JLG H340AJ 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 H340AJ

ANSI

AS/NZS

November 5, 2018 - Rev G

3121633

WARNING

Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing. For more information go to www.P65Warnings.ca.gov.

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.

3121633 a

FOREWORD

IMPORTANT

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 3121633

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG

IMPORTANT

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

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

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

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

Contact:

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

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

In USA:

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

Outside USA:

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

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

3121633 c

FOREWORD

REVISION LOG

Original Issue A - January 13, 2015

Revised B - April 25, 2017

Revised C - June 5, 2017

Revised D - September 25, 2017

Revised E - February 28, 2018

Revised F - June 29, 2018 - Revised Covers, Prop 65

Revised G - November 5, 2018

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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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

SECTION - 4 - MACHINE OPERATION

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

4.2 BOOM OPERATING CHARACTERISTICS AND

4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-7

Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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

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

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

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

Auto Start Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Operator Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Fuel Reserve / Shut-Off System (Diesel Engines

Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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TABLE OF CONTENTS

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

4.4 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-10

Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-12

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-13

Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-13

Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-13

4.8 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Automatic Operating Mode. . . . . . . . . . . . . . . . . . . . . . . 4-14

Battery Only Operating Mode. . . . . . . . . . . . . . . . . . . . . 4-14

Manual (Charge) Operating Mode. . . . . . . . . . . . . . . . . 4-15

4.9 INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.13 SHUT DOWN AND PARK/STORAGE POSITION . . . . . . . . 4-18

Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Storage Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.14 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

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 AUXILIARY DESCENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.5 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5.6 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-5

5.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE

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

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

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TABLE OF CONTENTS

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

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

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 6-16

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-17

SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

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

This Page Left Blank Intentionally

iv 3121633

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Ground Control Console with Machine Safety System

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

3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-8

3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-5. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-15

3-6. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-6

4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-7

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-5. Stowed Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-6. Storage Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-7. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-8. Decal Location - ANSI Markets - Sheet 1 of 6 . . . . . . . . . 4-23

4-9. Decal Location - ANSI Markets - Sheet 2 of 6 . . . . . . . . . 4-24

4-10. Decal Location - ANSI Markets - Sheet 3 of 6 . . . . . . . . . 4-25

4-11. Decal Location - ANSI Markets - Sheet 4 of 6 . . . . . . . . . 4-26

4-12. Decal Location - ANSI Markets - Sheet 5 of 6 . . . . . . . . . 4-27

4-13. Decal Location - ANSI Markets - Sheet 6 of 6 . . . . . . . . . 4-28

4-14. Decal Location - CSA - Sheet 1 of 6. . . . . . . . . . . . . . . . . . . 4-31

4-15. Decal Location - CSA - Sheet 2 of 6. . . . . . . . . . . . . . . . . . . 4-32

4-16. Decal Location - CSA - Sheet 3 of 6. . . . . . . . . . . . . . . . . . . 4-33

4-17. Decal Location - CSA - Sheet 4 of 6. . . . . . . . . . . . . . . . . . . 4-34

4-18. Decal Location - CSA - Sheet 5 of 6. . . . . . . . . . . . . . . . . . . 4-35

4-19. Decal Location - CSA - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . 4-36

4-20. Decal Location - CE/AUS - Sheet 1 of 6 . . . . . . . . . . . . . . . 4-39

4-21. Decal Location - CE/AUS - Sheet 2of 6 . . . . . . . . . . . . . . . 4-40

4-22. Decal Location - CE/AUS - Sheet 3 of 6 . . . . . . . . . . . . . . . 4-41

4-23. Decal Location - CE/AUS - Sheet 4 of 6 . . . . . . . . . . . . . . . 4-42

4-24. Decal Location - CE/AUS - Sheet 5 of 6 . . . . . . . . . . . . . . . 4-43

4-25. Decal Location - CE/AUS - Sheet 6 of 6 . . . . . . . . . . . . . . . 4-44

4-26. Decal Location - ANSI Export - Sheet 1 of 6. . . . . . . . . . . 4-47

4-27. Decal Location - ANSI Export - Sheet 2 of 6. . . . . . . . . . . 4-48

4-28. Decal Location - ANSI Export - Sheet 3 of 6. . . . . . . . . . . 4-49

4-29. Decal Location - ANSI Export - Sheet 4 of 6. . . . . . . . . . . 4-50

4-30. Decal Location - ANSI Export - Sheet 5 of 6. . . . . . . . . . . 4-51

4-31. Decal Location - ANSI Export - Sheet 6 of 6. . . . . . . . . . . 4-52

5-1. Auxiliary Descent Decal and Hand Pump . . . . . . . . . . . . . 5-4

6-1. Oil Sampling Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-2. Hydraulic Oil Operation Chart - Sheet 1 of 2. . . . . . . . . . . 6-6

