Operators and Safety Manual MODEL 15ELI 3120778 August 5, 2002 ANSI
CALIFORNIAN PROPOSITION 65 BATTERY WARNING Battery posts, terminals and related accessories contain lead and lead compounds, chemical known to the State of Califormia to cause cancer and reproductive harm.
FOREWORD The purpose of this manual is to provide users with the operating procedures essential for the promotion of proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine. REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
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INTRODUCTION - OPERATION/SAFETY PRECAUTIONS INTRODUCTION - OPERATION/SAFETY PRECAUTIONS All procedures herein are based on the use of the machine under proper operating conditions, with no deviations from original design intent ... as per OSHA regulations. 5. Load limits specified by the manufacturer shall not be exceeded. 6. Instruction and warning placards must be legible. 7.
INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS A. GENERAL C. MAINTENANCE This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others or damage to the equipment.
EFFECTIVITY PAGE EFFECTIVITY CHANGES February 1, 1999 - Original Issue of Manual April 20, 2000 – Revised – Added Proposition 65 to front of manual.
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TABLE OF CONTENTS TABLE OF CONTENTS SUBJECT - SECTION, PARAGRAPH PAGE NO. INTRODUCTION -- OPERATION/SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A INTRODUCTION -- MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B A GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B B HYDRAULIC SYSTEM SAFETY . . . . . . . . .
TABLE OF CONTENTS SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.2 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS 6.2 EMERGENCY CONTROLS AND THEIR LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Platform Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Ground Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 Manual Descent Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 Table 1-1. GENERAL This section prescribes the proper and safe practices for major areas of machine usage which have been divided into three basic categories: Transporting, Pre-Operation and Operation. In order to promote proper usage of the machine, it is mandatory that a daily routine be established based on instruction given in this section.
SECTION 1 - SAFETY PRECAUTIONS 1.4 TRANSPORT SAFETY • FULLY LOWER AND COMPLETELY EMPTY PLATFORM OF TOOLS AND DEBRIS BEFORE MOVING MACHINE. • NEVER ALLOW PERSONNEL IN PLATFORM WHILE MOVING MACHINE. FAILURE TO OBSERVE 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 DUE TO BEING PINNED OR CRUSHED BY THE UNIT. • ON A LEVEL SURFACE, ALWAYS TRAVEL WITH THE PLATFORM END LEADING THE WAY.
SECTION 1 - SAFETY PRECAUTIONS Figure 1-4. Two People May Be Required on Slopes Up To Five Degrees. Also Always Travel With Platform End On The Low Side of Slope. 1.5 • BEFORE OPERATION CHECK WORK AREA FOR MACHINE TRAFFIC SUCH AS FORKLIFTS, CRANES, AND OTHER CONSTRUCTION EQUIPMENT. PRE-OPERATIONAL SAFETY • SET-UP MACHINE FOR OPERATION ONLY ON A SMOOTH, FIRM LEVEL SURFACE. • ENSURE THAT OPERATORS OF OTHER OVERHEAD AND FLOOR LEVEL MACHINES ARE AWARE OF THE AERIAL PLATFORMS PRESENCE.
SECTION 1 - SAFETY PRECAUTIONS • NEVER OPERATE OR RAISE PLATFORM WHEN MACHINE IS ON A TRUCK OR OTHER VEHICLE. • APPROVED HEAD GEAR (I.E. HARD HAT, ETC.) MUST BE WORN WHEN REQUIRED BY ALL OPERATING AND GROUND PERSONNEL. • READ AND OBEY ALL DANGER, WARNINGS, CAUT I O N S A N D O P E R AT I N G I N S T R U C T I O N S O N MACHINE AND IN THIS MANUAL. • BE FAMILIAR WITH LOCATION AND OPERATION OF GROUND STATION AND EMERGENCY CONTROLS. 1.
SECTION 1 - SAFETY PRECAUTIONS Figure 1-9. Falling from Platform could cause Death or Serious Injury. Figure 1-8. All Personnel Must Stand Clear When Platform Is Being Raised Or Lowered. UNAUTHORIZED DECK EXTENSIONS OR ATTACHMENTS. • DO NOT TIE OFF MACHINE TO ANY ADJACENT STRUCTURE. NEVER ATTACH WIRE, CABLE OR ANY SIMILAR ITEMS TO PLATFORM. • TRANSFERS BETWEEN A STRUCTURE AND THE PLATFORM EXPOSE OPERATORS TO FALL POTENTIALS. THIS PRACTICE SHOULD BE DISCOURAGED WHEREVER POSSIBLE.
