Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
FOREWORD FOREWARD 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 DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. CAUTION INDICATES A POTENTIALIT Y HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.
FOREWORD For : 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. NOTICE 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. NOTICE JLG INDUSTRIES, INC.
FOREWORD REVISION LOG Original Issue of Manual . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE FOREWARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 3.4 3.5 3.6 PAGE SECTION - PARAGRAPH, SUBJECT Positioning and Leveling Machine . . . . . . . . . . . 3-6 Entering/Exiting The Platform. . . . . . . . . . . . . . . . 3-7 Platform Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 TRANSPORTING, LIFTING AND TIE-DOWN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8 Loading or Towing . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF TABLES LIST OF FIGURES 2-1. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 4-1. 5-1. 5-2. 5-3. 3121742 PAGE Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . 2-6 Machine Component Locations . . . . . . . . . . . . . . . . . 3-3 Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Charger AC Input Cable. . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT NOTES: NOTES: iv PAGE – JLG Lift – 3121742
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.
SECTION 1 - SAFETY PRECAUTIONS 1.2 TRANSPORTING Tipping Hazards FAILURE TO COMPLY WITH THE FOLLOWING TIPPING HAZARD INSTRUCTIONS COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING MOVED, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH. • On a level surface, always push machine from the platform end with the mast end leading the way. • Watch for obstructions around machine and overhead.
SECTION 1 - SAFETY PRECAUTIONS • Two persons are required on slopes up to 5°. A forklift must be used when moving units on slopes greater than 5°. • Always travel up or down a slope with the platform end of the machine positioned towards the low side of the slope. The operator and assistant must walk side by side to guide the machine. • Never position the unit sideways on a slope. • Do not elevate the platform or move the machine on a soft surface.
SECTION 1 - SAFETY PRECAUTIONS 1.3 • Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG. PRE-OPERATION Operator Training and Knowledge • This 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.
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. • Check the machine for modifications to original components. Ensure that any modifications have been approved 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. • Avoid accumulation of debris on platform deck.
SECTION 1 - SAFETY PRECAUTIONS 1.4 • Fully lower platform before leaving machine. 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.
SECTION 1 - SAFETY PRECAUTIONS • JLG recommends that the operator utilizes a fall/travel restraint system in the platform with a lanyard attached to an authorized lanyard anchorage point. For further information regarding fall protection requirements on JLG products, contact JLG. • Identify the designated lanyard anchorage point at the platform and securely attach the lanyard. Attach only one (1) lanyard per lanyard anchorage point. • Enter and exit only through gate area.
SECTION 1 - SAFETY PRECAUTIONS to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. Electrocution Hazard Table 1-1. Minimum Approach Distances (M.A.D.) NOTE: • This machine is not insulated and does not provide protection from contact or proximity to electrical current.
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 while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform. • Before operating 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.
SECTION 1 - SAFETY PRECAUTIONS be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel. • Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform. • During operation, keep all body parts inside platform railing. Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.
SECTION 1 - SAFETY PRECAUTIONS 1.5 MOVING, LIFTING AND REPOSITIONING 1.6 General • Never allow personnel in platform while moving, lifting or repositioning the machine. • This machine shall not be towed by a vehicle. • Do not move assembled unit on wheels over soft or uneven surfaces, or over obstructions, bumps, debris, etc. • Disassemble unit to transport over uneven or sloped ground, or in a vehicle.
SECTION 1 - SAFETY PRECAUTIONS • 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. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121742
SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 7. Means to avoid the hazards of unprotected electrical conductors. 8. Specific job requirements or machine application. PERSONNEL TRAINING The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - PREPARATION AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE NOTICE 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.
SECTION 2 - PREPARATION AND INSPECTION Table 2-1. Inspection and Maintenance Table TYPE PRIMARY RESPONSIBILITY FREQUENCY SERVICE QUALIFICATION REFERENCE Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection (See Note Below) Before each sale, lease, or rental delivery.
SECTION 2 - PREPARATION AND INSPECTION 2.3 PRE-START INSPECTION 2.4 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 proper maintenance personnel. 2. 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.
SECTION 2 - PREPARATION AND INSPECTION 6. Emergency Stop/Battery Isolator - Turn key switch in emergency stop button, then pull to release. 7. Bubble Level Indicator - Check bubble level indicator is clean, secure and responds to movement. 8. Battery/Charger Assembly/Hydraulic System Proper battery electrolyte level (if non-sealed battery), no battery terminal corrosion. Check hydraulic oil level in reservoir, check hydraulic lines for oil leaks. (See Section 5 - Operator Maintenance.) 9.