6-3. Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . . 6-7

6-4. Engine Oil Operation Chart - Kubota. . . . . . . . . . . . . . . . . . 6-9

6-5. Operator Maintenance and Lubrication Diagram. . . . . 6-10

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LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally

vi 3121633

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

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

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

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Kubota Z482 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

6-7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-8 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

6-9 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

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

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LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally

viii 3121633

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.

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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 3121633

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.

3121633 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 3121633

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.

3121633 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 R ange

(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 3121633

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.

3121633 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 3121633

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.

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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.

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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, if equipped, 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.

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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 3121633

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.

3121633 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 3121633

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, or drop-offs exist.

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.

3121633 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

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

2-2 3121633

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Type Frequenc y

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection (See Note)

Frequent Inspection (See Note)

Annual Machine Inspection (See Note)

Preventative Maintenance At intervals as specified in the Service and Maintenance

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

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualifie d JLG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of mo re than 3 months; or Purchase d used.

An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f p r i or inspection.

Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Owner, Dealer, or User Factory Trained

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Service

Qualification

Service Technician (Recommended)

Reference

and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

3121633 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Platform

2. Platform Console

3. SkyGuard (If Equipped)

4. Cross Rail

5. Jib

6. Fly Boom Section

7. Base Boom Section

8. Main Lift Cylinder

9. Master Cylinder

10. Upper Upright

11. Lower Upright

12. Tower Lift Cylinder

13. Tower Boom

14. Front Drive/Steer Wheels

15. Rear Drive Wheels

16. Frame

17. Turntable

2-4 3121633

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

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

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

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

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

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

5. Daily Walk-Around Inspection – Perform as instructed.

6. Battery – Charge as required.

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

proper fuel as necessary.

8. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.

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

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

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

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

3121633 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

OAC00300

Daily Walk-Around Inspection

2-6 3121633

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

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

1. Platform Assembly and Gate - Footswitch works properly, not modified, disabled or blocked. Latch and hinges in working condition.

2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legible, control markings legible.

3. Boom Sections/Uprights/Turntable - See Inspection Note.

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

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

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

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

7. Hood Assemblies - See Inspection Note.

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

hydraulic hoses undamaged, not leaking.

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

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

11. Hydraulic Pump - See Inspection Note.

12. Fuel Tank - See Inspection Note.

13. Hydraulic Reservoir - See Inspection Note.

14. Battery - Cables tight; see Inspection Note.

15. Platform Rotator - See Inspection Note.

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

3121633 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Prior to performing the function check, verify that the battery disconnect on the side of the frame works properly.

1. Position the Platform/Ground Select switch to the ground position.

2. Pull out the Power/Emergency Stop Switch on the ground console to power up the machine.

3. Turn the Battery Disconnect Switch to the Off position.

4. Watch the Indicator Gauge on the Ground Control Console to verify the power is disconnected.

NOTE: NOTE: If the Platform/Ground Select switch is in the Platform

position, it will take approximately 10 seconds for the Control System power to be shut down.

5. If the power shuts down properly, turn the Battery Disconnect Switch back to the On position. Look at the display to verify the power has been turned back on and resume the Function Check. If the power did not shut down or turn on properly, Report the problem to the proper maintenance personnel. Do not operate the machine until it is declared safe for operation.

2-8 3121633

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or locks

are in place;

b. Operate all functions and ensure proper operation;

c. Check auxiliary descent and ensure proper operation;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure all boom functions stop when the function

enable switch is released.

2. From the platform control console:

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

proper location;

b. Check that all guards protecting the switches or locks

are in place;

c. Operate all functions and ensure proper operation;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

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

switch is released.

