JLG M450 Operator Manual

Operation and Safety Manual

®

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

Boom Lift Models
E450A
E450AJ
M450A
M450AJ

ANSI

3121210

January 7, 2013

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.

3121210 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

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

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

b – JLG Lift – 3121210

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE­TINS. 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.

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:

3121210 – JLG Lift – c

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

FOREWORD

REVISION LOG

Original Issue - June 21, 2005

Revised - July 21, 2006

Revised - December 7, 2009

Revised - August 26, 2010

Revised - October 6, 2011

Revised - August 14, 2012

Revised - January 7, 2013

d – JLG Lift – 3121210

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 . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA­RATION, AND INSPECTION

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Platform Control Indicator Panel . . . . . . . . . . . . 3-12

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

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

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

Platform/Ground Select Switch. . . . . . . . . . . . . . 4-5

Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Loading From Ground Level . . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . . 4-8

3121210 – JLG Lift – i

TABLE OF CONTENTS

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

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

Raising and Lowering the Lower and Mid Boom 4-9

Raising and Lowering the Upper Boom . . . . . . 4-9

4.8 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Automatic Operating Mode . . . . . . . . . . . . . . . 4-10

Battery Only Operating Mode . . . . . . . . . . . . . 4-10

Manual (Charge) Operating Mode. . . . . . . . . . 4-10

4.9 INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 MACHINE FUNCTION SPEEDS . . . . . . . . . . . . . . 4-11

4.11 BOOM SYNCHRONIZING PROCEDURE . . . . . . . 4-11

4.12 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-12

4.13 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

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

5.6 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . .5-3

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE

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

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

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

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

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Torque Specifications. . . . . . . . . . . . . . . . . . . . . 6-5

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

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

Critical Stability Weights . . . . . . . . . . . . . . . . . . . 6-6

Serial Number Locations . . . . . . . . . . . . . . . . . . 6-7

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-9

6.4 BATTERY MAINTENANCE AND CHARGING. . . . .6-14

Battery Maintenance, Quarterly . . . . . . . . . . . . 6-14

Optional On Board Generator . . . . . . . . . . . . . 6-15

Battery Charging (On Board Charger) . . . . . . . 6-15

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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

ii – JLG Lift – 3121210

TABLE OF CONTENTS

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

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-17

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-19

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-9

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10

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

3-2. Ground Control Station w/ Function Enable . . . . . .3-4

3-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-7

3-4. Platform Control Console - w/Drive Orientation . . .3-8

3-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-13

3-6. Platform Control Indicator Panel w/Drive

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

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

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

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-5. Chassis & Platform Tie Down - Sheet 1 of 2 . . . . .4-14

4-6. Chassis & Platform Tie Down - Sheet 2 of 2 . . . . .4-15

4-7. Decal Installation - Sheet 1 of 3 . . . . . . . . . . . . . . .4-16

4-8. Decal Installation - Sheet 2 of 3 . . . . . . . . . . . . . . .4-17

4-9. Decal Installation - Sheet 3 of 3 . . . . . . . . . . . . . . 4-18

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . 6-7

6-2. Operator Maintenance & Lubrication Diagram . . . 6-8

3121210 – JLG Lift – iii

TABLE OF CONTENTS

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

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

3-1 Simultaneous Functions . . . . . . . . . . . . . . . . . . . . 3-11

4-1 E450A/E450AJP Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-2 E450A/E450AJP Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-3 M450A/M450AJ Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-4 M450A/M450AJ Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

6-1 Operating Specifications - Prior to

S/N 0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Operating Specifications - S/N 0300141435

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

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

6-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-6

6-10 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-9

6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-18

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

iv – JLG Lift – 3121210

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
machine use, 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 followed to ensure the
machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine
should not operate the machine 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.

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

• Read and understand this manual before operating the
machine.

• Do not operate this machine until complete training is per­formed by authorized persons.

• Only authorized and qualified personnel can operate the
machine.

3121210 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

• Use the machine in a manner which is within the scope of
its intended application set 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
operation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all haz­ards in the work area prior to machine operation.

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

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

• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.

Machine Inspection

• Before machine operation, perform inspections and func­tional checks. Refer to Section 2 of this manual for
detailed instructions.

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

• Be sure the footswitch and all other 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 WRITTEN PERMISSION FROM THE MANU­FACTURER

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

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

1-2 – JLG Lift – 3121210

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

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

• Never operate a machine that is not working properly. If a
malfunctions occurs, shut down the machine.

• 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. Contact
JLG for approved material handling accessories.

• 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.

• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.

• 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,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.

• Do not place boom or platform against any structure to
steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

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.

3121210 – JLG Lift – 1-3

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 use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.

• Never use the boom assembly to enter or leave the plat­form.

• Use extreme caution when entering or leaving platform.
Be sure that the boom is fully lowered. It may be neces­sary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.

Electrocution Hazards

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

1-4 – JLG Lift – 3121210

SECTION 1 - SAFETY PRECAUTIONS

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

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

1.

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations
are more stringent.

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

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3121210 – JLG Lift – 1-5

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.

1-6 – JLG Lift – 3121210

SECTION 1 - SAFETY PRECAUTIONS

• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.

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

• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi­tion unless the machine is on firm, level and smooth sur­faces.

• Keep the chassis of the machine at least 2 ft. (0.6m) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.

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

• Never attempt to use the machine as a crane. Do not tie­off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For
Reference Only).

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

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

• 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.

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.

3121210 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• 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.

• Limit travel speed according to conditions of ground sur­face, congestion, visibility, slope, location of personnel,
and other factors which may cause collision or injury to
personnel.

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

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

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

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

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

1.4 TOWING, LIFTING, AND HAULING

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

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

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

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

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

1-8 – JLG Lift – 3121210

SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL HAZARDS / SAFETY

• 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.

• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.

• Charge batteries only in a well ventilated area.

3121210 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

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

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

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 r ustle

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. Whistling heard in overhead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t 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.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121210

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, 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.

3121210 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

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

2-2 – JLG Lift – 3121210

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection
(See Note)

Frequent Inspection In ser vice for 3 months or 150 hours, whichever

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

Preventative Maintenance At intervals as specified in the Ser vice and Main-

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 Qualified JLG

comes first;
o r
Out of service for a period of more than 3 months;
o r
Purchased used.

prior inspection.

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory Qualified

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Mechanic

Service Technician
(Recommended)

Mechanic

Reference

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual

3121210 – JLG Lift – 2-3

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. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, EMI Safety Manual
(Domestic only), and ANSI Manual of Responsibilities

(Domestic only) is enclosed in the weather resistant
storage container.

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

6. Battery – Charge as required.

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

proper fuel as necessary.

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

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

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

2-4 – JLG Lift – 3121210

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

A functional check of all systems should be performed, once
the walk-around inspection is complete, in an area free of
overhead and ground level obstructions. First, using the
ground controls, check all functions controlled by the ground
controls. Next, using the platform controls, check all func­tions controlled by the platform controls.

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

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 TO STOP MACHINE.

1. Check boom limit switches. Raise and lower the Lower
Boom. Check for smooth operation.

NOTE: Perform checks from ground controls first, then from plat-

form controls.

2. Raise, extend, retract, and lower the Upper Boom.
Check for smooth operation.

3. If tower boom does not rest on stop with machine in the
stowed position, this indicates upright is out of plumb.

4. Telescope boom IN and OUT several cycles at various
degrees of elevation lengths. Check for smooth tele­scope operation.

5. Swing turntable to LEFT and RIGHT a minimum of 45
degrees. Check for smooth motion.

6. Check the chassis out of level indicator located on the
platform control console by driving, with the machine in
level position, up a suitable ramp of at least 6° slope.
Check the out of level alarm, with the machine on the
ramp, raise the upper boom until it is parallel with the
chassis. DO NOT RAISE ABOVE THE PARALLEL POSI­TION. If the light does not illuminate, return the machine
to a level surface, shut down the machine, and contact a
qualified technician before resuming operation.