SECTION 2 - PREPARATION AND INSPECTION 3 4 10 7. 8. 9 1 6 7 1. 2. 3. 4. 5. 6. 5 2 9. 10. Swivel Castor Auto-Lock Braked Wheel Gate/Gate Latch Platform Control Box Emergency Lowering Valve Emergency Stop/Battery Isolator Bubble Level Indicator Battery/Charger/Hydraulic Pump Assembly (Inside Base Frame) Platform Mast Assembly 8 Figure 2-1.
SECTION 2 - PREPARATION AND INSPECTION 2.5 FUNCTION CHECK The function check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a function check as follows: 1. Set-up machine for operation according to instructions in Section 3, Positioning and Leveling Machine. 2. Check that front caster wheel locks, when set, stop all machine rolling movement. 3. Power up machine.
SECTION 2 - PREPARATION AND INSPECTION NOTES: 2-8 – JLG Lift – 3121742
SECTION 3 - MACHINE OPERATION SECTION 3. MACHINE OPERATION 3.1 GENERAL 3.2 MACHINE DESCRIPTION NOTICE 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 function and operation. The machine is manually propelled machine, with a work platform mounted to an elevating mast mechanism.
SECTION 3 - MACHINE OPERATION 3.3 • Ensure Emergency lowering valve is closed. MACHINE OPERATION The following control conditions must be met before elevating the platform: • Make sure the pre-start inspection (Section 2) has been completed, and the machine is safe to use. • Batteries contain enough voltage to operate the machine. Check the battery charge indicator located on the platform control box.
SECTION 3 - MACHINE OPERATION Machine Component Locations 1. 2. 3. 4. 5. 6. 7. 8. 9. Tool Tray Platform Entry Gate and Latch Front Locking Caster Wheels Emergency Lowering Valve Rear Wheel (Auto Locking) Mast Assembly Bubble Level Indicator Emergency Stop with Key Switch 10. Battery Charger AC Plug 11. Platform Control Box 12. Platform Lift Up Release Latch 1 Figure 3-1.
SECTION 3 - MACHINE OPERATION Battery Charger Operation The battery charger is located under the base frame cover beneath the platform. (See Figure 3-2.). To access the charger, see Figure 5-2. Figure 3-3. Charger AC Input Cable The battery charge level can be monitored at the platform control box - battery charge indicator see Figure 3-4. or by observing the LEDs on the front of the battery charger, see Figure 3-5. Figure 3-2.
SECTION 3 - MACHINE OPERATION 1 Figure 3-4. Battery Charge Indicator (Located near the top of the Platform Control Box) 1. Green LED Figure 3-5. Charger LEDs If observing the charger LEDs, ensure the GREEN LED (front of charger) illuminates. and stays lit. The adjacent AMBER LED has three modes (see Figure 3-5.). 1. Rapid flash, indicates maximum charge rate. (Note, when switching charger on, the amber light must rapid flash. If not, there is a fault, check fuse and connections). 2.
SECTION 3 - MACHINE OPERATION Ground Controls Positioning and Leveling Machine 1. Position machine under work area on a firm, level, and uniform supporting surface. 2. Check that ALL wheels front and rear are in contact with the supporting surface. 3. Check that the bubble level indicator is centered and machine is level. (See Figure 3-6.) 1. Emergency Stop/Key Switch 2. Emergency Stop with Key Switch - This is the ground control emergency stop switch. When pressed in all platform movement will stop.
SECTION 3 - MACHINE OPERATION Entering/Exiting The Platform Platform Controls 1. Check there are no overhead obstructions before elevating 1 platform. 2. The enable button (1), this button must be pressed and held in to operate either the UP or DOWN buttons on the control box. 3. Battery Charge Indicator (2) shows the charge status of the onboard battery. 4. Press Up arrow button (3) to elevate the platform. 5. Press Down arrow button (4) to lower the platform. 6.
SECTION 3 - MACHINE OPERATION Loading or Towing To secure machine to the transport vehicle, use at least two straps, with one strap over the chassis, around the mast section and out to the rear of the machine. The other strap should be fed through the front tie down locations on the chassis and the straps taken forward, so that the machine is tied down in four diagonal directions.
SECTION 3 - MACHINE OPERATION If the storage period is for an undetermined period then it is advisable that the battery be removed and stored in a secure battery storage container. We would also advise that all external electrical and hydraulic connections be covered to prevent corrosion. Figure 3-7.
SECTION 3 - MACHINE OPERATION 3.6 DECAL INSTALLATION 10 3 15 9 11 16 1 14 13 4 5 7 6 22 6 8 14 13 5 2 20 7 2 19 12 12 17 8 7 7 12 12 18 Figure 3-8.
SECTION 3 - MACHINE OPERATION Table 3-1. Decal Installation Chart (See Figure 3-8.) Table 3-1. Decal Installation Chart (See Figure 3-8.
SECTION 3 - MACHINE OPERATION NOTES: 3-12 – JLG Lift – 3121742
SECTION 4 - EMERGENCY PROCEDURES SECTION 4. EMERGENCY PROCEDURES 4.1 GENERAL INFORMATION Platform Caught Overhead This section explains the steps to be taken in case of an emergency situation while operating the machine. If the platform becomes jammed or snagged in overhead structures or equipment, rescue the platform occupant prior to freeing the machine. 4.
SECTION 4 - EMERGENCY PROCEDURES 4.3 INCIDENT NOTIFICATION 4.4 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. JLG Phone: DO NOT CLIMB OUT OF THE PLATFORM WHILE ELEVATED. THIS MAY AFFECT THE MACHINE'S BALANCE, CAUSING IT TO TIP OVER. ONLY EXIT THE PLATFORM VIA THE PLATFORM GATES. DO NOT ATTEMPT TO CLIMB DOWN MAST.
SECTION 4 - EMERGENCY PROCEDURES Emergency Lowering 1001214251 A Figure 4-1.
SECTION 4 - EMERGENCY PROCEDURES 1.
SECTION 5 - GENERAL SPECIFICATIONS SECTION 5. GENERAL SPECIFICATIONS 5.1 Other Publications Available Specific to this Machine: INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine. Illustrated Parts Manual ANSI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 - GENERAL SPECIFICATIONS 5.2 Table 5-2. Machine Dimensions GENERAL SPECIFICATIONS CLOSED DIMENSION Machine Specifications Table 5-1. Machine Specifications Length 3.92 ft. (1.195m) Width 2.46 ft. (0.750m) 830P Height 5.11 ft. (1.560m) Maximum working height: 14.76 ft. (4.50 m) Weight 628 lbs. (285 kg) Maximum platform height: 8.20 ft. (2.50 m) WORKING DIMENSION Platform Dimensions: 3.28 ft. (L) x 2.39 ft.(W) (1m (L) x 0.73m (W)) Working footprint: 3.90 ft. x 2.46 ft. (1.
SECTION 5 - GENERAL SPECIFICATIONS Power Source: 16.4 ft (5.0m) 12V DC Battery Electric Motor - Standard 12V DC Hydraulic Pump - 3.1cc/rev 13.1 ft (4.0m) Hydraulic Pressure Relief: 942 psi/65 bar Battery Charger Specification: Table 5-3. Battery Charger Specification 9.84 ft (3.0m) 6.56 ft (2.0m) AC Input Voltage 90-135V AC Frequency 45-65 Hz Output 12V DC, 7A Lubrication Specification Hydraulic Oil - Grade 32 Mineral Oil 3.28 ft (1.0m) 0 Figure 5-1.
SECTION 5 - GENERAL SPECIFICATIONS 5.3 OPERATOR MAINTENANCE Accessing Hydraulic/Electrical Components In Base Frame 1. Using the platform control box, raise platform up an inch or two off the rear wheel brake, set bar. CAUTION WHEN REMOVING THE BASE FRAME COVER FOR MAINTENANCE PURPOSES, FIRST SWITCH MACHINE POWER OFF BY DEPRESSING THE EMERGENCY STOP BUTTON LOCATED ON THE BASE OF THE MACHINE. USE APPROPRIATE SAFETY/PERSONAL PROTECTIVE EQUIPMENT WHERE NECESSARY. 2.
SECTION 5 - GENERAL SPECIFICATIONS Hydraulic System Maintenance • Hydraulic Oil Specification - refill with grade 32 mineral oil. • Ensure the hydraulic oil reservoir is not overfilled. • The oil level must only be checked when the mast is fully lowered. • The correct oil level with the mast fully lowered is approximately 3/4 from the base of the reservoir, as indicated by the line on the side of the reservoir. (See Figure 5-3.
SECTION 5 - GENERAL SPECIFICATIONS NOTES: 5-6 – JLG Lift – 3121742
SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 6-1.
SECTION 6 - INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 6-1.
TRANSFER OF OWNERSHIP Title:_____________________________________________________________________ Name: ___________________________________________________________________ Who in your organization should we notify? Country: _________________________ Telephone: (_______) ____________________ _________________________________________________________________________ Address: _________________________________________________________________ Current Owner: _________________________________________________
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (Corporate) (800) 544-5438 (Service) (717) 485-6417 www.jlg.com 3121742 JLG Worldwide Locations JLG Industries 358 Park Road Regents Park NSW 2143 Sydney 2143 Australia +6 (12) 87186300 +6 (12) 65813058 Email: techservicesauc@jlg.com JLG Ground Support Oude Bunders 1034 Breitwaterstraat 12A 3630 Maasmechelen Belgium +32 (0) 89 84 82 26 Email: emeaservice@jlg.
