JLG M600 User Manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
R6
P/N - 3121684
September 22, 2014
NOTES:
SECTION - 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.
3121684 – JLG Lift – a
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
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,
COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN
ORANGE BACKGROUND.
b – JLG Lift – 3121684
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 INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY
OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
NOTICE
NOTICE
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH
MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT
THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES
WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE
HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Product Modifications
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
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
3121684 – JLG Lift – c
SECTION - REVISION LOG
Original Issue of Manual. . . . . . . . . . . . . . . . . . . . . September 22, 2014
REVISION LOG
d – JLG Lift – 3121684
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . B
Contact: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Outside USA:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Operator Training and Knowledge. . . . . . . . . . . . . . . . . . . . . .1-2
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Crushing and Collision Hazards. . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . .2-2
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . .2-6
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . .3-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.4 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.5 MACHINE CONTROL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.6 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . . .3-5
3.7 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Ground Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . .3-7
3121684 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Key Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Platform Lift/Lower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
MDI-Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
Overload Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.8 SCISSOR ARM - SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3.9 PLATFORM CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Platform Emergency Stop Switch) . . . . . . . . . . . . . . . . . . . . .3-13
Lift/Drive Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Forward/Reverse/Lift/Lower Direction Decal. . . . . . . . . . .3-13
Drive/Lift/Steer Joystick Control . . . . . . . . . . . . . . . . . . . . . . .3-14
Steering And Traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Traveling Forward and Reverse. . . . . . . . . . . . . . . . . . . . . . . .3-15
Raising And Lowering Platform. . . . . . . . . . . . . . . . . . . . . . . .3-17
Arm Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Overload Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
Tilt Indicator Warning Light and Alarm . . . . . . . . . . . . . . . .3-18
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
Low Battery Charge and System Fault Indicator . . . . . . . .3-18
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3.10 PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3.11 PARKING AND STOWING MACHINE. . . . . . . . . . . . . . . . . . . . . .3-20
Anti-Vandalism Package - Option. . . . . . . . . . . . . . . . . . . . . .3-21
3.12 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . .3-21
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3.13 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
Mechanical Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . .4-1
Platform Caught Overhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Righting of Tipped Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 PLATFORM MANUAL DESCENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Other Publications Available Specific to this Machine:. . . 5-1
5.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Machine Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
ii – JLG Lift – 3121684
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Lubrication Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.6 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Battery Maintenance and Safety Practices. . . . . . . . . . . . . . .5-9
Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . .5-9
5.7 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 DECAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9 DIAGNOSTIC TROUBLE CODES (DTC). . . . . . . . . . . . . . . . . . . . 5-14
5.10 DTC CHECK TABLE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.11 DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES . . . . 5-15
0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
2-4 Low/High Temperature Cutout . . . . . . . . . . . . . . . . . . . 5-19
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . 5-21
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . 5-21
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
6-6 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
8-2 LSS - Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . 5-27
8-4 Elevation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
SECTION - 6 - INSPECTION AND REPAIR LOG
3121684 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2. Machine Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . 2-9
3-1. R6 - Location of Machine Controls. . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Charger Decal LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. MDI Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3-5. Location of Manual Descent Control . . . . . . . . . . . . . . . . . .3-9
3-6. R6 - Scissor Arm - Safety Prop . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-7. Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-8. Platform Control Components. . . . . . . . . . . . . . . . . . . . . . .3-14
3-9. Grade and Sideslope Definition . . . . . . . . . . . . . . . . . . . . . .3-16
3-10. Platform Deck Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-11. Securing Control Station to Platform. . . . . . . . . . . . . . . . .3-20
3-12. Fork Lift Pockets - Location . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-13. Lifting Using Spreader Bar and Lift Lug Locations. . . . .3-22
3-14. Tie Down and Lift Lug Locations . . . . . . . . . . . . . . . . . . . . .3-23
3-15. Electric Brake Release - Location . . . . . . . . . . . . . . . . . . . . .3-24
3-16. Brake - Manual Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
4-1. Location of Manual Descent Control . . . . . . . . . . . . . . . . . .4-2
5-1. Hydraulic Oil Check Procedure. . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-3. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . .5-11
5-4. Machine Decal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . .1-7
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . . .1-8
2-1 Inspection and Maintenance Table. . . . . . . . . . . . . . . . . . . .2-3
2-2 High Drive Cutout Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-3 Tilt Activation Setting - Australia . . . . . . . . . . . . . . . . . . . . . .2-9
3-1 Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . .3-5
5-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 Platform Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-6 Electrical System Specifications . . . . . . . . . . . . . . . . . . . . . . .5-5
5-7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-8 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-10 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-12 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-13 Machine Decal Installation Chart. . . . . . . . . . . . . . . . . . . . .5-13
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
iv – JLG Lift – 3121684
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.
3121684 – 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 – 3121684
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.
3121684 – 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 – 3121684
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.
3121684 – 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 – 3121684
• 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 5, Table 5-2 or as shown on
the capacity placard on the platform billboard.
3121684 – 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 – 3121684
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.
