carefully activate Swing control lever and position boom over left side of machine.

12. With boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

13. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.

14. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders.

15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3121654 – JLG Lift – 2-15

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.5 INSPECTION AND USE OF FALL ARREST SYSTEM

The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the plat- form. Exit/Enter the platform through the gate area only. The system is designed for use by one person.

Personnel must use fall protection at all times. A full body harness and shock absorbing lanyard, not to exceed 6 feet (1.8 m) in length, is required when using the external fall arrest system.

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM. BE CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.

THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTIFICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A COMPETENT PERSON.

If inspection services are required, contact:

Latchways plc Hopton Park Devises Wiltshire SN10 2JP United Kingdom Tel: +44 (0)1380 732700 Fax: +44 (0)1380 732701 e-mail: info@latchways.com

Prior to accessing areas outside of the fall arrest platform, the user(s) must complete an appropriate job plan/risk assessment for the work to be accomplished and the environment at hand. It is the user’s responsibility to completely and adequately complete the job plan/risk assessment - special consideration must be given to the arresting distance of the deployed shock absorbing lanyard compared to the proximity of lower levels, or the ground, in the event of a fall.

2-16 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Inspecting Cable Tension and Slip Indicator

IF THE FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY INSPECTED. REFER TO THE SERVICE MANUAL.

Prior to Use Inspection

Fall arrest systems must be inspected prior to each use. Replace if there are any signs of wear or damage to any of the components.

Prior to use inspection should include a visual inspection of the following items:

Cable: Proper tension, broken strands, corrosion. Fittings: Loose fittings and fractures, damage to hanger Transfastener: Damage, free and proper sliding Attaching Hardware: Loose, missing, properly tightened

Cable tension is adjusted by using the Line Tenser. The Line Tenser is the disc at the end of the cable (shown below). When proper tension is achieved, the disc will spin by hand. When less than proper tension is present the disc will not turn by hand. The cable will stretch normally over time. In order to tension the cable the turnbuckle can be tightened. Rotate the turnbuckle until the proper tension is achieved.

3121654 – JLG Lift – 2-17

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

The slip indicator is the short tube crimped beside the end connection of the cable. If the cable slips from the end connection a gap will be present between the slip indicator and the end connection. No gap is acceptable. A cable that has slipped must be taken out of service immediately and the system replaced.

Shown below is the slip indicator as it should appear.

Shown below is the slip indicator with a gap, signifying that the fall arrest system should be replaced immediately.

2-18 – JLG Lift – 3121654

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-7. Fall Arrest System

1. Transfastener

2. Bracket

3. Cable

4. Swage/Slip Indicator

5. Turnbuckle

6. Line Tenser

3121654 – JLG Lift – 2-19

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-20 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control panels that use symbols

to indicate control functions. On ANSI machines refer to decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions.

NOTE: The indicator panels use different shaped symbols to alert the

operator to different types of operational situations that could arise. The meaning of those symbols are explained below.

Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

3121654 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

Ground Control Console

(See Figure 3-1., Ground Control Console)

NOTE: If equipped, the Function Enable switch must be

held down in order to operate Main Boom Telescope, Tower Lift, Swing, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions.

1. Platform Rotate

Provides rotation of the platform.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

2. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade.

3. Jib (If Equipped)

This switch provides raising and lowering of the jib.

3-2 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-1. Ground Control Console

1. Platform Rotate

2. Platform Leveling Override

3. Jib

4. Power/Emergency Stop

5. Engine Start/Auxiliary Power Switch/Function Enable

6. Hourmeter

7. Platform/Ground Select

8. Swing

9. Tower Lift

10. Main Boom Lift

11. Main Boom Telescope

3121654 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When Power/Emergency Stop switch is in the “On” position and

engine is not running, an alarm will sound, indicating Ignition is “On”.

WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.

NOTE: On machines with diesel engines, when Glow Plug Indicator is

lighted (Yellow), wait until light goes out before cranking engine.

4. Power/Emergency Stop Switch

A two-position red mushroom shaped switch supplies power to Platform/Ground Select switch when pulled out (on). When pushed in (off), power is shut off to the Platform/Ground Select switch.

