JLG E300AJ, E300AJP Operation And Safety Manual

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Operation and Safety Manual

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

Boom Lift Models E300AJ E300AJP

S/N 0300138358 to Present

ANSI

3121252

January 5, 2015

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.

3121252 – 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 – 3121252

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

3121252 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - June 26, 2009

Revised - September 29, 2009

Revised - October 28, 2009

Revised - November 19, 2009

Revised - November 8, 2010

Revised - February 6, 2012

Revised - August 9, 2012

Revised - January 5, 2015

d – JLG Lift – 3121252

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

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

SECTION - 4 - MACHINE OPERATION

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

4.2 BOOM OPERATING CHARACTERISTICS AND

4.3 MOTOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-13

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Power/Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . 4-6

Platform/Ground Select Switch . . . . . . . . . . . . . . . . . . . . 4-6

Motor Activation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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

Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 4-9

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

3121252 – JLG Lift – i

TABLE OF CONTENTS

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

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

Raising and Lowering the Upper Boom. . . . . . . . . . . . 4-11

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

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

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

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

5.5 MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.6 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

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

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

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

Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.4 BATTERY MAINTENANCE AND CHARGING . . . . . . . . . . . 6-13

Battery Maintenance, Quarterly . . . . . . . . . . . . . . . . . . . 6-13

Battery Charging, Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . 6-15

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

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-16

SECTION - 7 - INSPECTION AND REPAIR LOG

ii – JLG Lift – 3121252

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . 2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . 2-9

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

3-1. Ground Control Station - E300AJ . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Ground Control Station - E300AJ with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-4

3-3. Ground Control Station - E300AJP . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Ground Control Station - E300AJP with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-6

3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-6. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-14

4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-3

4-2. Position of Least Backward Stability - E300AJ . . . . . . . . . 4-4

4-3. Position of Least Backward Stability - E300AJP . . . . . . . . 4-5

4-4. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-6. Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-7. Decal Location Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-8. Decal Location Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-9. Decal Location Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-10. Decal Location Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

5-1. Manual Descent Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

6-1. Operator Maintenance and Lubrication Diagram. . . . . . 6-8

3121252 – JLG Lift – iii

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

iv – JLG Lift – 3121252

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

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 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

6-1 Operating specifications - E300AJ. . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Operating specifications - E300AJP . . . . . . . . . . . . . . . . . . . 6-2

6-3 Dimensional Data - E300AJ . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6-4 Dimensional Data - E300AJP. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

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

6-8 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-9 DTE 10 Excel 15 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

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

6-12 Mobil EAL Envirosyn H Specs . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-13 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-14 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

6-15 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-16 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

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

3121252 – JLG Lift – v

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

vi – JLG Lift – 3121252

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.

3121252 – 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 – 3121252

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.

3121252 – 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.

• 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.

• Hydraulic cylinders are subject to thermal expansion and contraction. This may result in changes to the boom and/or platform position while the machine is stationary. Factors affecting thermal movement can include the length of time the machine will remain stationary, hydraulic oil temperature, ambient air temperature, and boom and platform position.

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 – 3121252

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.

Electrocution Hazards

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

3121252 – 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 – 3121252

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.

3121252 – 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 – 3121252

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.

3121252 – 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 – 3121252

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.

3121252 – 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 – 3121252

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.

3121252 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121252

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

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

Operator Training

Operator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential malfunction.

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

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

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121252 – 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 – 3121252

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Type Frequ ency

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 Operator 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

3121252 – 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. Operation and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage container.

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

6. Battery – Charge as required.

7. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-

lic oil is added as required.

8. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

2-4 – JLG Lift – 3121252

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific 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.

Function Check

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or locks

are in place;

b. Operate all functions and ensure proper operation;

c. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

d. Ensure all boom functions stop when the function

enable switch is released.

2. From the platform control console:

a. Ensure that the control console is firmly secured in the

proper location;

b. Check that all guards protecting the switches or locks

are in place;

c. Operate all functions and ensure proper operation;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure that all machine functions stop when the foot-

switch is released.

3. With the platform in the stowed position:

a. Drive the machine on a grade, not to exceed the rated

gradeability, and stop to ensure the brakes hold;

b. Check that the tilt indicator is illuminated to ensure

proper operation.

4. Swing the boom over either of the rear tires and ensure that the Drive Orientation indicator illuminates and that the Drive Orientation Override switch must be used for the drive function to operate.

3121252 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test

From the Platform Console:

Test the SkyGuard feature by operating the telescope out functions and then activating the SkyGuard sensor. The telescope out function will stop and the telescope in function will operate for a short duration and the horn will sound until the SkyGuard sensor and footswitch are disengaged.

NOTE: If the machine is equipped with both SkyGuard and Soft Touch,

functions will not reverse, only stop.

NOTE: If equipped, ensure the blue beacon illuminates when SkyGuard

is activated.

Disengage the SkyGuard sensor, release controls, recycle the foot switch, make sure normal operation is available.

