JLG E45A-AJ Operator Manual

CORPORATE OFFICE

BS E N ISO 9001 C ertificate N o.6917

JLG INDUSTRIES, INC. 1 JLG Drive McConnellsburg, PA 17233-9533 USA Telephone: (717) 485-5161 Fax: (717) 485-6417

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE) Kilmartin Place, Tannochside Park, Uddingston, Scotland, G71 5PH Telephone: 01698 811005 Fax: 01698 811055

AUSTRALIAN OFFICE

JLG INDUSTRIES (AUSTRALIA) P.0. Bo x 9 7 2 11 Bolwarra Road Port MacQuarie N.S.W. 44 Australia Telephone: 1 (065) 811111 Fax: 1 (065) 81 012 2

Models M45A M45AJ E45A E45AJ

Issued: April 1, 1999 PRINTED IN U.S.A. 3120883 Updated: March 15, 2000

OPERATORS & SAFETY

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ON LY AS SAFE AS THE OPERATOR.

BECAUSE THE MANUFACTURER HAS NO DI RECT CONTROL OVER MACHINE APPLICATION AND OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER OPERATING CONDITI ONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM JLG INDUSTRIES, PER OSHA REGUL ATIONS AND APPLICABLE ANSI STANDARDS.

THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper u se of the mac hine are of pr imary conc ern, DANGER, WARNIN G, CAUTION, IMPORTANT, INST RUCTIONS an d NOTE are inserted thr oughout this manual to e mphasize these

areas. They are defined as follows :

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH.]

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES

JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC. OR THE LOCAL AUTHOR IZED JLG DISTRIBUTO R FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED, MAY RESULT IN A MALFUNCTION OR DAMAG E TO THE MACHINE.

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.

3120883 – JLG Lift – a

FOREWORD

This page left blank intentionally.

b – JLG Lift – 3120883

FOREWORD

All procedures herein are based on the use of the machine under proper operating conditions, with no deviation s fr om or igin al desi gn i nte nt. .. as p er OSHA regulations.

READ & HEED!

The ownership, use, service, and/or maintenance of this machine is subject to various governmental and local laws and regu la tio ns. It is th e re sp ons ibil it y of the owner/user to be knowledgeable of these laws and regulations and to comply with them. The most prevalent regulations of this type in the United States are the Federal OSHA Safety Regulation s*. Listed below, in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the date of publication of this handbook.

The listing of these requirements shall not relieve the owner/user of the responsibility and obligation to determine all applicable laws and regulations and their exact wording and re quirements, and t o comply with the requirements. Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of JLG Industries, Inc.

1. Only trained and authoriz ed operat ors shall be permitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until repaired.

3. The controls shall be plainly marked as to their function.

4. The controls shall be tested each day prior to use to determ in e that they are in safe operat in g condition.

5. All personnel in the platform shall, at all times, wear approved fall protection devices and other safety gear as required.

6. Load limits specified by the manufacturer shall not be exceeded.

7. Instruction and warning placards must be legible.

8. Aerial lifts may be field modified for uses other than those in te nd ed by the manufa cturer only if certified in writ ing by the m anufac turer to be i n conformity to JLG requirements and to be at least as safe as it was prior to modification.

9. Aerial lifts shall not be used near electric power lines unless the lines have been de energized or adequate clearance is maintained.

10. Employees using aeri al lifts shall be instructed on how to rec ognize and avoid un safe conditions and hazards.

11. Ground controls shall not be operated unless permission has be en obtained fro m personnel in the platform, except in case of an emergency.

12. Regular inspection of the job site and aerial lift shall be performed by competen t persons.

13. Person n el sha ll always stand on the floor of the platform, not on b oxes, planks, railing or oth er devices, for a work position.

*Applicable Federal OSHA regulations for the United States, as of the date of publicat ion of this manual, include, but are not limited to, 29 CFR

1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR

1926.28, and 29 CFR 1926.453.

3120883 – JLG Lift – c

FOREWORD

REVISON LOG

April 1, 1999 - Original Issue 3-9 - Updated 5-7-99 3-9 - Updated 5-12-99 2-5 - Updated 5-21-99 4-3 - Updated 5-21-99 2-10 & 2-11 - Updated 6-1-99 3-10 thru 3-12 - Updated 6-1-99 6-1 - Updated 6-1-99 3-7 - Updated 7-13-99 3-13 - Updated 7-13-99 2-11 - Updated 8-4-99 4-1 - Updated 8-4-99 4-5 thru 4-7 - Updated 8-4-99 3-5 thru 3-8 - Updated 8-18-99 4-7 - Updated 9-21-99 2-9 - Updated 11-3-99 2-11 - Updated 11-3-99 5-1 - Updated 11-3-99 6-1 - Updated 12-1-99 4-1 - Updated 3-15-00 4-8 - Updated 3-15-00

d – JLG Lift – 3120883

TABLE OF CONTENTS

TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION - FOREWORD

SECTION 1 - SAFE TY PRECAUTIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 Pre-Operational. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

SECTION 2 - PREPAR ATI ON AND INSPECTION

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2.7 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

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

3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 Controls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

SECTION 4 - MACHINE OPERATION

4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.4 Traveling (Driving). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.6 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.7 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.8 Generator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9 Machine Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.10 Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.11 Machine Lifting and Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.12 Boom Synchronizing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SECTION 5 - OPTIONAL EQUIPMENT

5.1 Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Foam Filled Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 Non-marking Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.4 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.5 Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.6 Wheel Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.7 Battery Packs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.8 Platform Light s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.9 Control Console Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.10 Cylinder Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.11 Work Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

3120883 – JLG Lift – i

TABLE OF CONTENTS

(Continued)

TABLE OF CONTENTS (continued) SUBJECT - SECTION, PARAGRAPH PAGE NO. SECTION 6 - EMERGENCY PROCEDURES

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Emergency Cont rols and Their Locat ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 Emergency Ope ra t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPEC TION AND REPAIR LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Basic Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

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

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

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

3-4. Platform Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-5. Caution, Danger, Warning Decal Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-6. Control Panel Symbols (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-7. Control Panel Symbols (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

4-1. Grade and Side Sl opes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-2. Upright Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Chassis & Platform Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 M inimum Safe Approach Dis t anc e s (M .S.A.D.) to energi ze d (exposed or insulated)

power lines and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

3-1 Simultaneous Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

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

ii – JLG Lift – 3120883

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section prescribes the prope r and safe practices for major areas of machine usage. In order to promote proper usage of the machine, it is mandatory that a daily routine be establish ed based on instructions given in thi s s e ction. A maintenance pr ogram must also be establishe d by a qualified person and must be follow ed to ensure that the machine is safe to operate.

The owner/user/operator of the machine should not accept operating responsibility until this manual has been read and understood, and operation of the machine, under the supervisio n of an exper ienced and qualif ied person, has been completed. If there is a question on application and/or op eration, JLG Industri es Inc., sho uld be consulted.

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

1.2 DRIVING/TOWING

Before driving the machine, the user must be familiar with the drive, steer and stopping characteristics. This is especially important when driving in close quarters.

The user should be familiar with the driving surface before driving. The surface s hould be firm and level and grade s should not exceed the allowable grade for the machine.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

The machine is not equipped with provisions for towing. Refer to Section 6 for emergency towing procedures.

SPECIAL NOTE:

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION AND ON THE MACHINE COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH, AND IS A SAFETY VIOLATION.

3120883 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

Table 1-1. Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V to 50 KV 3

Over 50KV to 200 KV 5 Over 200 KV to 350 KV 6 Over 350 KV to 500 KV 8 Over 500 KV to 750 KV 11

Over 750 KV to 1000 KV 14

DANGER: DO NOT maneuver machine or personnel inside PROHIBITED ZONE. ASSUME all electrical parts and wiring are ENERGIZED unless known otherwise.

1.3 ELECTROCUTION HAZARD

MINIMUM SAFE APPROACH DISTANCE

in Meters

FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.

• MAINTAIN A CLEARANCE OF AT LEAST 3 M (10 FEET) BETWEEN ANY PART OF THE MACHINE OR ITS LOAD AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. 30.5 cm ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30,000 VOLT S OR LESS.

1.4 PRE-OPERATIONAL

• R EAD YOUR MANUAL. UNDERSTAND WHAT YOU’VE READ - THEN BEGIN OPERATIONS.

• MAINTAIN SAFE CLEARANCE FROM ELECTRICAL LINES AND APPARATUS. ALLOW FOR BOOM SWAY, ROCK OR SAG AND ELECTRICAL LINE SWAYING. THE MACHINE DOES NOT PROVIDE PROTECTION

• ALLOW ONLY AUTHORIZED AND QUALIFIED PERSONNEL TO OPERATE MACHINE W HO HAVE DEMONSTRATED THAT THEY UNDERSTAND SAFE AND PROPER OPERATION AND MAINTENANCE OF THE UNIT.

1-2 – JLG Lift – 3120883

SECTION 1 - SAFETY PRECAUTIONS

• AN OPERATOR MUST NOT ACCEPT OPERATING RESPONSIBILITIES UNTIL ADEQUA TE TRAINING HAS BEEN GIVEN BY COMPETENT AND AUTHORIZED PERSONS.

• BEFORE OPERATION, CHECK WORK AREA FOR OVERHEAD ELECTRIC LINES, MACHINE TRAFFIC SUCH AS BRIDGE CRANES , HIGH W AY, RAILWAY AND CONSTRUCTION EQUIPMENT.

• NEVER DISABLE OR MODIFY THE FOOTSWITCH OR ANY OTHER SAFETY DEVICE. UNAUTHORIZED MODIFICATION OF THE MACHINE IS A SAFETY VIOLATION.