3121684 – 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 – 3121684
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.
3121684 – 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 – 3121684
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.
Operator Training
Operator training must cover:
• Use and limitations of the controls in the platform and at the
ground, emergency controls and safety features.
• Control labels, instructions, and warnings on the machine.
• Rules of the employer and government regulations.
• Use of approved fall protection equipment.
• Enough knowledge of the mechanical operation of the machine to
recognize a malfunction or potential malfunction.
• The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes,
and drop-offs exist.
• Means to avoid the hazards of unprotected electrical conductors.
• Specific job requirements or machine application.
• Reading and understanding the Operation and Safety Manual.
3121684 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
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.
NOTE: The Manufacturer or Distributor will provide qualified
people for training assistance with the first unit(s) delivered and from that time forward as requested by the user
or his/her personnel.
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
Table 2-1 explains 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.
2-2 – JLG Lift – 3121684
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE
Table 2-1. Inspection and Maintenance Table
TYPE FREQUENCY
Pre-Start Inspec tion Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection
(see note below)
Frequent Inspection In service for 3 months or 150 hours, whichever comes
Annual Machine
Inspection
(see note below)
Preventative Maintenance At intervals as specified in the Ser vice and Mainte-
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
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.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG
first; or Out of service for a period of more than 3
months; or Purchased used.
Annually, no later than 13 months from the date of
prior inspection.
nance Manual.
PRIMARY
RESPONSIBILITY
User or Operator User or Operator Operation and Safety Manual
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Factory Trained Ser-
Owner, Dealer, or User Qualified JLG
SERVICE
QUALIFICATION
Mechanic
Mechanic
vice 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
3121684 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.3 PRE-START INSPECTION
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil or battery fluid) or foreign objects. Report this to the proper
maintenance personnel.
2. Structure - Inspect the machine structure for dents,
damage, weld or parent metal cracks or other discrepancies. Report this to the proper maintenance personnel.
.
Parent Metal Crack Weld Crack
3. Decals and Placards – Check all for cleanliness and
legibility. Ensure none of the decals and placards are
missing. Ensure all illegible decals and placards are
cleaned or replaced. (See Section 5.8, DECAL INSTALLATION)
4. Operation and Safety Manuals - Ensure that a copy
of the Operation and Safety Manual is enclosed in the
weather resistant storage container.
5. “Walk-Around” Inspection – Refer to Figure 2-1. on
page 2-7.
6. Battery – Charge as required.
7. Hydraulic Oil Level - Check the hydraulic oil level in
the pump reservoir, add as required. (See Section 5.5)
8. Accessories/Attachments - Reference the Operation
and Safety Manual of each attachment or accessory
installed upon the machine for specific inspection,
operation, and maintenance instructions.
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 3 for more specific instructions
on the operation of each function.
2-4 – JLG Lift – 3121684
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
10. Platform Gate - Keep gate and surrounding area
clean and unobstructed. Check that gate closes and
latches securely and is not bent or damaged. During
operation keep gate closed.
Self-Closing Swing Gate
11. Lanyard Anchorage Points - JLG Industries, Inc. recommends personnel in the platform wear a full body
harness with a lanyard attached to an authorized lanyard anchorage point (1).
3121684 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE
2.4 DAILY WALK-AROUND INSPECTION
Begin the “Walk-Around Inspection” at item 1, see Figure 2-1. on
page 2-7. 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 UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING
THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE
EXTENSIVE MACHINE DAMAGE.
INSPECTION NOTE: On all components, make sure there are no
loose or missing parts, that they are securely fastened, and that
no visible damage, leaks or excessive wear exists in addition to
any other criteria mentioned.
1. Frame/Chassis - See Inspection Note. Also ensure that
pothole-protection components on frame are in place,
undamaged, not bent or worn.
2. Ground Controls - Placard secure and legible, control
switches return to neutral position, emergency stop
switch functions properly. Control markings legible.
3. Hydraulic Pump/Motor, Control Valve Installation - No
unsupported wires or hoses; no damaged or broken
wires - See Inspection Note.
4. Front Wheels - Steer linkage, and Steer Cylinder - See
Inspection Note.
5. Battery Compartment - See Inspection Note.
6. Rear Wheels, Tires and Drive Motors - Properly
secured, no missing lug nuts. Refer to Section 5.7,
TIRES AND WHEELS. Inspect wheels for damage and
corrosion - See Inspection Note.
7. Manual Descent Control - See Inspection Note.
8. Beacon (if equipped) - See Inspection Note.
9. Scissor Arms, Pivot Pins and Sliding Wear Pads, Lift Cyl-
inder - See Inspection Note.
10. Platform/Handrail/Gate Installation - Deck extension
slides in and out and locks in place properly. Gate
closes and latches properly. All handrails in place and
secure - See Inspection Note.
11. Platform Control Console - Ensure that the control
console is firmly secured in the proper location. Placards secure and legible, control lever and switches
return to neutral, and emergency stop switch function
properly, required manuals in storage box.
2-6 – JLG Lift – 3121684
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