JLG E45A-AJ Operator Manual

4 (1)
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
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
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
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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
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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
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