JLG E600, M600J, M600JP, E600J, E600JP Operation And Safety Manual

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Operation and Safety Manual

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

Boom Lift Models E600 E600J E600JP M600 M600J M600JP

ANSI

3121217

March 9, 2016

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

3121217 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

b – JLG Lift – 3121217

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

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

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

• Accident Reporting

•Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA

or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

3121217 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - June 7, 2005

Revised - July 21, 2006

Revised - December 7, 2009

Revised - March 2, 2010

Revised - September 1, 2010

Revised - April 26, 2012

Revised - January 5, 2015

Revised - October 27, 2015

Revised - March 9, 2016

d – JLG Lift – 3121217

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

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

Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,

AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2

Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1

4.3 MOTOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

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

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

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

Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Power/Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Platform/Ground Select Switch . . . . . . . . . . . . . . . . . . . . 4-2

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-5

Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

3121217 – JLG Lift – i

TABLE OF CONTENTS

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

Raising and Lowering the Upper Boom. . . . . . . . . . . . . 4-8

4.8 GENERATOR (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Automatic Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . 4-8

Battery Only Operating Mode. . . . . . . . . . . . . . . . . . . . . . 4-9

Manual (Charge) Operating Mode. . . . . . . . . . . . . . . . . . 4-9

4.9 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.10 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.11 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-10

4.13 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.14 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.15 TOWING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.16 DRIVE HUB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Disengaging for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Engaging after Towing is Complete . . . . . . . . . . . . . . . 4-16

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

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

5.6 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

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

Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

6.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 6-12

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-15

SECTION - 7 - INSPECTION AND REPAIR LOG

ii – JLG Lift – 3121217

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-7

2-2. Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . 2-8

2-3. Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . 2-9

2-4. Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . . . . .2-10

2-5. Daily Walk-Around Inspection - Sheet 2 of 4 . . . . . . . . .2-11

2-6. Daily Walk-Around Inspection - Sheet 3 of 4 . . . . . . . . .2-12

2-7. Daily Walk-Around Inspection - Sheet 4 of 4 . . . . . . . . .2-13

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

3-2. Ground Control Station w/ Function Enable. . . . . . . . . . . 3-3

3-3. Ground Control Station w/ Machine Safety System

Override (MSSO) (CE Only) -

Prior to S/N 0300204368 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Ground Control Station w/ Machine Safety System

Override (MSSO) (CE Only) - S/N 0300204368

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-5. Platform Control Station - w/Drive Orientation. . . . . . . 3-11

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

3-7. Platform Control Indicator Panel

w/Drive Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

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

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

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4-6. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . .4-17

4-7. Decal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-18

4-8. Decal Installation - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-19

4-9. Decal Installation - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-20

5-1. Manual Descent Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

6-1. Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-2. Operator Maintenance and Lubrication Diagram. . . . . . 6-7

3121217 – JLG Lift – iii

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

iv – JLG Lift – 3121217

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6

1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3

4-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-2 Decal Legend - Prior to S/N 0300141450 . . . . . . . . . . . . .4-21

4-3 Decal Legend - S/N 0300141450 to Present . . . . . . . . . .4-25

6-1 Operating Specifications - Prior to S/N 0300141450 . . . 6-1 6-2 Operating Specifications - S/N 0300141450

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-6 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

6-8 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-9 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-15

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

3121217 – JLG Lift – v

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

vi – JLG Lift – 3121217

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

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

The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge

• The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

3121217 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.

• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.

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

• Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG.

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

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

Workplace Inspection

• Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.

• Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG.

• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.

• Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

• Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.

1-2 – JLG Lift – 3121217

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.

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

• Ensure all safety devices are operating properly. Modification of these devices is a safety violation.

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

• Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.

• Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1.3 OPERATION

General

• Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.

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

• Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.

• Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

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

• Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.

3121217 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless approved by JLG.

• When two or more persons are in the platform, the operator shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

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

• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leaving machine.

• Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.

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

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

Trip and Fall Hazards

• During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

• Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

1-4 – JLG Lift – 3121217

SECTION 1 - SAFETY PRECAUTIONS

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

• Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.

• Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

Electrocution Hazards

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

3121217 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

1-6 – JLG Lift – 3121217

SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• The user must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

• Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.

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

3121217 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

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

• Do not operate the machine when wind conditions, including gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, Beaufort scale (For Reference Only) or use other means to monitor wind conditions.

• Wind speed can be significantly greater at height than at ground level.

• Wind speed can change rapidly. Always consider approaching weather events, the time required to lower the platform, and methods to monitor current and potential wind conditions.

• Do not increase surface area of the platform or the load. Increased areas exposed to wind will decrease stability.

• Do not increase the platform size with unauthorized modifications or attachments.

1-8 – JLG Lift – 3121217

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

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

SECTION 1 - SAFETY PRECAUTIONS

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically

1 1-3 0.3-1.5 Light air Wind motion visible in smoke

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle

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

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.

8 39-46 17.2-20.7 Fresh Gale Twigs broken fro m trees. Cars veer on road.

9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

becomes difficult.

3121217 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards

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

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

• During operation, keep all body parts inside platform railing.

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

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

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

• Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel.

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

• Do not use high speed drive in restricted or close quarters or when driving in reverse.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1-10 – JLG Lift – 3121217

SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting, or hauling.

• This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lifting information.

1.5 MAINTENANCE

This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.

• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.

3121217 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

• Ensure replacement parts or components are identical or equivalent to original parts or components.

• Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

• Use only approved non-flammable cleaning solvents.

• Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.

• Refer to the Service and Maintenance Manual for the weights of critical stability items.

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

1-12 – JLG Lift – 3121217

Battery Hazards

SECTION 1 - SAFETY PRECAUTIONS

• Always disconnect batteries when servicing electrical components or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery during charging or servicing.

• Do not contact tools or other metal objects across the battery terminals.

• Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.

3121217 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

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

Operator Training

Operator training must cover:

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

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

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential malfunction.

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

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

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121217 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

2-2 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Typ e Fr equ enc y

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspect ion (See Note) Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual

Frequent Inspection In service for 3 months or 1 50 hours, whichever comes first;

o r Out of service for a period of more than 3 months; o r Purchase d used.