If SkyGuard remains activated after function reversal or cutout, depress and hold the SkyGuard Override Switch to allow normal use of machine functions until the SkyGuard sensor is disengaged.

2-6 – JLG Lift – 3121252

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Platform

2. Platform Console

3. Jib Rotator (E300AJP Only)

4. Boom Fly Section

5. Main Boom

6. Turntable

7. Counterweight

8. Non-Drive Hub

9. Battery Box

10. Drive Hub

11. Ground Console

12. Powertrack

13. Jib

14. Platform Rotator

15. SkyGuard (If Equipped)

3121252 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-8 – JLG Lift – 3121252

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.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

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

1. Platform Assembly and Gate - 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. Boom Sections/Uprights/Turntable - See Inspection Note.

4. Swing Motor and Worm Gear - No evidence of damage.

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

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

6. Drive Motor, Brake, and Hub - No evidence of leakage.

7. Hood Assemblies - See Inspection Note.

8. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

9. Turntable Bearing - Evidence of proper lubrication. No evidence of loose bolts or looseness between bearing and machine.

10. Tie Rod Ends and Steering Spindles - See Inspection Note.

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

3121252 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

11. Hydraulic Pump and Reservoir - See Inspection Note.

12. Platform Rotator - See Inspection Note.

13. Jib Rotator - See Inspection Note.

14. Battery Compartment - Batteries have proper electro-

lyte level; cables tight; see Inspection Note.

15. Counterweight - See Inspection Note.

16. Manual Descent - See Inspection Note.

17. SkyGuard - See Inspection Note.

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

2-10 – JLG Lift – 3121252

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 o perating 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.

3121252 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charge Status

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 Station

(See Figure 3-1., Figure 3-2., Figure 3-3. and Figure 3-4. )

NOTE: When machine is shut down the Platform/Ground Select switch

and Emergency Stop must be positioned to OFF.

NOTE: When Power/Emergency Stop Switch is in the on position and

motor is not running, an alarm will sound, indicating power is on.

NOTE: The Function Enable switch must be held down in

order to operate Boom Telescope, Lower Lift, Swing, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions.

Three LED lights indicate charge status of battery. Green; indicates 100% charged. Yel l o w ; indicates charger on. Red; indicates abnormal battery condition.

2. Function Enable

The enable switch must be held "DOWN" to enable all boom controls when the machine power is on.

3. Main Boom Lift

Provides raising/lowering of the main boom when positioning up or down.

4. Lower Boom Lift

Provides raising and lowering of the upright and lower booms.

5. Swing

Provides 350 degrees non-continuous turntable rotation. To activate SWING, position switch to LEFT or RIGHT.

3-2 – JLG Lift – 3121252

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001109630 B

Figure 3-1. Ground Control Station - E300AJ

1. Battery Charge Status

2. Function Enable

3. Main Boom Lift

4. Lower Boom Lift

5. Swing

6. Platform/Ground Select

7. Power/Emergency Stop

8. Telescope

9. Jib Lift

10. Not Used

11. Platform Level

12. Platform Rotate

13. Platform Overload

14. Battery Condition/Hourmeter

3121252 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-2. Ground Control Station - E300AJ with Machine Safety System Override (MSSO) (CE Only)

1. Battery Charge Status

2. Function Enable

3. Main Boom Lift

4. Lower Boom Lift

5. Swing

6. Platform/Ground Select

7. Power/Emergency Stop

8. Telescope

9. Jib Lift

10. Not Used

11. Platform Level

12. Platform Rotate

13. Platform Overload

14. Battery Condition/Hourmeter

15. Machine Safety System Override (MSSO)

3-4 – JLG Lift – 3121252

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001109655 B

1. Battery Charge Status

2. Function Enable

3. Main Lift

4. Lower Lift

5. Swing

6. Platform/Ground Select

7. Power/Emergency Stop

8. Telescope

9. Jib Lift

10. Jib Swing

11. Platform Level

12. Platform Rotate

13. Platform Overload

14. Battery Condition/Hourmeter

Figure 3-3. Ground Control Station - E300AJP

3121252 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charge Status

2. Function Enable

3. Main Lift

4. Lower Lift

5. Swing

6. Platform/Ground Select

7. Power/Emergency Stop

8. Telescope

9. Jib Lift

10. Jib Swing

11. Platform Level

12. Platform Rotate

13. Platform Overload

14. Battery Condition/Hourme ter

15. Machine Safety System Override (MSSO)

Figure 3-4. Ground Control Station - E300AJP with Machine Safety System Override (MSSO) (CE Only)

3-6 – JLG Lift – 3121252

NOTE: When the Platform/Ground Select Switch is in the center posi-

tion, 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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.

7. Power/Emergency Stop Switch

6. 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, power is shut off to platform and only ground controls are operable.

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.

8. Telescope Control

Provides extension and retraction of the boom.

3121252 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Jib Lift

Provides raising and lowering of the jib.

10. Jib Swing

Allows swinging of the jib.

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.

11. 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.

