Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
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.
FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH.
FOREWORD For: 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. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
FOREWORD REVISION LOG d Original Issue - July 19, 2005 Revised - August 8, 2006 Revised - November 30, 2009 Revised - August 30, 2012 – JLG Lift – 3121213
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 2.3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operator Training and Knowledge . . . . . . . . . . . 1-1 Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2 OPERATION . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 4 - MACHINE OPERATION 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 ii DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 ENGINE OPERATION . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT MAINTENANCE 6.1 6.2 6.3 6.4 6.5 LIST OF FIGURES INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . .6-1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES 1-1 1-2 2-1 4-1 4-2 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 7-1 iv Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3 Decal Installation - Prior to S/N 0300103758 . . . . 4-15 Decal Installation - S/N 0300103758 to Present . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 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.
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.
SECTION 1 - SAFETY PRECAUTIONS 1.3 OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • 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 use the machine for any purpose other than positioning personnel, their tools, and equipment.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. • 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.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) 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: • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 11.
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.
SECTION 1 - SAFETY PRECAUTIONS • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. • 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. • Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
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.
SECTION 1 - SAFETY PRECAUTIONS 1.5 ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • 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. 3121213 – JLG Lift – • Charge batteries only in a well ventilated area.
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) 1-10 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 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.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs. The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Type Pre-Start Inspection Primary Responsibility Frequency Before using each day; or whenever there’s an Operator change.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection (Domestic only) is enclosed in the weather resistant storage container. 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. 5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the transport (stowed) position: Perform the Function Check as follows: 1. From the ground control panel with no load in the platform: a. Check that all guards protecting the switches or locks are in place; a. Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold; b. Check the tilt sensor alarm to ensure proper operation. b.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION GENERAL 3. Axle Jack/Extension Switches - See Inspection Note; decals in place and legible. 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 following checklist. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF. DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Drive Hub, Drive Motor and Drive Brake - See Inspection Note. 10. Steer/Drive Wheel/Tire Assembly - Properly secured; no loose or missing lug nuts; no visible damage. 11. Hose and Cable Guards/Clamps - See Inspection Note. 12. Power Track - See Inspection Note. 13. Muffler and Exhaust System - See Inspection Note. 14. Engine Air Filter Assembly - See Inspection Note; element clean. 15.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 25. Boom Limit Switches - Properly secured; no damage to cams or switches; cams free from excess dirt and grease. 26. Boom Sections - No visible damage; wear pads secure; boom chain adjusting nuts secure and undamaged; lift and telescope cylinders - rod end shafts and barrel end shafts properly secured; no evidence of leakage; evidence of proper lubrication. 27. Hydraulic Oil Supply - Recommended oil level.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 DAILY FUNCTIONAL CHECK 1. From ground controls, activate the machine hydraulic system. A functional check of all systems should be performed, under no load, 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.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Axle Retraction System Function Cut-Outs and Restrictions 1. From ground controls, activate the machine hydraulic system. 1. Platform Gate Interlock The engine will not start unless the platform gate is closed and latched. 2. Position JACK cylinder switch on axle to DOWN and hold until wheels rise from the ground. 2. Swing Cut-Out 3. Remove lock pin from left tie rod.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 4. Tower Boom Horizontal Cut-Out 8. Main Boom Lift Cut-Out With the tower boom above horizontal, HIGH DRIVE and 2 SPEED are cut out. In addition, with tower boom above horizontal, selecting DRIVE or MAIN LIFT cuts out HIGH ENGINE on TOWER LIFT and TOWER TELESCOPE functions, DRIVE function automatically goes to CREEP mode, and HIGH ENGINE is cut out except as noted in step (9).
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Tower Boom Sequence 2. Visually check the two valves in the turntable to ensure the plungers are fully extended 1. Place the machine on level ground and with the tower boom in the stowed position. Identify the hydraulic valve switch adjacent to the tower lift cylinder at the bottom end (rear) of the tower base boom. .