Annual Machine Inspection Annually, no later than 13 months from the date of prior

inspection.

Preventative Maintenance At intervals as specified in the Service and Maintenance

Manual.

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Q ualified JLG Mechanic Service and Maintenance Manual

Owner, Dealer, or User Factory Trained

Owner, Dealer, or User Q ualified JLG Mechanic Service and Maintenance Manual

Service

Qualification

Service Technician (Recommended)

Reference

and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

3121217 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection

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

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

2. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

3. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container.

4. “Walk-Around” Inspection – Refer to Figure 2-4., Figure 2-

5., and Figure 2-7.

5. Battery – Charge as required.

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

proper fuel as necessary.

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

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

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.

2-4 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or locks

are in place.

b. Operate all functions and check all limiting and cut-out

switches.

c. Check auxiliary power (or manual descent).

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is activated.

2. From the platform control console:

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

proper location;

b. Check that all guards protecting the switches or locks

are in place;

c. Operate all functions and check all limiting and cut-out

switches;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. With machine in the transport (stowed) position, drive

on a grade (not to exceed the rated gradeability) and stop to ensure the brakes hold;

f. With machine in the transport (stowed) position, check

the tilt sensor indicator light to ensure proper operation.

3121217 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test

From the Platform Console:

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

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

functions will not reverse, only stop.

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

is activated.

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

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

2-6 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature - Sheet 1 of 3

1. B at t er y Pa c k

2. F ue l Tan k

3. Hydraulic Tank

4. M ai n Ter m in a l B o x

5. Swing Drive

6. Tu rn t ab l e L o ck

7. F ra m e

8. Tu rn t ab l e

9. B at t er y C ha r ge r

10. Generator Control Mo d u le ( M M o de l s)

3121217 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Basic Nomenclature - Sheet 2 of 3

1. F ra m e

2. M ai n Va lv e

3. G en e ra t or S ta r t Ba t te r y (M M o de ls )

4. G en e ra t or ( M M o de l s)

5. B at t er y Pa c k

6. G ro u nd C on tr o l

7. Tu r nt a bl e

2-8 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-3. Basic Nomenclature - Sheet 3 of 3

1. P la t fo r m

2. R ot a to r

3. B o om

4. L i ft Cy l in d er

5. U pr i gh t

6. To we r Bo o m

7. To we r Li f t

8. B o om L in k

9. M as t er Cy l in d er

10. Slave Cylinder

11. Jib

12. Platform Control Box

13. SkyGuard (If Equipped)

14. Cross Rail (If Equipped)

3121217 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-4. Daily Walk-Around Inspection - Sheet 1 of 4

2-10 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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 conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING “WALKAROUND INSPECTION”.

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missing parts,

that they are securely fastened and that no visible damage exists in addition to any other criteria mentioned.

1. Platform Assembly - Platform mounting pins secure. Footswitch in good working order; not modified, disabled or blocked.

2. Platform & Ground Control Console - Switches and control levers; 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. Rotator - See Note.

4. All Hydraulic Cylinders - No visible damage; Pivot pins and

hydraulic hoses undamaged, not leaking.

5. Boom - Pivot pins secure; Upright in vertical position. See Note.

6. Drive Axle and Motor - See Note

7. Wheel/Tire Assembly - No loose or missing lug nuts,

proper inflation (pneumatic). Inspect for worn tread, cuts, tears, or other discrepancies. Inspect wheels for damage and corrosion

8. Frame (top and underside) - See Note.

Figure 2-5. Daily Walk-Around Inspection - Sheet 2 of 4

3121217 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Boom Limit Switch - Switch operable; 10. Cowling and Latches - See Note

11. Hydraulic Pump and Reservoir - Recommended hydraulic

fluid level on dipstick (system shut down, boom in stowed position). Breather cap/dipstick secure and working.

12. Manual Descent Valve - See Note

13. Control Valve - No unsupported or damaged wires or

hoses.

14. Generator Start Battery - See Note

15. Engine Oil Supply - Full mark on dipstick; filler cap and fil-

ter secure.

16. Battery Compartment Right Side - See Note

17. Counterweight - See Note

18. Limit Switches - Switches operable.

19. Tie Rod Ends and Steering Spindles - Tie rod end stubs

locked.

Figure 2-6. Daily Walk-Around Inspection - Sheet 3 of 4

2-12 – JLG Lift – 3121217

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

20. Oscillating Axle and Lockout Valve (If Equipped) - Check the lockout valve plunger in the depressed position. Swing the turntable until the axle lockout bracket passes the plunger and make sure the plunger is fully extended as shown below

21. Battery Compartment - See Note

22. Fuel Supply - Fuel filler cap secure; Tank - Decals secure

and legible.

23. Hydraulic Oil Filter Housing - See Note

24. Battery Charger - See Note

25. Turntable Bearing - Evidence of proper lubrication. No

loose bolts or looseness between bearing and structure.

26. Swing Motor - Evidence of proper lubrication.

27. Platform Pivot Pins - See Note

28. Platform Gate - Latch and Hinges in working condition.

29. SkyGuard (If Equipped) - See Inspection Note.

Figure 2-7. Daily Walk-Around Inspection - Sheet 4 of 4

3121217 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-14 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: The optional generator engine will automatically shut down

under the following conditions:

Batteries Fully Charged High Oil Temperature Low Oil Pressure Engine Overspeed Overvoltage

NOTE: The optional generator 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.

Ground Control Station

See Figure 3-1., Figure 3-2., and Figure 3-3.

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

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.

NOTE: If equipped, the Function Enable switch must be held down in

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

1. Power/Emergency Stop

A two-position red mushroom shaped switch furnishes power to Platform/Ground Select switch when pulled out (on). When pushed in (off), power is shut off to the Platform/ Ground Select switch.