5. Engine Start/ Auxiliary Power Switch /Function Enable

To start the engine, the switch must be held "Up" until the engine starts.

To use auxiliary power, the switch must be held “Down” for duration of auxiliary pump use.

When the engine is running, the switch must be held "Down" to enable all boom controls.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR.)

3-4 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Hourmeter

Registers the amount of time the machine has been in use, with engine running. By connecting into the oil pressure circuit of the engine, only engine run hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset.

NOTE: When the Platform/Ground Select Switch is in the

center position, power is shut off to the controls at both operating stations. Remove the key to prevent the controls from being actuated. The key is removable in the platform position on CE specification machines. The key must be available to ground personnel in the event of an emergency.

7. Platform/Ground Select Switch

The three position, key operated switch supplies power to the platform control console when positioned to Platform. With the switch key turned to the Ground position only ground controls are operable.

3121654 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope,

Tower Telescope, Platform Rotate, and Auxiliary Power control switches are spring-loaded and will automatically return to neutral (off) when released.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

8. Swing Control

Provides 360 degrees continuous turntable rotation.

9. Towe r Lif t

This switch provides raising and lowering of the tower boom. This function works only when the tower boom is fully retracted.

10. Main Boom Lift Control

Provides raising and lowering of the main boom.

11. Main Telescope Control

Provides extension and retraction of the main boom.

3-6 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel

(See Figure 3-2., Ground Control Indicator Panel)

1. No Alternator Output Indicator

Indicates a problem in the charging circuit, and service is required.

2. Engine Oil Pressure Indicator

Indicates that engine oil pressure is below normal and service is required.

3. High Engine Coolant Temperature Indicator (Liquid Cooled Engines)

Indicates that engine coolant temperature is abnormally high and service is required.

4. Engine Oil Temperature Indicator (Deutz, If Equipped)

Indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. Glow Plug/ Wait to Start Indicator

Indicates the glow plugs are on. The glow plugs are automatically turned on with the ignition circuit and remain on for approximately seven seconds. Start the engine only after the light goes out.

3121654 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. No Alter nator Output

2. Low Engine Oil Pressure

3. High Engine Coolant Temperature

4. High Engine O il Temperature

5. Glow Plug

6. Boom Malfunc tion

7. Platform Overload

8. Drive and Steer Disable

Figure 3-2. Ground Control Indicator Panel

3-8 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Boom Malfunction Indicator

If the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. The function is not permitted at the current boom configuration.

If the Boom Malfunction Indicator is flashing or on steady without a boom function attempt, the upright is out of al ig nm en t or th e m on it or in g s ys te m i s i n n ee d o f c al ib ra ti on .

DISCONTINUE OPERATION IF THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY.

IF THE UPRIGHT IS OUT OF ALIGNMENT WITH THE PLATFORM RAISED, LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND. THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION. REPORT THE PROBLEM TO THE PROPER SERVICE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL THE MALFUNCTION IS CORRECTED.

7. Platform Overload Indicator. (If Equipped)

Indicates the platform has been overloaded.

8. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function has been activated.

3121654 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Console

(See Figure 3-3.)

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

1. Drive Speed/Torque Select

The machine has a two position switch - The forward position gives maximum drive speed. The back position gives maximum torque for rough terrain and climbing grades.

2. Steer Select (If Equipped)

When equipped with four wheel steering, the action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is for normal driving at maximum speeds. The forward position is for “crab” steering. When in this mode both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This can be used for positioning the machine in aisle ways or against buildings. The back switch position is for “coordinated” steering. In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas.

To re-synchronize the front and rear axles, position the rear drive wheels to the forward drive position by selecting either crab or compound steer, then select front steer (center switch position) to operate the normal steering function.

3-10 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Drive Speed / Torque Select

2. Steer Selec t

3. Platform Level Override

4. Horn

5. Power/Emergency Stop

6. Engine Start / Aux Power

7. Fuel Select

8. Drive Orientation Override

9. Drive/Steer

10. Telescope

11. Lights

12. Jib (800AJ)

13. Soft Touch Override

14. Tower Lift

15. Soft Touch Indicator

16. Platform Rotate

17. Function Speed Control

18. Main Lift / Swing

Figure 3-3. Platform Control Console

3121654 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Engine Start/Auxiliary Power

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

3. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade.