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: If the plunger is not fully extended, contact a qualified service technician to further evaluate this condition before operating the machine. 6. Fully retract the tower boom. Lift the main boom several feet. Attempt to lower the tower boom. NOTE: 3. Try to extend the tower boom assembly. NOTE: The boom should not extend and the red check light in the ground console panel should illuminate.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Platform Leveling Systems 1. Activate hydraulic system. Activate footswitch. Operate TOWER BOOM TELESCOPE and hold controller. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a qualified service technician. Check that platform automatic self-leveling system functions properly during raising and lowering of boom. Check platform level adjustment system for proper operation. 2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-16 – JLG Lift – 3121213
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL Ground Control Panel THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. This section provides the necessary information needed to understand control functions. 3.2 DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform/Ground Select Switch 6. Voltmeter A three-position, center-off PLATFORM/GROUND SELECT SWITCH supplies operating power to the controls on the platform control console, when positioned to PLATFORM. With the switch in GROUND position, power is shut off to the controls at the platform station, and only the controls on the ground control panel and remote box are operable.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. Master Switch Platform/Ground Select Switch Axles Set Indicator High Engine Circuit Breaker Hourmeter Voltmeter Oil Pressure Gauge Water Temperature Gauge Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. Master Switch Platform/Ground Select Switch Axles Set Indicator High Engine Circuit Breaker Hourmeter Voltmeter Oil Pressure Gauge Water Temperature Gauge Figure 3-2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. N/A Platform/Ground Select Switch Axles Set Indicator High Engine Circuit Breaker Hourmeter Voltmeter Oil Pressure Gauge Water Temperature Gauge Tower Proximity Switch Check Indicator Figure 3-3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Remote Box c. Position PLATFORM/GROUND SELECT SWITCH to GROUND. NOTE: d. Position MASTER SWITCH to ON. If equipped, the Function Enable switch must be held down in order to operate Main Boom Telescope, Tower Lift, Swing, Main Lift, Platform Level Override, and Platform Rotate functions. e. Operate appropriate switch for desired function and direction. f. 1. Auxiliary Power Switch g.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Auxiliary Power Platform Rotate Platform Leveling Override Start Creep Speed Emergency Stop Main Telescope Swing Tower Telescope Tower Lift Main Lift Manual Descent Valves (Not Shown) Function Enable Platform Overload Figure 3-4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Emergency Stop Button The EMERGENCY STOP button supplies electrical power from the IGNITION ON relays to the START button when the button is pulled out and the MASTER SWITCH is in the ON position. When depressed, the button shuts off electrical power to the machine. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Tower Lift Controller 13. Function Enable The TOWER LIFT controller provides raising and lowering of the tower boom when positioned to UP or DOWN. 11. Main Lift Controller If equipped, the enable switch must be held "DOWN" to enable all boom controls when the engine is running. 14. Platform Overload (If equipped) The MAIN LIFT controller provides raising and lowering of the main boom when positioned to UP or DOWN.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Station ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. WHEN DRIVING FORWARD AND OPERATING THE REAR STEER WHEELS, THE REAR WHEELS WILL TURN IN THE OPPOSITE DIRECTION OF MACHINE TRAVEL, I.E., DEPRESSING THE LEFT SIDE OF THE ROCKER SWITCH WILL CAUSE THE WHEELS TO TURN TO THE RIGHT. 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Ignition/Emergency Stop Button 11. Broken Chain (CE) The IGNITION/EMERGENCY STOP button, when pulled out, supplies power to the start button. When depressed, the button shuts off machine power in case of an emergency. 7. Main Telescope Controller The red BROKEN CHAIN indicator light will illuminate to warn the operator of a broken fly extend chain in the main boom or a broken fly retract chain in the main boom. 12.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 15. Steer Switch 18. Pump Volume Switch The STEER control controls operation of the front steer wheels of the machine. When the steer switch is positioned to RIGHT or LEFT, the machine will steer to the corresponding direction. The two-position PUMP VOLUME control switch allows the operator to select high pump flow, providing additional speed to machine functions when positioned to HIGH.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 21. Chassis Out of Level (Tilt Alarm) Warning Light (Red) 23. Auxiliary Power. A warning light on the control console that lights when the chassis is on a severe slope. The AUXILIARY POWER control switch energizes the electrically-operated hydraulic pump when actuated. Switch must be held ON for duration of auxiliary pump use.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Auxiliary power is primarily intended for platform lowering in the event of primary power failure. However, auxiliary power may be used for platform positioning when operating in close quarters in the following sequence: a. Position PLATFORM/GROUND switch to PLATFORM. b. Position IGNITION/EMERGENCY STOP switch to ON. c. Depress and hold footswitch. d. Operate appropriate control switch or lever for desired function and hold. 24.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: For engine starting, the footswitch must be in the released (up) position. Footswitch must be actuated in order for controls to function. NOTE: The platform gate must be latched in order to operate the machine. A platform gate limit switch disconnects power to the ignition switch when the gate is not latched. 27. Footswitch (Not Shown) A safety feature makes it necessary to depress the footswitch to allow operation of the controls.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom. The JLG Lift has a primary operator Control Station in the platform. From this Control Station, the operator can drive and steer the machine in both forward and reverse directions.