3121217 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Platform/Ground Select

3. Platform Rotate

4. Platform Leveling Override

5. Main Lift

6. Telescope

7. Swing

8. Battery Indicator and Hourmeter

9. Generator Enabled Indicator

10. Generator/Engine Start

11. Jib Boom

12. Jib Rotate

13. Platform Overload

Figure 3-1. Ground Control Station

3-2 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Platform/Ground Select

3. Platform Rotate

4. Platform Leveling Override

5. Main Lift

6. Telescope

7. Swing

8. Battery Indicator and Hourmeter

9. Generator Enabled Indicator

10. Generator/Engine Start

11. Jib Boom

12. Jib Rotate

13. Platform Overload

14. Function Enable

Figure 3-2. Ground Control Station w/ Function Enable

3121217 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1704428 B

1. Power/Emergency Stop

2. Platform/Ground Select

3. Platform Rotate

4. Platform Leveling Override

5. Main Lift

6. Telescope

7. Swing

8. Not Used

9. Generator Enabled Indicator

10. Generator/Engine Start

11. Jib Boom

12. Jib Rotate

13. Platform Overload

14. Function Enable

15. Indicator Gauge

16. Charger Status

17. Machine Safety System Override (MSSO)

Figure 3-3. Ground Control Station w/ Machine Safety System Override (MSSO) (CE Only) - Prior to S/N 0300202137

3-4 – JLG Lift – 3121217

1001196785 B

1. Power/Emergency Stop

2. Platform/Ground Select

3. Platform Rotate

4. Platform Leveling Override

5. Main Lift

6. Telescope

7. Swing

8. Not Used

9. Generator Enabled Indicator

10. Generator/Engine Start

11. Jib Boom

12. Jib Rotate

13. Platform Overload

14. Function Enable

15. Indicator Gauge

16. Not Used

17. Machine Safety System Override (MSSO)

Figure 3-3. Ground Control Station w/ Machine Safety System Override (MSSO) (CE Only) - S/N 0300202137 to Present

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121217 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Platform/Ground Select

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.

NOTE: With PLATFORM/GROUND SELECT switch in the center position,

power is shut off to controls at both operating stations.

3. Rotate

A three position switch permits rotation of the platform.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

4. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade.

5. Boom Lift

Provides for raising and lowering of the Boom.

6. Telescope

Provides for extension and retraction of the Boom.

7. Swing

This switch provides 400 degrees non-continuous turntable rotation. To activate SWING, position switch to LEFT or RIGHT.

3-6 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Battery Indicator and Hourmeter

An hourmeter is installed in the upper portion of the Ground Control Box. The hourmeter registers up to 9,999.9 hours and cannot be reset.

9. Generator Enabled Indicator

The generator enabled indicator lights to signify the generator is enabled and may start at any time as the batteries require. If the indicator flashes, it signifies an abnormal condition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an electrical system fault.

NOTE: Refer to the Service Manual for the generator fault codes.

10. Generator/Engine Start Button (if equipped)

The generator/engine start push-button switch allows the generator to be started manually to top-off the battery charge. The generator will start automatically when the batteries reach a low-charge level.

11. Articulating Jib Boom (If Equipped)

This switch provides raising and lowering of the jib.

12. Jib Rotate (If Equipped)

A three position switch permits rotation of the jib and platform.

13. Platform Overload (If Equipped)

Indicates the platform has been overloaded.

14. Function Enable (If Equipped)

If equipped, the enable switch must be held "DOWN" to enable all boom controls when the engine is running.

3121217 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

15. Indicator Gauge

Registers the amount of time the machine has been in use, with functions operating. In the event of a fault, the hourmeter also displays the three digit fault code. Refer to the Service Manual for a listing of fault codes. Additionally, there is a small, red indicator light that will blink when there is a fault on the machine to draw operator attention to the display.

16. Charger Status

The Charger Status LEDs give a visual indicator of the status of the battery charger. The red LED indicates Charging Abnormal. The yellow LED indicates charging in progress. The green LED indicates charging is complete.

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

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

Platform Control Station

(See Figure 3-4., Platform Control Station)

1. Power/Emergency Stop

A two-position red mushroom shaped switch furnishes power to PLATFORM Controls when pulled out (on). When pushed in (off), power is shut off to the platform functions.

Within about 2 seconds of pulling the switch out, the machine will perform a diagnostic 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.

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

3-8 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Generator Enable Control (if equipped)

This switch allows the operator to prevent the generator engine from starting to charge the batteries when using the machine indoors.

3. Lights (If Equipped)

This switch operates accessory light packages if the machine is so equipped.

4. Drive/Steer

The DRIVE joystick provides for driving either forward or backward. The controller is ‘ramped’ to allow variable drive speed.

Steering is controlled by a thumb operated switch on top of the joystick.

5. Telescope Control

This switch allows extension and retraction of the main boom.

6. Articulating Jib (If Equipped)

This switch controls the raising and lowering of the jib (up or down).

7. Jib Rotate (If Equipped)

A three position switch permits rotation of the jib and platform (left or right).

8. Platform Rotate

This switch controls the rotation of the basket (left or right).

3121217 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Generator Enable

3. Lights

4. Drive/Steer

5. Telescope

6. Articulating Jib Boom

7. Jib Rotate

8. Platform Rotate

9. Function Speed

10. Main Lift/Swing

11. Posi Track

12. Platform Leveling Override

13. Horn

Figure 3-4. Platform Control Station

3-10 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Generator Enable

3. Lights

4. Drive/Steer

5. Telescope

6. Articulating Jib Boom

7. Jib Rotate

8. Platform Rotate

9. Function Speed

10. Main Lift/Swing

11. Posi Track

12. Platform Leveling Override

13. Horn

14. Drive Orientation Override

15. Soft Touch/SkyGuard Override

16. Soft Touch/SkyGuard Indicator

Figure 3-5. Platform Control Station - w/Drive Orientation

3121217 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Function Speed Control

Controls the speed of Boom and Swing Functions. Rotate CCW for slower speed and CW for faster speed. To adjust to creep, turn knob fully CCW until it clicks.

10. Main Lift/Swing

The dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lower. Move right to swing right, move left to swing left. Proportional control of these functions can be attained by using the Function Speed control.

NOTE: Main lift and swing functions may be selected at the same time.

Maximum speed is reduced when both functions are selected.