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SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 GENERAL 2.3 This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness, and lists checks that are performed prior to use of the machine. It is important that the information contained in this section be read and understood before any attempt is made to operate the machine.
SECTION 2 - PREPARATION AND INSPECTION an SAE viscocity of 10W-30 or 10W-20 and a viscosity index of 152. See Section 1 of the Service Manual for more details about hydraulic oil for this machine. 2. Floor Brake - Properly secured to frame, no visible damage (cracks, distortion, etc.) and is functioning properly. Machine Controls - (Platform and Ground) 3. Base Frame - No visible damage; components properly secured, no loose wires dangling below base; bubble level in place and functioning properly.
SECTION 2 - PREPARATION AND INSPECTION Daily Walk-Around Inspection Items 8 9 10 7 1. Wheels & Casters 2. Floor Brake 3. Base Frame 4. Battery Box/Charger 5. Motor/Pump/Reservoir Unit 6a. 6b. 6a 11 5 Manual Descent Control Valve Location Prior to S/N- 0900019526 Since S/N- 0900019526 7. Ground Controls 8. Mast Installation 9. Platform Controls 10. Guard Rail Installation 11. Platform Assembly 4 3 6b 1 2 1 Figure 2-1. Daily Walk-Around Inspection.
SECTION 2 - PREPARATION AND INSPECTION 2.5 DAILY FUNCTIONAL CHECK 2.7 TO AVOID INJURY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION. Once the walk-around inspection is complete, a functional check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a functional check in accordance with the following procedures: 1.
SECTION 2 - PREPARATION AND INSPECTION a. First all five (5) LED’s on the face of the charger flash three (3) times. b. Then each LED lights in sequence. c. Then all five (5) LED’s flash three (3) times again. 4. When ready to charge, the CHARGER ON LED and the INCOMPLETE CHARGE (25%) LED on the front panel of the charger will light up, the charger will then begin to charge the batteries.
SECTION 2 - PREPARATION AND INSPECTION % OF CHARGE IN PROGRESS (GREEN LED’S) CIRCUIT BREAKERS CHARGER ON (GREEN LED) A/C VOLTAGE SELECT SWITCH ABNORMAL CYCLE (YELLOW LED) Figure 2-4. Dual Voltage Battery Charger - Front Panel.
SECTION 2 - PREPARATION AND INSPECTION 3 1 2 Figure 2-5. Lubrication Locations (See Table below). Table 2-1. Lubrication Intervals for Various Components INTERVAL HOURS ITEM 1 COMPONENT Hydraulic Oil NO/TYPE LUBE POINTS Fill To Line on Reservoir 5 Qt. Reservoir LUBE/METHOD 6 MONTHS 300 Hrs. HO - Check Hyd. Oil Level HO - Change Hyd. Oil 1 YEAR 600 Hrs. 2 YEARS 1200 Hrs.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-6. Torque Chart.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS SECTION 3. USER RESPONSIBILITIES & MACHINE CONTROLS 3.1 Statutes, including training in the recognition and avoidance of potential hazards in the work place; with particular attention to the work to be performed. GENERAL 4. Proper use of all required personnel safety equipment.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS 3.3 tion. When left unattended removing key will prevent unauthorized machine use. OPERATING CHARACTERISTICS AND LIMITATIONS 2. EMERGENCY STOP Button General An emergency stop (RED button) is mounted on both the ground control station and the platform control panel. When the button is depressed, all machine functions will stop. To re-activate power to the machine, turn emergency stop button clockwise until button is reset.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS control, to close the valve (stop platform lowering) release the valve knob (spring loaded). NOTE: Check hydraulic oil only when platform is completely lowered and after cycling platform up/down a few times. A 20 amp reset type circuit breaker is located on the cover of the electrical box on ELI-AC Models. On ELI-DC Models, a 5 Amp fuse is located inside the ground control station. Platform Control Station (See Figure 3-3.) 1.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-4.
20778 – JLG Lift – Death or serious injury could occur from a tip-over. Machine must be on smooth, firm and level surface before elevating platform. Set floor stop. Check bubble level provided on machine to ensure base is level before elevating platform. Do not expose platform to high winds or horizontal forces. Do not exceed platform rated capacity or rated number of people. TIP-OVER HAZARD Falling from platform could cause death or serious injury. Keep both feet on platform floor.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-6.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS Figure 3-7.
SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS ATTACH LANYARD HERE 1703815A P/N - 1703815 P/N - 1703681 Figure 3-8.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 MACHINE DESCRIPTION ELI machines are manually propelled machines, with a platform mounted to an elevating aluminum mast mechanism. The mast is raised and lowered by a hydraulic cylinder extending between mast section-1 and -2, the remaining mast sections are proportionally extended and retracted using steel chains and cables. Hydraulic pressure is supplied to the lift cylinder by an electrically powered hydraulic pump.
SECTION 4 - MACHINE OPERATION 4.3 MACHINE SET-UP AND OPERATION The following sequence of set-up procedures must be followed to safely operate this machine. 1. Position machine in work area. Work area must be a smooth, firm, level surface. NOTE: If AC powered machine, connect machine to a grounded AC receptacle with a heavy duty extension cord equipped with an equipment grounding conductor. Also, the cord must be capable of handling the maximum amperage draw of the machine’s electric pump motor.
SECTION 4 - MACHINE OPERATION Platform Installation 1. Using either two people or suitable lifting equipment capable of lifting the weight of the unmounted platform, lift the platform and set the platforms’ upper support rail into the upper platform mount on the mast. PLATFORM UPPER MOUNT 2. Swing the platform lower support rail into the lower platform mount on the mast. 3. Secure the platform support rails with the two (2) platform upper mount pins, and the two (2) lower platform mount pins.
SECTION 4 - MACHINE OPERATION 4.6 Lifting TRANSPORTING, LIFTING AND TIE DOWN If it becomes necessary to lift the machine, use suitable lifting equipment capable of handling the weight of the machine, see below. General The ELI machine may be transported from worksite to worksite using any of the following methods: NOTE: Fork lifts, cranes, chains, slings, etc. must be capable of handling the following weights: • Pushing the machine around on its base wheels. Table 4-2.
SECTION 5 - OPTIONAL EQUIPMENT SECTION 5. OPTIONAL EQUIPMENT 5.1 Fluorescent Tube Caddy OPTIONAL EQUIPMENT The following optional equipment is available for ELI models: 22" x 25" Quick-Change Platform The fluorescent tube caddy is attached to the top rail of the platform allowing for convenient handling when replacing fluorescent tubes.
SECTION 5 - OPTIONAL EQUIPMENT 5.2 Extending Platform EXTENDIBLE PLATFORM OPERATION The optional extendible platform is designed to increase operator reach over the front of the machine, this allows the operator access to work areas which may otherwise be unreachable from the standard platform. The following procedures describe proper use of the Extendible Platform. (Refer to Figure 5-1.) 1.
SECTION 5 - OPTIONAL EQUIPMENT PLATFORM EXTEND HANDLE (SHOWN BOTH LOCKED IN HANDLE SPRING CLAMP AND RAISED FOR EXTENDING PLATFORM.) HANDLE SPRING CLAMP PLATFORM EXTEND HANDLE GATE LOCK PIN RELEASE CABLE RE TR AC T EX TE ND Figure 5-1. Extendible Platform.
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SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES 6.1 GENERAL INFORMATION 6.3 This section provides information on procedures to be followed, and systems and controls to be used in the event an emergency situation is encountered during machine operation. Prior to operation of the machine and periodically thereafter, the entire operating manual, including this section, should be reviewed by all personnel whose responsibilities include any work or contact with the machine. 6.
SECTION 6 - EMERGENCY PROCEDURES Platform Caught Overhead 6.4 If the platform becomes jammed or snagged in overhead structures or equipment, do not continue operation of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location. Only then should an attempt be made to free the platform using any necessary equipment and personnel.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Machine Serial Number: _________________________ Table 7-1.
JLG Industries, Inc. TRANSFER OF OWNERSHIP To: JLG, Gradall, Lull and Sky Trak product owner: If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each JLG product and uses this information in cases where owner notification is necessary.
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W.