SECTION 4 - MACHINE OPERATION 4. Place ENGINE SPEED control switch on platform control console to LOW position. TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE. 4.3 NOTE: Footswitch must be in released (pedal up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE. NOTE: The platform gate must be latched in order to operate the machine.
SECTION 4 - MACHINE OPERATION The position of Least Forward Stability is with the tower boom fully elevated and fully retracted, with the main boom fully extended at horizontal over the side of the machine. Figure 4-1.
4-4 – JLG Lift – Figure 4-2. Position of Least Backward Stability The position of Least Backward Stability is with the tower boom fully elevated and fully extended, with the main boom fully elevated and fully retracted over the side of the machine.
SECTION 4 - MACHINE OPERATION Shutdown Procedure 4.4 IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION. 1. Position ENGINE SPEED/HIGH ENGINE control switch on platform control console to LOW. 2. Remove all load and allow engine to operate at low speed setting for 3 to 5 minutes; this allows for further reduction of internal engine temperature. 3. Position MASTER SWITCH to OFF position.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse 4.5 To steer machine using front steer wheels, position STEER control switch on platform control console to RIGHT for traveling right, or to LEFT for traveling left. To steer machine using rear steer wheels, position STEER rocker switch on top of DRIVE controller to RIGHT for traveling right, or to LEFT for traveling left. 1.
SECTION 4 - MACHINE OPERATION 4.7 PLATFORM Platform Level Adjustment Loading From Ground Level 1. Leveling UP. To raise platform, position LEVEL control switch to UP and hold until platform is level. 1. Position chassis on a smooth, firm and level surface. 2. If total load (personnel, tools and supplies) is 500 lbs. (227 kg) or less for single capacity use, distribute load uniformly on platform floor and proceed to work position. If total load (personnel, tools and supplies) is 1,000 lbs.
SECTION 4 - MACHINE OPERATION 4.8 BOOM TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE. A RED TILT ALARM WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE (5° OR GREATER). DO NOT SWING, RAISE TOWER BOOM OR EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.
SECTION 4 - MACHINE OPERATION Raising and Lowering the Boom 4.9 To raise or lower boom, position LIFT controller (standard controls) or control lever (hydraulic controls) to UP or DOWN and hold until desired height is reached. Telescoping the Tower Boom To extend or retract tower boom, ensure tower boom is fully elevated, then position TOWER TELESCOPE controller to IN or OUT and hold until tower boom reaches desired position. 1. Drive machine to a reasonably well protected area. 2.
SECTION 4 - MACHINE OPERATION 4.10 TIE DOWN AND LIFTING SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER. Tie Down When transporting machine, boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck. A lifting/tie down eye is provided at each of the four corners of the machine frame.
SECTION 4 - MACHINE OPERATION Figure 4-4.
SECTION 4 - MACHINE OPERATION Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 5.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
SECTION 5 - EMERGENCY PROCEDURES 3. Connect suitable equipment, remove chocks, and move machine. After moving machine, complete the following procedures: 1. Position machine on a firm, level surface. 2. Chock wheels securely. Ground Control Station 3. Engage drive hubs by reversing disconnect caps on hubs. 4. Remove chocks from wheels. 5.
SECTION 5 - EMERGENCY PROCEDURES To activate auxiliary power from the platform: 6. Position MASTER SWITCH to OFF. 1. Position PLATFORM/GROUND SELECT SWITCH to PLATFORM. Manual Descent and Retraction 2. Position MASTER SWITCH to ON. 3. Depress and hold footswitch. 4. Operate appropriate control switch or controller for desired function and hold. 5. Position AUXILIARY POWER switch to ON and hold. 6. Release AUXILIARY POWER switch and appropriate control switch or controller and footswitch. 7.