11. Posi-Track Control

Activating the Posi-Track switch distributes available power evenly between the two drive wheels for improved traction. The control system may also engage the posi-track function automatically when more traction is required.

NOTE: The optional 4 Wheel Assist will also engage with the Posi-Track

Control.

12. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade.

3-12 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

13. Horn

If pressed, this switch supplies power to the horn.

14. Drive Orientation Override

When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. Before driving, locate the black/ white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction.

15. Soft Touch/SkyGuard Override Switch (If equipped)

The machine can be equipped with one of three options. It may have Soft Touch, SkyGuard, or both Soft Touch and SkyGuard.

If equipped with Soft Touch, the switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed, allowing the operator to move the platform away from the obstacle that caused the shutdown situation.

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

If equipped with both Soft Touch and SkyGuard, the switch operates like described above and allows the operator to override the system that has experienced a cutout situation.

16. Soft Touch/SkyGuard Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated. All controls are cut out until the override button is pushed. For Soft Touch, controls are then active in the Creep Mode or for SkyGuard, controls will work normally.

3121217 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. T il t Al a rm Wa r ni n g

2. O ve r l oa d in d ic a to r

3. S ys t em D is t re s s

4. P os i Tra c k

5. F oo t sw i tc h /E n ab l e I n di c at o r

6. L ow B at t er y I nd i ca to r

7. C re e p I n di c at o r 8-11. Not Used

Figure 3-6. Platform Control Indicator Panel

Platform Control Indicator Panel

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

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

bols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below.

Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

3-14 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1704239 E

1001110226A

1. Tilt

2. Platform Overload

3. System Distress

4. Posi-Track

5. Enable

6. Low Battery

7. Creep

8. Drive Orientation Override

9. Soft Touch Indicator

Figure 3-7. Platform Control Indicator Panel w/Drive

Orientation

1. Tilt Alarm Warning Light and Alarm

This orange illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation. If the boom is above horizontal and the machine is on a slope, the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

2. Platform Overload (If Equipped)

Indicates the platform has been overloaded.

3121217 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. System Distress Light

The system distress light indicates an abnormal condition for machine control system.

The three likely causes of a system fault are:

a. The seven second enable time has been allowed to

lapse or a function was selected before pushing down the footswitch.

b. The maximum power limit has been reached and the

machine is not moving. This condition is the same as stalling the engine by asking it to provide more power than it was designed to do.

c. There is some other fault in one of the circuits. Refer to

the service manual.

4. Posi-Track Indicator

This indicator lights when posi-traction is operating.

5. Footswitch/Enable Indicator

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next func-

tion, the enable light will go out and the footswitch must be released and depressed again to enable the controls.

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

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

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

6. Low Battery Light

This light indicates when battery voltage is below 45 volts and flashes below 40 volts. The machine will shut down below 33 volts.

7. Creep Speed Indicator

When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed.

3-16 – JLG Lift – 3121217

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct.

9. Soft Touch Indicator (If Equipped)

When illuminated (Yellow) the Soft Touch bumper is against an object. All controls are disabled until the override button is pushed, at which time controls are active in the Creep mode.

3121217 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-18 – JLG Lift – 3121217

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, articulating and rotating boom.

The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the boom to the left or right. Standard boom swing is 400 degree non-continuous left and right of the stowed position. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so. The Ground Control is also to be used in Pre-Start Inspection.

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

The boom can be raised above horizontal with or without any load in platform, if:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG.

Stability

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

3121217 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Platform/Ground Select Switch

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

4.3 MOTOR OPERATION

Power/Emergency Stop

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

The Platform/Ground Select switch directs power to the Ground or Platform controls as selected. For power, the POWER/EMERGENCY STOP switch must also be pulled out (on).

4-2 – JLG Lift – 3121217

Figure 4-1. Position of Least Forward Stability

BOOM FULLY EXTENDED

@ 5° ELEVATION

MACHINE WILL TIP OVER IN

THIS DIRECTION IF OVERLOADED OR

OPERATED ON AN OUT- OF-LEVEL

SURFACE

LEVEL SURFACE

SECTION 4 - MACHINE OPERATION

3121217 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability

MAIN BOOM FULLY

RETRACTED AND

ELEVATED

MACHINE WILL TIP OVER IN

THIS DIRECTION IF OVERLOADED OR

OPERATED ON AN OUT-OF-LEVEL

SURFACE

LEVEL SURFACE

PLATFORM ROTATED 90°

4-4 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

4.4 TRAVELING (DRIVING)

NOTE: When the upper boom is raised approximately 11 degrees above

horizontal, the high drive function will automatically be in low drive.

IF THE MACHINE IS OPERATED AT A VERY SLOW SPEED OR STALLED WHEN CLIMBING A GRADE OF 20% OR GREATER, DRIVE FUNCTION WILL STOP. REMOVE YOUR FOOT FROM FOOT-SWITCH, AND PUSH THE FOOTSWITCH DOWN AGAIN TO RESET IT.

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

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

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED.

Traveling Forward and Reverse

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

2. Position Drive controller to FORWARD or REVERSE as desired.

This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner:

1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

3121217 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON MANUFACTURER’S NAMEPLATE

LEVEL

4-6 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

Figure 4-4. Traveling on a Grade

Traveling on a Grade

When traveling a grade, maximum braking and traction are obtained with the boom stowed, in position over the rear (drive) axle, and in line with the direction of travel. Drive the machine forward when climbing a grade, and in reverse when descending a grade. Do not exceed the machine's maximum rated gradability.

IF THE BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS.

4.5 STEERING

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

4.6 PLATFORM

Platform Level Adjustment

To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.

Platform Rotation

To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached.

3121217 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

4.7 BOOM

DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM.

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

IF THE 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.

Swinging the Boom

To swing boom, use SWING control switch to select RIGHT or LEFT direction.

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

Raising and Lowering the Upper Boom

To raise or lower the Upper Boom, use Upper Boom Lift switch to select UP or DOWN movement.

4.8 GENERATOR (OPTIONAL)

Automatic Operating Mode

The generator will operate in automatic mode when:

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

2. The Generator Enable switch on the platform control con-

sole is in the On or Enable position.