12. Platform Rotate

Provides rotation of the platform.

13. Platform Overload (If equipped)

Indicates the platform has been overloaded.

14. Battery Indicator and Hourmeter

The battery indicator displays the present charge of the batteries. The hourmeter counts the amount of machine operating time, up to 9,999.9 hours, and cannot be reset.

15. Machine Safety System Override (MSSO) (CE Only)

Provides emergency override of function controls that are locked out in the event of Load Sense System activation.

3-8 – JLG Lift – 3121252

Platform Station

SECTION 3 - MACHINE CONTROLS AND INDICATORS

(See Figure 3-5., Platform Control Console)

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. Posi-Track

When one wheel is slipping and the machine is not descending a grade, automatic traction control will provide added torque to both drive wheels. While this function is automatic, it may also be manually engaged by moving the toggle switch to the forward position. Positrac will be engaged for approximately 20 seconds.

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. Horn

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

4. 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.

3121252 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Posi-Track

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Drive Orientation Override

6. Drive/Steer

7. Telescope

8. Jib

9. SkyGuard Override

10. Jib Swing

11. Lower Boom Lift

12. SkyGuard Indicator

13. Platform Rotate

14. Function Speed

15. Main Lift/Swing

Figure 3-5. Platform Control Console

3-10 – JLG Lift – 3121252

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. 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: To operate the Drive joystick, pull up on the locking ring below

the handle.

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

to neutral (off) position when released.

6. 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.

NOTE: When boom is positioned above horizontal and Posi-Track

engaged or Function speed are positioned to high, high function speeds are automatically cut out and the machine continues to operate at a lower speed.

7. Telescope

Provides extension and retraction of the main boom.

8. Jib

Provides for raising or lowering of the jib by positioning up/ down.

9. SkyGuard Override Switch (If equipped)

The switch enables functions cut out by the Skyguard system to be operated again, allowing the operator to resume use of machine functions.

10. Jib Swing (If equipped)

Provides jib swing right or left.

11. Lower Boom Lift

Provides for raising and lowering of Upright when positioned to UP or DOWN.

3121252 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

12. SkyGuard Indicator (If Equipped)

Indicates the SkyGuard sensor has been activated. All controls are cut out until the override button is pushed. Controls will then work normally.

13. Platform Rotate

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

14. Function Speed Control

Adjusts speed of Boom and Swing Functions. Rotate counterclockwise for slower speed and clockwise for faster speed. To adjust Drive, Swing, and Main Boom Lift to creep, turn knob fully counterclockwise until it clicks.

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.

15. 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. Proportional control of these functions can be attained by using the Function Speed knob.

3-12 – JLG Lift – 3121252

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Tilt Angle Market

3° CE & Australia

5° ANSI & Japan

Platform Control Indicator Panel

(See Figure 3-6., Platform Control Indicator Panel)

NOTE: The platform control indicator panel uses different shaped sym-

bols 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.

1. Tilt Alarm Warning Light and Alarm

This red 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.

3121252 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001110226 A

1. Tilt

2. Platform Overload

3. System Distress

4. Drive Orientation

5. Posi-Track

6. Enable

7. Low Battery

8. Creep

Figure 3-6. Platform Control Indicator Panel

The four likely causes of a system fault are:

a. The seven second enable time has been allowed to

lapse or a function was selected before depressing the footswitch. The system reads this condition as a fault, just as it would if the footswitch were jammed in the depressed position or a function switch were stuck in the on position. Re-depress the footswitch to power the controls and extinguish the light.

b. The maximum power limit has been reached and the

machine is not moving. This could happen when the machine is stuck or when attempting to travel over rough terrain or on steep grades which exceed the rated gradeability of the machine. This condition is comparable to stalling the engine by asking it to provide more power than it was designed to do.

c. The batteries are nearly depleted, and should be

charged very soon to prevent having the machine stop

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. System Distress Indicator

The system distress indicator lights to signify an electrical system fault.

3-14 – JLG Lift – 3121252

4. Drive Orientation Indicator

at an inconvenient place.

d. There is some other fault in one of the circuits. Deter-

mine the cause by counting the flash code, a number of flashes followed by a pause followed by another number of flashes, and refer to the service manual.

When the boom is swung beyond the rear drive tires or fur-

ther 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).

5. Posi-Track Indicator

This indicator lights to show that posi-track is operating.

6. Enable Indicator/Footswitch

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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

7. Low Battery Indicator

Indicates the batteries are low and need to be charged.

8. 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.

3121252 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-16 – JLG Lift – 3121252

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 350 degree non-continuous. 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.

3121252 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

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 manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Machine is as originally equipped from JLG.