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN THE WORK AREA MUST BE TAKEN BY THE OPERATOR AND HIS SUPERVISOR BEFORE STARTING THE WORK.

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS BEEN SERVICED AND MAINTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE.

• ENSURE DAILY INSPECTION AND FUNC TION CHEC K IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION.

• DO NOT OPERATE MACHINE WHEN WIND CONDITIONS EXCEED 12.5 M/S (30MPH).

• NEVER OPERATE BOOM FUNCTIONS (TELE, SWING, LIFT) WHEN MACHINE IS ON A TRUCK, OTHER VEHICLE, OR ABOVE GROUND STRUCTURE.

• THIS MACHINE CAN BE OPERATED IN NOMINAL AMBIENT TEMPERATURES OF -20° C TO 40° C (0° F TO 104°F). CONSULT FACTORY TO OPTIMIZE OPERATION OUTSIDE THIS RANGE.

• APPROVED HEAD GEAR MUST BE WORN BY ALL OPERATING AND GROUND PERSONNEL.

3120883 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• R EAD AND OBEY ALL DANGERS, WARNINGS, CAUTIONS AND OPERATING INSTRUCTIONS ON MACHINE AND IN THIS MANUAL.

• BE FAMILIAR WITH LOCATION AND OPERATION OF GROUND STATION CONTROLS.

• ALWAYS POSITION BOOM OVER REAR (DRIVE) AXLE IN LINE WITH DIRECTION OF TRAVEL. REMEMBER, IF BOOM IS OVER FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPOSITE FROM NORMAL OPERATION.

• ALWAYS USE THREE POINT CONTACT WHEN ENTERING OR EXITING THE MAC HINE. FACE THE MACHINE WHEN YOU ENTER OR LEAVE. THREE POINT CONTACT MEANS THAT TWO HANDS AND ONE FOOT OR O NE HAND AN D TWO F EET ARE IN CONTACT WITH THE MACHINE AT ALL TIMES DURING MOUNT AND DISMOUNT.

1.5 DRIVING

• WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING.

• DO NOT USE DRIVE FUNCTION TO POSITION PLATFORM CLOSE TO OBSTACLES. USE BOOM FUNCTION INSTEAD.

• WHEN DRIVING IN HIGH SPEED, SWITCH TO LOW SPEED BEFORE STOPPING. TRAVEL GRADES IN LOW DRIVE, HIGH ENGINE ONLY.

• DO NOT USE HIGH SPEED DRIVE WHEN IN RESTRICTED OR CLOSE QUARTERS, OR WHEN DRIVING IN REVERSE.

• BE AWARE OF STOPPING DISTANCES WHEN TR AVELING IN HIGH AND LOW SPEEDS.

• ALWAYS POST A LOOKOUT AND SOUND HORN WHEN DRIVING IN AREAS WHERE VISION IS OBSTRUCTED.

• KEEP NON-OPERATING PERSONNEL AT LEAST 2 M (6 FEET) AWAY FROM MACHINE DURING DRIVING OPERATIONS.

1-4 – JLG Lift – 3120883

SECTION 1 - SAFETY PRECAUTIONS

1.6 OPERATION.

• R EAD YOUR MANUAL. UNDERSTAND WHAT YOU’VE READ - THEN BEGIN OPERATIONS.

• CHECK TRAVEL PATH FOR PERSONS, HOLES, BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS, AND COVERINGS WHICH MAY CONCEAL HOLES AND OTHER HAZARDS.

• TRAVEL IS PERMITTED ON GRADES NO GREATER THAN THOSE INDICATED ON THE SERIAL NUMBER PLATE.

• DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5°.

• DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES, AS TIPPING WILL OCCUR.

• DO NOT DRIVE MACHINE NEAR PITS, LOADING DOCKS OR OTHER DROP-OFFS.

• PRIOR TO ENTERING AND EXITING PLATFORM AT GROUND LEVEL, FULLY LOWER THE BOOM. EXTEND BOOM UNTIL END OF FLY B OOM CONTACTS GROUND. WITH BOOM LIFT IN THIS CONFIGURATION, ENTER AND/OR EXIT PLATFORM THROUGH GATE OPENING.

• JLG RECOMMENDS ALL PERSONS IN THE PLATFORM TO WEA R LANYARDS WITH AN APPR OVED FALL PROTECTION DEVICE. SECURE LANYARD TO DES IG NAT ED LA NYA RD AT TAC H P OI NT ON P LATFORM. KEEP GATE CLOSED AT ALL TIMES.

• TO AVOID FALLING - USE EXTREME CAUTION WHEN ENTERING OR LEAVING PLATFORM ABOVE GROUND. ENTER OR EXIT THRU GATE ONLY. PLATFORM FLOOR MUST BE WITHIN 30CM (1 FOOT) OF ADJACENT - SA FE AND SECURE - S TRUCTURE. ALLOW FOR PLATFORM VERTICAL MOVEMENT AS WEIGHT IS TRANSFERRED TO OR FROM PLATFORM.

3120883 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• TRANSFERS BETWEEN A STRUCTURE AND THE AERIAL PLATFORM EXPOSE O PERATORS TO FALL HAZARDS. THIS PRACTICE SHOULD BE D ISCOURAGED WHEREVER POS SIBLE. WHERE TRAN SFER MUST BE ACCOMPLISHED TO PERFORM THE JOB TWO LANYARDS WITH AN APPROVED FALL PROTECTION DEVICE WILL BE USED. ONE LANYARD SHOULD BE ATTACHED TO THE AERIAL PLATFORM. THE OTHER TO TH E STRUCTURE . THE LANYARD THAT IS ATTACHED TO THE AERIAL PLATFORM SHOULD NOT BE DISCONNECTED UNTIL S UCH TIME AS THE TRANSFER TO THE STRUCTURE IS COMPLETE. OTHERWIS E, D O NOT STEP OUTSID E OF PLATFORM.

• DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS TO THE PLATFORM. ADDITION OF SUCH ITEMS INCREASES THE EXPOSED WIND AREA OF THE MACHINE.

• NEVER POSITION LADDERS, STEPS, OR SIMILAR ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH FOR ANY PURPOSE.

• WHEN RIDING IN OR WORKING FROM PLATFORM, BOTH FEET MUST BE FIRMLY POSITIONED ON THE FLOOR.

• KEEP OIL, MUD AND SLIPPERY SUBSTANCES CLEANED FROM FOOT WEAR AND PLATFORM FLOOR.

• NEVER "WALK" THE BOOM TO GAIN ACCESS TO OR LEAVE PLATFORM.

• NEVER PLACE HANDS OR ARMS IN TOWER BOOM OR UPRIGHT MECHANISM.

• KEEP ALL NON-OPERATING PERSONNEL AT LEAST 2 METERS AWAY FROM THE MACHI NE AT ALL TIMES.

• IF PLATFORM OR BOOM IS CAUGHT SO THAT ONE OR MORE WHEELS ARE OFF THE FLOOR, ALL PERSONNEL MUST BE REMOVED FROM PLATFORM BEFORE ATTEMPTING TO FREE MACHINE. USE CRANES, FORKLIFT TRUCKS OR OTHER EQUIPMENT TO REMOVE PERSONNEL AND STABILIZE MACHINE MOTIO N , IF NECESSARY.

• THE OPERATOR IS RESPONSIBLE TO AVOID OPERATING MACHINE OVER GROUND PERSONNEL AND TO WARN THEM NOT TO WORK, WALK OR STAND UNDER A RAISED B OOM OR PL ATFORM. POSITI ON BARRICADES ON FLOOR IF NECESSAR Y.

1-6 – JLG Lift – 3120883

SECTION 1 - SAFETY PRECAUTIONS

• ENSURE MACHINE IS POSITIONED ON A FIRM, LEVEL AND UNIFORM SUPPORTING SURFACE BEFORE RAISING OR EXTENDING BOOM.

• CHECK CLEARANCES AB OVE, ON SIDES AND BOTTOM OF PLATFORM WHEN RAISING, LOWERING, SWINGING, AND TELESCOPING BOOM.

• EXERCISE EXTREME CAUTION AT ALL TIMES TO PREVENT OBSTACLES FROM STRIKING OR INTER-

FERING WITH OPERATING CONTROLS AND PERSONS IN PLATFORM.

• ENSURE THAT OPERATORS OF OTHER OVERHEAD AND FLOOR MACH INES ARE AWARE OF THE AERI AL PLATFORMS PRESENCE. DISCONNECT POWER TO OVERHEAD CRANES. POSITION BARRICADES ON FLOOR IF NECESSARY.

• NEVER "SLAM" A CONTROL SWITCH OR LEVER THROUGH NEUTRAL TO THE OPPOSITE DIRECTION. ALWAYS RETU RN SWITCH TO NEUTRA L AND STOP; THEN MOVE SWITCH TO THE DE SIRED POSI TION. OPERATE LEVERS WITH SLOW, EVEN PRESSURE.

• DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC.

• NEVER PUSH OR PULL THE MACHINE OR OTHER OBJECTS BY TELESCOPING THE BOOM.

• NEVER USE BOOM FOR ANY PURPOSE OTHER THAN POSITIONING PERSON NEL, THEIR TO OLS AND EQUIPMENT.

• NEVER EXCEED MANUFACTURERS RATED PLATFORM CAPACITY - REFER TO CAPACITY DECAL ON MACHINE. DISTRIBUTE LOADS EVENLY ON PLATFORM FLOOR.

• NEVER OPERATE A MALFUNCTIONING MACHINE. IF A MALFUNCTION OCCURS, SHUT DOWN THE MACHINE, RED TAG IT, AND NOTIFY PROPER AUTHORITIES.