When the above conditions apply, the generator’s controller will monitor status of the batteries, will turn on automatically when

4-8 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

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:

1. Ground Control EMS is pulled out, and

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

Disable position.

The batteries can be used until they are fully discharged.

Manual (Charge) Operating Mode

The generator will operate in manual mode when:

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 begin the charging cycle even if the batteries are charged above the level of automatic start.

4.9 FUNCTION SPEED CONTROL

This control affects the speed of all boom functions and Platform Rotate. When in the CCW maximum position, Drive is placed in creep speed.

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

The Machine Safety System Override (MSSO) is used to override function controls for Emergency Platform Retrieval only. Refer to Section 5.6, Machine Safety System Override (MSSO)(CE Only)for operating procedures.

3121217 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.11 SKYGUARD OPERATION

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

Table 4-1. Skyguard Function Table

Main

Tel e

Swing

Lift

RC/R*RRIRR C C C C C

R = Indicates Reversal is Activated

C = Indicates Cutout is Activated

I = Input is Ignored

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

* Reversal only applies to Ma in Tele Out. Main Te le In would be cut out

Drive

Forw ard

Drive

Reverse

Platform

Level

Platform

Rotate

Jib

Lift

Jib

Rotate

Tel e

4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

Refer to Section 6.4, Oscillating Axle Lockout Test (If Equipped) for

Jib

procedure.

4-10 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

4.13 SHUT DOWN AND PARK

NOTE: When parking overnight, batteries should be charged properly

to ensure readiness for following workday.

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

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

To shut down and park the machine, the procedures are as follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Position

Platform/Ground Select switch to center OFF.

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

4.14 LIFTING AND TIE DOWN

Lifting

1. Refer to the Machine Serial Number Plate, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to the

machine and so the machine remains level.

Tie Down

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

1. Place the boom in the stowed position.

2. Remove all loose items from the machine.

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

adequate strength.

3121217 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Figure 4-5. Lifting and Tie Down Chart

4-12 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

STEER/TOW SELECTOR

TOW BA R

4.15 TOWING INSTRUCTIONS

THE MACHINE HAS NO TOWING BRAKES. THE TOWING VEHICLE MUST BE ABLE TO CONTROL THE MACHINE AT ALL TIMES. TOWING IS NOT PERMITTED ON HIGHWAY.

KEEP ALL BODY PARTS AWAY FROM MOVING COMPONENTS.

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUS INJURY.

MAXIMUM TOWING SPEED: 5 MPH (8 KPH) FOR A DISTANCE OF 5 MILES (8K).

MAXIMUM TOWING GRADE: 25%

The following instructions are for towing using the optional tow bar.

1. Lock the turntable in the travel position, with the boom fully lowered and retracted.

2. Lower the tow bar to the towing position and connect to the towing vehicle.

3. Disengage the drive hubs.

4. Position the steer/tow selector to the towing (out) position.

5. To return the machine to the self-propelled mode, follow the

above steps in the reverse order.

3121217 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

BOLT

4.16 DRIVE HUB

Disengaging for Towing

MAKE SURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL.

1. Remove the two hex head bolts from the cover.

2. Remove the cover.

4-14 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

COVER

ROTATED

3. Rotate the cover to show the inside diameter

4. Install the bolts and torque 6.3 ft. lbs. (8.8 Nm) until they are

flush with the cover.

5. The machine is ready to be towed.

BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE, EITHER THE DRIVE HUB HAS TO BE REENGAGED OR PROPER STEPS MUST BE TAKEN TO PREVENT THE MACHINE FROM MOVING.

3121217 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

Engaging after Towing is Complete

THE COVER IS UNDER SPRING FORCE

1. Remove the 2 hex head bolts securing the cover evenly and remove the cover.

2. Rotate the cover 180 degrees and secure with the two hex head bolts.

3. Torque the hex head bolts 6.3 ft.lbs. (8.8 Nm).

4. The gear drive should now be reengaged and the machine

can be disconnected from the towing vehicle.

4-16 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

Figure 4-6. Decal Installation - Sheet 1 of 4

3121217 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-7. Decal Installation - Sheet 2 of 4

4-18 – JLG Lift – 3121217

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Installation - Sheet 3 of 4

3121217 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Installation - Sheet 4 of 4

4-20 – JLG Lift – 3121217

Table 4-2. Decal Legend - Prior to S/N 0300141450

SECTION 4 - MACHINE OPERATION

Item # ANSI

0270129-14

1 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

2 1704575 1705822 1704667 1704668 - - - - - - - -

3 1703805 - - 1703938 1703939 1703935 1703936 1703937 1703940

4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

5 1704661 - - - - - - 1704661 1704661 - - - -

6 1707035 - - - - - - 1707035 1707035 - - - -

7- -- -- -- -- -- -- -- -

8- -- -- -- -- -- -- -- -

9- -- -- -- -- -- -- -- -

10- -- -- -- -- -- -- -- -

11 1702868 - - - - - - 1704001 1704000 - - 1704002

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1701645 1705978 1701645 1707058 1707056 1707055 1707060 1707134

14 1707013 1705978 1707013 1707042 1707049 1707047 1707044 1707133

15 3251813 1705084 - - - - 3251813 3251813 - - 3251813

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

CE/Aus

0275062-5

Japan

0270146-12

Korean/Eng 0270148-13

Eng/Spanish

0270150-13

Eng/French

0270152-14

Chinese/Eng

0270154-13

Port ./Spa

0270156-13

3121217 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - Prior to S/N 0300141450

Item # ANSI

0270129-14

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - - - - - 1704007 1704006 - - 1704008

