JLG 80SL Operator Manual

Operation, Safety, and

Maintenance Manual

Keep this manual with the machine at all times.

Model

80SL

ANSI

P/N - 3121324

June 1, 2009

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.

3121324 – 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 POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

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

b – JLG Lift – 3121324

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

NOTICE

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.

NOTICE

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

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742

or Your Local JLG Office (See addresses on manual rear cover)

In USA:

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

Outside USA:

Phone: 240-420-2661 E-mail: ProductSafety@JLG.com

FOREWORD

3121324 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue . . . . . .. . . . . . . . . . . . . . . September 29, 2006

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . October 25, 2006

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . December 21, 2006

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . February 22, 2007

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . March 28, 2007

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . May 13, 2008

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . October 23, 2008

Revised. . . . . . . . . . .. . . . . . . . . . . . . . . June 1, 2009

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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. . . . . . . . . . . . . 1-8

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-9

1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-10

Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-10

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

2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . 2-4

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

Limit Switch Checks . . . . . . . . . . . . . . . . . . . . . . 2-6

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

SECTION - 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

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

3.2 OPERATING CHARACTERISTICS AND

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

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

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

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

3.3 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-2

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

Engine Control. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Main Terminal Box. . . . . . . . . . . . . . . . . . . . . . . . 3-5

Ground Control Console . . . . . . . . . . . . . . . . . . . 3-7

3.4 PLATFORM CONTROL CONSOLE. . . . . . . . . . . . . 3-9

SECTION - 4 - MACHINE OPERATION

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

General Description of the Functions and

Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 LIFTING AND LOWERING . . . . . . . . . . . . . . . . . . . 4-2

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TABLE OF CONTENTS

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

4.4 AUTOMATIC SELF LEVELING CHASSIS . . . . . . . . 4-3

4.5 DRIVING THE MACHINE FROM THE PLATFORM . 4-4

4.6 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.7 HYDRAULIC PLATFORM EXTENSION . . . . . . . . . . 4-6

4.8 EMERGENCY LOWERING - MANUAL DESCENT . 4-6

4.9 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-6

4.10 TIE DOWN/LIFT LUGS. . . . . . . . . . . . . . . . . . . . . . . 4-7

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.11 TRANSPORT AND STORAGE OF THE MACHINE . 4-8

Platform Rail Lowering Procedure . . . . . . . . . . . 4-9

Rail Raising Procedure . . . . . . . . . . . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

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

Emergency Stop Switch . . . . . . . . . . . . . . . . . . 5-1

Platform Caught Overhead . . . . . . . . . . . . . . . . 5-1

Righting of Tipped Machine. . . . . . . . . . . . . . . . 5-1

Post-Incident Inspection . . . . . . . . . . . . . . . . . . 5-1

5.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-2

Use of Ground Controls. . . . . . . . . . . . . . . . . . . 5-2

Operator Unable to Control Machine . . . . . . . . 5-2

Incident Notification . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 MANUAL PROCEDURES. . . . . . . . . . . . . . . . . . . . . 5-3

Manual Platform Deck Retraction . . . . . . . . . . . 5-3

Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.4 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . .5-6

Prior to Towing . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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

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

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

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

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

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Component Weights. . . . . . . . . . . . . . . . . . . . . . 6-4

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-8

6.4 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . .6-13

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-14

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-14

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-15

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. Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . .2-8

2-2. Walk - Around Inspection Diagram . . . . . . . . . . . . .2-9

2-3. Walk - Around Inspection Points (Sheet 1) . . . . . .2-10

2-4. Walk - Around Inspection Points (Sheet 2) . . . . . .2-11

3-1. Ground Control Stations . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Engine Control Box . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3. Main Terminal Box . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-4. Ground Control Console . . . . . . . . . . . . . . . . . . . . .3-7

3-5. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-9

3-6. Decal Location (ANSI) - Sheet 1 of 2 . . . . . . . . . . .3-12

3-7. Decal Location (ANSI) - Sheet 2 of 2 . . . . . . . . . . .3-13

3-8. Decal Location (CSA) - Sheet 1 of 2 . . . . . . . . . . .3-14

3-9. Decal Location (CSA) - Sheet 2 of 2 . . . . . . . . . . .3-15

4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . .4-5

4-2. Lifting and Tie Down Points . . . . . . . . . . . . . . . . . . .4-7

4-3. Rail Lowering Tool . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

5-1. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . .5-6

6-1. Engine Operating Temperature Specifications

(Deutz) - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . .6-5

6-2. Engine Operating Temperature Specifications

(Deutz) - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . .6-6

6-3. Operator Maintenance and Lubrication Diagram . .6-8

LIST OF TABLES

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

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

2-2 Cutout Switch Limits . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3-1 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