4. Horn

A push-type Horn switch supplies electrical power to an audible warning device when pressed.

5. Power/Emergency Stop Switch

A two-position red mushroom shaped switch furnishes power to Platform Controls when pulled out (on). When pushed in (off ), power is shut off to the platform functions.

When pushed forward, the switch energizes the starter motor to start the engine.

The Auxiliary Power control switch energizes the electrically operated hydraulic pump. (Switch must be held on for duration of auxiliary pump use.)

The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate tower boom lift, tower telescope, main boom lift, main telescope and swing.

7. Fuel Select (Dual Fuel Engine Only) (If Equipped)

Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position. It is unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is running.

3-12 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Drive Orientation Override

When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows.

NOTE: Lift, Swing, and Drive control levers are spring-loaded and will

automatically return to neutral (off) position when released.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

NOTE: To operate the Drive joystick, pull up on the lock-

ing ring below the handle.

NOTE: The Drive joystick is spring loaded and will automatically return

to neutral (off) position when released.

9. Drive/Steer

Push forward to drive forward, pull back to drive in reverse. Steering is accomplished via a thumb-activated rocker switch on the end of the steer handle.

3121654 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Main Boom Telescope

Provides extension and retraction of the main boom.

11. Lights (If Equipped)

This switch operates control console panel lights and head lights if the machine is so equipped. The ignition switch does not have to be on to operate the lights, so care must be taken to avoid draining the battery if left unattended. The master switch and / or the ignition switch at the ground control will turn off power to all lights.

12. Jib (If Equipped)

Push forward to lift up, pull back to lift down. Variable lift speed is using the Function Speed Control.

13. Soft Touch Override Switch (If equipped)

This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed, allowing the operator to move the platform away from the obstacle that caused the shutdown situation.

14. Towe r Lif t

This switch provides for raising and lowering of the tower boom when positioned to “up” or “down”. Tower Lift must be fully elevated “up” before operating Tower Telescope. (Tower Lift should not function when Tower Telescope is extended).

3-14 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

15. Soft Touch Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode.

16. Platform Rotate

Provides rotation of the platform when positioned to the right or left.

17. Function Speed Control

This control affects the speed of telescope and platform rotate. Turning the knob all the way counterclockwise until it clicks puts drive, main lift and swing into creep mode.

NOTE: To operate the Main Boom Lift/Swing joystick,

pull up on the locking ring below the handle.

NOTE: The Main Boom Lift/Swing joystick is spring

loaded and will automatically return to neutral (off) position when released.

18. Main Lift/Swing Controller

Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected.

NOTE: Main boom lift and swing functions may be selected in combi-

nation. Maximum speed is reduced when multiple functions are selected.

3121654 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Console Indicator Panel

(See Figure 3-4., Platform Console Indicator Panel)

1. Tilt Alarm Warning Light and Alarm

This illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation. If the boom is above horizontal and the machine is on a slope, the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

NOTE: In certain markets, when the tilt sensor alarm is activated the

Drive function will be disabled if the boom is elevated above horizontal.

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. Boom Malfunction Indicator

When an audible alarm sounds and the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. This function is not permitted at the current boom configuration.

When an audible alarm sounds and the Boom Malfunction Indicator illuminates steady without a boom function attempt, the upright is out of alignment.

DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED.

3-16 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Tilt

2. Overload

3. Boom Malfunctgion

4. Capacity

5. Enable

6. Glow Plug

7. Low Fuel

8. System Distress

9. AC Generator

10. Drive Orientation

11. Creep

Figure 3-4. Platform Console Indicator Panel

3121654 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. Capacity Indicator

Indicates the maximum platform capacity for the current position of the platform. Restricted capacities are permitted at restricted platform positions (shorter boom lengths and higher boom angles).

NOTE: Refer to the capacity decals on the machine for

restricted and unrestricted platform capacities.

5. Footswitch/Enable Indicator

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next function, the enable light will go out and the footswitch must be released and depressed again to enable the controls.

Releasing the footswitch removes power from all controls and applies the drive brakes.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

3-18 – JLG Lift – 3121654

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Glow Plug/Wait to Start Indicator

Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine.

7. Low Fuel Indicator (Yellow)

Indicates the fuel tank is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

8. System Distress Indicator

The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

9. AC Generator (If Equipped)

Indicates the generator is in operation.

10. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (i.e. controls reversed situations).

11. Creep Speed Indicator

When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed.

3121654 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-20 – JLG Lift – 3121654

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the boom or swing the boom to the left or right. Standard boom swing is 360 degree continuous rotation. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so.

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Raising boom above horizontal with or without any load in platform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG

Stability

Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machine position of least forward stability is shown in Figure 4-1. and its positions of least backward stability is shown in Figure 4-2.

TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE.

3121654 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

AT HORIZONTAL (0 DEGREES)

MACHINE WILL UPSET IN THIS DIRECTION IF OVERLOADED OR OPE RATE D ON AN OUT- OF-LEVEL SURFACE.

LEVEL SURFACE

TOWER BOO M A T MAX ANGLE

Figure 4-1. Position of Least Forward Stability

4-2 – JLG Lift – 3121654

RET RA CTED AND F ULLY RETRACTED

TOWER BOOM FULLY LOWERED

LEVEL SURFACE

MACHINE WILL UPS E T IN THIS DIRECTION IF OPERAT ED ON AN OUT-OF -LEVEL SURFACE

Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2)

SECTION 4 - MACHINE OPERATION

3121654 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

EL EVATED AND

RET RA C TE D

TOWER BOOM FULLY

ELEVATED

MACHINE WILL UPSET

IN THIS DIRECTION IF

OPERATED ON AN

OUT-OF-LEVE L SURFACE

LEVEL SURFACE

Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2)

4-4 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

NOTE: Initial starting should always be per-

formed from the Ground Control station.

Starting Procedure

IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.

NOTE: Diesel engines only: After turning on ignition,

operator must wait until glow plug indicator light goes out before cranking engine.

1. Turn key of Platform/Ground Select switch to Ground.

2. Pull the Power/Emergency Stop switch to On.

3. Push the Engine Start switch until engine starts.

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

4. After engine has had sufficient time to warm up, push in the Power/Emergency Stop switch and shut engine off.

5. Turn Platform/Ground Select switch to Platform.

6. From Platform, pull Power/Emergency Stop switch out.

3121654 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

7. Push the Engine Start switch until engine starts.

NOTE: Footswitch must be in released (up) position before starter will

operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.

Shutdown Procedure

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.

1. Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature.

2. Push Power/Emergency Stop switch in.

3. Turn Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

Fuel Reserve / Shut-Off System

NOTE: Reference the Service and Maintenance Manual along with a

qualified JLG Mechanic to verify your machine setup.

The Fuel Shutoff System monitors the fuel in the tank and senses when the fuel level is getting low. The JLG Control System automatically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

If fuel level reaches the Empty range, the Low Fuel light will begin to flash once a second and there will be approximately 60 minutes of engine run time left. If the system is in this condition and automatically shuts down the engine or if the operator manually shuts down the engine before the 60 minute run time is complete, the Low Fuel light will flash 10 times a second and the engine will react according to machine setup. Setup options are as follows:

• Engine One Restart - When the engine shuts down, the operator will be permitted to cycle power and restart the engine once with approximately 2 minutes of run time. After the 2 minute run time is complete or if the engine is shut down by the operator prior to the completion of the 2 minute run time, it cannot be restarted until fuel is added to the tank.

4-6 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

• Engine Restart - When the engine shuts down, the operator will be permitted to cycle power and restart the engine for approximately 2 minutes of run time. After the 2 minutes of run time is complete, the operator may cycle power and restart the engine for an additional 2 minutes of run time. The operator can repeat this process until there is no more fuel available.

CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE.

• Engine Stop - When the engine shuts down, no restarts will be permitted until fuel is added to the tank.

4.4 TRAVELING (DRIVING)

See Figure 4-4., Grade and Sideslopes

NOTE: Refer to the Operating Specifications table for Gradeability and

Sideslope ratings.

All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted.

Traveling is limited by two factors:

1. Gradeability, which is the percent of grade of the incline the machine can climb.

2. Sideslope, which is the angle of the slope the machine can be driven across.

3121654 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-4. Grade and Sideslopes

4-8 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED TRAVELING.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED.

1. At Platform Controls, pull out Emergency Stop switch and activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as desired.

This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner:

3121654 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

4.5 STEERING

Position thumb switch on Drive/Steer controller to Right for steering right, or to Left for steering left.

4.6 PLATFORM

Platform Level Adjustment

To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.

Platform Rotation

To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached.

4-10 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

4.7 BOOM

AN ORANGE TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE. DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. CHASSIS MUST BE LEVEL BEFORE SWINGING, EXTENDING OR RAISING TOWER BOOM ABOVE HORIZONTAL.

TO AVOID UPSET, IF ORANGE TILT AL ARM WARNING LIGH T LIGHTS WHEN MAIN BOO M IS EXTENDED OR RAISED ABOVE HORIZONTAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTENDING OR RAISING MAIN BOOM.

TRAVELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON THE SERIAL NUMBER PLACARD.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

TO AVOID A 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.

Swinging the Boom

To swing boom, use Swing control switch to select Right or Left direction.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

NOTE: On CE Market machines, when boom functions are being oper-

ated there is an interlock that prevents the use of Drive and Steer functions.

3121654 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Raising and Lowering the Tower Boom

To raise or lower the Tower Boom, depress footswitch, position Tower Lift controller Up or Down, and hold until the desired height is reached.

DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED.

Raising and Lowering the Main Boom

To raise or lower the Main Boom, position the Main Boom Lift switch to Up or Down until the desired height is reached.

Telescoping the Main Boom

To extend or retract the main boom, use the Main Telescope Control Switch to select In or Out movement.

4.8 SHUT DOWN AND PARK

1. Drive machine to a protected area.

2. Assure boom is fully retracted and lowered over rear (Drive)

axle; all access panels and doors closed and secured.

3. Remove all load and allow engine to operate 3-5 minutes at idle to permit reduction of engine internal temperatures.

4. At Ground Controls, turn Key Select switch to (center) Off Position, Power/Emergency Stop switch (down) to Off. Remove key.

5. Cover Platform Control console to protect instruction placards, warning decals and operating controls from hostile environment.

4-12 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

4.9 LIFTING AND TIE DOWN

See Figure 4-5.

Lifting

1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position with the turntable locked.

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the designated

lifting points.

5. Properly adjust the rigging to prevent damage to the machine and so the machine remains level.

Tie Down

WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST.

1. Place the boom in the stowed position with the turntable locked.

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or chains of

adequate strength and attached to the designated tie down points.

3121654 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

ROTATION

CENTER

GRAVITY

"A"

LIFT HERE

"A" Dimensio n

Steer A xl e T o C en ter O f Gr avi ty

52" (1320 mm)

(SPREADER BAR REQUIRED)

Figure 4-5. Lifting Chart

4-14 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

Refer to Section 2.4, Oscillating Axle Lockout Test (If Equipped) for procedure.

4.11 TOWING

The machine is not equipped with a tow package. Refer to Section 5 for emergency towing procedures.

4.12 TOW BAR (IF EQUIPPED)

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)

MAXIMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

1. Retract, lower and position boom in travel position; lock turntable.

2. Lower tow bar and connect to towing vehicle

3. Disconnect drive hubs by inverting disconnect cap.

3121654 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

Figure 4-6. Tow Bar

4-16 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

4. Position steer/tow selector valve for towing; pull valve knob out for towing. The machine is now in the towing mode.

After towing the machine, complete the following:

1. Actuate steer/tow selector valve for steering; push valve

knob in to the actuated position.

2. Reconnect drive hubs by inverting disconnect cap.

3. Disconnect tow bar from towing vehicle and place it in the

stowed position as shown in Figure 4-6. The machine is now in the driving mode.

4.13 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Description

The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas. The system includes pressurized cylinders mounted on the frame, and the valves and switches needed to switch the fuel supply from gasoline to LP gas or from LP gas to gasoline.

A two position, Fuel Select switch at the platform control station supplies electrical power to open the gasoline shut-off solenoid and close the LP gas shut off solenoid when positioned to the Gasoline position. This switch also allows electrical power to open the LP gas shut-off solenoid and close the gasoline shut-off solenoid when positioned to the LP position.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOPPING THE ENGINE. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.

3121654 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Changing From Gasoline to LP Gas

1. Start engine from Ground Control Console.

2. Open hand valve on LP gas supply tank by turning counterclockwise.

3. While the engine is operating, place the two position LPG/Gasoline switch at the platform control station to the "LP" position.

Changing From LP Gas to Gasoline

1. With engine operating on LP under a no-load condition, position FUEL SELECT switch at Platform Control Station to GASOLINE position.

2. Close hand valve on LP gas supply tank by turning clockwise.

4.14 RE-SYNCHRONIZE UPRIGHT

Releveling Valve

A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90° (vertical) relative to the chassis (Refer to Figure 2.9 and Figure 2.10). This valve is located in the tank compartment area.

Perform the following steps with the aid of an assistant:

1. Turn the key switch to the ground control position.

2. Start the engine.

3. Pull and hold the red relevel knob located next to

the main control valve. Refer to Figure 4-7.

4. Raise the tower boom 6 feet (1.8 m).

5. Release the red relevel knob.

4-18 – JLG Lift – 3121654

6. Lower the tower boom fully and con-

Figure 4-7. Releveling Valve

tinue to hold down the switch to Tower Down for an additional 20 seconds.

7. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis.

SECTION 4 - MACHINE OPERATION

3121654 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

4.15 AIR COMPRESSOR

Normal Startup Procedure

1. Check compressor oil level - top up if necessary.

2. Air service valve (beside the compressor) closed.

3. Start the engine.

4. Compressor switch (in the platform) ON - compressor should

activate.

5. Allow the compressor to warm up for several minutes before operating.

Normal Shutdown Procedure

1. Close service valve and allow compressor to unload and cool down (approx. 5 min.).

2. Position the compressor switch in the platform to OFF.

3. Shut down the engine.

Daily Operation

Before Starting:

1. Check compressor oil level.

2. Check for any leaks or loose bolts.

3. Check drive belt is tight.

After Starting:

1. Check pressure gauge for correct operating pressure.

2. Check for leaks.

4-20 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Installation - Sheet 1 of 5

3121654 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Installation - Sheet 2 of 5

4-22 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Installation - Sheet 3 of 5

3121654 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Installation - Sheet 4 of 5

4-24 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Installation - Sheet 5 of 5