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21- -- -- -- -- -- -- -- -

22 1706948 3252523 1706948 1706948 1706948 1706948 1706948 1706948

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

27- -- -- -- -- -- -- -- -

28- -- -- -- -- -- -- -- -

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

30- -- -- -- -- -- -- -- -

31 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1703946

32- -- -- -- -- -- -- -- -

33- -- -- -- -- -- -- -- -

34 3252347 1705828 1703980 1703981 1703983 1703984 1703982 1703985

35 1704708 1704708 1704708 1704708 1704708 - - 1704708 1704708

CE/Aus

0275062-5

Japan

0270146-12

Korean/Eng 0270148-13

Eng/Spanish

0270150-13

Eng/French

0270152-14

Chinese/Eng

0270154-13

Port ./Spa

0270156-13

4-22 – JLG Lift – 3121217

Table 4-2. Decal Legend - Prior to S/N 0300141450

SECTION 4 - MACHINE OPERATION

Item # ANSI

0270129-14

36 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644

37 1704705 1704705 1704705 1704705 1704705 1704705 1704705 1704705

38 1702901 1706392 1704119 1704120 1704117 1704116 1704121 1704118

39- -- -- -- -- -1705514- -- -

40 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

41 1704248 1706378 1704331 1704332 1704328 1704329 1704333 1704330

42 1702155 - - 1702155 1702155 1702155 1702155 1702155 1702155

43 1704412 - - 1704412 1704412 1704412 1704412 1704412 1704412

44- -- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -- -

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

47- -- -- -- -- -- -- -- -

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50- -- -- -- -- -- -- -- -

51 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

52 3252673 1706377 3252738 3252739 3252740 3252743 3252741 3252742

53- -- -- -- -- -- -- -- -

CE/Aus

0275062-5

Japan

0270146-12

Korean/Eng 0270148-13

Eng/Spanish

0270150-13

Eng/French

0270152-14

Chinese/Eng

0270154-13

Port ./Spa

0270156-13

3121217 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - Prior to S/N 0300141450

Item # ANSI

0270129-14

54 1704254 - - 1704254 1704254 1704254 1704254 1704254 1704254

55- -- -- -- -- -- -- -- -

56- -- -- -- -- -- -- -- -

57- -- -- -- -- -- -- -- -

58- -- -- -- -- -- -- -- -

59- -- -- -- -- -- -- -- -

60 - - - - - - - - 1703929 1703930 1703931 1703934

61- -- -- -- -- -- -- -- -

62 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

63 1702391 1701517 1701517 1701517 1701517 1701517 1701517 1701517

64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618

65- -- -- -- -- -- -- -- -

66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

67- -- -- -- -- -- -- -- -

68- -- -- -- -- -- -- -- -

69 1705351 - - - - 1705427 1705910 1705429 - - - -

70- -- -- -- -- -- -- -- -

CE/Aus

0275062-5

Japan

0270146-12

Korean/Eng 0270148-13

Eng/Spanish

0270150-13

Eng/French

0270152-14

Chinese/Eng

0270154-13

Port ./Spa

0270156-13

4-24 – JLG Lift – 3121217

Table 4-3. Decal Legend - S/N 0300141450 to Present

SECTION 4 - MACHINE OPERATION

Item # ANSI

0270129-15

1 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

2 1704575 1705822 1704667 1704668 - - - - - - - -

3 1703805 - - 1703938 1703939 1703935 1703936 1703937 1703940

4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

5 1704661 - - - - - - 1704661 1704661 - - - -

6 1707035 - - - - - - 1707035 1707035 - - - -

7- -- -- -- -- -- -- -- -

8- -- -- -- -- -- -- -- -

9- -- -- -- -- -- -- -- -

10- -- -- -- -- -- -- -- -

11 1702868 - - - - - - 1704001 1704000 - - 1704002

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1001121801 1705978 1001121801 1001121918 1001121805 1001121803 1001121810 1001121920

14 1001121814 1705978 1001121814 1001121921 1001121818 1001121816 1001121823 1001121923

15 3251813 1705084 - - - - 3251813 3251813 - - 3251813

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

CE/Aus

0275062-5

Japan

0270146-13

Korean/Eng 0270148-14

Eng/Spanish

0270150-14

Eng/French

0270152-15

Chinese/Eng

0270154-14

Port ./Spa

0270156-14

3121217 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - S/N 0300141450 to Present

Item # ANSI

0270129-15

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - - - - - 1704007 1704006 - - 1704008

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21- -- -- -- -- -- -- -- -

22 1706948 3252523 1706948 1706948 1706948 1706948 1706948 1706948

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

27- -- -- -- -- -- -- -- -

28- -- -- -- -- -- -- -- -

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

30- -- -- -- -- -- -- -- -

31 1703953 1701518 1703944 1703945 1703941 1703942 1703943 1703946

32- -- -- -- -- -- -- -- -

33- -- -- -- -- -- -- -- -

34 3252347 1705828 1703980 1703981 1703983 1703984 1703982 1703985

35 1704708 1704708 1704708 1704708 1704708 - - 1704708 1704708

CE/Aus

0275062-5

Japan

0270146-13

Korean/Eng 0270148-14

Eng/Spanish

0270150-14

Eng/French

0270152-15

Chinese/Eng

0270154-14

Port ./Spa

0270156-14

4-26 – JLG Lift – 3121217

Table 4-3. Decal Legend - S/N 0300141450 to Present

SECTION 4 - MACHINE OPERATION

Item # ANSI

0270129-15

36 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644

37 1704705 1704705 1704705 1704705 1704705 1704705 1704705 1704705

38 1702901 1706392 1704119 1704120 1704117 1704116 1704121 1704118

39- -- -- -- -- -1705514- -- -

40 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

41 1704248 1706378 1704331 1704332 1704328 1704329 1704333 1704330

42 1702155 - - 1702155 1702155 1702155 1702155 1702155 1702155

43 1704412 - - 1704412 1704412 1704412 1704412 1704412 1704412

44- -- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -- -

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

47- -- -- -- -- -- -- -- -

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50- -- -- -- -- -- -- -- -

51 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

52 3252673 1706377 3252738 3252739 3252740 3252743 3252741 3252742

53- -- -- -- -- -- -- -- -

CE/Aus

0275062-5

Japan

0270146-13

Korean/Eng 0270148-14

Eng/Spanish

0270150-14

Eng/French

0270152-15

Chinese/Eng

0270154-14

Port ./Spa

0270156-14

3121217 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - S/N 0300141450 to Present