• DO NOT REMOVE, MODIFY, OR DISABLE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

• DO NOT AS SIST A STUCK OR DISABLED MACHINE BY PUSHING OR PULLIN G EXCEPT BY PULLING AT CHASSIS TIE-DOWN LUGS.

• NEVER ATTEMPT USING BOOM AS A CRANE. STRUCTURAL DAMAGE OR TIPPING MAY OCCUR.

• STOW B OOM AND SHUT OFF ALL POWER BEFORE LEAVING MACHINE.

• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.

3120883 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• NEVER ATTEMPT TO FREE A MACHINE STUCK IN SOFT GROUND OR A S SI ST A MACH INE UP A STEE P HILL OR RAMP BY USING BOOM "LIFT", "TELESCOPE", OR "SWING " FU N C TIONS.

• NEVER ATTACH WIRE, CABLE, OR ANY SIMILAR ITEMS TO PLATFORM.

• DO NOT PLACE BOOM OR PLATFORM AGAINST ANY STRUCTURE TO STEADY PLATFORM OR SUPPORT STRUCTURES.

• DO NOT USE THE LIFT, SWING, OR TELESCOPE FUNCTIONS FOR THE BOOM, TO MOVE EITHER THE MACHINE OR OTHER OBJECTS.

• HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT FULLY EXTENDED OR RETRACTED FOR ANY LENGTH OF TIME. ALWAYS "BUMP" CONTROL IN OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION BEING USED REACHES END OF TRAVEL. THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE.

• DO NOT OPERATE ANY MACHINE ON WHICH DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE.

• MACHINE MUST ALWAYS BE SHUT DOWN WHEN REFUELING. NO SMOKING IS MA NDATORY. NEVER REFUEL DURING AN ELECTRICAL STORM. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES.

1.7 TOWING AND HAULING

• DO NOT TOW A MACHINE EXCEPT IN AN EMERGENCY. SEE SECTION 6 FOR EMERGENCY TOWING PROCEDURES.

• LOCK TURNTABLE BEFORE TRAVELING LONG DISTANCES OR BEFORE HAULING MACHINE ON A TRUCK OR TRAILER.

1-8 – JLG Lift – 3120883

SECTION 2 - PREPARATION AND IN SPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine. Ensure that all the necessary inspections have been completed successfully before placing the machine into service. These procedures will aid in obtainin g maximum service life and safe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANC E, SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE

Before a new machine is put into operation it must be carefully inspecte d for any e vidence of damage resulting from shipment and inspected pe riodically thereafter, as outlined in Delivery and Frequent Inspection. (During initial start-up and run,) the unit should be thoroughly checked for hydraulic leaks. A check of all components should be made to assure their security.

All preparation n ecessar y to pl ace the machin e in oper ation readiness status is the responsibility of management personnel. Preparation requires good common sense, (i.e. lift works smoothly and brakes operate properly) coupled with a series of visual inspections. The mandatory requirements are given in the Daily Walk Around Inspection.

It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service.

Frequent inspection shall be performed every 3 months or 150 hours whichever come first, or more often when required by environment, severity, and frequency of usage.

Chassis

1. Check front tires and wheel assemblies for loose or worn spindles, components and hardware for security, tires for wear, damage and proper inflation.

2. Check front axle for loose, missing, and worn parts, pivot pin for security.

3. Check steering assembly for loose or bent steer cylinder rods, steer cylinder and hydraulic lines for leaks and security, and hardware for proper installation.

4. Check rear tires and wheel assemblies for security, tires for wear, damage and prope r inflation.

5. Check drive hubs for da ma ge an d lea ks, a nd mo tors for damage.

6. Check oil level in drive hubs by removing the fill plugs and check plugs on top of each drive hub. Fill each of the cavities until oil flows from each of the check ports. Use Mobil DTE-11. Replace all plugs.

7. Check valves and hydraulic lines for damage, leakage and security.

8. Check pump/motor and accessories for damage, loose or missing parts, leakage and security. Check electrical connections for corrosion and tightness and wiring for insulation damage. Check hydraulic filter for condition of element. Replace as required.

NOTE: JLG recommends replacing the hydraulic filter ele-

ment after the first 50 hours of operation and then every 600 hours thereafter, unless operating conditions requ ire earlier replacement.

2.3 DELIVERY AND FREQUENT INSPECTION

NOTE: This machine requires periodic safety and mainte-

nance inspections by an authorized JLG Dealer. A decal located on the frame provides a place to record (stamp) inspection dates. Check decal and notify dealer if inspection is overdue.

The following checklist provides a systematic inspection to assist in detecting defective, damaged, or improperly installed parts. The checklist denotes the items to be inspected and conditions to exam ine.

9. Check hydraulic reservoir and hydraulic lines for damage, leakage and security.

10. Check batteries for damage, loose or missing vent caps, electrical connections for tightness and evidence of corrosion, and electrolyte level. Add only clean distilled water to battery after it has been charged.

11. If equipped with on-board generator, check engine and accessorie s for damage, loose or missing pa rt s , leakage and security. Check throttle solenoid and linkage for damage, electrical connections for tightness, and evidence of corrosion and wiring for insu-

3120883 – JLG Lift – 2-1

SECTION 2 - PREPARAT ION AND INSPECTION

lation damage. Check exhaust for damage, wear and leakage.

Turntable

1. Check turnt abl e for dama ge , loo se or mi ssi ng p arts, and security. Check lift cylinders and hydraulic lines for damage, leakage and security. Check swing drive motor for damage, loose or missing parts, hydraulic lines and component housings for evidence of leakage; worm gear for proper mesh with swing gear.

2. Check swing bearing for damage, wear, lubrication and loose or missing bearing bolts.

3. Check valves and hydraulic lines for damage, leakage, security and electrical connections for tightness and evidence of corrosion.

4. Check ground controls for damage, loose or missing parts, security, electrical connections for tightness and evidence of corrosion and wiring for insulation damage. Assure that all switches function properly.

5. Check all cowl and access doors for damage, proper operation and security.

6. Check Lower Boom pivot bushings for lubrication and wear.

7. Check Lower Boom Lift Cylinder and hydraulic lines for damage, leakage and security.

8. Check all pin and shaft retaining hardware for security and wear.

9. Check all electrical cables for damage, loose and corroded connections.

Boom

1. Check Lower Boom and leveling link for damage, missing parts and security.

2. Check all pin and shaft retaining hardware for security and wear.

8. Check Mid Boom pivot shaft and lift cylinder for damage, missing parts and security.

9. Check all pin and shaft retaining hardware for security and wear.

10. Check Upper Upright, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

11. Check Upper Upright for damage, wear, lubrication and security.

12. Check hydraulic lines mounted on upright for damage, leakage and security.

13. Check Upper Boom Lift Cylinder and cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

14. Check Upper Boom pivot pin for damage, wear, lubrication and security.

15. Check Upper Boom for damage, missing parts and security.

16. Check Upper Boom wear pads for damage, missing parts and security.

17. Check Upper Boom telescope cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

18. Check Platform Leveling Cylinder, cross pins and hydraulic lines for damage, wear, lubrication, leak-

age and security.

Platform

1. Check platform and control console for damage, loose or missing part s , and security.

2. Check control switches and levers for damage, loose or missing parts and security. Assure that lever and lever lock functions properly.

3. Check control switches, levers and electrical connections for tightness and evidence of corrosion, and wiring for defects and chafing damage. Assure that switches function properly.

3. Check hydraulic lines and electrical cable for damage, missing parts and security.

4. Check limit sw itch connecti ons and plunger fo r corrosion and security.

5. Check Lower Upright cross pins and hydraulic lines for damage, wear, lubrication, leakage and security.

6. Check Lower Upright for damage, wear, lubrication and security.

7. Check hydraulic lines mounted on upright for damage, leakage and security.

2-2 – JLG Lift – 3120883

SECTION 2 - PREPARATION AND IN SPECTION

Figure 2-1. Basic Nomenclat ure

4. Check footswitch for damage, loose or missing parts and security. Assure that footswitch functions properly and that wiring has no defects or chafing.

5. Check Platform Rotator mechanism for proper operation, damage, and security.

NOTE: Check all DANGER, WARNING, CAUTION, and

INSTRUCTION placards for legibility and security on the entire machine.

TO AVOID INJURY, DO NOT OPERATE MACHINE IF ALL PLACARDS ARE NOT ON MACHINE OR ARE DEFACED AND NOT READABLE. USE OF MACHINE WITHOUT CORRECT PLACARDS IS A SAFETY VIOLATION.

3120883 – JLG Lift – 2-3

SECTION 2 - PREPARAT ION AND INSPECTION

2.4 DAILY WALK-AROUND INSPECTION

It is the operators responsibility to inspect the machine before the start of each workday. It is recommended that each operator inspect the machine before operation, even if the machine has already been put into service under another operator. This Daily Walk-Around Inspection is the preferred method of inspection. (Figure 2- 3)

In addition to the Daily-Walk Around Inspection be sure to include the f o l lowing as par t of the daily inspection :

1. Overall Cleanliness.

TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION.

NOTE: Check boom limit switches on upright for proper

operation and security, both visually and manually. Lower switch cuts out drive speed when Lower Boom is above horizontal. Upper switch cuts out drive speed when Upper Boom is above horizontal. Only creep drive speed will continue to function.

Check all standing surfaces for hydraulic oil spillage and foreign objects. Ensure overall cleanliness.

2. Placards. Keep all information and operating placards clean

and unobstructed. Cover when spray painting or shot blasting to protect legibility.

3. Operators and Safety Manual. Ensure that a copy of this manual is enclosed in the

manual storage holder.

4. Machine Log. Ensure a machine operating record or log is kept,

check to see that it is current and that no entries have been left uncleared, leaving machine in an unsafe condition for operation.