Stability

Machine stability is based on two (2) conditions which are called FORWARD and BACKWARD stability. The machine’s position of least FORWARD stability is shown in Figure 4-1., and its position of least BACKWARD stability is shown in Figure 4-2. and Figure 4-

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

4-2 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

LOWER BOOM

FULLY ELEVATED

MAIN BOOM HORIZONTAL

MAIN BOOM

FULLY EXTENDED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

3121252 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability - E300AJ

LOWER BOOM

FULLY ELEVATED

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

4-4 – JLG Lift – 3121252

Figure 4-3. Position of Least Backward Stability - E300AJP

LOWER BOOM

FULLY ELEVATED

PLATFORM ROTATED

90 DEGREES

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

SECTION 4 - MACHINE OPERATION

3121252 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

4.3 MOTOR OPERATION

Power/Emergency Stop Switch

This red, mushroom-shaped switch provides battery power to the Platform/Ground Select switch, when pulled out (on), for all machine functions. The switch should be pushed in (off) when recharging the batteries or parking the machine overnight.

Platform/Ground Select Switch

The Platform/Ground Select switch functions to direct battery power to the desired control station when the POWER/EMERGENCY STOP switch is pulled out (on). With the switch in the GROUND position, battery power is supplied to the ground control station. When the switch is in the PLATFORM position, battery power is supplied to the platform control station.

The key is removable in the platform position on CE machines. The key must be available to ground personnel in the event of an emergency.

Motor Activation

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION, OTHERWISE FUNCTION WILL NOT OPERATE.

The motor becomes activated and operates the desired function when the Emergency Stop switch is pulled out (on), the Platform/ Ground select switch is in the appropriate position and the Footswitch is depressed.

IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT THE CAUSE BEFORE RESUMING ANY OPERATION.

ALWAYS POSITION EMERGENCY STOP SWITCH TO THE ‘OFF’ POSITION (PUSHED IN) WHEN MACHINE IS NOT IN USE.

4-6 – JLG Lift – 3121252

4.4 TRAVELING (DRIVING)

See Figure 4-4., Grade and Side Slopes

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.

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

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.

MATCH THE BLACK AND WHITE DIRECTION ARROWS ON BOTH PLATFORM CONTROL PANEL AND THE CHASSIS TO DETERMINE THE DIRECTION THE MACHINE WILL TRAVEL.

SECTION 4 - MACHINE OPERATION

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.

3121252 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

GRADE

LEVEL

SIDE SLOPE

Figure 4-4. Grade and Side Slopes

4-8 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

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:

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 manually Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the desired platform position is obtained.

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.

3121252 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.7 BOOM

A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL OR DRIVING WITH THE BOOM ELEVATED.

TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM.

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON SERIAL NAMEPLATE ON THE FRAME.

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 SWITCH TO STOP THE MACHINE.

4-10 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

Swinging the Boom

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

Raising and Lowering the Upper Boom

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

4.8 FUNCTION SPEED CONTROL

This control affects the speed of boom functions and platform rotate Lift, Telescope, and Swing. When in the fully counterclockwise position, Drive is placed in creep speed.

3121252 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

The Machine Safety System Override (MSSO) is used to override function controls for Emergency Platform Retrieval only. Refer to Section 5.7, Machine Safety System Override (MSSO)(CE Only)for operating procedures.

4.10 SKYGUARD OPERATION

Skyguard is used to provide enhanced control panel protection. When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table below outlines these functions.

Table 4-1. Skyguard Function Table

Main

Tel e

Swing

Lift

RC/R*RRIRR C C C C C

R = Indicates Reversal is Activated

C = Indicates Cutout is Activated

I = Input is Ignored

Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.

* Reversal only applies to Main Tele Out. Main Tele In would be cut out

Drive

Forwa rd

Drive

Reverse

Platform

Level

Platform

Rotate

Jib

Lift

Jib

Rotate

Tel e

Jib

4-12 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

4.11 SHUT DOWN AND PARK

NOTE: When parking battery powered units overnight, batteries should

be charged in accordance with instructions in Section 6 to ensure readiness for following workday.

NOTE: Electric machines are equipped with a static strap due to static

electricity build-ups. Strap is located under rear of machine chassis.

The procedures to shut down and park the machine are as follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Shut down Emergency Stop at Platform Controls.

4. Shut down Emergency Stop at Ground Controls. Position

Platform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instruction placards, warning decals, and operating controls from hostile environment.

4.12 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.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to the

machine and so the machine remains level.

3121252 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Tie Down

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

1. Place the boom in the stowed position.

2. Remove all loose items from the machine.

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

adequate strength.

4-14 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

41.4”/1.04m

44.0”/1.11m

E300AJ/AJP

1001112461B

A B

Figure 4-5. Lifting and Tie Down Chart

3121252 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

BOTH

SIDES

BOTH

SIDES

BOTH

SIDES

HYD TANK VIEW

INSIDE HOOD

14199

Figure 4-6. Decal Location Sheet 1 of 5

4-16 – JLG Lift – 3121252

452931

Figure 4-7. Decal Location Sheet 2 of 5

SECTION 4 - MACHINE OPERATION

3121252 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Location Sheet 3 of 5

4-18 – JLG Lift – 3121252

SEE DETAIL A

DETAIL A

3482029

Figure 4-9. Decal Location Sheet 4 of 5

SECTION 4 - MACHINE OPERATION

3121252 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

BOTH SIDES

LOCATE ON SIDE

OF CONTROL BOX.