Item # ANSI

0270129-15

54 1704254 - - 1704254 1704254 1704254 1704254 1704254 1704254

55- -- -- -- -- -- -- -- -

56- -- -- -- -- -- -- -- -

57- -- -- -- -- -- -- -- -

58- -- -- -- -- -- -- -- -

59- -- -- -- -- -- -- -- -

60 - - - - - - - - 1703929 1703930 1703931 1703934

61- -- -- -- -- -- -- -- -

62 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

63 1702391 1701517 1701517 1701517 1701517 1701517 1701517 1701517

64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618

65- -- -- -- -- -- -- -- -

66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

67- -- -- -- - - -- -- -

68- -- -- -- - - -- -- -

69 1705351 - - - - 1705427 1705910 1705429 - - - -

70- -- -- -- - - -- -- -

CE/Aus

0275062-5

Japan

0270146-13

Korean/Eng 0270148-14

Eng/Spanish

0270150-14

Eng/French

0270152-15

Chinese/Eng

0270154-14

Port ./Spa

0270156-14

4-28 – JLG Lift – 3121217

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

This section explains the steps to be taken in case of an emergency situation while operating.

5.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 10 FT. (3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

In USA: JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

ProductSafety@JLG.com

Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

3121217 – JLG Lift – 5-1

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

1. Other personnel should operate the machine from ground controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine.

SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine.

5.4 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.

5.5 MANUAL DESCENT SYSTEM

The manual descent system is used, in the event of total power failure, to lower the boom using gravity. To operate the manual descent system, proceed as follows:

TELESCOPING IN AND LOWERING THE BOOM

1. Install the spool plug in the location shown and push the control lever on the valve up.

2. Install the handle into the hand pump and pump the handle until the desired platform position is reached.

3. Push the control lever down when complete. Remove the handle from the hand pump and the spool plug from the valve.

5-2 – JLG Lift – 3121217

SECTION 5 - EMERGENCY PROCEDURES

LOWERING THE BOOM

1. Push the control lever on the valve up.

2. Install the handle into the hand pump and pump the handle

until the desired platform position is reached.

3. Push the control lever down when complete. Remove the handle from the hand pump.

SWING RIGHT

1. Install the spool plug in the location shown.

2. Install the handle into the hand pump and pump the handle

until the desired platform position is reached.

3. Remove the handle from the hand pump.

3121217 – JLG Lift – 5-3

SECTION 5 - EMERGENCY PROCEDURES

SWING LEFT

1. Install the spool plug in the location shown.

2. Install the handle into the hand pump and pump the handle

until the desired platform position reached.

3. Remove the handle from the hand pump.

REMOVE ALL SPOOL PLUGS BEFORE RETURNING UNIT TO SERVICE.

5-4 – JLG Lift – 3121217

SECTION 5 - EMERGENCY PROCEDURES

Figure 5-1. Manual Descent Decal

3121217 – JLG Lift – 5-5

SECTION 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

To operate the MSSO:

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

2. Pull out the Power/Emergency Stop control.

3. Start the engine.

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

the desired function.

5-6 – JLG Lift – 3121217

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual- ANSI, CSA.......................3121117

Service and Maintenance Manual - CE ...................................3121813

Illustrated Parts Manual - ANSI, CSA.........................................3121118

Illustrated Parts Manual - CE........................................................3121814

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications - Prior to S/N 0300141450

Maximum Work Load (Capacity) Un r es t ri c te d : 50 0 lb ( 23 0 kg )

Maximum Travel Grade (Gradeability) with Boom retracted and approximately horizontal. Tower Boom fully lowered.

Maximum Travel Grade (Side Slope) with Boom retracted and approximately horizontal. Tower Boom fully lowered. 5°

Tilt Alarm Setting (See Section 3) AN S I, C SA CE E /M 6 0 0 & E /M 6 00 J CE E /M 6 0 0J P

Maximum Vertical Platform Height: 60 ft. (18.29 m)

Maximum Horizontal Platform Reach E6 0 0 E6 0 0J

Machine Width 2W D 4W D

43 ft. (13.11 m)

42 ft. 9 in. (13.11 m)

7 ft. 11 7/16 in. (2.42 m)

7 ft. 11 3/8 in. (2.42 m)

30%

5° 4° 3°

3121217 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications - Prior to S/N 0300141450

Machine Length E/ M 60 0 E/ M 60 0 J E/ M 60 0 JP

30 ft. 11 5/16 in. (9.43 m) 30 ft. 8 15/16 in. (9.37 m)

33 ft. 3 3/4 in. (10.15 m)

Turning Radius (outside) 15 ft. 3 in. (4.65 m)

Turning Radius (inside) 4 ft. (1.23 m)

Maximum Tire Load: 7700 lbs. (3493 kg)

Maximum Ground Bearing Pressure

E600J/M600J

E600JP/M600JP

52 psi (3.7 kg/cm

51 psi (3.6 kg/cm

Maximum Drive Speed: 3.0 mph (1.3 m/s)

Electrical System Voltage 48 volts

Maximum Hydraulic System Pressure 3200 psi (221 Bar)

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 400N

Table 6-1. Operating Specifications - Prior to S/N 0300141450

Gross Machine Weight (Platform Empty) Prior to S/N 0300104944

E600J/M600J

E600JP/M600JP

16,300 lb. (7,393 kg) 16,800 lb. (7,620 kg)

Gross Machine Weight (Platform Empty) S/N 0300104944 to Present

E600J/M600J

E600JP/M600JP

16,710 lb. (7,580 kg) 17,210 lb. (7,806 kg)

Table 6-2. Operating Specifications - S/N 0300141450 to Present

Maximum Work Load (Capacity) AN S I M a r ke ts Un r es t ri c te d : 50 0 lb . ( 2 27 k g)

Maximum Work Load (Capacity) CE & Au s tr a li a Ma r ke t s Un r es t ri c te d : 50 0 lb . ( 2 30 k g)

Maximum Travel Grade (Gradeability) with Boom

30% retracted and approximately horizontal. Tower Boom fully lowered.