3121654 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

0274483-C

1- -- -- - - -

2 1701499 1701499 1701499 1701499

3- -- -- - - -

4- -- -- - - -

5 1701509 1701509 1701509 1701509

6- -- -- - - -

7 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412

11 - - - - 1705084 1705084

12 - - 1705514 - - - -

13- -- -- - - -

14- -- -- - - -

15 1705337 - - - - - -

16- -- -- - - -

17- -- -- - - -

18 1703953 1703942 - - - -

French

0274488-CCE0274484-5

Aus

1001114464-C

Table 4-1. Decal Legend

Item # ANSI

0274483-C

19- -- -- - - -

20 1702868 1704000 - - - -

21 1703797 1703924 1705921 1705921

22 1705336 1705347 1705822 1705822

23 1703804 1703948 1701518 1701518

24 1703805 1703936 1705961 1705961

25 3252347 1703984 1705828 1705828

26- -- -- - - -

27- -- -- - - -

28- -- -- - - -

29 1703477 1703477 1703960 1703960

30 1702631 1702631 1702631 1702631

31 1705007 1705007 1705007 1705007

32 1701501 1701501 1701501 1701501

33 1001121801 1001121803 1705978 1705978

34 1001121814 1001121816 1705978 1705978

35- -- -- - - -

36 1706948 1706948 - - - -

French

0274488-CCE0274484-5

Aus

1001114464-C

4-26 – JLG Lift – 3121654

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

0274483-C

37 1001096141 1705977 1705977 1705977

38 1703959 1001131269 1703959 1703959

39 1001131269 1700584 - - 1001131269

40 1001108495 1001108495 - - - -

41 1001095809 1001095809 - - - -

42- -- -- - - -

43- -- -- - - -

44- -- -- - - -

45- -- -- - - -

46- -- -- - - -

47- -- -- - - -

48- -- -- - - -

49 1701505 1701505 1701505 1701505

50- -- -- - - -

51- -- -- - - -

52- -- -- - - -

53- -- -- - - -

54- -- -- - - -

French

0274488-CCE0274484-5

Aus

1001114464-C

Table 4-1. Decal Legend

Item # ANSI

0274483-C

55- -- -- - - -

56 1705351 1705429 - - - -

57 - - - - - - 1001112551

French

0274488-CCE0274484-5

Aus

1001114464-C

3121654 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

NOTES:

4-28 – JLG Lift – 3121654

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

This section explains the steps to be taken in case of an emergency situation while operating.

5.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

In USA: JLG Phone: 877-JLG-SAFE (554-7233)

Outside USA: 240-420-2661

E-mail:

ProductSafety@JLG.com

Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE:

1. Other personnel should operate the machine from ground controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine.

3121654 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine.

Boom Movement Prevented By Boom Control System

Lowering the boom onto an object or structure, with the boom at high angles, may cause the boom control system to prevent movement of the machine. This can include movement necessary to lift the boom off the object. Movement of the boom can be regained by observing the following:

1. Shut off the engine.

2. Rescue platform occupants prior to freeing machine.

3. Use cranes, forklifts or other equipment to stabilize motion

of the machine as required.

4. From the ground control position, use the Auxiliary Power System to carefully raise the boom off the object.

5. Once clear, restart the engine and return the platform to the ground.

6. Inspect the machine for damage before continued use of the machine.

5.4 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.

5-2 – JLG Lift – 3121654

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual .............................................3121651

Illustrated Parts Manual - Global................................................3121652

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications

Maximum Work Load (Capacit y) AN S I Un re s tr i c te d : CE / AU S Un r es t ri c te d :

Maximum Travel Grade with boom in stowed position

(Gradeability) 4WD Figure 4-4.

Maximum Travel Grade

(Side Slope)Figure 4-4.

Maximum Vertical Platform Height: 74 ft. (22.5 m)

Maximum Horizontal Platform Reach 51 ft. 10 in. (15.8 m)

Ground Clearance 12 in. (30 cm)

Wheelbase 10 ft. (3.05 m)

Maximum Tire Load: 17,755 lbs. (8060 kg)

Maximum Drive Speed: 3.0 mph (4.8 kph)

Maximum Hyd. Operating Pressure 4500 psi (310 Bar)

Electrical System Voltage 12 volts

Jet Blast Rating 90 mph (145 kph)

with boom in stowed position

500 lb (227 kg) 500 lb (230 kg)

5° ANSI

3° CE/AUS

45%

3121654 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications

Max. Ground Bearing Pressure

Gross Machine Weight 36,200 lb. (16,420 kg)

84 psi (5.3 kg/cm

Dimensional Data

Table 6-2. Dimensional Data

Turning Radius (Outside) 14 ft.- 6 in. (4.42 m)

Turning Radius (Inside) 11 ft.- 0 in. (2.13 m)

Boom Elevation Ab o ve G ra d e B el o w G r ad e

Machine Height Stowed 9 ft. 9.5 in.(2.98 m)

Machine Length (Stowed) 36 ft.-6 in. (11.13 m)

Machine Width 8 ft.-0 in. (2.44 m)

Wheelbase 10 ft.- 0 in. (3.05 m)

+80 ft.-3 in. (24.46 m)

-13 ft.- 1 in. (3.99 m)

)

Capacities

Table 6-3. Capacities

Fuel Tank Approx. 39 gallons (147.6 liters)

Hydraulic Tank Approx. 40 gallons (151.4 liters)

Hydraulic System (Including Tank) 77 Gal. (291.4 L)

Drive Hub 44 ounces (1.3 L)