Figure 4-10. Decal Location Sheet 5 of 5

4-20 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001109493-B

1- -- -- -- -- -- -- -- -

2- -- -- -- -- -- -- -- -

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

6 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

7 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

8 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

9 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642

11 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644

12 1701645 1705978 1707059 1707058 1707056 1707055 1707060 1707134

13 1702155 1702155 1702155 1702155 1702155 1702155 1702155 1702155

14 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

15 1702391 1701517 1001113166 1001113509 1001113171 1001113169 1001113168 1001113170

16 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

17- -- -- -- -- -- -- -- -

18- -- -- -- -- -- -- -- -

19- -- -- -- -- -- -- -- -

CE/Australia

1001110824-C

Japan

1001110825-B

Korea

1001110827-B

Spanish

1001110828-B

French

1001110829-C

Chinese

1001110830-B

Port uguese

1001110831-B

3121252 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001109493-B

20 1702868 - - - - 1705969 1704001 1704000 1705968 1704002

21 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

22 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934

23 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

24 1703805 1705961 1703938 1703939 1703935 1703936 1703937 1703940

25 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

26- -- -- -- -- -- -- -- -

27 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

28 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

29- -- -- -- -- -- -- -- -

30 1706126 1706126 1706126 1706126 1706126 1706126 1706126 1706126

31- -- -- -- -- -- -- -- -

32 1707013 - - 1707054 1707042 1707049 1707047 1707044 1707133

33 3251243 - - - - - - - - 3251243 3251243 - -

34 3251813 - - 3251813 - - 3251813 3251813 3251813 3251813

35- -- -- -- -- -- -- -- -

36- -- -- -- -- -- -- -- -

37- -- -- -- -- -- -- -- -

38 1001110196 1001110196 1001110196 1001110196 1001110196 1001110196 1001110196 1001110196

39 1001110276 - - 1001110276 1001110276 1001110276 1001110276 1001110276 1001110276

CE/Australia

1001110824-C

Japan

1001110825-B

Korea

1001110827-B

Spanish

1001110828-B

French

1001110829-C

Chinese

1001110830-B

Port uguese

1001110831-B

4-22 – JLG Lift – 3121252

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001109493-B

40 1001110389 - - 1001110389 1001110389 1001110389 1001110389 1001110389 1001110389

41 1001112461 1001112461 1001112461 1001112461 1001112461 1001112461 1001112461 1001112461

42 1001112777 1001112777 1001112777 1001112777 1001112777 1001112777 1001112777 1001112777

43 1705351 - - 1705426 1705427 1705910 1705429 1705430 1001113680

44 - - 1705828 1703980 1703981 1703983 1703984 1703982 1703985

45- -- -- -- -- -1705514- -- -

46- -- -- -- -- -- -- -- -

CE/Australia

1001110824-C

Japan

1001110825-B

Korea

1001110827-B

Spanish

1001110828-B

French

1001110829-C

Chinese

1001110830-B

Port uguese

1001110831-B

3121252 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

NOTES:

4-24 – JLG Lift – 3121252

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) (8am till 4:45pm EST)

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 INCIDENT, 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 stabilize motion of the machine.

3121252 – 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.

5.4 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited. However, provisions for moving the machine have been incorporated. The following procedures are to be used ONLY for emergency movement to a suitable maintenance area.

THE ALLOWABLE TOWING SPEED IS 1.9 MPH (3 KPH). THE MAXIMUM ALLOWABLE TOWING DISTANCE IS 0.6 MILES (1 KM).

1. Chock wheels securely.

2. Engage the mechanical release on both drive hubs by loos-

ening, completely reversing, and tightening the two bolts on each hub.

3. Connect suitable equipment, remove chocks, and move machine.

After moving machine, complete the following procedure:

1. Position machine on a firm level surface.

2. Chock wheels securely.

3. Disengage the mechanical release on both drive hubs by

loosening, completely reversing, and tightening the two bolts on each hub.

4. Remove chocks from wheels as desired.

5.5 MANUAL DESCENT SYSTEM

(See Figure 5-1., Manual Descent Location)

The manual descent system is used, in the event of total power failure or in case the key is not accessible to the ground personnel, to lower the upper and lower booms using gravity. The jib lift cylinder must be pumped down. To operate the manual descent system, proceed as follows:

1. Locate the manual descent knob on the boom function valve. Push the knob in to lower the tower and pull the knob out to lower the main boom. The knob must be held in place to perform the lowering function; it is spring loaded to return to center when released. Install handle into manual descent pump and lower the selected cylinders by pumping the handle until the boom is completely lowered.

2. If equipped with a jib, locate the split ring on the boom function valve. Push the split ring in to lower the jib or pull the split ring out to raise the jib by pumping the handle until it is completely lowered or raised. Stow the handle in bracket provided.