3. With the platform in the stowed position:

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

gradeability, and stop to ensure the brakes hold;

b. Check that the tilt indicator is illuminated to ensure

proper operation.

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

3121633 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test

NOTE: Refer to Section 4.12 for additional information on SkyGuard

operation.

From the Platform Console in an area free from obstructions:

1. Operate the telescope out function.

2. Activate the SkyGuard sensor:

a. SkyGuard - Apply approximately 50 lb (222 Nm) of

force to yellow bar.

b. SkyGuard - SkyLine - Press cable to break magnetic

connection between the cable and right bracket.

c. SkyGuard - SkyEye - Put arm or hand in path of sensor

beam.

3. Once the sensor has been activated, verify the following conditions:

a. Telescope out function stops and telescope in function

operates for a short duration.

b. The horn sounds.

c. If equipped with a SkyGuard beacon, the beacon illumi-

nates.

4. Disengage the SkyGuard sensor, release controls, then recycle the footswitch. Ensure normal operation is available.

NOTE: On machines equipped with SkyLine, reattach magnetic end of

the cable to the bracket.

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 sensor is disengaged.

2-10 3121633

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 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.

NOTE: Ensure boom is fully retracted, lowered, and centered between

rear wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control console, start engine.

3. Place the Drive control lever to the forward position and

carefully drive machine up ascension ramp until left front wheel is on top of block.

4. Carefully activate Swing control lever and position boom over right side of machine.

5. With boom over right side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground.

7. Carefully activate Swing control lever and return boom to stowed position (centered between rear wheels). When

boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders.

8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel.

9. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block.

10. With boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.

12. Carefully activate Swing control lever and return boom to stowed position (centered between rear wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate Drive to release cylinders.

13. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3121633 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-12 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

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

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

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control consoles that use sym-

bols to indicate control functions. On ANSI machines refer to decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions.

NOTE: The indicator panels use different shaped symbols to alert the

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

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

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

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

3121633 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Indicator Gauge

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

Ground Control Console

(See Figure 3-1., Ground Control Console)

1. Indicator Panel

The Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation.

NOTE: The Function Enable switch must be held down in

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

Registers the amount of time the machine has been in use, with functions operating and also displays the state of battery discharge. 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 illuminate when there is a fault on the machine to draw operator attention to the display.

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

3. Power/Emergency Stop Switch

A two-position red mushroom shaped switch supplies power to PLATFORM/GROUND SELECT switch when pulled out (on). When pushed in (off ), power is shut off to the PLATFORM/GROUND SELECT switch.

3-2 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001119230 A

Figure 3-1. Ground Control Console

1. Indicator Panel

2. Indicator Gauge

3. Power/Emergency Stop

4. Platfor m/Ground Select

5. Telescope

6. Not Used

7. Main Boom Lift

8. Tower Boom Lift

9. Swing

10. Engine Start/Auxiliary Descent Enable/ Fu n ct i o n E n ab l e

11. Platform Rotate

12. Platform Level

13. Jib Lift

3121633 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001165852A

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

1. Indicator Panel

2. Indicator Gauge

3. Power/Emergency Stop

4. Platfor m/Ground Select

5. Telescope

6. Machine Safe ty System Override (MSSO)

7. Main Boom Lift

8. Tower Boom Lift

9. Swing

10. Engine Start/Auxiliary Descent Enable/ Fu n ct i o n E n ab l e

11. Platform Rotate

12. Platform Level

13. Jib Lift

3-4 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

tion, power is shut off to the controls at both operating consoles. Remove the key to prevent the controls from being actuated.

4. Platform/Ground Select Switch

The three position, key operated switch supplies power to the platform control console when positioned to PLATFORM. With the switch key turned to the GROUND position only ground controls are operable.

5. Telescope Control

Provides extension and retraction of the boom.

6. 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.

7. Main Boom Lift

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

8. Towe r Boom Li f t

Provides raising and lowering of the tower boom.

3121633 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Swing

Provides 355 degrees non-continuous turntable rotation.

10. Engine Start/ Auxiliary Descent Enable /Function Enable

To start the engine, the switch must be toggled "UP" until the engine starts.

To use auxiliary descent enable, the switch must be held “DOWN” for duration of function use.