5. Start each day with fully charged batteries.

6. Check platform footswitch for proper operation. Switch must be depressed to operate machine.

7. Check that drive brakes hold when machine is driven up a grade and stopped.

NOTE: 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.

8. Assure that all items requiring lubrication are serviced. Refer to Lubrication Chart, Figure 2-4, for specific requirements.

2.5 DAILY FUNCTIONAL CHECK

A functional check of all systems should be performed, once the walk-around inspection is complete, in an area free of overhead and ground level obstructions. First, using the ground control s, check all funct ions control led by the ground controls. Next, using the platform controls, check all functions controlled by the platform controls.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO N OT RETURN TO THE OFF POS ITION WHEN RELEASED.

TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE.

1. Check boom limit switches. Raise and lower the Lower Boom. Check for smooth operation. Check Boom Upright tilting. (See Section 4).

NOTE: Perfor m checks from ground controls first, then from

platform controls.

2-4 – JLG Lift – 3120883

2. Raise, extend, retract, and lower the Upper Boom. Check for smooth operation.

3. If tower boom does not rest on stop with machine in the stowed position, this indicates upright is out of plumb.

4. Telescope boom IN and OUT several cycles at various degrees of elevation lengths. Check for smooth telescope operation.

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

6. Check the chassis out of level indicator located on the platform control console by driving, with the machine in level position, up a suitable ramp of at

least 4° slope. Check the out of level alarm, with the machine on the ramp, raise the upper boom until it is parallel with the chassis. DO NOT RAISE ABOVE THE PARALLEL POSITION. If the light does not illuminate, return the machine to a level surface, shut down the machine, and contact a qualified technician before resuming operation.

DO NOT DRIVE ON GRADES WHICH EXCEED THE RAT ED GRADEABILITY OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO NOT DR IVE ON SIDESLOPES WHICH EXCEED 3 DEGREES.

7. Check that platform self-leveling system functions properly during raising and lowering of boom.

8. Check rotator for smooth operation and assure platform will rotate 75 degrees in both directions from centerline of boom.

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

SECTION 2 - PREPARATION AND IN SPECTION

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION CONTROL, OTHERWISE THE FUNCTION WILL NOT WORK.

With footswitch depressed, operate LIFT and hold control. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a qualified service technician.

12. Place the GROUND/PLATFORM SELECT switch to GROUND. Platform controls should not operate.

13. Place GROUND/PLATFORM SELECT switch to OFF. Platform/Ground controls should not operate.

2.6 TORQUE REQUIREMENTS

The Torque Chart ( Fig ur e 2 -5 ) co nsi st s o f s tan d ard tor qu e values based on bolt diameter and grade, also specifying dry, wet and loctite torque values in accordance with recommended shop practices. This chart is provided as an aid to the operator in the event he/she notices a condition that requires prompt at tention during t he walk-around inspection or during operation, until the proper service personnel can be notified. The Service and Mainte nance section provides specifi c to rque valu es and period ic ma intenance procedures with a listing of individual components. Utilizing this torque chart in conjunction with preventive maintenance section will enhance safety, reliability, and performance of the machine.

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

11. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" (6 MM) OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

Updated 5-21-99

3120883 – JLG Lift – 2-5

SECTION 2 - PREPARAT ION AND INSPECTION

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

2-6 – JLG Lift – 3120883

SECTION 2 - PREPARATION AND IN SPECTION

GENERAL

Begin your Walk-Around Inspection at item 1, as noted on the diagram. Continue to your right (counterclockwise viewed from the top) checking each item in sequence for the conditio ns l isted in the fol lowing checklist.

TO AVOID INJURY DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF

DURING “WALK-AROUND INSPECTION”.

NOTE: Do not overlook visual inspection of chassis under-

side. Checking thi s area may result in discover y of conditions which could cause extensive machine damage.

1. Platform Assembly - No loose or missi ng parts; no visible damage. Platform mounting pins secure. Footswitch in good working order; not modified, disabled or blocked.

2. Platform Control Console - Switches and control lever properly secured; no loose or missing parts; no visible damage; placards secure and legible; control lever and switches return to neutral; control lever lock functions properly; emergency stop switch functions properly; control markings legible.

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

4. Rotator Cylinder - No visible damage; motor and cylinder pins secure; hydraulic hoses undamaged, not leaking.

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

6. Boom Sections/Lift Cylinders and Master Cylinder No visible damage; pivot pins secure; hydraulic hoses undamaged, not leaking.

7. Telescope Cylinder and Power Track - No visible damage; no loose or missing hardware.

8. Limit Switches - Swit ches o perable; no visi ble da mage.

10. Drive Wheel/Tire Assembly, Right Rear - Properly secured; no loose or missing wheel bolts; no visible damage.

11. Hydraulic Oil Filter Housing - Secure; no visible signs of damage or l e akage.

12. Hydraulic Pump and Reservoir - Properly secured; no visible damage or hydraulic leaks. Recommended hydraulic fluid level on dipstick (system shut down, boom in stowed position). Breather cap/ dipstick secure and working.

13. Turntable Bearing - No loose or missing hardwa re; no visible damage; evidence of proper lubrication. No loose bolts or looseness between bearing and structure.

14. Fuel Supply - Fuel filler cap secure; Tank - no visible damage, decals secure and legible.

15. Battery Compartment Right Side - Batteries have proper electrolyte level; cables tight; no visible damage or corrosion.

16. Cowling and Latches - All cowling, doors and latches in working condition; properly secured; no loose or missing parts.

17. Battery Charger - No damage; properly secured.

18. Valve - No loose or missing parts; evidence of leakage, unsupported wires or hoses; damaged or broken wires.

19. Boom/Upright - No visible damage; All pins properly secured. Upright in vertical position. If Upright does not rest on stop with machine in the stowed position, this indicates upright is out of plumb.

20. Steer Wheel/Tire Assembly, Right Front - Properly secured; no loose or missing wheel bolts; no visible damage.

21. Counterweight - No loose or missing hardware; properly secured.

22. Steer Cylinder - Properly secured; no visible damage or signs of leakage; evidence of proper lubrication.

23. Engine Oil Supply - Full mark on dipstick; filler cap and filter secure.

9. Drive Axle and Motor - No loose or missing hardware; No visible damage; no evidence of leakage.

Figure 2-2., Daily Walk -Aro und Inspectio n

(Sheet 2 of 3)

3120883 – JLG Lift – 2-7

SECTION 2 - PREPARAT ION AND INSPECTION

24. Tie Rod Ends and Steering Spindles - No loose or missing parts; no v isi ble damage. Tie rod end st ubs locked.

25. Drive Wheel/Tire Assembly, Left Rear - Properly secured; no loose or missing wheel bolts; no visible damage.

26. Ground Controls - Switches operable; no visible damage; emergency stop switch functions properly; placards secure and legible.

27. Manual Descent Valve - No visible damage; no evidence of leakage.

28. Cowling and Latches - All cowling, doors and latches in working condition; properly secured; no loose or missing parts.

29. Battery Compartment - Batteries have proper electrolyte level; cables tight; no visible damage or corrosion.

30. Control Valve - No loose or missing parts; evidence of leakage; unsupported wires or hoses; damaged or broken wires.

Figure 2-2., Daily Walk- Around Inspection

31. Swing Motor and Worm Gear - No loose or missing hardware; no visible damage; evidence of proper lubrication.

32. Drive Wheel/Tire Assembly, Left Rear - Properly secured; no loose or missing wheel bolts; no visible damage.

33. Frame - No visible damage; no loose or missing hardware (top and underside).

34. Cowling and Latches - All cowling, doors and latches in w orking condition; properly secured ; no loose or missing parts.

35. Platform Pivot Pins - Properly secured.

36. Plat form Gat e - Latc h and Hinge s in wor king c ondition; properly secured; no loose or missing parts.

(Sheet 3 of 3)

2.7 BATTERY MAINTENANCE AND CHARGING

Battery Maintenance, Qu arterly

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 disti lled w ater to batteries , no n-metalli c

containers 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" 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 bat-

teries 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 re quired.

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.

2-8 – JLG Lift – 3120883

SECTION 2 - PREPARATION AND IN SPECTION

Optional On Board Generator

EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY.

WHEN THE GENERATOR ENABL E CONTROL LOCATED IN TH E PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IN ON (PULLED OUT), THE GENERATOR WILL START AUTOMATICALLY WHEN THE BATTERIES REACH A L OW-CHARGE STATE A UTOMATICALLY CHARGING THE BATTERIES.

NOTE: The engine will automatically shut down under the

following conditions: High Engine Oil Temperature

Low Engine Oil Pressure Engine Overspeed Generator Overvoltage

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

Battery Charging (On Board Charger)

1. For maximum battery life: a. Avoid completely discharging the batteries.

b. Fully charge the batteries each day the machine

is used.

c. Charge the batteries at available times between

full charges.

d. Be sure the battery fluid covers the battery

plates before charging, but to avoid overflow, do not top off the fluid level until charging.

2. To charge the batteries, connect the charger to a

115 or 220 volt source with a 20 amp minimum capacity.

3. The charge cycle is complete when the ammeter

reads 0 amps. Any reading indicates the charge cycle is not complete.

4. The Charger will shut off automatically when the bat-

teries are fully charged.

5. Depleted batteries will take approximately 17 hours

to charge.