5-2 – JLG Lift – 3121252

Figure 5-1. Manual Descent Location

SPLIT RING

MANUAL DESCENT KNOB

SECTION 5 - EMERGENCY PROCEDURES

3121252 – JLG Lift – 5-3

SECTION 5 - EMERGENCY PROCEDURES

5.6 MANUAL SWING OVERRIDE

The manual swing override is used to manually swing the boom and turntable assembly in the event of a total power failure when the platform is positioned over a structure or obstacle. To operate the manual swing override, proceed as follows:

1. Using a 7/8 inch socket and ratchet wrench, locate nut on swing worm gear on left side of machine.

2. Install wrench on nut and ratchet in the direction desired.

5.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

The Machine Safety System Override (MSSO) is only to be used to retrieve an operator that is pinned, trapped, or unable to operate the machine and function controls are locked out from the platform due to a platform overload situation.

NOTE: If the MSSO functionality is used, the fault indicator will flash

and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician.

NOTE: No functional checks of the MSSO system are necessary. The JLG

Control system will set a Diagnostic Trouble Code if the control switch is faulty.

To operate the MSSO:

1. From the ground control console, place the Platform/ Ground Select switch in the Ground position.

2. Pull out the Power/Emergency Stop control.

3. Start the engine.

4. Press and hold the MSSO switch and the control switch for

the desired function.

5-4 – JLG Lift – 3121252

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 .............................................3121253

Illustrated Parts Manual ................................................................3121254

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Operating Specifications

Table 6-1. Operating specifications - E300AJ

Capacity: Unrestricted: ANSI 500 lbs. (227 kg)

Capacity: Unrestricted: CE & Australia 500 lbs. (230 kg)

Maximum Travel Grade, stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, stowed Position (Side Slope) see Figure 4-3.

Drive Speed (High Drive) - 200 ft. (60.9 M) 45-50 sec

Drive Speed( Above Horz.) - 50 ft. (15.24 M) 55-68 sec (

Gross Machine Weight - Approximate 15060 lbs. (6831 kg)

Ground Bearing Pressure - Maximum

Maximum System Voltage 48V DC

170 psi (11.95 kg/cm

25%

0.6 mph[0.9 kph])

5°

)

3121252 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating specifications - E300AJ

Maximum Main Relief Hyd. Pressure 3000 psi (207 bar)

Table 6-2. Operating specifications - E300AJP

Capacity: Unrestricted: ANSI 500 lbs. (227 kg)

Capacity: Unrestricted: CE & Australia 500 lbs. (230 kg)

Maximum Travel Grade, stowed Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, stowed Position (Side Slope) see Figure 4-3.

Drive Speed (High Drive) - 200ft. (60.9 m) 45-50 sec (

Drive Speed( Above Horz.) - 50 ft. (15.24 M) 55-68 sec (

Gross Machine Weight- Approximate 15400 lbs. (6985 kg)

Ground Bearing Pressure - Maximum

Maximum System Voltage 48V DC

Maximum Main Relief Hyd. Pressure 3000 psi (207 bar)

170 psi (11.95 kg/cm

25%

5°

3 mph [4.8 kph])

0.6 mph[0.9 kph])

Dimensional Data

Turning Radius (Inside) 5 ft. (1.52 m)

Turning Radius (O utside) 10ft. 2in. (3.1 m)

Machine Height (stowed) 6ft. 7in. (2.01 m)

Machine Length (stowed) 18ft. 2in. (5.54 m)

Up and Over Platform Height 13ft. 2in. (4.01 m)

Horizontal Reach Up and Over 20ft. 3in. (6.17 m)

Machine Width 4ft. (1.22 m)

Wheel Base 5ft. 5in. (1.65 m)

Platform Height 30ft. 2in. (9.19m)

)

Ground Clearance 4in. (10 cm)

Table 6-3. Dimensional Data - E300AJ

6-2 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-4. Dimensional Data - E300AJP

Turning Radius (Inside) 5 ft. (1.52 m)

Turning Radius (Outside) 10ft. 2in. (3.1 m)

Machine Height (stowed) 6ft. 7in. (2.01 m)

Machine Length (stowed) 18ft. 10in. (5.74 m)

Up and Over Platform Height 13ft. 2in. (4.01 m)

Horizontal Reach Up and Over 20ft. 1in. (6.12 m)

Machine Width 4ft. (1.22 m)

Wheel Base 5ft. 5in. (1.65 m)

Platform Height 29ft. 5in. (8.97 m)

Ground Clearance 4in. (10 cm)

Capacities

Table 6-5. Capacities

Hydraulic Oil Tank 2.9 Gal. (11 L)

2. 1 Ga l . ( 8 L) t o F u ll M ar k

Drive Hub*

25.5 oz. (0.75 L)(1/2 Full)

*Drive hubs should be one half full of lubricant.