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

11. Platform Rotate

Provides rotation of the platform.

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

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.

13. Jib Lift

Provides raising and lowering of the jib.

3-6 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel

(See Figure 3-3., Ground Control Indicator Panel)

1. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function has been activated.

2. High Engine Temperature Indicator

Indicates that engine coolant temperature is abnormally high and service is required.

3. Low Engine Oil Pressure Indicator

Indicates that engine oil pressure is below normal and service is required.

4. Genset Auto Indicator

Indicates the genset control is positioned to allow automatic starting when the batteries need charged.

5. Low Fuel Level Indicator

Indicates the fuel level is low. The Fuel Reserve/Cut-Out System will shut the engine

down (or allow it start and run for an additional minute, depending upon machine setup) before the fuel tank is emptied.

6. Glow Plug Indicator

Indicates the glow plugs are operating.

7. System Distress Indicator

The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

The system distress indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

8. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

3121633 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-3. Ground Control Indicator Panel

1. Drive and Steer Disable

2. High Engine Coolant Temperature

3. Low Engine Oil Pressure

4. Genset Automatic

5. Low Fuel

6. Glow Plug

7. System Distress

8. Platform Overload

3-8 3121633

Platform Console

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

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

1. Maximum Speed/Reduced Speed

The forward position gives maximum drive speed. The back position gives reduced speed for improved maneuvering in tight areas.

2. Platform Leveling Override

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

3. Horn

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

4. Power/Emergency Stop Switch

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

3121633 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Maximum Speed/Reduced Speed

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Start/Au xiliary Descent Enable

6. Generator Enable

7. Drive Orientation Override

8. Drive/Steer

9. Telescope

10. Lights

11. Jib Lift

12. SkyGuard Override

13. Towe r Boom Lift

14. SkyGuard Indicator

15. Platform Rotate

16. Function Speed Control

17. Main Lift/Swing Controller

Figure 3-4. Platform Control Console

3-10 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Start/Auxiliary Descent Enable

When pushed forward, the switch energizes the starter motor to start the engine.

NOTE: After turning on ignition, the JLG Control System

will wait until glow plug indicator light goes out before cranking engine.

When pushed back, it energizes Auxiliary Descent Enable which allows the boom and jib to be lowered in the event of system malfunction. Gravity is used to control valves and lower the booms and jib. The functions that can be operated with this control are:

• Main Lift Down

• Tower Lift Down

• Jib Lift Down

6. Generator Enable Control

The Generator Enable control switch, when in the off position, allows the operator to prevent the generator engine from starting when using the machine indoors. When in the on position (and the ground Emergency Stop Switch on [pulled out]), the generator is enabled to automatically start when the batteries need charged.

7. Drive Orientation Override

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

3121633 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: To operate the Drive joystick, pull up on the lock-

ing ring below the handle.

NOTE: The Drive joystick is spring loaded and will auto-

matically return to neutral (off) position when released.

8. Drive/Steer

Push forward to drive forward, pull back to drive in reverse. Steering is accomplished via a thumb-activated rocker switch on the end of the steer handle.

9. Telescope

Provides extension and retraction of the main boom.

10. Lights (If Equipped)

This switch operates the chassis lights if the machine is so equipped.

11. Jib Lift

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

12. Skyguard Override Switch (If equipped)

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

13. Towe r Boom Li f t

Provides for raising and lowering of tower boom when positioned up or down.

14. SkyGuard Indicator (If Equipped)

Indicates the SkyGuard sensor has been activated. All controls are cut out until the override button is pushed.

3-12 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

15. Platform Rotate

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

16. Function Speed Control

This control affects the speed of telescope, tower lift and jib lift. Turning the knob all the way counterclockwise until it clicks puts drive, tower lift and swing into creep mode.

NOTE: To operate the Main Boom Lift/Swing joystick,

pull up on the locking ring below the handle.

NOTE: The Main Boom Lift/Swing joystick is spring

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

17. Main Lift/Swing Controller

Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected.

3121633 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Tilt Angle Market

4° CE & Australia

5° ANSI, CSA & Japan

Platform Control Indicator Panel

(See Figure 3-5., Platform Control Indicator Panel)

NOTE: The indicator lights will illuminate for approximately 1 second

when the key is positioned to the on position to act as a self test.