Updated 11-3-99

3120883 – JLG Lift – 2-9

SECTION 2 - PREPARAT ION AND INSPECTION

Figure 2-3. Lubrication Chart

Updated 6-1-99

2-10 – JLG Lift – 3120883

SECTION 2 - PREPARATION AND IN SPECTION

Table 2-1. Lubrication Chart

Components

Lubrication

Swing Bearing - Internal

Ball Bearing

Swing Bearing - Teeth

End Bearings - Worm

Gear*

Hydraulic Fluid (Oil)

Hydraulic Filter

Wheel Dri ve Hub

Wheel Bearing

Spindles/Bushing

Boom Pivot Pins/

Bushing

Engine

Number/Type

Lube Points

2 Grease Fittings A/R MPG X

Spray On A/R OGL X More frequent lubr ication interv als may be

2 Grease Fittings A/R MPG X Remove grease fitt ings and install pl ugs after

Fill Cap 15.1 liters (t ank) HO X Check oil every 10 hours of operati on.

N/A N/A N/A X Replace filte r element afte r first 50 hour s and

Fill Plug/Half F ull 0.5 liters (1/2 F ull) EPG L X Check oil level at s ide plug on hub d aily .

Repack A/R MPG X

N/A A/R LL At Spindle/Bushi ng Replacement Coat I.D. of bushi ngs prior to in stalling king

N/A A/R LL At boom pivot pi ns/bushing re placement Coat I.D. of bushing s prior to inst alling pins.

Fill Cap Refer to Engine

Capacity Lube

Manual

EO Check daily. Change in accordance with

Interval Hours

3 Months

150 hrs

6 Months

300 hrs

1 Year

600 hrs

2 Years

1200 hrs

Comments

required.

greasing.

Change oil every 1200 hours of operation.

every 300 hours the reafter .**

Change after firs t 150 hours th en every 1200 hours of operati on.

pins.

engine manual.

NOTES: KEY TO LUBR ICANTS

Lubrication intervals are bas ed on machine operation under norm al conditions. For machines used in multi shift operations and/ or exposed to hostile environments or conditions, lubri cation frequencies must be increased accordingly .

* If necessary in stall grease f ittings into worm gear housin g and grease bearings.

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN BLOWING OUTER SEA L IN HO US ING .

** Under certain conditions, it may be necessary to replace the hydraul ic filter on a more frequent basis. A common symptom of a dirty filter is sluggishness experienced in h ydraulic functions .

EPGL

MPG

OGL

Engine Oil Extreme Pressure Ge ar Lube Hydraulic Fluid (Mobil DTE-1 1M) Multi-Purpose Grease Synthetic Lithium Lubr icant Open Gear Lubric ant - Mobiltac 3 75 or equivalent

Updated 11-3-99

3120883 – JLG Lift – 2-11

SECTION 2 - PREPARAT ION AND INSPECTION

UNPLATED

CAP SCREWS

WITH LOC-WEL PATCH

UNBRAKO 1960 SERIES

SOCKET HEAD CAP SCREW

TORQUE

(as received)

(KG)

CLAMP LOAD

)

(LOCTITE

242 OR 271

262)

(LOCTITE

(LUB.)

1442

1651

2377

2631

3493

3983

4822

109

102

5384

122

149

156

6437

7253

183

163

130

146

122

109

210

224

8256

9208

224

258

188

209

149

176

285

298

10251

11612

326

359

244

277

231

244

495

542

15150

16919

570

631

408

456

380

434

793

861

20956

23088

895

983

658

724

624

678

1173

1241

27488

30074

1492

1342

931

1079

922

1003

1681

1871

34610

38828

1898

2136

1396

1566

1464

1302

2373

2549

43954

48671

2712

2983

1970

2183

1844

2034

3145

3308

52391

59648

3559

4068

2586

2935

2413

2766

4122

4433

63731

71669

4712

5322

3430

3856

3200

3607

SAE GRADE 8

SAE GRADE 5

VALUES FOR ZINC PLATED BOLTS ONLY

(DRY OR

SAE GRADE 8 BOLTS & GRADE 8 NUTS

CLAMP

(LOCTITE

TORQUE

(DRY OR

SAE GRADE 5 BOLTS & GRADE 2 NUTS

CLAMP

AREA

STRESS

THREAD

DIA.

BOLT

LOC. 263)

(KG)

LOAD

)

242 OR 271

262)

(LUB.)

LOC. 263)

(KG)

LOAD

(SQ. CM)

(CM)

245

272

172

191

0.0153

0.0168

0.2845

372

417

263

277

0.0232

0.0258

0.3505

572

599

408

426

0.0356

0.0374

0.4166

717

817

508

583

0.0445

0.0508

0.4826

1297

1488

916

1052

0.0808

0.0925

0.6350

2141

2821

1515

1678

0.1473

0.1331

0.7938

3175

3583

2241

2540

0.2230

0.1969

0.9525

109

4332

4854

3085

3425

0.3015

0.2700

1.1112

149

163

5783

6532

115

136

108

102

122

4105

4854

0.4061

0.3604

1.2700

204

231

7539

8278

163

183

133

148

109

122

149

163

5874

5262

0.5156

0.4623

1.4288

298

326

9231

10433

224

258

183

207

149

176

204

231

7394

6532

0.6502

0.5740

1.5875

515

570

15241

13653

387

448

325

363

271

298

353

407

9662

10796

0.9474

0.8484

1.9050

814

895

18870

20775

644

705

523

576

434

475

583

637

14697

13336

1.2929

1.1735

2.2225

1220

1356

23360

27080

915

997

785

858

651

719

868

949

19142

17509

1.6840

1.5392

2.5400

1736

1953

31162

34927

968

1087

814 1139

895 1254

1085

1193

21546

19187

2.1742

1.9380

2.8575

2468

2712

38554

43818

1593

1762

1368

1516

1139

1247

1519

1681

27035

24404

2.7254

2.4613

3.1750

3227

3688

47174

53570

2068

2373

1792

2042

1492

1708

1980

2278

29076

33113

2.9337

3.3401

3.4925

4284

4827

57380

142200

2746

3118

2379

2676

1980

2630

35381

3.5687

4.0132 39781 2983 2224

3.8100

Figure 2-4. Torque Chart

THD

SIZE

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1-1/8

1-1/4

1-1/2

Note: These torque values do not apply to cadium plated fasteners.

2-12 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL

3.1 GENERAL

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITY OF THE USER AND HIS/HER OPERATING PERSONNEL.

This section provides the necessary information needed to understand control functions. Included in this section are the operating characteris tic s and limitations, and functions and purposes of controls and indicators. It is important that the user read and understand the proper procedures before operating the machine. These procedures will aid in obtaining op timum lift service and s afe operation.

3.2 PERSONNEL TRAINING

The aerial platform is a personnel handling device; therefore, it is essential that it be operated and maintained only by authorized and qua lified personnel w ho have demonstrated that they understand the proper use and maintenance of the machine. It is important that all personnel who are assigned to and are responsible for the operation and maintenance of the machine undergo a thorough training program a nd check out perio d i n order t o bec ome familiar with the characteristics prior to operating the machine.

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

Operator Training.

Operator training must include instruction in the following areas:

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

2. Knowledge and understanding of this manual and of the control markings, instructions and warnings on the machine itself.

3. Knowledge and understanding of all safety work rules of the employer and of Federal, State and local statutes, including training in the recognition and avoidance of potential hazards in the work place; with particular attention to the work to be performed.

4. Proper use of all required personnel safety equipment, in particular th e wea ring of a safety harness or other approved fall protection devices with a lanyard attached to a designated attach point, on the platform, at all times.

5. Sufficient 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, dropoffs, etc. on the supporting surface exist.

7. Means to av oid the hazards o f unprotected el e ctrical conductors.

8. Any other requirements of a specific job or machine application.

Training Supervision.

Training must be done under the supe rvis ion of a qualified person in an open area free of obstru ctions until the trainee has developed the ability to safely control a machine in congested work locations.

Operator Responsibility.

The operator must be in structed that he/she has t he responsibility and authori ty to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site and to request further information from his/her supervisor or an authorized JLG Distributor before proceeding.

NOTE: Manufacturer or Di st r i but or w il l pr ovi de qu al i fie d pe r -

sons for train ing assistan ce with first unit (s) deli vere d and thereafter as requested by the user or his/her personnel .

3120883 – JLG Lift – 3-1

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

3.3 OPERATING CHARACTERISTICS AND LIMITATIONS

General

A thorough knowledge of the operating characteristics and limitations of the machine is always the first requirement for any user, regardless of the users experience with similar types of equipment.

Placards

Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This information is placed at various locations for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine. See FOREWORD for definitions of the above placards.

TO AVOID FORWARD OR BACKWARD UPSET, DO NOT O VERLOAD MACHINE, OPERATE ON OUT-OF-LEVEL SURFACE OR OPERATE WITH THE BOOM UPRIGHT TILTING. (SEE FIGURE 4-2. UPRIGHT POSITIONING).

3.4 CONTROLS AND INDICATORS

These machines are equipped with control panels that use symbols and words to in dicate control function s. On some machines, the contro l panels may use symbols only. Refer to Table 3-1 for these symbols and their corresponding functions.

Ground Control Station

DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.

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. Proper tire pressure.

5. Machine is as originally equipped from JLG.

Stability

This machine as originally manufacture d by JLG Industries, Inc., when operated within its rated capacity on a smooth, firm and level supporting surface and in accordance with the instructions provided on the machine and in this manual, provides a stable machine for all positions.

Machine stability is based on two (2) conditions which are called FORWARD stability and BACKWARD stability. The

machine’s position of least FORWARD stability is shown in Figure 3-1 and its position of least BACKWARD stability is shown in Figure 3-2.

PERFORM AS MANY PRE-OPERATIONAL CHECK AND INSPECTIONS FROM GROUND CONTROLS AS POSSIBLE.

NOTE: When machine is shut down the Platform/Ground

Select switch and Emergency Stop must be positioned to OFF.