For units equipped with optional tilt cutout, verify that the
drive function is cutout when the boom is elevated and
tilt alarm is activated.

3121210 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

With footswitch depressed, operate LIFT and hold control.
Remove foot from footswitch, motion should stop. If it

DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITY
OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO
NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

7. Check that platform self-leveling system functions prop­erly during raising and lowering of boom.

8. Check rotator for smooth operation and assure platform
will rotate 75 degrees in both directions from centerline
of boom.

9. Drive forward and reverse; check for proper operation.

10. Steer left and right; check for proper operation.

11. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER­ATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF
SWITCH OPERATES WITHIN LAST 1/4" (6 MM) OF TRAVEL, TOP OR
BOTTOM, IT SHOULD BE ADJUSTED.

does not, shut down machine and contact a qualified ser­vice technician.

12. Place the GROUND/PLATFORM SELECT switch to
GROUND. Platform controls should not operate.

13. Place GROUND/PLATFORM SELECT switch to OFF.
Platform/Ground controls should not operate.

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC­TION CONTROL, OTHERWISE THE FUNCTION WILL NOT WORK.

2-6 – JLG Lift – 3121210

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1 . P la t fo r m C on t ro l Co ns ol e
2 . Pl a tf o r m
3 . Up p er B oo m

4. Telescope Cylinder
5 . Ma s te r Cy l in d e r
6 . Up p er U pr i gh t
7 . Up p er L if t C yl i n de r

8. Mid Lift Cylinder
9 . L ow er B oo m

10. Turntable

11. Frame

12. Steer Wheels

13. Drive Wheels

14. Battery Box

15. Lower Lift Cylinder

16. Lower Link

17. Lower Upright

18. Upper Link

19. Mid Boom

20. Slave Cylinder

21. Footswitch

3121210 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3, 4

5

6,7

8

9

10

11

12

13

15

10

19

7

20

10

10

23, 16

27

14212215

16

14

17, 18

1

7242

Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3

2-8 – JLG Lift – 3121210

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the “Walk-Around Inspection” at Item 1, as noted on
the diagram. Continue to the right (counterclockwise
viewed from top) checking each item in sequence for the
conditions listed in the “Walk-Around Inspection Checklist”.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR­ING "WALK-AROUND INSPECTION".

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

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

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

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

2. Platform & Ground Control Console - Switches and
levers return to neutral and are properly secured,
decals/placards secure and legible, control marking
legible.

3. Rotator - See Note.

4. Jib - See Note.

5. Jib Rotator - See Note.

6. Boom Sections - See Note.

7. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

8. Limit Switches - See Note.

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

3121210 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Drive Axle and Motor - See Note.

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

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

11. Swing Motor and Worm Gear - See Note.

12. Hydraulic Pump and Reservoir - Properly secured; no

visible damage or hydraulic leaks. Recommended
hydraulic fluid level on dipstick (system shut down,
boom in stowed position). Breather cap/dipstick
secure and working.

13. Turntable Bearing - No loose or missing hardware; no
visible damage; evidence of proper lubrication. No
loose bolts or looseness between bearing and struc­ture.

14. Battery Compartment Right Side - Batteries have
proper electrolyte level; cables tight; no visible dam­age or corrosion.

15. Cowling and Latches - See Note.

16. Battery Charger - See Note.

17. Valve - See Note.

18. Boom/Upright - No visible damage; All pins properly

secured. Upright in vertical position. If Upright does
not rest on stop with machine in the stowed position,
this indicates upright is out of plumb.

19. Counterweight - See Note.

20. Tie Rod Ends and Steering Spindles - See Note. Tie

rod end stubs locked.

21. Manual Descent Valve - See Note.

22. Control Valve - See Note.

23. Frame - See Note.

24. Platform Pivot Pins - Properly secured.

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

2-10 – JLG Lift – 3121210