1. AC Inverter (If Equipped)

Indicates the inverter is in operation.

2. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

3. Tilt Alarm Warning Light and Alarm

This red illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on an excessive slope and the boom is out of transport position. If lit when boom is out of transport position, 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.

3-14 3121633

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001170083 C

910

1. AC Inverter

2. Platform Overload

3. Tilt

4. Glow Plug/Wait to Start

5. Enable/Footswitch

6. Fuel Level

7. Creep

8. System Distress

9. Drive Orientation

10. Low Battery

Figure 3-5. Platform Control Indicator Panel

3121633 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

LOW F UEL

(FLASHES THR EE

TIMES

PER SECOND

Figure 3-6. Fuel Level Indicator

4. Glow Plug/Wait to Start Indicator

Indicates the glow plugs are operating.

6. Fuel Level Indicator

Indicates the level of fuel in the tank.

5. Enable Indicator/Footswitch

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

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

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

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

3-16 3121633

7. Creep Speed Indicator

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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. The light will be on continuously if the operator selects creep speed or if the control system puts the machine into creep speed. In addition, if the control system puts one or more individual functions in creep speed, the indicator flashes when that function is selected.

8. System Distress Indicator

9. 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 verify that the drive control is being operated in the proper direction (i.e. controls reversed situations).

10. Low Battery Indicator

Indicates the batteries are low and need to be charged.

3121633 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-18 3121633

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

This machine is a mobile elevating work platform used to position personnel, along with their necessary tools and materials at work locations.

The primary operator control console is in the platform. From this control console, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the boom or swing the boom to the left or right. Standard boom swing is 355 degree non-continuous. The machine has a Ground Control Console which will override the Platform Control Console. Ground Controls operate all functions except drive and steer, 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.

3121633 4-1

SECTION 4 - MACHINE OPERATION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Raising boom above horizontal with or without any load in platform, is based on the following criteria:

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

2. Load is within manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Machine is as originally equipped from JLG.

Stability

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

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

4.3 ENGINE OPERATION

NOTE: When operating a machine at high altitudes, a decrease in

machine performance may occur due to a decrease in air density.

NOTE: When operating a machine at high ambient temperatures, a

decrease in machine performance and an increase in engine coolant temperature may occur.

NOTE: Contact JLG Customer Service for operation under abnormal

conditions.

There are three engine starting modes: Auto Start, Operator Start, and Jump Start. In the Auto Start mode, an audible warning will sound before the GenSet will start the engine. The other two modes require the operator to engage the Start switch to begin the engine start sequence.

NOTE: The engine is started by the genset, not the engine starter. The

engine starter only functions for Jump Start operation.

4-2 3121633

SECTION 4 - MACHINE OPERATION

Auto Start Mode

The JLG Control System will automatically start the engine when the Generator Enable switch is in the On position and the JLG Control system reads the battery stack state of charge is in a Low Discharged State and an engine start is required to supply a charge to the battery stack.

Operator Start

NOTE: Initial starting should always be performed

from the Ground Control console.

IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.

1. Turn key of Platform/Ground Select switch to Ground.

2. Pull the Power/Emergency Stop switch to On.

3. Push the Engine Start switch.

NOTE: After turning on ignition, the JLG Control System

will wait until glow plug indicator light goes out before cranking engine.

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

4. After engine has had sufficient time to warm up, push in the Power/Emergency Stop switch and shut engine off.

3121633 4-3

SECTION 4 - MACHINE OPERATION

5. Turn Platform/Ground Select switch to Platform.

6. Pull out the Ground Console Power/Emergency Stop switch to provide power to the platform controls.

7. From Platform, pull Power/Emergency Stop switch out.

8. Push the Engine Start switch.

NOTE: Footswitch must be in released (up) position before genset or

starter will operate. If genste or starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.

Shutdown Procedure

If the genset is in automatic mode, the engine will shut down

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.

1. Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature.

2. Push Power/Emergency Stop switch in.

3. Turn Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

4-4 3121633

SECTION 4 - MACHINE OPERATION

Jump Starting

The JLG Control System allows the operator to jump start the engine from an external battery in order to recover from a battery stack voltage that is too low in power for the GenSet module to start the engine. The JLG Control System senses the machine is in Jump Start mode when an external battery has been connected to machine jump terminal.

To start the machine in Jump Start Mode:

1. Connect the positive battery contact of the external battery to the machine jump terminal.

2. Connect the negative battery contact of the external battery to a grounded location on the machine.

3. Refer to Operator Start and start the engine.

Fuel Reserve / Shut-Off System (Diesel Engines Only)

The Fuel Shutoff System senses when the fuel level is getting low and automatically shuts the engine down before the fuel tank is emptied.

Depending upon machine setup, the machine will either keep the engine shut down until the fuel tank is refilled or the operator will be able to restart and run the engine for an additional minute. After 2 minutes, the engine will shut off for a second time and the machine will return to the engine shutdown mode until the fuel tank is refilled.

3121633 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

LOWER BOOM

FULLY ELEVATED

MAIN BOOM

HORIZONTAL

MAIN BOOM

FULLY EXTENDED

MACHINE WILL "TIP OVER" IN THIkyg

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

4-6 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability

LOWER BOOM

FULLY ELEVATED

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

PLATFORM ROTATED

90 DEGREES

3121633 4-7

SECTION 4 - MACHINE OPERATION

4.4 TRAVELING (DRIVING)

See Figure 4-3., Grade and Side Slopes

NOTE: Refer to the Operating Specifications table for Gradeability and

Sideslope ratings.

All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted.

Traveling is limited by two factors:

1. Gradeability, which is the percent of grade of the incline the machine can climb.

2. Sideslope, which is the angle of the slope the machine can be driven across.

DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE 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 IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.

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, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF TRAVEL.

4-8 3121633

GRADE

LEVEL

SI DE SLOPE

Figure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION

3121633 4-9

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

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

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

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

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

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

4-10 3121633

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.

3121633 4-11

SECTION 4 - MACHINE OPERATION

4.6 PLATFORM

Platform Level Adjustment

NOTE: On CE market machines, the Platform Leveling Override function

will only operate when no other functions are being activated.

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.

4.7 BOOM

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

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (4 DEGREE OR GREATER ON CE & AUSTRALIA SPEC MACHINES, 5 DEGREE OR GREATER ON ANSI, CSA, & JAPAN SPEC MACHINES). CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL OR DRIVING WITH THE BOOM ELEVATED.

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

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.

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

4-12 3121633

SECTION 4 - MACHINE OPERATION

Raising and Lowering the Main Boom

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

Swinging the Boom

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

Raising and Lowering the Tower Boom

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

To raise or lower the Main Boom, use Main Boom Lift controller to select UP or DOWN movement.

Telescoping the Main Boom

To extend or retract the main boom, use the Main Telescope Control Switch to select IN or OUT movement.

3121633 4-13

SECTION 4 - MACHINE OPERATION

4.8 GENERATOR

The machine is equipped with an engine powered DC generator connected in parallel to the 48V DC battery bank.

Automatic Operating Mode

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

1. Ground Control Emergency Stop Switch is pulled out (on), and

2. The Generator Enable switch on the platform control console 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 the battery voltage drops as a result of discharge and will turn off when batteries are fully charged.

Battery Only Operating Mode

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

1. Ground Control Emergency Stop Switch is pulled out (on), and:

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

In this mode the machine will operate as a conventional battery operated unit. The batteries can be used until they are fully discharged.

4-14 3121633

SECTION 4 - MACHINE OPERATION

Manual (Charge) Operating Mode

The generator will operate in manual mode always when the following three conditions apply.

1. Ground Control Emergency Stop Switch is pulled out (on), and

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

3. The Manual Charge push button is activated.

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

4.9 INVERTER

The inverter converts 48 VDC to 110 VAC to allow operation of power tools from the machine’s batteries.

• The inverter is operational when the emergency stop switch is pulled out.

• The machine and inverter can be operated at the same time.

• The inverter will shut off at approximately 42 VDC and stay off until the emergency stop switch is recycled. It will operate again until voltage drops to 42 VDC.

• The machine will operate down to 36 VDC.

• The inverter will shut down if the high temperature light indicated overheating. It will automatically turn back on when cooled.

• The overload light indicates an output wiring short circuit or a load that is too large for the rating of the inverter.