1. Power/Emergency Stop Switch. A two-position red mushroom shaped switch fur-

nishes power to PLATFORM/GROUND SELECT switch when pulled out (on). When pushed in (off), power is shut off to the PLATFORM/GROUND SELECT switch.

2. Platform/Ground Select Switch. A three position, key operated switch supplies

power to the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground controls are operable. When released from GROUND position the switch spring returns to the (off) position.

NOTE: With PLATFORM/GROUND SELECT switch in the

center position, power is shut off to controls at both operating stations.

3-2 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-1. Position of Least Forward Stability

3120883 – JLG Lift – 3-3

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

Figure 3-2. Position of Least Backward Stability

3-4 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-3. Ground Control Station

Updated 8-18-99

3120883 – JLG Lift – 3-5

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

3. Rotate. A three position ROTATE control switch permits rota-

tion of the platform when positioned to left or right.

4. Platform Leveling Override. A three position LEVEL control switch allows the

operator to compensate for any difference in the automatic self leveling system by positioning the control switch to UP or DOWN.

5. Articulating Jib Boom (If equipped) The Articulating Jib Boom control switch provides

raising and loweri ng of the jib when positioned up or down.

6. Lower Boom Lift. Provides for raising and lowering of Lower Boom

when positioned to UP or DOWN.

7. Upper Boom Lift. Provides for raising and lowering of Upper Boom

when positioned to UP or DOWN.

8. Telescope. Provides for extension and retraction of Upper Boom

when positioned to IN or OUT.

9. Swing. The SWING control switch provides 360 degrees

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

10. Circuit Breakers. The circuit breakers open (pop out) to indicate a

short or overload somewhere on the machine.

NOTE: The engine will automatically shut down under the

following conditions: High Oil Temperature

Low Oil Pressure Engine Overspeed Overvoltage

NOTE: The engine will not start if the batteries are fully

charged or if the Generator Enable switch on the platform console is not in the on position.

13. Generator/Engine Start Button. The generator/engine start push-button switch

allows the generator to be started manually to topoff the battery charge. The generator will start automatically when the batteries reach a low-charge state and the Generator Enable switch on the platform console is in the on position.

Platform Control Station

1. Footswitch. The footswitch is a safety feature. To operate any

function, the footswitch must be depressed and the function se lect ed wit hin sev en seco nds. The en able light in the light panel indicates that the controls are enabled; as long as functions continue to be used the controls remain 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 recycled to re-enable the controls.

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

11. Battery Indicator and Hourmeter. An hourmeter, installed in the upper porti on of the

Ground Control Box, registers the amount of machine operating time. The hourmeter registers up to 9,999.9 hours and cannot be reset.

12. System Distress Indicator . The system distress indicator lights to signify an

abnormal condition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an electrical system fault.

Updated 8-18-99

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

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

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

3-6 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-4. Platform Console

2. Power/Emergency Stop. A two-position red mushroom shaped switch fur-

nishes power to PLATFORM Controls when pulled out (on). When pushed in (off), power is sh ut off to the platform functions.

Within about 2 seconds of pulling the switch out, the machine will perform a d iagnostic check of the various electrical circuits, and if everything is OK, the platform alarm will beep once. During this time the lights on the indicator panel will also blink once as a bulb check.

3. Lower Boom Lift. Provides for raising and lowering of Lower and Mid

Boom when positioned to UP or DOWN. Upper lift will not function when operating lower lift.

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

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

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

Updated 8-18-99

3120883 – JLG Lift – 3-7

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

4. Main Lift/Swing. The dual axis joystick is provided for main lift and

swing. Push forward to lift up, pull backward to lift 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.

NOTE: Main lift and swing functions may be selected in

combination. The handle features a round gate so that maximum speed is reduced when multiple functions are selected.

Lower lift will not function when operating upper lift.

5. Telescope Control. The TELESCOPE control switch affords extension

and retraction of the main boom when positioned to IN or OUT.

6. Drive/Steer. The DRIVE controller provides for driving either for-

ward or backward when positioned to FORWARD or

REVERSE. The controller is ‘ramped’ to allow infinitely variable drive speed between fast and slow.

Positioning the steer control thumb operated switch RIGHT or LEFT enables steering the machine to the right or left respectively.

NOTE: When lower boom is raised above horizontal, or the

upper boom is raised approximately 16 inches (40.64 cm) above boom rest, the high drive function will automatically switch to low drive. This also occurs when Function Speed Control is clicked on creep.

NOTE: DRIVE control lever is spring-loaded and will auto-

matically return to neutral (OFF) position when released.

7. Posi-Track Control. Activating the Posi-Track switch allows the operator

to engage positive traction for the time period preset in the controller. Posi-traction occurs by changing the drive motors from a series to parallel arrangement, causing available power to be distributed evenly between the two drive wheels. The control system may also engage the posi-track function automatically.

8. Posi-Track Indicator. This indicator lights to show that posi-traction is

operating.

9. Platform Leveling Override. The PLATFORM LEVEL control switch allows the

operator to adjust the level or the platform by positioning the switch to UP or DOWN.

10. Articulating Jib Boom (If Equipped) Push toggle switch forward to lift up, pull back to lift

down.

11. Platform Rotate. The PLATFORM ROTATE control switch allows the

operator to rotate the basket to the left or right when positioned to the desired direction.

12. Function Speed Control. Adjusts speed of Boom and Swing Functions.

Rotate CCW for slower speed and CW for faster speed. To adjust Drive, Swing, and Main Lift to creep, turn knob fully CCW until it clicks.

13. Machine Out Of Level. This red illuminator indicates that the chassis is on a

slope (over 3 degrees). If the boom is above horizontal and the machine is on a 3 degree slope, an alarm will sound and CREEP is automatically activated.

14. System Distress Indicator . The system distress indicator lights to signify an

abnormal condition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an electrical system fault.

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.

Updated 8-18-99

3-8 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

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 s teep grades which exceed the rated gradeability of the machine. This condition is comparable to stalling the engi ne by asking it to provide more power than it was designed to do.

c. The batteries are nearly depleted, and sh ould be

charged very soon to prevent having the machine st op at an inconve nient place.

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

so determine the cause by counting t he flash code, a number of flashes followed by a pause followed by another numb e r of flashes, and refer to the service manual.

NOTE: The engine will automatically shut down under the

following conditions: High Engine Oil Temperature

Low Engine Oil Pressure Engine Overspeed Generator Overvoltage

15. Generator Enable Control. The Generator Enable control switc h, w hen in the off

position, allows the operator to prevent the generator engine from starting when using the machine indoors. When in the on position (and the ground Emergency Stop Swi tch on [ pull ed out] ), the gene rator is enabled to automatically start when the batteries need charged.

16. Horn. A push-type HORN switch supplies electrical power

to an audible warning device when pressed.

17. Circuit Breakers. The circuit breakers open (pop out) to indicate a

short or overload somewhere on the machine.

Table 3-1.Simultaneous Functions

If This Function is Selected:

Swing Lower Lift Swing* Upper Lift Swing No T elescope Swing* Lower Lift** Upper Lift** Jib Swing* Lower Lift** Upper Lift** T elescope Platform Ro tate No No No No Note: Boom functions may be slower when selected with another function than when operated individually, due to sharing of oil. * These functions may move very slowly (or not at all) if the first function selected (Lower Lift or Swing) is being operated at full speed,

due to sharing of oil. ** Lower Lift and Upper Lift will not function simultaneously. Upper lift alway prevails.

These Functions Will Also Work at the Same Time:

Lower Lift** Upper Lift** T elescope

No T elescope*

T elescope

Updated 5-12-99

3120883 – JLG Lift – 3-9

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

Figure 3-5. Caution, Danger, Warning Decal Location

Updated 6-1-99

3-10 – JLG Lift – 3120883

1701518

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

1701518

DANGER

BEWARE OF LIVE ELECTRICAL CONDUCTORS.

CONTACT THE LOCAL ELECTRICITY AUTHORITIES TO

ENSURE ADEQUATE CLEARANCES.

THIS MACHINE IS NOT ELECTRICALLY INSULATED

DAILY CHECK LIST

1. CHECK TYRES AND THEIR CONDITION.

2. CHECK BOOM AND AXLE CUT-OUT SWITCHES.

3. CHECK SAFETY PROTECTION ITEMS.

4. CHECK ALL OPERATIONS FOR MALFUNCTION.

5. CHECK BRAKES.

6. ENSURE THAT JLG OPERATION AND SAFETY MANUAL IS WITH THE MACHINE.

7. DO NOT OPERATE A MALFUNCTIONING MACHINE.

8. CHECK THE ENGINE AND DRIVE SPEED CUT-OUT SWITCHES.

9. MAXIMUM OPERATING SLOPE: 3 DEGREES.

CAUTION

THIS MACHINE MAY BE OPERATED

BY TRAINED PERSONNEL ONLY.

230kg MAX

+ 70kg

400N MAX

REFERENCE SHOULD BE MADE TO THE

JLG OPERATION AND SAFETY MANUAL TO

3120883 – JLG Lift – 3-11

ENSURE SAFE OPERATION OF THIS MACHINE.

1703806-A

12.5 m/s MAX

1703806 A

Updated 6-1-99

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

1703807-A

THIS MACHINE IS NOT ELECTRICALLY INSULATED

BEWARE OF LIVE ELECTRICAL CONDUCTORS.

CONTACT THE LOCAL ELECTRICITY AUTHORITIES TO

ENSURE ADEQUATE CLEARANCES.

THIS MACHINE MAY BE OPERATED

BY TRAINED PERSONNEL ONLY.

REFERENCE SHOULD BE MADE TO THE

JLG OPERATION AND SAFETY MANUAL TO

ENSURE SAFE OPERATION OF THIS MACHINE.