Tires

Table 6-6. Tires

Size 25x7x12

Maximum Tire Load 8200 lbs. (3719 kg)

Type Solid Non-Marking

3121252 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-7. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F

(-18° to +83° C)

10W

+0° to + 210° F

(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Hydraulic Oil

NOTE: Hydraulic oils require anti-wear qualities at least API Service

Classification GL-3, and sufficient chemical stability for mobile hydraulic system service.

NOTE: Machines may be equipped with Mobil EAL224H biodegradable

and non-toxic hydraulic oil. This is vegetable oil based and possesses the same antiwear and rust protection characteristics as mineral oils, but will not adversely affect the ground water or the environment when spilled or leaked in small amounts. Mobil EAL224H has a viscosity of 34 cSt at 40° C. and viscosity index of

213. The operating temperature range of this oil is -18° C. to +83° C.

6-4 – JLG Lift – 3121252

NOTE: Aside from JLG recommendations, it is not advisable to mix oils

of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 11M is desired, contact JLG Industries for proper recommendations.

Table 6-8. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Visc osity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-9. DTE 10 Excel 15 Specs

ISO Viscosity Grade #15

Pour Point, Max -65°F (-54°C)

Flash Point, Min. 360°F (182°C)

Viscosity

at 40° C 15.8 cSt

at 100° C 4.1cSt

at 100° F 15.8 cSt

at 210° F 4.1 cSt

Viscos ity I ndex 168

Table 6-10. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscos ity I ndex 152

3121252 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-11. Mobil EAL 224H Specs

Typ e

Biodegradable Vegetable

Oil

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max -25°F (-32°C)

Flash Point, Min. 428°F (220°C)

Operating Temp. 0 to 180°F (-17 to 162°C)

Weight 7.64 lb. per gal.

(0.9 kg per liter)

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscos ity I ndex 213

NOTE: Must be stored above 32°F (0°C)

Table 6-12. Mobil EAL Envirosyn H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32

Specific Gravity .950

Pour Point, Max -59°F (-51°C)

Flash Point, Min. 514°F (268°C)

Viscosity

at 40° C 33.1 cSt

at 100° C 6.36 cSt

Viscos ity I ndex 147

6-6 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-13. Quintolubric 888-46

Density

0.91 @ 15°C (59°F)

Pour Point

<-20°C (<-4°F)

Flash Point

275°C (527°F)

Fire Point

325°C (617°F)

Autoignition Temperature

450°C (842°F)

Visc osity

at 0° C (32°F) 360 cSt

at 20° C (68°F) 102 cSt

at 40° C (104°F) 46 cSt

at 100° C (212°F) 10 cSt

Viscosity Index 220

Major Component Weights

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

Counte rweig ht (AJ) 6188 2807

Counte rweig ht (AJP ) 6348 2880

Tire and Wheel 120 54.4

Platform (including console) 169 78

Battery (minimum each) - 305AH 87 39.5

Battery (minimum each) - 375AH & UL 110 50

Table 6-14. Critical Stability Weights

Components LBS. KG .

3121252 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3,4

Figure 6-1. Operator Maintenance and Lubrication Diagram

6-8 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-15. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350 degrees F.

Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classific ation GL-5 or

Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.

6.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-1., Oper-

ator Maintenance and Lubrication Diagram.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.

3121252 – JLG Lift – 6-9

1. Swing Bearing

Lube Point(s) - Remote Fitting Capacity - A/R Lube - BG Interval - Every 3 months or 150 hrs of operation Comments - Apply grease and rotate in 90 degree intervals until bearing is completely lubricated

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - Grease Fitting Capacity - A/R Lube - BG Interval - A/R

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING.

Lube Point(s) - Grease Fitting Capacity - A/R Lube - Mobile SHC 007 Interval - A/R

6-10 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3. Hydraulic Tank

Lube Point(s) - Fill Cap Capacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full Mark Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir.

4. Hydraulic Return Filter

Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - Under certain conditions, it may be necessary to replace the hydraulic filter on a more frequent basis.

3121252 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

OIL LEVEL CHECK AND FILL

5. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug Capacity - 25.5 oz. (0.75 L)(1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation

6. Wheel Bearings

Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation

6-12 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.4 BATTERY MAINTENANCE AND CHARGING

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS WEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.

Battery Maintenance, Quarterly

1. Open battery compartment cover to allow access to battery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries, non-metallic contain-

ers and/or funnels must be used.

To avoid electrolyte overflow, add distilled water to batteries after charging.

When adding water to the battery, fill only to level indicated or 3/ 8" (9.5 mm) above separators.

2. Remove all vent caps and inspect electrolyte level of each cell. Electrolyte level should be to the ring approximately one inch from top of battery. Fill batteries with distilled water only. Replace and secure all vent caps.

3. Remove battery cables from each battery post one at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or ammonia) and wire brush. Replace cables and/or cable clamp bolts as required.

4. Clean battery post with wire brush then re-connect cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly.

5. When all cables and terminal posts have been cleaned, ensure all cables are properly positioned and do not get pinched. Close battery compartment cover.