Drive Brake 2.7 ounces (80 ml)

Engine Crankcase D eu t z D 2 01 1 L0 4 D eu t z T D 2. 9 L GM

Air Compressor 4 qts. (3.8 L)

11 quarts (10.5 L)

2.4 Gallon (8.9 L) w/Filter

4.5 qts. (4.25 L) w/Filter

6-2 – JLG Lift – 3121654

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Engine Data

Type Liquid Cooled (Oil)

Fuel Diesel

Oil Capacity Co o li n g S y st em Cr a nk c as e Tot a l C a pa c it y

Idle RPM 1000

Low RPM 1800

High RPM 2600

Alternator 55 Amp, belt drive

Fuel Consumption 0.88 GPH (3.33 lph)

Battery 1000 Cold Cranking Amps, 210 minutes

Horsepower 61.6 @ 2600 RPM, full load

Table 6-4. Deutz D2011L04 Specifications

5 Quarts (4.5 L)

11 Quarts (10.5 L) w/Filter

16 Quarts (15 L)

Reserve Capacity, 12 VDC

Table 6-5. Deutz TD 2.9 Specifications

Fuel Ultra Low Sulfur Diesel (15 ppm)

Output 67 hp (50 kW)

Torque 173 ft.lbs. (234 Nm) @ 1800rpm

Oi l Ca p ac i t y ( Cr a nk c as e ) 2. 4 Ga l lo n ( 8. 9 L) w /F i lt e r

Cooling System 3.3 Gallon (12.5 L)

Low RPM 1200 ±50 rpm

High RPM 2600±50 rpm

Alternator 95 Amp

Fuel Consumption 0.65 GPH (2.48 lph)

3121654 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-6. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4

BHP G as o li n e LP

Bore 4.0 in. (101.6 mm)

Stroke 3.6 in. (91.44 mm)

Displacement 181 cu.in. (3.0 L, 2966 cc)

Oil Capacity w/filter 4.5 qts. (4.25 L)

Minimum Oil Pressure at i dl e Ho t

Compression Ratio 9.2:1

Firing Order 1-3-4-2

Max. RPM 2800

83 hp @ 3000 rpm 75 hp @ 3000 rpm

6 psi (0.4 Bar) @ 1000 rpm

18 psi (1.2 Bar) @ 2000 rpm

Tires

Table 6-7. Tire Specifications

Size Type Ply Rating

15-625 pneumatic 16 H 95PSI

15-625 foam-filled 16 H N/A

18-625 foam-filled 16 H N/A

Load

Range

Pressure

(6.5 Bar)

6-4 – JLG Lift – 3121654

JLG 740AJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 GENERAL

SECTION 1. SAFETY PRECAUTIONS

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 MAINTENANCE

Maintenance Hazards

Battery Hazards

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

2.3 FUNCTION CHECK

From the Ground Control Station with No Load in the Platform:

From the Platform Control Station:

2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

2.5 INSPECTION AND USE OF FALL ARREST SYSTEM

Inspecting Cable Tension and Slip Indicator

Prior to Use Inspection

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Console

Ground Control Indicator Panel

Platform Console

Platform Console Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 ENGINE OPERATION

Starting Procedure

Shutdown Procedure

Fuel Reserve / Shut-Off System

4.4 TRAVELING (DRIVING)

Traveling Forward and Reverse

4.5 STEERING

4.6 PLATFORM

Platform Level Adjustment

Platform Rotation

4.7 BOOM

Swinging the Boom

Raising and Lowering the Tower Boom

Raising and Lowering the Main Boom

Telescoping the Main Boom

4.8 SHUT DOWN AND PARK

4.9 LIFTING AND TIE DOWN

Lifting

Tie Down

4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

4.11 TOWING

4.12 TOW BAR (IF EQUIPPED)

4.13 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Description

Changing From Gasoline to LP Gas

Changing From LP Gas to Gasoline

4.14 RE-SYNCHRONIZE UPRIGHT

Releveling Valve

4.15 AIR COMPRESSOR

Normal Startup Procedure

Normal Shutdown Procedure

Daily Operation

5.1 GENERAL

SECTION 5. EMERGENCY PROCEDURES