1. CHECK TYRES AND THEIR CONDITION.

2. CHECK BOOM AND AXLE CUT-OUT SWITCHES.

3. CHECK SAFETY PROTECTION ITEMS.

4. CHECK ALL OPERATIONS FOR MALFUNCTION.

5. CHECK BRAKES.

6. ENSURE THAT JLG OPERATION AND SAFETY MANUAL IS WITH THE MACHINE.

7. DO NOTOPERATE A MALFUNCTIONING MACHINE.

8. CHECK THE ENGINE AND DRIVE SPEED CUT-OUT SWITCHES.

9. MAXIMUM OPERATING SLOPE: 3 DEGREES.

DAILY CHECK LIST

DANGER

CAUTION

1703807 A

1704286-A

Updated 6-1 -9 9

3-12 – JLG Lift – 3120883

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-6. Control Panel Symbols (Sheet 1 of 2)

Updated 7-13-99

3120883 – JLG Lift – 3-13

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTRO L

Figure 3-7. Control P anel Symbols (Sheet 2 of 2)

3-14 – JLG Lift – 3120883

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating, articulat-

ing and rotating boom. The JLG Lift’s intended purpose is to position perso nnel with thei r to ols an d supp lie s at po sitions above ground level, and can be used to reach work areas located above machinery or equipment.

The JLG Lift has a primary operator Control Station 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 l ower the upp er or lowe r boom or swing the boom to the left or r ight. Standard boom swing is 360 degree non-continuous left and right of the stowed position . The machin e has a G round Control Station which will override the Platfor m Control Station. Ground Controls operate Upper and Lower Boom Lift and Swing, and are to be u sed in an em ergency to lo wer the platform to the ground should the operator in the platform be unable to do so. Grou nd Control also to be used in Pre-Operation check.

Instructions and hazard alerts are posted on the operator control stations and at other places on the machine. It is extremely important that operators know what instructions and hazard alerts are placed on the machine, and review these periodically so that they are fresh in their minds. Vibrations emitted by these machi nes are not hazardous to an operator in the work platform.

The JLG Lift is design ed to pro vid e efficient and safe operation when main taine d and op era ted in a ccordance with warnings on the machine, in the Operators & Safety Manual, and all jobsite and government rules and regulations. As with any type of machinery, the operator is very important to efficient and safe operation. It is absolutely necessary that the JLG Lift be regularly maintained in accordance with this section and the Preparation and Inspection section, and that any evidence of lack of maintenance, malfunction, excessive wear, damage or modification to the machine be reported immediately to the machine owner or the jobsite supervi sor or safety manager and that the machine be taken out of service until all discrepancies are corrected.

The JLG Lift is not intended to be used to lift material other than supplies which personnel in the platform require to do their job. Supplies or tools which extend outside the platform are prohibited. It must not be used as a forklift, crane, support for overhead structure, or to push or pull another obje ct .

The JLG Lift is powered using a hydraulic pump and cylinders for various functions. The hydraulic components are controlled by electrical ly activat ed hydraul ic valves us ing switches and control levers. Th e speeds of boom functions are variable from zero to maximum speed depending upon the position of the function speed control. Functions controlled by toggle switches are either on or off. A foot operated switch in the platform must be depressed before any controls will function and provides a means of emergency stop when the operators foot is removed from the footswitch.

The JLG Lift is a two wheel drive machine with drive power being supplied by 2 electric mot ors thru plane tary gear reducers.

The unrestricted capacity of the JLG Lift is 230 kg. This means that with a platform load of 230 kg. or less, the platform may be positioned anywhe re the boom will reach, with the machine on a smooth, firm, and level surface.

4.2 GENERAL

This section provides the necessary information needed to operate the machine. Included in this section are procedures for traveling, steering, parking, platform loa ding and transporting. It is important that the user read and understand the proper procedures bef ore operating the machine.

4.3 MOTOR OPERATION Power/Emergency Stop

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.

NOTE: If equipped with the optional on-board generator, the

Emergency Stop switch must be left on (pulled out) to allow for automatic charging of the batteries.

Within about 2 seconds of pulling the sw itch out, the machine will p erform a di agnosti c check o f the vari ous electrical circuits, and if everything is OK, the platform alarm will beep once. During this time the lights on the indicator panel will also blink once as a bulb check.

Updated 3-15-00

3120883 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Platform/Ground Select Switch

The Platform/Ground Select switch functions to direct battery power to the desired control station when the POWER/EMERGENCY STOP s witch is pulled ou t (on). With the switch held 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 statio n.

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

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

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 approp riate position and the Footswitch is depressed.

IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DE TERMINE AND CORRE CT CAUSE BEFOR E RESUMING ANY OPERATION.

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

4.4 TRAVELING (DRIVING)

NOTE: When lower boom is raised above horizontal, or the

upper boom is raised approximately 40 cm above boom rest, the high drive function will automatically be in low drive.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 3 DEGREES.

AVOID ANY TERRAIN FEATURES WHICH COU LD CAUSE THE MACHINE TO TIPOVER.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WIT H PLATFORM ELEVATED AND WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUCTION.

BEFORE DRIVING, M AKE SURE BOOM IS PO SITIONED OVER REAR DRIVE AXLE. IF BOOM IS OVER STEER WHEELS, STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE MOTION.

Traveling Forward and Reverse

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

1. If machine is shut down, pull out Emergency Stop at Ground Cont rols and plac e Platform/G round Sele ct switch to PLATFORM.

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

3. Position Drive controller to FORWARD or REVERSE

IF THE MACHINE IS OP ERATED AT A VERY SLOW SPEED OR STALLED WHEN CLIMBING A GRADE OF 20% OR GREATER, DRIVE FUNCTION WILL STOP. REMOVE FOOT FROM FOOTSWITCH, AND DEPRESS FOOTSWITCH TO RESET.

4.5 STEERING

as desired. Angle of controller will determine travel speed.

Depress footswitch, position thumb switch on Drive/Steer controller to RIGHT for steering right, or to LEFT for steering left.

4.6 PLATFORM Loading From Ground Level

1. Position chassis on a smooth, firm and level surface.

4-2 – JLG Lift – 3120883

Figure 4-1. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION

2. If total load (personnel, tools and supplies) is 230 kg. or less, distribute load uniformly on platform floor and proceed to work position.

Loading From Positions Above Ground Level

Before loading weight to platform above ground level:

1. Determine what the total weight will be after additional weight is loaded (personnel, tools and supplies).

2. If total weight in platform will be 230 kg. or less, proceed with adding weight.

Platform Level Adjus tment

1. Leveling UP. Depress footswitch to raise platform, position PLATFORM/LEVEL control switch UP and hold until platform is level.

2. Leveling DOWN. Depress footswitch to lower platform, position PLATFORM/LEVEL control switch to DOWN and hold until platform is level.

Platform Rotation

1. Depress footswitch to rotate platform to the left, PLATFORM ROTATE control switch is positioned to the LEFT and held until desired position is reached.

4.7 BOOM

A RED TILT WA RNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 3 DEGREE OR GREATER SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (3 DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL.

TO AVOID UPSET 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 NOT EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLL ING

PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

2. Depress footswitch to rotate platform to the right, PLATFORM ROTATE control switch is positioned to the RIGHT and held until desired position is reached.

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.

Updated 5-21-99

3120883 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Swinging the Boom

Depress footswitch to swing boom, with footswitch activated, position SWING cont rol switch to RIGHT or LEFT for direction desire d.

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

Raising and Lowering the Lower and Mid Boom

Depress footswitch to raise or lower the Lower and Mid Boom, with footswitch activated, position Lower Boom Lift switch to UP or DOWN as desired.

Raising and Lowering the Upper Boom

Depress footswitch to rai se o r lower the Upper Boom, with footswitch activated, position Upper Boom Lift switch to UP or DOWN until desired height is reached.

4.8 GENERATOR

The machine is equipped with an engine powe red DC generator co nnected in para llel to the 48V DC batter y bank.

Automatic Operating Mode

The generator will operate in automatic mode always when the following two conditions apply.

1. Ground Control EMS is pull ed out ( on ), and

2. The Generator Enable switch on the platform control console is in the On or Enable position.

When the abov e conditions apply, the generator’s controller will monitor status of th e b atteries, w ill turn on automatically when the battery voltage drops as a result of discharge and will turn off when batteries are fully charged.

Battery Only Operating Mode

The machine will operate in the battery only mode when the following two conditio ns apply:

1. Ground Control EMS is pulled out, and

2. The switch on the platform control console is in the Off or Disable position.

Manual (Charge) Operating Mode

The generator w ill oper ate in manual mode always when the following three conditions apply.

1. Ground Control EMS is pulled out, and

2. The switch on the platform control console is in the On or Enable position and

3. The Manual Charge push button is activated.

Activation of the Manual Charge button will start the engine and initiate the charging cycle even if the batteries are charged above the level of automatic start. The operator can initiate the charge cycle to charge the batt eries to the maximum level. The charging cycle will include finishing phase similar to conven tional chargers.

4.9 MACHINE FUNCTION SPEEDS

The Function Speed Control affects the speed of bo om functions Lower Lift, Telescope, and Rotate. Turn the control CW to increase function speed or CCW to decrease function speed. When in the CCW maximum position, Drive is placed in creep speed.

4.10 SHUT DOWN AND PARK

NOTE: When par king batter y powered units over night, bat-

teries should be charged in accordance with instructions in Section 2 to ensure readiness for following workd ay.

NOTE: Electric machines are equipped with a static strap

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

To shut down a nd park the mach ine, th e proce dures 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.

In this mode the machi ne will operate as a con ventional battery operated unit. The batteries can be used until they are fully discharged.