6. Start hydraulic system and ensure that it functions properly.

3121252 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Battery Charging, Daily

NOTE: To avoid excessive battery charging time, do not allow batteries

to become completely discharged.

To avoid electrolyte overflow, add distilled water to batteries after charging.

When adding water to the battery, fill only to level indicated or 3/ 8" above separators.

1. Charge batteries at the end of each work day, or when machine performance is significantly reduced due to batteries becoming discharged.

2. Charge batteries in accordance with the following procedure:

a. Open battery compartment, and battery charger com-

partment covers.

WHEN BATTERY CHARGER IS TO BE USED, CHARGING HARNESS MUST BE PLUGGED INTO A GROUNDED RECEPTACLE. IF RECEPTACLE IS NOT GROUNDED AND A MALFUNCTION SHOULD OCCUR, THE MACHINE COULD CAUSE SERIOUS ELECTRICAL SHOCK.

b. Remove charging harness cable and connect to a

receptacle or the correct voltage.

c. Allow batteries to charge until 100% LED is illuminated.

NOTE: When batteries are completely charged, disconnect charging

harness cable from receptacle. Store charging harness cable.

d. Ensure battery cables are properly positioned and are

not pinched. Close and secure all compartment doors.

6-14 – JLG Lift – 3121252

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.5 TIRES & WHEELS

Tire Replacement

JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the original

• Approved for the application by the tire manufacturer (including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

Wheel and Tire Replacement

The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.

Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.

Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer tighten the lug nuts to the proper torque. Over-tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels. The proper procedure for attaching wheels is as follows:

3121252 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence.

3. The tightening of the nuts should be done in stages. Follow-

ing the recommended sequence, tighten nuts per wheel torque.

Table 6-16. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check the torque after the first 10 miles, 25 miles, and again at 50 miles. Check periodically thereafter.

6.6 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines.

For electric powered machines, the equivalent continuous AWeighted sound pressure level at the work platform is less than 70dB(A)

For combustion engine powered machines, guaranteed Sound Power Level (LWA) per European Directive 2000/14/EC (Noise Emission in the Environment by Equipment for Use Outdoors) based on test methods in accordance with Annex III, Part B, Method 1 and 0 of the directive, is 104 dB.

The vibration total value to which the hand-arm system is sub-

jected does not exceed 2,5 m/s value of weighted acceleration to which the whole body is sub-

jected does not exceed 0,5 m/s

. The highest root mean square

6-16 – JLG Lift – 3121252

SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 7-1. Inspection and Repair Log

Date Comments

SECTION 7 - INSPECTION AND REPAIR LOG

3121252 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Date Comments

Table 7-1. Inspection and Repair Log

7-2 – JLG Lift – 3121252

TRANSFER OF OWNERSHIP

To Pr oduc t O wner:

If you now own but ARE NOT the original purchaser of the product covered by this manual,

we would like to know who you are. For the purpose of receiving safety-related bulletins, it is

very important to keep JLG Industries, Inc. updated with the current ownership of all JLG

products. JLG maintains owner information for each JLG product and uses this information in

cases where owner notification is necessary.

Please use this form to provide JLG with updated information with regard to the current

ownership of JLG products. Please return completed form to the JLG Product Safety &

Reliability Department via facsimile or mail to address as specified below.

Thank You,

Product Safety & Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

Telephone: +1-717-485-6591

Fax: +1-301-745-3713

NOTE: Leased or rented units should not be included on this form.

Mfg. Model: _______________

_______________________________________________________

Serial Number: ____________________________________________________________________

Previous Owner: __________________________________________________________________

Address: _________________________________________________________________________

_________________________________________________________________________________

Country: _____________________________ Telephone: (_______

) ________________________

Date of Transfer: ______________________________________

Current Owner: ___________________________________________________________________

Address: __________________

_______________________________________________________

_________________________________________________________________________________

Country: _____________________________ Telephone: (_______

) ________________________

Who in your organization should we notify?

Name: ___________________________________________________________________________

Title:____________________________________________________________________

An Oshkosh Corporation Company

JLG E300AJ, E300AJP Operation And Safety 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

Function Check

SkyGuard Function Test

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Platform Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 MOTOR OPERATION

Power/Emergency Stop Switch

Platform/Ground Select Switch

Motor Activation

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 Upper Boom

4.8 FUNCTION SPEED CONTROL

4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

4.10 SKYGUARD OPERATION

4.11 SHUT DOWN AND PARK

4.12 LIFTING AND TIE DOWN

Lifting

Tie Down

5.1 GENERAL

SECTION 5. EMERGENCY PROCEDURES

5.2 INCIDENT NOTIFICATION

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

Platform or Boom Caught Overhead

5.4 EMERGENCY TOWING PROCEDURES

5.5 MANUAL DESCENT SYSTEM

5.6 MANUAL SWING OVERRIDE

5.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Operating Specifications

Dimensional Data

Capacities

Tires

Hydraulic Oil

Major Component Weights

6.3 OPERATOR MAINTENANCE