JLG E300A Operation And Safety Manual

Operation and Safety Manual

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

Boom Lift Models E300A

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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.

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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

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FOREWORD

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

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

Contact:

Product Safety and Reliability Department JLG Industries, Inc.

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

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FOREWORD

REVISION LOG

Original Issue - June 13, 2005

Revised - July 12, 2006

Revised - November 6, 2006

Revised - May 7, 2007

Revised - May 15, 2008

Revised - December 10, 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 . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

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

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

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

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

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

Platform Control Indicator Panel . . . . . . . . . . . . 3-11

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND

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TABLE OF CONTENTS

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

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

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

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

4.8 BOOM FUNCTION SPEEDS . . . . . . . . . . . . . . . . . . 4-9

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

4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-10

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

SECTION - 5 - EMERGENCY PROCEDURES

MAINTENANCE

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

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

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

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

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

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

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

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

6.4 BATTERY MAINTENANCE AND CHARGING. . . . .6-11

Battery Maintenance, Quarterly . . . . . . . . . . . . 6-11

Battery Charging, Daily. . . . . . . . . . . . . . . . . . . 6-12

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TABLE OF CONTENTS

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

LIST OF FIGURES

2-1. Boom Cutout Switches . . . . . . . . . . . . . . . . . . . . . .2-6

2-2. Basic Nomenclature - E300A . . . . . . . . . . . . . . . . . .2-7

2-3. Basic Nomenclature - E300AJ & E300AJP . . . . . . .2-8

2-4. Daily Walk - Around Inspection (Sheet 1 of 3). . . . .2-9

2-5. Daily Walk-Around Inspection - Sheet 2 of 3. . . . .2-10

2-6. Daily Walk-Around Inspection - Sheet 3 of 3. . . . .2-11

3-1. Ground Control Station - 300A . . . . . . . . . . . . . . . .3-2

3-2. Ground Control Station - 300AJ. . . . . . . . . . . . . . . .3-3

3-3. Ground Control Station - 300AJP . . . . . . . . . . . . . .3-4

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

3-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-12

LIST OF TABLES

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

Beaufort Scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

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

Simultaneous Functions . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

E300A Decal Legend - Part 1 of 2 . . . . . . . . . . . . . . . . . . 4-16

E300A Decal Legend - Part 2 of 2 . . . . . . . . . . . . . . . . . . 4-20

E300AJ Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

E300AJP Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28

Operating specifications - E300A . . . . . . . . . . . . . . . . . . . 6-1

Operating specifications - E300AJ . . . . . . . . . . . . . . . . . . 6-2

Operating specifications - E300AJP . . . . . . . . . . . . . . . . . 6-3

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TABLE OF CONTENTS

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

This page left blank intentionally.

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SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

The owner/user/operator/lessor/lessee of the machine should not operate the machine until this manual has been

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the machine.

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SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

Workplace Inspection

• This machine can be operated in temperatures of 0

o

F to

104

o

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

side this range.

Machine Inspection

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

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

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

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SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

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

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

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

• Do not allow personnel to tamper with or operate the

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

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

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

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

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

Trip and Fall Hazards

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SECTION 1 - SAFETY PRECAUTIONS

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

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

Electrocution Hazards

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

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SECTION 1 - SAFETY PRECAUTIONS

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

Voltage Range

(Phase to Phase)

MINIMUM APPROACH DISTANCE

in Feet (Meters)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

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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.

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SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

Crushing and Collision Hazards

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

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

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SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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 capac-

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SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

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

• Charge batteries only in a well ventilated area.

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SECTION 1 - SAFETY PRECAUTIONS

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

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

Beaufort

Number

Wind Speed

Description Land Conditions

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises ver tically

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. Leav es rustle

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

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

Operator Training

Operator training must cover:

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

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

8. Specific job requirements or machine application.

Training Supervision

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

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

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.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Type Frequen cy

Primary

Responsibility

Service

Qualification

Reference

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

User or Operator User or Operator Operator and Safety Manual

Pre-Delivery Inspection (See Note)

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

Mechanic

Service and Maintenance Manual and appli cable JLG inspection form

Frequent Inspection (See Note)

In service for 3 months or 150 hours, whichever comes first; or Out of service f or a period of more than 3 months;

Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance Manual and appli cable JLG inspection form

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection

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

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

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

(Domestic only) is enclosed in the weather resistant storage container.

5. “Walk-Around” Inspection – Refer to Figure 2-4. thru Figure 2-6.

6. Battery – Charge as required.

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

proper fuel as necessary.

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

9. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or

locks are in place;

b. Operate all functions and check boom limit

switches; drive speed should switch to creep mode if lower boom is elevated or main boom is above horizontal.

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabled

Cutout Description Market

Tilt

&

High

Drive

5 degree-reduces t he maximum speed of all boom functions to creep whe n tilted and above elevation. Reduces drive speed to creep when tilted. (See Figure 2-1.)

ANSI & Japan

3 degree-reduces t he maximum speed of all boom functions to creep whe n tilted and above elevation. Reduces drive speed to creep when tilted.(See Figure 2-1.)

CE & Australia

Drive Ba ttery Charger Cutout-cuts out drive when the bat-

tery charger is plugg ed in.

All

Battery Charger Cutout and Simultaneous Drive and Boom Functions disabled above elevation. (See Fig-

CE & Australia

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

UPPER BOOM ANGLE TO BE 1° BELOW HORIZONTAL TO 3° ABOVE HORIZONTAL TO ACTIVATE SWITCH. UPPER BOOM ANGLE TO BE 1° TO 4° BELOW HORIZONTAL TO RESET SWITCH.

LOWER BOOM ANGLE TO BE 1° TO 5° ABOVE HORIZONTAL TO ACTIVATE SWITCH. LOWER B OO M A N GL E T O BE 0° T O 5 ° B E LOW HORIZONTAL TO RESET SWITCH.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

11. Master Cylinder

1 2. B a se B oo m

13. Fly Boom

1 4. P la t f or m Co n t ro l Bo x

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Base Boom

13. Fly Boom

14. Jib Cylinder

15. Jib

16. Platfor m Control Box

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

GENERAL

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

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

3. Fly Boom Nose and Platform Support - Ensure fly boom nose and platform support are free of debris, obstructions, etc.

4. All Hydraulic Cylinders - No visible damage; pivot pins and hydraulic hoses undamaged, not leaking.

5. Slave Cylinder - No visible damage; pivot pins secure; hydraulic hoses undamaged, not leaking.

6. Boom Sections/Uprights/Turntable - See Inspection Note.

7. Limit Switches - Switches operable; See Inspection Note.

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JLG E300A Operation And Safety Manual

Specifications and Main Features

Frequently Asked Questions

User Manual