6-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

6-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Engine Battery Specifications. . . . . . . . . . . . . . . . . 6-4

6-7 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-9 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-7

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

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TABLE OF CONTENTS

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

This page left blank intentionally.

iv – JLG Lift – 3121324

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. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should 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.

These sections contain 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 Operators and Safety Manual must be read in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

3121324 – 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 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 floor 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 operate the machine when wind conditions exceed 28 mph (12.5 m/s).

• This machine can be operated in nominal ambient tem-

peratures of 5 optimize operation outside of this temperature range.

F to 113oF (-15oC to 45oC). Consult JLG to

1-2 – JLG Lift – 3121324

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

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

• 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 deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck.

1.3 OPERATION

General

• 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.

• 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.

3121324 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.

• Stow scissor arm assembly and shut off all power before leaving machine.

Trip and Fall Hazards

• JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.

• Prior to operation, ensure all gates and rails are fastened and secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. Attach only one (1) lanyard per lanyard anchorage point.

1-4 – JLG Lift – 3121324

SECTION 1 - SAFETY PRECAUTIONS

• 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.

• Never use the scissor arm assembly to gain access to or leave the platform.

• Use extreme caution when entering or leaving platform. Ensure that the scissor arm 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.

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

Electrocution Hazards

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

3121324 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

• Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in accordance with the Minimum Approach Distance (M.A.D.) as specified in Table 1-1, Minimum Approach Distances (M.A.D.).

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50KV 10 (3)

Over 50 KV 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 (3 m) 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.

• 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

MINIMUM APPROACH DISTANCE

in Feet (Meters)

1-6 – JLG Lift – 3121324

SECTION 1 - SAFETY PRECAUTIONS

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

• 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.

• The user should be familiar with the driving 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 uniformly supported 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.

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

3121324 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

• Do not operate the machine when wind conditions exceed the maximum allowable wind speed.

• Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine.

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

• If scissor arm assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel.

Crushing and Collision Hazards

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

• Keep hands and limbs out of the scissor arm assembly during operation.

• Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.

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

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

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

• Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, conges-

1-8 – JLG Lift – 3121324

SECTION 1 - SAFETY PRECAUTIONS

tion, visibility, slope, location of personnel, and other factors causing hazards of 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.

• Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes. Barricade floor area if necessary.

• Avoid operating over ground personnel. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary.

1.4 TOWING, LIFTING, AND HAULING

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

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

• Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling.

• Refer to Section 4 for lifting information.

1.5 MAINTENANCE

General

This 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 maunual 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.

3121324 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

Maintenance Hazards

• Shut off power to all controls and ensure that all operating systems 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.

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

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

• Shut down the engine (if equipped) while fuel tanks are being filled.

• 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.

• Remove all rings, watches, and jewelry when performing any maintenance. Do not wear loose fitting clothing or

long hair unrestrained which may become caught or entangled in equipment.

• Use only clean approved non-flammable cleaing solvents.

• Never alter, remove, or substitute any items such as counterweights, tires, batteries, platforms or other items that may reduce or affect the overall weight or stability of the machine.

• Reference 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.

Battery Hazards

• 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.

1-10 – JLG Lift – 3121324

• 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.

SECTION 1 - SAFETY PRECAUTIONS

3121324 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-12 – JLG Lift – 3121324

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 equipment.

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 over-

head obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

7. Means to avoid the hazards of unprotected electrical

conductors.

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121324 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

NOTICE

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

2-2 – JLG Lift – 3121324

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Typ e Frequency

Pre-Start Inspection

Pre-Deliver y

Inspection (See Note)

Frequent Inspection

(See Note)

Annual Machine

Inspection (See Note)

Preventative

Maintenance

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

Before using each day; or whenever there’s an Operator change.

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance

In service for 3 months or 1 50 hours, whichever comes first; or

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

Purchased used.

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

At intervals as specified in the Ser vice and Maintenance Manual.