4-4 – JLG Lift – 3120883

SECTION 4 - MACHINE OPERATION

4.11 MACHINE LIFTING AND TIE DOWN Lifting

1. Call JLG Industries or weigh the individual unit to obtain GVW.

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.

Tie Down

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.

4.12 BOOM SYNCHRONIZING PROCEDURE

NOTE: If the Lower Boom assembly does not fully lower:

1. Remove all personnel from the platform.

2. Pull the red knob located besided the main control valve.

3. From Ground Control, activate the lift control switch, raise Lower Boom 1.8 m (6 feet).

4. After raising Lower Boom, release the red knob.

5. Activate Lower Boom Down, fully lower boom.

6. Repeat st ep 1 thru 5 if n ecessary.

Updated 8-4-99

3120883 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-2. Upright Positioning

Updated 8-4-99

4-6 – JLG Lift – 3120883

SECTION 4 - MACHINE OPERATION

Figure 4-3. Lifting Chart

Updated 9-21-99

3120883 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-4. Chassis & Platform Tie Down

Updated 3-15-00

4-8 – JLG Lift – 3120883

SECTION 5 - OPTIONAL EQUIPMENT

SECTION 5. OPTIONAL EQUIPMENT

5.1 MOTION ALARM

A motion alarm horn provides an audible warning when the platform controls are selected at the PLATFORM/ GROUND SELECT switch, the EMERGENCY STOP switch is ON, and the footswitch is depressed. The alarm warns personnel in the jobsite area to avoid the operating machine.

5.2 FOAM FILLED TIRES

NOTE: Foam Filled tires are required on J model machines.

Eliminates flats by filling tires with polyurethane foam. For use where sharp objects are frequently enc ountered on operating surface of jobsite .

5.3 ROTATING BEACON

An amber rotating beacon may be installed on the machine hood, and is activated whenever platform controls are selected at the PLATFORM/GROUND SELECT switch. When activated, the light provides a vi sual warning

of the machine’s operation.

5.4 TILT ALARM

An audible warning horn that will sound when the machine is out of level three degrees in any direction with the boom raised above horizontal.

5.6 BATTERY PACKS

Spare battery packs are available to enable the operator to remove battery packs for char ging and replace them with fresh battery packs to keep machine operating with minimal down time. Battery packs are interchangeable and include applica ble cables and connect ors for “pl ugin” use.

5.7 PLATFORM LIGHTS

Platform lights may be inst alled on t he machine platform rails, to provide more lighting for the operator.

5.8 CONTROL CONSOLE COVER

The control console cover is a one piece clear acrylic cover which attaches to the platform rails over the control console. The cover, when in position, will protect the entire platform control console and the control handle on the right side of the console.

5.9 CYLINDER BELLOWS

A one piece accordion shaped rubber bellows may be attached to the rod end of the cylinder barrel and the cylinder rod as close to the rod attach bushing as possible. The bellows affords protection to the cylinder rod in either the extended or retracted position. The bellows are installed on the lift cylinders, slave cylinder, master cylinder, and steer cylinder.

5.5 WHEEL COVERS

Provide protection fo r wheels and wheel bear ings from dirt, grease, mud, rocks, etc.

5.10 WORK PLATFORM

These machines are available with a 0.76 x1.52M size platform.

Updated 11-3-99

3120883 – JLG Lift – 5-1

SECTION 5 - OPTIONAL EQUIPMENT

This page left blank intentionally.

5-2 – JLG Lift – 3120883

SECTION 6. EMERGENCY PROCEDURES

6.1 GENERAL

This section provides information on the procedures to be followed and on the systems and controls to be used in the event an emergency situation is encountered during machine operation. Prior to operation of the machine and periodically there after , the entir e operating manua l, including this section, should be reviewed by all personnel whose responsibilities include any work or contact with the machine.

6.2 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine, in case of a malfunction or power failure, have been incorporated. The following procedur es are to be used ON LY for emergency movement to a suitable main te nance area.

1. Chock wheels securely.

2. Disengage drive hubs by reversing disconnect caps.

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

After moving machine, complete the following procedures:

1. Position machine on a firm and level surface.

2. Chock wheels securely.

3. Engage drive hubs by reversing disconnect caps on hubs.

4. Remove chocks from wheels as needed.

6.3 EMERGENCY CONTROLS AND THEIR LOCATIONS

Emergency Stop Switch.

There is one of these red mushroom shaped switches at either Ground Controls or Platform Controls. When depressed it will immediately stop all function s at that station and shut down t h e machine.

SECTION 6 - EMERGENCY PROCEDURES

CHECK DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS FUNCTIONING AND THAT CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE.

Ground Control Station

The Ground Contr ol Station is locate d on the left side of the turntable. The controls on this panel provide the means for overriding the platform controls and for controlling boom swing and lift from the ground. The PLATFORM/GROUND SELECT SWITCH is a self-centering switch. Hold SELECT SWITCH in GROUND position and operate the desired function switch.

Manual Descent System

The manual desc ent syst em is used, in th e event of total power failure, to lower the upper and lower booms using gravity. To ope rate t he manu al des cent system , proc eed as follows:

1. Locate manual descent knob o n main valve and turn CW(clockwise). Install handle into manual descent pump and lower the Mid and Lower Booms by pumping the handle until they are completely lowered.

2. Turn manual descent knob CCW (counterclockwise) and lower the Upper (or main) Boom by pumping the handle until it is completely lowered. Return manual descent knob to center position and stow handle in bracket provided.

Manual Swing Override

The manual swing override is used to manual ly swing 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 ove rride, proceed as follows:

1. Using a 7/8 in ch socket and ratchet wrench , locate nut on swing worm gear on left side of machine. Install wrench on nut and ratchet in the direction desired.

Updated 12-1-99

3120883 – JLG Lift – 6-1

SECTION 6 - EMERGENCY PROCEDURES

6.4 EMERGENCY OPERATION Use of Ground Controls

1. Know how to use Ground Controls in an emergency situation.

Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control functions. Training should include operation of the machine, review and understanding of this section and hands-on operation of the controls in simulated emergencies.

Operator Unable to Control Machin e

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

1. Operate the machine from ground controls only with the assistance of other personnel and equipment (cranes, overhead hoists, etc.) as may be required to safely remove the danger or emergency condition.

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 which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunction when used.

Platform or Boom Caught Overhead

If the platform or boom be comes jammed or snag ged in overhead structures or equipment, do not continue operation of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location. Only then should an attempt be made to free the platform using any necessary equip m ent and personnel. Do not operate controls to cause one or more wheels to leave the ground.

Following any accident, thoroughly inspect the machine and test all fu nction s firs t fro m the gr ound contro ls, th en from the platform controls. Do not lift above 3 meters until you are sure that all damage has been repaired, if required, and that all controls are operating correctly.

6.5 INCIDENT NOTIFICATION

It is imperative that JLG Industries, Inc. be notified immediately of any in ciden t inv olvin g a JLG pr oduc t. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

Contact your local JLG office. It should be noted that 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.

6-2 – JLG Lift – 3120883

SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Table 7-1.Inspection and Repair Log

Date Comments

3120883 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1.Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3120883

To: JLG, Gradall, Lull and Sky Trak product owner:

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 (717) 4856573 or mail to address as specified on the back of this form.

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

Mfg. Model:

Serial Number:

Previous Owner:

Address:

City: State:

Zip: Telephone: ( )

Date Of Transfer:

Current Owner:

Address:

City: State:

Zip: Telephone: ( )

Who in your organization should we notify?

Name:

Title:

JLG Industries, Inc.

TRANSFER OF OWNERSHIP

Thank you, Product Safety & Reliability Department

JLG IIndustries, IInc. 1 JLG Drive McConnellsburg, PA 17233-9533 Telephone: (717) 485-5161 Fax: (717) 485-6573

Please cut on the dotted line and fax to 717-485-6573



McConnellsburg PA. 17233-9533

Customer Support Toll Free: (877) 554-5438

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia Phone: (61) 2 65 811111 Fax: (61) 2 65 810122

JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil Phone: (55) 19 3295 0407 Fax: (55) 19 3295 1025

JLG Industries (Europe) Kilmartin Place, Tannochside Park Uddingston G71 5PH Scotland Phone: (44) 1 698 811005 Fax: (44) 1 698 811055

JLG Industries (UK) Unit 12, Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone: (44) 870 200 7700 Fax: (44) 870 200 7711

JLG Europe B.V. Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone: (31) 23 565 5665 Fax: (31) 23 557 2493

JLG Industries (Pty) Ltd. Unit 1, 24 Industrial Complex Herman Street Meadowdale Germiston South Africa Phone: (27) 11 453 1334 Fax: (27) 11 453 1342

JLG Deutschland GmbH Max Planck Strasse 21 D-27721 Ritterhude/lhlpohl Bei Bremen Germany Phone: (49) 421 693 500 Fax: (49) 421 693 5035

JLG Industries (Norge AS) Sofeimyrveien 12 N-1412 Sofienyr Norway Phone: (47) 6682 2000 Fax: (47) 6682 2001

Plataformas Elevadoras JLG Iberica, S.L. Trapadella, 2 P.I. Castellbisbal Sur 08755Castellbisbal Spain Phone: (34) 93 77 24700 Fax: (34) 93 77 11762

JLG Industries (Italia) Via Po. 22 20010 Pregnana Milanese - MI Italy Phone: (39) 02 9359 5210 Fax: (39) 02 9359 5845

JLG Polska UI. Krolewska 00-060 Warsawa Pol an d Phone: (48) 91 4320 245 Fax: (48) 91 4358 200

JLG Industries (Sweden) Enkopingsvagen 150 Box 704 SE - 175 27 Jarfalla Sweden Phone: (46) 8 506 59500 Fax: (46) 8 506 59534

JLG E45A-AJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual