JLG M4069 Operator Manual

0 (0)
Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Model 3369LE/4069LE
M3369/M4069
ANSI
P/N - 3121638
June 10, 2014
FOREWORD
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.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DIS­TANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO­NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.
3121638 – JLG Lift – a
FOREWORD
NOTICE
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 POTENTIALITY 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 A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE AN ORANGE BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO­TECTION OF PROPERTY.
b – JLG Lift – 3121638
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
NOTICE
NOTICE
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY­RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
For:
• Accident Reporting
•Product Safety Publica­tions
•Current Owner Updates
• Questions Regarding Product Safety
FOREWORD
• Standards and Regulations Compliance Information
• Questions Regarding Spe­cial Product Applications
• Questions Regarding Prod­uct Modifications
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.
3121638 – JLG Lift – c
Contact:
Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742
or Your Local JLG Office (See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661 E-mail: ProductSafety@JLG.com
FOREWORD
REVISION LOG
Original Issue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 10, 2014
d – JLG Lift – 3121638
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 . . . . . . . . . . . . . . . 1-8
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . 1-9
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . .1-10
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
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
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Preparing the Machine for Operation. . . . . . . . . 2-5
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . 2-11
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . .3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-1
Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 POWER SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Platform/Ground Select. . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 RAISING AND LOWERING. . . . . . . . . . . . . . . . . . . . . . . .4-1
Raising & Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 LEVELING JACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . .4-2
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.6 PLATFORM HANDRAILS FOLD DOWN
PROCEDURE (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . .4-2
4.7 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Traveling Forward and Reverse. . . . . . . . . . . . . . . 4-4
4.8 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.9 SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.10 BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . .4-5
4.11 TIE DOWN/LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . .5-1
5.4 MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . . . . . .5-2
5.5 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . .5-2
Operator Unable to Control Machine . . . . . . . . . .5-2
Platform Caught Overhead . . . . . . . . . . . . . . . . . . .5-2
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 SUPPLEMENTAL INFORMATION. . . . . . . . . . . . . . . . . 6-1
6.3 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Batteries (Electric Machines). . . . . . . . . . . . . . . . . . 6-7
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-8
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-12
6.5 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
SECTION - 7 - INSPECTION AND REPAIR LOG
ii – JLG Lift – 3121638
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Walk-Around Inspection (Sheet 1 of 3) . . . . . . . . . . 2-8
2-2. Walk-Around Inspection (Sheet 2 of 3) . . . . . . . . . . 2-9
2-3. Walk-Around Inspection (Sheet 3 of 3) . . . . . . . . .2-10
2-4. Limit Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . .2-11
3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-3. Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-4. Decal Installation (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-5. Decal Installation (ANSI Export) . . . . . . . . . . . . . . . .3-11
3-6. Decal Installation (CE/AUS) . . . . . . . . . . . . . . . . . . . . 3-17
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-2. Lifting & Tie Down Chart - Sheet 1 of 2 . . . . . . . . . . 4-6
4-3. Lifting & Tie Down Chart - Sheet 2 of 2 . . . . . . . . . . 4-7
6-1. Engine Operating Temperature Specifications -
(Kubota) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-2. Engine Operating Temperature Specifications -
(Kubota) Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-3. Operator Maintenance and
Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
2-2 Drive Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2-3 Tilt vs. Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 Decal Location Legend (ANSI) . . . . . . . . . . . . . . . . . . 3-9
3-2 Decal Location Legend (ANSI Export) . . . . . . . . . . 3-12
3-3 Decal Location Legend (CE/AUS) . . . . . . . . . . . . . . 3-18
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-5 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-6 Engine Battery Specifications. . . . . . . . . . . . . . . . . . . 6-7
6-7 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-9 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6-10 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . 6-11
6-11 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . 7-1
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This page left blank intentionally.
iv – JLG Lift – 3121638

SECTION 1. SAFETY PRECAUTIONS

SECTION 1 - SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to pro­mote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. 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.
These sections contain 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.
3121272 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS

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.
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 floor surfaces for holes, bumps, drop-offs, obstruc­tions, debris, concealed holes, and other potential hazards.
1-2 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
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.
This machine can be operated in nominal ambient temper­atures of 0 mize operation outside of this temperature range.
o
F to 104o F (-20o C to 40o C). Consult JLG to opti-

Machine Inspection

Do not operate this machine until the inspections and func­tional checks have been performed as specified in Section 2 of this manual.
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 deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck.

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.
3121272 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
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.
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.
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.
The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A-Weighted sound pressure level at the work platform is less than 70dB(A). For combustion engine powered machines, guaranteed Sound Power Level (LWA) per European Directive 2000/ 14/ EC (Noise Emission in the Environment by Equipment for Use Outdoors) based on test methods in accordance with Annex III, Part B, Method 1 and 0 of the directive, is 109 dB. The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s2. The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s2.
1-4 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS

Trip and Fall Hazards

Prior to operation, ensure all gates and rails are fastened and secured in their proper position.
JLG Industries, Inc. recommends that all persons in the plat­form wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.
Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. 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.
.
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.
Never use the scissor arm assembly to gain access to or leave the platform.
Keep oil, mud, and slippery substances cleaned from foot­wear and the platform floor.
3121272 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS

Electrocution Hazards

This machine is not insulated and does not provide protec­tion from contact or proximity to electrical current.
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.
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.
1-6 – JLG Lift – 3121272
The minimum approach distance may be reduced if insulat-
ing 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
VOLTAGE RANGE
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
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 govern-
mental regulations are more stringent.
SECTION 1 - SAFETY PRECAUTIONS

Tipping Hazards

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.
The user must be familiar with the driving 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.
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 operate the machine when wind conditions exceed specifications shown in Section 6 of this manual or as shown on the capacity placard on the platform billboard.
3121272 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 5, TABLE 5-2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLAT­FORM BILLBOARD.
Table 1-2. Beaufort Scale (For Reference Only)
BEAUFORT
NUMBER
WIND SPEED
DESCRIPTION LAND CONDITIONS
mph m/s
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 becomes difficult.
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 from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
1-8 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
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.
Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addi­tion of such items increases the exposed wind area of the machine.
Do not increase the platform size with unauthorized deck extensions or attachments.
If the scissor arm assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel.

Crushing and Collision Hazards

Approved head gear must be worn by all operating and ground personnel.
Keep hands and limbs out of the scissor arm assembly dur­ing operation and when elevated without safety prop engaged.
Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bot­tom of platform when lifting or lowering platform.
3121272 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
During operation, keep all body parts inside platform rail­ing.
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 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.
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.
Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes. Barricade floor area if necessary.
Do not operate over ground personnel. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary.
1-10 – JLG Lift – 3121272
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 emergency towing procedures.
Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling.
When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of ade­quate capacity.
Refer to Section 3 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.
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.
3121272 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS
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.
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.
Reference 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.

Battery Hazards

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.
1-12 – JLG Lift – 3121272
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 equipment.
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, drop-offs.
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.
3121638 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE

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-CERTIFIED SERVICE TECHNI­CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3121638
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type Freque ncy
Pre-Star t
Inspection
Pre-Delivery
Inspection (See Note)
In service for 3 months or 150 hours, whichever
Frequent
Inspection
Annual Machine Inspec-
tion
(See Note)
Preventative
Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
3121638 – JLG Lift – 2-3
Out of service for a period of more than 3 months;
Annually, no later than 13 months from the date
At intervals as specified in the Service and Mainte-
Before using each day; or
whenever there’s an Operator change.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic
comes first ; or
or
Purchased used.
of prior inspection.
nance Manual.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic
Owner, Dealer, or User
Owner, Dealer, or User Qualified JLG Mechanic
Service
Qualification
Factory Certified Service
Technician
(Recommended)
Reference
Service and Maintenance Man-
ual and applicable JLG inspection
form
Service and Maintenance Man-
ual and applicable JLG inspection
form
Service and Maintenance Man-
ual and applicable JLG inspection
form
Service and Maintenance Man-
ual
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Parent Metal Crack
Weld Crack

2.3 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. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual is enclosed in the weather resistant storage container.
5. “Walk-Around” Inspection Refer to Figure 2-1., Walk-Around Inspection (Sheet 1 of 3).
6. Battery – Charge as required.
7. Fuel - (Combustion Engine Powered Machines) – Add
the proper fuel as necessary.
8. Engine Oil Supply - Ensure that the engine oil level is at the full mark on the dipstick and the filler cap is secure
9. Fluid Levels - Be sure to check the engine oil and the hydraulic oil levels.
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 instructions on the operation of each function.
2-4 – JLG Lift – 3121638
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