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance

Owner, Dealer, or User Factory Cer tified Service

Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance

Primary

Responsibility

Service

Qualification

Te ch ni c ia n (Recommended)

Reference

Manual and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

Manual

3121324 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.3 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 discrepencies.

Parent Metal Crack

3. Decals and Placards – Check all for cleanliness and

legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

Weld Crack

4. Operators and Safety Manuals – Make sure a copy of

the Operator and Safety Manual is enclosed in the weather resistant storage container.

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

Around Inspection Diagram.

6. Battery – Charge as required.

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

the proper fuel as necessary.

8. Engine Oil Supply - Ensure that the engine oil level is at

the full mark on the dipstick and the filler cap is secure

9. Fluid Levels - Be sure to check the engine oil and the

hydraulic oil levels.

10. Accessories/Attachments - Reference the Operator

and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

11. Function Check – Once the “Walk-Around” Inspection

is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions on the operation of each function.

2-4 – JLG Lift – 3121324

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

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.

Function Check

Perform the Function Check as follows:

1. From the ground control panel with no load in the plat-

form:

a. Check that all function control switches and locks

are in place.

b. Operate all functions and check all limiting and cut-

out switches.

c. Check for proper lifting and lowering of the plat-

form.

d. If the platform extension is extended, check that the

extension retracts.

NOTE: Be sure the platform extension is retracted before lower-

ing.

e. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

f. Check manual descent.

g. Check for proper lifting and lowering of the plat-

form.

2. From the platform control console:

a. Ensure that the control console is firmly secured in

the proper location.

b. Check that all guards protecting the switches are in

place.

c. Operate all functions

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is pushed in.

e. Ensure that all LED’s in the control box are working

properly.

f. Check that the platform extension extends and

retracts properly.

g. With the platform in the transport (stowed) position

and with outriggers not selected:

i. Drive the machine on a level grade and stop to

ensure the brakes hold.

ii. To ensure proper operation of the tilt sensor, drive

the machine onto a tilt greater than the preset 3° and attempt to lift.

3121324 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

Limit Switch Checks

Check that the following limit switches function properly by attempting to exceed the preset limits.

1. Lowered Position Limit Switch - Outriggers cannot be

deployed beyond the height of 9.8 ft (3m).

2. Limit Switches for Drive Mode

a. High Drive Speed Limit Switch - high drive speed is

possible up to a platform height of 12.14 ft (3.7 m). When the platform exceeds this limit, only low drive speed is possible.

b. Maximum Drive Height/Maximum Height without

Outriggers Limit Switch - The driving function is permitted up to a platform height of 65 ft (20 m). Once the limit is exceeded driving will be disabled. The lifting function, without the outriggers deployed, is only permitted up to a platform height of 65 ft (20 m) as well.

3. Maximum Height Limit Switch - The Maximum Height

Limit Switch cuts out the lifting function once the platform reaches 80.4 ft (24.5 m). This maximum height is only achieved when the outriggers are selected and deployed.

4. Tilt Switch - If the machine is exceeding a tilt angle of 3°,

the platform cannot be elevated beyond 12.14 ft (3.7 m), or if driving while elevated, the drive function will be cut out.

5. Outrigger Interlocks - These switches allow the machine

to be driven when all outriggers are completely retracted. The switch also prevents the platform from being lifted until the machine is level.

6. Oscillating Axle Limit Switch - When the platform is

raised above 12.8 ft (3.9 m) and the axle inclination is >1°, the drive function is cutout. When the platform is below 3.9 m, the inclination of the axle is ignored and driving is possible.

2-6 – JLG Lift – 3121324

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

Table 2-2. Cutout Switch Limits

Limit and Cutout Switch Limit

Lowered Position 9.8 ft (3.2 m)

High Drive Speed Cutout * 12.14 ft (3.7 m)

Maximum Drive Height/Maximum Height without Outriggers *

Maximum Height:* 80.4 ft (24 .5 m)

Tilt * 3°

Outrigger Interlock drive cut out when outriggers activated;

Oscillating Axle >1° and 12.8 ft (3.9 m)

NOTE: * - these limit switches have corresponding LED’s on

the platform control console (refer to Figure 3-5., Platform Control Console). See pages 3-9 and 3-10 for LED functionality.

65 ft (20 m)

lift cut out when not level

3121324 – JLG Lift – 2-7

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