SECTION 5 - EMERGENCY PROCEDURES 5.5 EMERGENCY OPERATION 2. Other qualified personnel on the platform may use the platform controls with regular or auxiliary power. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY. Use of Ground Controls KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION. Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control functions.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine NOTE: Table 6-2. Capacities Fuel Tank 68 gallons (257 liters) Hydraulic Oil Tank 124 gallons (469 liters) Hydraulic System 150 gallons (568 liters) Drive Hub Swing Hub Engine Crankcase Cooling System System - 21.4 quarts (20.2 liters) Engine - 7.4 quarts (7.0 liters) Radiator - 14.0 quarts (13.2 liters) RPM Tolerances are ± 100. Table 6-3. Cummins 4B3.9C Horsepower 90 ounces (2.7 liters) Fuel 60 ounces (1.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Dimensional Data Table 6-5. Tires Size 445/65R22.5 Table 6-6. Dimensional Data Type Pressure Ply Foam-Filled N/A 22 Turning Radius (Outside) w/axles retracted w/axles extended Length Stowed w/main boom fully retracted and platform in normal position w/main boom telescoped out and platform tilted to stow at minimum height 3121213 – JLG Lift – 24 ft. 2 in. (7.4 meters) 27 ft. 2 in. (8.3 meters) 39 ft. 5 in. (12.0 meters) 41 ft.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil . Table 6-7.Hydraulic Oil Hydraulic System Operating Temperature Range SAE Viscosity Grade 0° to +23° F(-18° to -5° C) 10W 0° to +210° F(-18° to +100° C) 10W-20, 10W-30 +50° to +210° F(+10° to +99° C) 20W-20 NOTE: NOTE: 6-4 Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-9. Mobil EAL 224 H Specs Table 6-10. Mobil DTE 13M Specs Type Biodegradable Vegetable Oil Type Petroleum Base ISO Viscosity Grade 32/46 ISO Viscosity Grade 32 Specific Gravity .922 Specific Gravity .877 Pour Point, Max -25°F (-32°C) Pour Point, Max -40°F (-40°C) Flash Point, Min. 428°F (220°C) Flash Point, Min. 330°F (166°C) Weight 7.64 lb. per gal. (0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-11. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity NOTE: 6-6 at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index 376 Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity. Critical Stability Weights Table 6-12. Critical Stability Weights LB. KG. Counterweight 3285 1490 Tire & Wheel Assembly 1020 494 Engine 680 308 8 ft.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations For machine identification, a serial number plate is affixed to the machine. The plate is located on the left side of the turntable, just behind the fuel tank. If the serial number plate is missing, the machine serial number is stamped on the left side of the frame, below the turntable bearing.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120° F(49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F(43° C) 100° F(38° C) 90° F(32° C) WINTER GRADE FUEL SAE 15W-40 SAE 10W-30 ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82°C) OR ABOVE. 180° F (82° C) (HYD. OIL TANK TEMP.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 NOTE: OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 64., Operator Maintenance & Lubrication Diagram. It is recommended as a good practice to replace all filters at the same time. 1. Torque Hubs Table 6-13. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Steer Spindles 3.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Steer Cylinder Barrel Ends 5.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Extending Axles 7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Lower Master Cylinder Barrel End 9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Swing Bearing Lube Point(s) - 2 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turntable 12. Platform Hinges Lube Point(s) - 2 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 13. Platform Door Latch 11.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Platform Rotate Pivot/Rotator Worm Gear Lube Point(s) - 2 Grease Fittings on pivot; 1 Grease Fitting on worm gear Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 15.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 16. Level Cylinder Rod End 18. Engine Crankcase Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Lube Point(s) - Fill Cap/Drain Plug Capacity - 10 quarts (9.5 L) w/o filter Lube - EO Comments - Check daily. Refer to Engine Manual for Change interval. 17.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 19. Engine Oil Filter 21. Main Boom Extend Chain Sheave Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align access holes in mid and fly boom 22. Main Boom Lift Cylinder Lube Point(s) - N/A Lube - EO Comments - Refer to Engine Manual for Change interval. 20.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 23. Main Boom Retract Chain Sheave 25. Tower Boom Pivot Pin Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align with access hole in base boom. 24.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 26. Level Links 27.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 28. Upper Master Cylinder Barrel End 30. Hydraulic Oil Lube Point(s) - Fill Cap/Drain Plug Capacity - A/R Lube - HO Interval - Check daily. Change every 2 years or 1200 hours Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. 31.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 32.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 TIRES & WHEELS • any damage to the bead area cords of the tire Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque. Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. 6.5 SUPPLEMENTAL INFORMATION 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.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
TRANSFER OF OWNERSHIP Title:____________________________________________________________________ Name: ___________________________________________________________________ Who in your organization should we notify? Country: _________________________ Telephone: (_______) ____________________ _________________________________________________________________________ Address: _________________________________________________________________ Current Owner: __________________________________________________
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121213 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000 +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG France SAS Z.I.
