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: [phone]
Fax: [phone]

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)
Kilmartin Place,
Tannochside Park,
Uddingston, Scotland, G71 5PH
Telephone: [phone]
Fax: [phone]

AUSTRALIAN OFFICE

JLG INDUSTRIES (AUSTRALIA)
P.0. Bo x 9 7 2
11 Bolwarra Road
Port MacQuarie
N.S.W. 44
Australia
Telephone: [phone]
Fax: [phone]

Models
M45A
M45AJ
E45A
E45AJ

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

OPERATORS & SAFETY

FOREWORD

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