4.10 FUNCTION SPEED CONTROL

This control affects the speed of telescope, tower boom lift and jib lift. Turning the knob all the way counterclockwise until it clicks puts drive, main lift, platform rotate, and swing into creep mode.

3121633 4-15

SECTION 4 - MACHINE OPERATION

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

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

4.12 SKYGUARD OPERATION

SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actuation will reverse or cutout. The SkyGuard Function Table provides more details on these functions.

During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

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

Consult the following illustrations to determine which type of SkyGuard the machine has. Regardless of type, SkyGuard function according to the SkyGuard Function Table does not change.

SkyGuard

Approximately 50 lb (222 Nm) of force is applied to yellow bar.

SkyGuard - SkyLine

Cable is pressed, breaking the magnetic connection between the cable and right bracket.

4-16 3121633

Reattach magnetic end of cable to bracket if it becomes disconnected.

SkyGuard Function Table

SECTION 4 - MACHINE OPERATION

SkyGuard - SkyEye

Operator passes through path of sensor beam.

Drive

Forw ard

R * / C ** R C R R C R R R C C C C

R = Indicates Re versal is Activated

C = Indicates Cutout is Ac tivated

* DO S En a bl e d D i s re ga r d w h en b oo m is i n l i n e a n d d r iv i ng f or w a rd wi t h or w it h ou t st e er i ng a nd n o o t he r fu n c ti o n a c t iv e

* * DOS Disabled and any function is active if the machine is driving forward and in line

Drive

Reverse

Steer Swing

Towe r Lift Up

Towe r

Lift

Down

Boom

Lift Up

Boom

Lift

Down

Boom

Tel e Out

Boom Tel e In

Jib Lift

Basket

Level

Basket Rotate

3121633 4-17

SECTION 4 - MACHINE OPERATION

4.13 SHUT DOWN AND PARK/STORAGE POSITION

Shut Down and Park

See Figure 4-5.

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

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Shut down Emergency Stop at Platform Controls.

4. Shut down Emergency Stop at Ground Controls. Position

Platform/Ground Select switch to center OFF.

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

Storage Position

(See Figure 4-6.)

The procedure to place the machine in the storage position is as follows:

1. Place the machine in the stowed position. Refer to Figure 4-

5. From the ground control station, raise the main boom at least to the elevation shown in Figure 4-6. The main boom must be raised to prevent the platform basket from hitting the ground during this procedure.

2. Activate Platform Level Down until the platform is in the position shown.

THE PLATFORM BASKET MUST NOT BE IN CONTACT WITH THE GROUND, BLOCKING, OR ANY TIE DOWN EQUIPMENT.

3. Place blocking under the platform support, lower the platform support down onto the blocking by using Main Boom Lift Down, and tie it down as shown in Figure 4-6.

4-18 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-5. Stowed Position

3121633 4-19

SECTION 4 - MACHINE OPERATION

7.09 f t.

2.15 m

Figure 4-6. Storage Position

BLOCKING/SUPPORT

TIE DOWN STRAP

4-20 3121633

SECTION 4 - MACHINE OPERATION

4.14 LIFTING AND TIE DOWN

(See Figure 4-7.)

Lifting

1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to the

machine and so the machine remains level.

Tie Down

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

1. Place the boom in the stowed position or storage position.

2. Remove all loose items from the machine.

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

adequate strength.

3121633 4-21

SECTION 4 - MACHINE OPERATION

43.4”/1.10m

B 41.4”/1.05m

H340AJ

1001119576 B

Figure 4-7. Lifting and Tie Down Chart

4-22 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Location - ANSI Markets - Sheet 1 of 6

3121633 4-23

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Location - ANSI Markets - Sheet 2 of 6

4-24 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location - ANSI Markets - Sheet 3 of 6

3121633 4-25

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Location - ANSI Markets - Sheet 4 of 6

4-26 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Location - ANSI Markets - Sheet 5 of 6

3121633 4-27

SECTION 4 - MACHINE OPERATION

Figure 4-13. Decal Location - ANSI Markets - Sheet 6 of 6

4-28 3121633

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001169310-E

1- -

2- -

3- -

4- -

5 1001131269

6 1701500

7 1701499

8 1701504

9 1701509

10 1702391

11 1703804

12 1703953

13 1701642

14 1702300

15 1702631

16 - -

17 - -

18 - -

19 - -

Item # ANSI

1001169310-E

20 1704277

21 1704412

22 - -

23 1703797

24 1703798

25 3252347

26 1703805

27 1001121801

28 1001121814

29 - -

30 - -

31 - -

32 - -

33 1001119576

34 1001170058

35 - -

36 - -

37 1702868

38 1705351

39 - -

3121633 4-29

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001169310-E

40 - -

41 - -

42 - -

43 1001170056

44 1001170057

45 1001120002

46 1001119981

47 1701529

48 1001127549

49 1001127588

50 1701644

51 1702155

52 1705929

54 1001174449

55 1001170676

56 1001170061

57 1705514

58 1001182809

4-30 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-14. Decal Location - CSA - Sheet 1 of 6

3121633 4-31

SECTION 4 - MACHINE OPERATION

7751

Figure 4-15. Decal Location - CSA - Sheet 2 of 6

4-32 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-16. Decal Location - CSA - Sheet 3 of 6

3121633 4-33

SECTION 4 - MACHINE OPERATION

34 54

Figure 4-17. Decal Location - CSA - Sheet 4 of 6

4-34 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-18. Decal Location - CSA - Sheet 5 of 6

3121633 4-35

SECTION 4 - MACHINE OPERATION

1111

14532

Figure 4-19. Decal Location - CSA - Sheet 6 of 6

4-36 3121633

SECTION 4 - MACHINE OPERATION

Item # Eng/French

1001169314-E

1- -

2- -

3- -

4- -

5 1001131269

6 1701500

7 1701499

8 1701504

9 1701509

10 1001113169

11 1703948

12 1703942

13 1701642

14 1702300

15 1702631

16 - -

17 - -

18 - -

19 - -

Item # Eng/French

1001169314-E

20 1704277

21 1704412

22 - -

23 1703924

24 1705347

25 1703984

26 1703936

27 1001121803

28 1001121816

29 - -

30 - -

31 - -

32 - -

33 1001119576

34 1001170058

35 - -

36 - -

37 1704000

38 1705429

39 - -

3121633 4-37

SECTION 4 - MACHINE OPERATION

Item # Eng/French

1001169314-E

40 - -

41 - -

42 - -

43 1001170056

44 1001170057

45 1001120004

46 1001119981

47 1701529

48 1001127549

49 1001127588

50 1701644

51 1702155

52 1706097

54 1001174449

55 1001170672

56 1001170061

57 1705514

58 1001182809

4-38 3121633

SECTION 4 - MACHINE OPERATION

Figure 4-20. Decal Location - CE/AUS - Sheet 1 of 6

3121633 4-39

SECTION 4 - MACHINE OPERATION

7 751

243454

Figure 4-21. Decal Location - CE/AUS - Sheet 2of 6

4-40 3121633

SECTION 4 - MACHINE OPERATION

6 614 14

Figure 4-22. Decal Location - CE/AUS - Sheet 3 of 6

3121633 4-41

SECTION 4 - MACHINE OPERATION

147

Figure 4-23. Decal Location - CE/AUS - Sheet 4 of 6

4-42 3121633

JLG H340AJ 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

Daily Walk-Around Inspection

Function Check

SkyGuard Function Test

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Console

Ground Control Indicator Panel

Platform Console

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 ENGINE OPERATION

Auto Start Mode

Operator Start

Shutdown Procedure

Jump Starting

Fuel Reserve / Shut-Off System (Diesel Engines Only)

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

Raising and Lowering the Main Boom

Swinging the Boom

Raising and Lowering the Tower Boom

Telescoping the Main Boom

4.8 GENERATOR

Automatic Operating Mode

Battery Only Operating Mode

Manual (Charge) Operating Mode

4.9 INVERTER

4.10 FUNCTION SPEED CONTROL

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

4.12 SKYGUARD OPERATION

SkyGuard

SkyGuard - SkyLine

SkyGuard Function Table

SkyGuard - SkyEye

4.13 SHUT DOWN AND PARK/STORAGE POSITION

Shut Down and Park

Storage Position

4.14 LIFTING AND TIE DOWN

Lifting

Tie Down