Maximum Travel Grade (Side Slope) with Boom retracted and approximately horizontal. Tower Boom fully lowered. 5°

6-2 – JLG Lift – 3121217

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-2. Operating Specifications - S/N 0300141450 to Present

Tilt Alarm Setting (See Section 3) AN S I, C SA CE E /M 6 0 0 & E /M 6 00 J CE E /M 6 0 0J P

5° 4° 3°

Maximum Vertical Platform Height: 60 ft. (18.29 m)

Maximum Horizontal Platform Reach E6 0 0 E6 0 0J

43 ft. (13.11 m)

42 ft. 9 in. (13.11 m)

Machine Width 2W D 4W D

7 ft. 11 7/16 in. (2.42 m)

7 ft. 11 3/8 in. (2.42 m)

Machine Length E/ M 60 0 E/ M 60 0 J E/ M 60 0 JP

30 ft. 11 5/16 in. (9.43 m) 30 ft. 8 15/16 in. (9.37 m)

33 ft. 3 3/4 in. (10.15 m)

Turning Radius (outside) 15 ft. 3 in. (4.65 m)

Turning Radius (inside) 4 ft. (1.23 m)

Maximum Tire Load: 7700 lbs. (3493 kg)

Maximum Ground Bearing Pressure

E600J/M600J

E600JP/M600JP

52 psi (3.7 kg/cm

51 psi (3.6 kg/cm

Maximum Drive Speed: 3.0 mph (1.3 m/s)

Electrical System Voltage 48 volts

Table 6-2. Operating Specifications - S/N 0300141450 to Present

Maximum Hydraulic System Pressure 3200 psi (221 Bar)

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 400N

Gross Machine Weight (Platform Empty) Prior to S/N 0300104944

E600J/M600J

E600JP/M600JP

16,300 lb. (7,393 kg) 16,800 lb. (7,620 kg)

Gross Machine Weight (Platform Empty) S/N 0300104944 to Present

E600J/M600J

E600JP/M600JP

16,710 lb. (7,580 kg) 17,210 lb. (7,806 kg)

3121217 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Capacities Tires

Table 6-3. Capacities

Generator Fuel Ta nk (M Models Only) 13 gallons (49.2 liters)

Hydraulic Tank Pr i or t o S / N 5 1 94 1 S/N 51941 to Present

Drive Hub 0.4 gal. (1.5 liters)

15 gallons (57 liters)

15.9 gal.(60.2 L)

12 . 4 g a l. ( 46 . 9 L ) to f ul l ma r k

Table 6-4. Tires

Size Type Pressure

36/14 LL-22.5 pneumatic 55 psi (4.0 Bar)

36/14 LL-22.5 foam filled N/A

6-4 – JLG Lift – 3121217

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-5. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F

(-18° to +83° C)

10W

+0° to + 210° F

(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Hydraulic Oil

ISO Viscosity Grade #15

NOTE: Hydraulic oils must have anti-wear qualities at least to API Ser-

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

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same

3121217 – JLG Lift – 6-5

required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 11M is desired, contact JLG Industries for proper recommendations.

Table 6-6. Mobil DTE 11M Specs

Gravity API 31.9

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Visc osity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

Viscos ity Ind ex 140

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-1. Serial Number Location

SERIAL NUMBER

PLATE

SERIAL NUMBER

STAMPED ON FRAME

Major Component Weights Serial Number Location

Table 6-7. Component Weights

Component Pou nds Kilograms

Frame (bare) 1381 626

T/T (bare) 2093 950

Boom Assembly (E/M 600) 4464 2025

Boom Assembly (E/M 600J) 4464 2025

Tire & Wheel 226 102.5

Swing Drive 70 32

Swing Bearing 100 45.4

Platform Console 25 11

Side Entry Platform - 3 0x72 (bare) 175 80

Side Entry Platform - 3 0x48 (bare) 144 66

Counterweight 2560 1161

A serial number plate is affixed to the right side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame at the top.

6-6 – JLG Lift – 3121217

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-2. Operator Maintenance and Lubrication Diagram

3,4

3121217 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-8. Lubrication Specifications.

KEY SPECIFICATIONS

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

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

EPGL Ext reme Pressure Gear Lube (oil) meeting API Service Classification GL-5

or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG

Part No. 3020027)

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

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part No. 3020022)

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/

CD class, MIL-L-2104B/MIL-L-2104C.

6.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-2., Oper-

ator Maintenance and Lubrication Diagram.

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

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

NOTE: It is recommended as a good practice to replace all filters at the

same time.

1. Swing Bearing - Internal Ball Bearing

Lube Point(s) - 1 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation

6-8 – JLG Lift – 3121217

JLG E600, M600J, M600JP, E600J, E600JP Operation And Safety Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 GENERAL

SECTION 1. SAFETY PRECAUTIONS

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 MAINTENANCE

Maintenance Hazards

Battery Hazards

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

Function Check

SkyGuard Function Test

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Platform Control Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

Platform/Ground Select Switch

4.3 MOTOR OPERATION

Power/Emergency Stop

4.4 TRAVELING (DRIVING)

Traveling Forward and Reverse

Traveling on a Grade

4.5 STEERING

4.6 PLATFORM

Platform Level Adjustment

Platform Rotation

4.7 BOOM

Swinging the Boom

Raising and Lowering the Upper Boom

4.8 GENERATOR (OPTIONAL)

Automatic Operating Mode

Battery Only Operating Mode

Manual (Charge) Operating Mode

4.9 FUNCTION SPEED CONTROL

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

4.11 SKYGUARD OPERATION

4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

4.13 SHUT DOWN AND PARK

4.14 LIFTING AND TIE DOWN

Lifting

Tie Down

4.15 TOWING INSTRUCTIONS

4.16 DRIVE HUB

Disengaging for Towing

Engaging after Towing is Complete

5.1 GENERAL

SECTION 5. EMERGENCY PROCEDURES

5.2 INCIDENT NOTIFICATION

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

Platform or Boom Caught Overhead

5.4 EMERGENCY TOWING PROCEDURES

5.5 MANUAL DESCENT SYSTEM

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

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION