Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
NOTE: This manual also applies to the following machine with the following Serial Number: E0300001068.
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 Original Issue d - April 1, 2013 – JLG Lift – 3121292
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 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 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 PAGE STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8 Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Swinging the Boom . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 6.5 PAGE SECTION - PARAGRAPH, SUBJECT SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-25 6-1. 6-2. SECTION - 7 - INSPECTION AND REPAIR LOG 6-3. LIST OF FIGURES 2-1. 2-2. 2-3. 2-4. 2-5. 3-1. 3-2. 3-3. 3-4. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 3121292 Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . .2-6 Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . .2-7 Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES 1-1 1-2 2-1 4-1 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 6-15 6-16 6-17 6-18 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 Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Operating Specifications . . . . . . . . . .
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. 3121292 – 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 2 4-7 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. Description Land Conditions Calm Calm. Smoke rises vertically 0.3-1.
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, dropoffs. 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 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) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. 4.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions. e. Ensure all boom functions stop when the function enable switch is released. 2. From the platform control console: a.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11 12 10 4 9 13 16 8 7 3 17 14 2 15 6 5 18 1 Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. Front Drive/Steer Wheels Rear Drive Wheels Tower Lift Cylinder Lower Upright Main Lift Cylinder Main Boom Assembly Power Track Level Cylinder Jib Cylinder Platform Platform Console Jib Fly Boom Section Base Boom Section Master Cylinder Tower Boom Turntable Frame Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION GENERAL Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist. 2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legible, control markings legible. 3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Tie Rod Ends and Steering Spindles - See Inspection Note. 10. Turntable Bearing - Evidence of proper lubrication. No evidence of loose bolts or looseness between bearing and machine. 11. Swing Motor and Worm Gear - Evidence of proper lubrication; No evidence of damage. 12. Auxiliary Hydraulic Pump - See Inspection Note. 13. Main Hydraulic Pump - See Inspection Note. 14. Platform Rotator - See Inspection Note. 15.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 5. With boom over right side of machine, place Drive control lever to Reverse and drive machine off of block and ramp. 6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground. 12. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate Drive to release cylinders. 2-12 13.
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL 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 CONTROLS AND INDICATORS NOTE: All machines are equipped with control panels that use symbols to indicate control functions.
SECTION 3 - MACHINE CONTROLS AND INDICATORS TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. Ground Control Station ONLY USE THE PLATFORM LEVELING FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/ OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Platform Rotate Platform Leveling Jib Lift Engine Start/Auxiliary Power/Function Enable Power/Emergency Stop Platform/Ground Select Hourmeter Swing Tower Boom Lift Main Boom Lift Telescope Indicator Panel 12 2 11 3 10 4 9 5 6 QUARTZ 1 10 HOURS 7 8 Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Engine Start/ Auxiliary Power Switch /Function Enable NOTE: To start the engine, the switch must be held "UP" until the engine starts. To use auxiliary power, the switch must be held “DOWN” for duration of auxiliary pump use. Aux power can only be used if the engine is not running. When the Platform/Ground Select Switch is in the center position, power is shut off to the controls at both operating stations.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 9. Tower Boom Lift Ground Control Indicator Panel Provides raising and lowering of the Lower and Mid Booms. 1. Battery Charging Indicator Indicates a problem in the battery or charging circuit, and service is required. 10. Main Boom Lift 2. Engine Oil Pressure Indicator Provides raising and lowering of the Main Boom. Indicates that engine oil pressure is below normal and service is required. 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 9 1. 2. 3. 4. 5. Battery Charging Low Engine Oil Pressure High Engine Coolant Temp. Engine Oil Temp. System Distress 6. Low Fuel 7. Glow Plug Wait to Start 8. Platform Overload 9. Drive and Steer Disable Figure 3-2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. System Distress Indicator 7. Glow Plug Wait to Start Indicator The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval. The system distress indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test. 8.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Station TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. ONLY USE THE PLATFORM LEVELING FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/ OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 2. Platform Leveling 1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. Drive Speed/Torque Select Platform Leveling Horn Power/Emergency Stop Start/Auxiliary Power 6. 7. 8. 9. Not Used Drive Orientation Override Drive/Steer Telescope 10. 11. 12. 13. Lights Jib Lift Soft Touch Override Soft Touch Indicator 14. 15. 16. 17. Tower Boom Lift Platform Rotate Function Speed Main Lift/Swing Controller Figure 3-3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Drive Orientation Override When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 9. Telescope Control 13. Soft Touch Indicator (If Equipped) This switch allows extension and retraction of the main boom. Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode. 10. Lights (If Equipped) This switch operates the chassis lights if the machine is so equipped. 14.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 16. Function Speed Control This control affects the speed of telescope, tower lift and jib lift. Turning the knob all the way counterclockwise until it clicks puts drive, tower lift and swing into creep mode. This slow speed is used for fine positioning of the platform when close to obstacles. 1. AC Generator (Green) (If equipped) Indicates the generator is in operation. 2. Platform Overload Indicator.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 3 2 9 1. AC Generator 2. Platform Overload 3. Tilt Alarm Warning 4. Glow Plug/Wait to Start 5. Enable/Footswitch 6. Fuel Level 4 5 8 7 6 7. Creep Speed 8. System Distress 9. Drive Orientation Figure 3-4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Tilt Alarm Warning Light and Alarm Tilt Angle 4. Glow Plug/Wait to Start Indicator Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before starting engine. Market 3° CE & Australia 5° ANSI, CSA & Japan This illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a severe slope and the boom is above horizontal.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Enable Indicator/Footswitch 6. Low Fuel Indicator (Yellow) To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. System Distress Indicator 9. Drive Orientation Indicator The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.
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, articulating and rotating boom. Capacities The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the boom or swing the boom to the left or right.
SECTION 4 - MACHINE OPERATION Stability 4.3 Machine stability is based on two (2) conditions which are called FORWARD and BACKWARD stability. The machine’s position of least FORWARD stability is shown in (See Figure 4-1.), and its position of least BACKWARD stability is shown in (See Figure 4-2.) TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.
SECTION 4 - MACHINE OPERATION 2. After engine has had sufficient time to warm up, shut engine off. Shutdown Procedure 3. Turn SELECT switch to PLATFORM. 4. From Platform, pull POWER/EMERGENCY STOP switch out, then push the ENGINE START switch until engine starts. IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE. NOTE: Footswitch must be in released (up) position before starter will operate.
SECTION 4 - MACHINE OPERATION MAIN BOOM HORIZONTAL TELESCOPE FULLY EXTENDED TOWER BOOM STOWED POSITION MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-1.
SECTION 4 - MACHINE OPERATION 4.4 . TRAVELING (DRIVING) NOTE: ROTATE PLATFORM 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OPERATED ON AN OUT-OF-LEVEL SURFACE Refer to the Operating Specifications table in Section 6 for Gradeability and Sideslope ratings. All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted. MAIN BOOM FULLY ELEVATED TOWER BOOM FULLY ELEVATED Traveling is limited by two factors: 1.
SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER TAG OR AS NOTED IN THE OPERATORS MANUAL. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES (ANSI MARKETS) OR 4 DEGREES (CE & AUSTRALIA MARKETS).
SECTION 4 - MACHINE OPERATION GRA DE LOPE S E D SI LEVEL Figure 4-3.
SECTION 4 - MACHINE OPERATION 4.5 STEERING 4.7 BOOM Position thumb switch on Drive/Steer controller to RIGHT for steering right, or to LEFT for steering left. 4.6 A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT. PLATFORM ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL.
SECTION 4 - MACHINE OPERATION Raising and Lowering the Main Boom TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED. TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE.
SECTION 4 - MACHINE OPERATION 4.9 AUXILIARY PUMP 4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR. The main function of auxiliary power is to lower the platform in the event of primary power failure. Determine the reason for primary power failure and have the problem corrected by a certified JLG service technician.
SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 4.12 LIFTING AND TIE DOWN The procedures to shut down and park the machine are as follows: Lifting 1. Drive machine to a reasonably well protected area. 1. Refer to the Serial Number Tag, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight. 2. Ensure boom is lowered over rear drive axle. 3. Shut down Emergency Stop at Platform Controls. 2. Place the boom in the stowed position. 4.
SECTION 4 - MACHINE OPERATION 510AJ 64.3 in 450AJ 450A SERIES II SERIES II 62.8 in A (1634 mm) (1595 mm) B 47.1 in 48.1 in (1196 mm) (1222 mm) 63.7 in (1618 mm) 47.2 in (1199 mm) 1701500 1702300 1701500 1702300 CG CL A B 1001143110 A Figure 4-4.
SECTION 4 - MACHINE OPERATION 4.13 TOWING 2. Disconnect drive hubs by inverting disconnect cap. (See Figure 4-5.) After towing the machine, complete the following: RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. 3. Reconnect drive hubs by inverting disconnect cap. (See Figure 4-5.) MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.
SECTION 4 - MACHINE OPERATION 6 47 18 51 2 44 36 7 14 37 26 38 Figure 4-6.
SECTION 4 - MACHINE OPERATION 3 40 52 15 43 45 Figure 4-7.
SECTION 4 - MACHINE OPERATION 9 35 7 24 25 26 20 22 21 33 25 48 35 24 Figure 4-8.
SECTION 4 - MACHINE OPERATION 26 3 4 4 27 4 27 26 Figure 4-9.
SECTION 4 - MACHINE OPERATION 5 39 41 42 12 50 41 12 1 11 13 10 40 9 45 34 Figure 4-10.
SECTION 4 - MACHINE OPERATION 12 11 13 49 32 31 28 23 4 Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine. 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.
SECTION 5 - EMERGENCY PROCEDURES 5.3 EMERGENCY OPERATION 5.4 Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE: EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4. 1. Other personnel should operate the machine from ground controls only as required. 2.
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 Reach Specifications Table 6-1. Operating Specifications Maximum Drive Speed: 4.5 mph (2.0 m/s) Maximum Hyd. Operating Pressure 4500 psi (310 Bar) Electrical System Voltage 6-2 12 volts Table 6-2. Reach Specifications Max. Platform Height 51ft. (15.81 M) Max. Horizontal Reach 31 ft. 1 in. (9.48 M) Up & Over Height 25 ft. 2 in. (7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Chassis Table 6-3. Dimensional Data Overall Width Tailswing Table 6-4. Chassis Specifications 7 ft. 8.25 in. (2.34 m) 0 Swing Rated Gradeability 360° non-continuous 45% Stowed Height 7 ft. 6 in. (2.29 m) Max. Tire Load 8000 lb. (3629 kg) Stowed Length 25 ft. 1 in. (7.68 m) Axle Oscillation 8 in. (0.2 m) 7 ft. 8 in. (2.34 m) System Voltage 12 Volts Wheel base Ground Clearance 11.5 in. (0.29 m) Max.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Table 6-5. Capacities Fuel Tank NOTE: 17 gallons (64.3 liters) Hydraulic Tank 27 gallons (102 liters) 23.6 gal. (89 liters) to the mid point of upper sight window (cold) Drive Hub 23.75 oz. (0.7 liters) Drive Brake 2.7 oz. (0.08 liters) Tires Table 6-6. Tires Size Type Pressure Weight 12x16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg) 12x16.5 Foam-Filled N/A 328 lbs. (149 kg) 33/1550x16.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Major Component Weights Table 6-8. Caterpillar C2.2 Fuel No. of Cylinders 4 BHP 46.5 hp (34 kW) Bore 3.307 in. (84 mm) Stroke Displacement Oil Capacity Compression Ratio Firing Order Max. RPM Table 6-9. Component Weights Diesel 3.9370 in. (112 mm) 134.3 cu. in. (2.2L) Pounds Kilograms Frame (Bare) Component 2164 982 Turntable (Bare) 1527 693 Boom Link 190 86 Boom Timing Link 34 15 3.8 quarts (3.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil 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. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations. Table 6-10. Hydraulic Oil NOTE: NOTE: 6-6 Hydraulic System Operating Temperature Range S.A.E.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-12. Mobil DTE 13M Specs Table 6-13. UCon Hydrolube HP-5046 #32 Type Synthetic Biodegradable Specific Gravity 0.877 Specific Gravity 1.082 Pour Point, Max -40°F (-40°C) Pour Point, Max -58°F (-50°C) Flash Point, Min. 330°F (166°C) pH 9.1 ISO Viscosity Grade Viscosity Viscosity 33cSt at 0° C (32° F) 340 cSt (1600SUS) at 100° C 6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-14. Mobil EAL H 46 Specs Synthetic Biodegradable Specific Gravity 32.1 ISO Viscosity Grade 46 Pour Point -76°F (-60°C) Specific Gravity .910 Flash Point 217°F (103°C) Pour Point -44°F (-42°C) Flash Point 500°F (260°C) Operating Temp. 0 to 180°F (-17 to 162°C) Weight 7.64 lb. per gal. (0.9 kg per liter) Type Viscosity 6-8 Table 6-15. Exxon Univis HVI 26 Specs at 40° C 45 cSt at 100° C 8.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-16. Quintolubric 888-46 Density 0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Location A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame. xxxxx SERIAL NUMBER PLATE SERIAL NUMBER STAMPED ON FRAME Figure 6-1.
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) ENGINE SPECIFICATIONS SUMMER GRADE FUEL 80°F(27°C) 70°F(21°C) 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 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 AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120°F(49°C) 110°F(43°C) 100°F(38°C) 90°F(32°C) 80°F(27°C) 70°F(21°C) ENGINE SPECIFICATIONS 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) 20°F(-7°C) 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.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE AMBIENT AIR TEMPERATURE 120° F (49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F (43° C) 100° F (38° C) PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100° F (38° C) OR ABOVE.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 NOTE: OPERATOR MAINTENANCE The following numbers correspond to those in Figure 66., Operator Maintenance and Lubrication Diagram. Table 6-17. Lubrication Specifications KEY MPG SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Bearing/Worm Gear Teeth Lube Point(s) - Grease Fitting* Capacity - A/R Lube - Mobile SHC 007 Interval - A/R Lube Point(s) - Grease Fitting Capacity - A/R Lube - Lubriplate 930-AAA Interval - A/R DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING. *If necessary install grease fitting into worm gear housing and grease. Replace fitting with pipe plug when complete.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. Wheel Drive Hub 5. Hydraulic Charge Filter Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.5 L) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation 4. Hydraulic Return Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Interval - Change after first 50 hrs.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank 7. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters) to mid point of upper sight window (cold) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 3121292 – JLG Lift – Fill Cap/Spin-on Element (JLG P/N 7016641) Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts (4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Caterpillar 9. Fuel Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855) Capacity - 10 Quarts (9.4 L) Lube - EO Interval - Every Year or 500 hours of operation Comments - Check level daily/Change in accordance with engine manual. Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 10.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11.
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 and Tire Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. Table 6-18. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 40 ft. lbs. (55 Nm) 100 ft. lbs. (130 Nm) 170 ft. lbs. (255 Nm) 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-26 – JLG Lift – 3121292
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 3121292 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.
