Operation, Safety, and Maintenance Manual 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 POTENTIALITY 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 SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety NOTICE JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
FOREWORD REVISION LOG Original Issue. . . . . . . . . . . . . . . . . . . . September 29, 2006 Revised. . . . . . . . . . . . . . . . . . . . . . . . . October 25, 2006 Revised. . . . . . . . . . . . . . . . . . . . . . . . . December 21, 2006 Revised. . . . . . . . . . . . . . . . . . . . . . . . . February 22, 2007 Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 28, 2007 Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 13, 2008 Revised. . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . 1-3 OPERATION . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE 4.4 4.5 4.6 4.7 4.8 4.9 4.10 AUTOMATIC SELF LEVELING CHASSIS . . . . . . . . 4-3 DRIVING THE MACHINE FROM THE PLATFORM . 4-4 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 HYDRAULIC PLATFORM EXTENSION . . . . . . . . . . 4-6 EMERGENCY LOWERING - MANUAL DESCENT . 4-6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-6 TIE DOWN/LIFT LUGS. . . . . . . . . . . . . . . . . . . . . . . 4-7 Tie Down . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF FIGURES 2-1. 2-2. 2-3. 2-4. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 4-1. 4-2. 4-3. 5-1. 6-1. 6-2. 6-3. 3121324 PAGE LIST OF TABLES Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . .2-8 Walk - Around Inspection Diagram . . . . . . . . . . . . .2-9 Walk - Around Inspection Points (Sheet 1) . . . . . .2-10 Walk - Around Inspection Points (Sheet 2) . . . . . .2-11 Ground Control Stations . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally.
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 • An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. • Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection 1.3 • Do not operate this machine until the inspections and functional checks have been performed as specified in Section 2 of this manual. OPERATION General • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. • Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs. • Stow scissor arm assembly and shut off all power before leaving machine. Trip and Fall Hazards • JLG Industries, Inc.
SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards . • This machine is not insulated and does not provide protection from contact or proximity to electrical current. • Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose. • Never use the scissor arm assembly to gain access to or leave the platform. • Use extreme caution when entering or leaving platform.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1.Minimum Approach Distances (M.A.D.) • Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in accordance with the Minimum Approach Distance (M.A.D.) as specified in Table 1-1, Minimum Approach Distances (M.A.D.). • Allow for machine movement and electrical line swaying.
SECTION 1 - SAFETY PRECAUTIONS reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment. . DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.
SECTION 1 - SAFETY PRECAUTIONS • Keep the chassis of the machine a minimum of 2 ft (0.6 m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level. • Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. • Keep hands and limbs out of the scissor arm assembly during operation. • Watch for obstructions around machine and overhead when driving.
SECTION 1 - SAFETY PRECAUTIONS tion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel. 1.4 • Never allow personnel in platform while towing, lifting, or hauling. • Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only. • This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading.
SECTION 1 - SAFETY PRECAUTIONS Maintenance Hazards long hair unrestrained which may become caught or entangled in equipment. • Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to performing any adjustments or repairs. • Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.
SECTION 1 - SAFETY PRECAUTIONS • Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-12 – JLG Lift – 3121324
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 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 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Table 2-1. Inspection and Maintenance Table Type Pre-Start Inspection Pre-Delivery Inspection (See Note) Frequent Inspection (See Note) Frequency Primary Responsibility Service Qualification Reference Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.3 PRE-START INSPECTION The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, 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 discrepencies. 4.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION f. IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. Function Check g. Check for proper lifting and lowering of the platform. 2. From the platform control console: a. Ensure that the control console is firmly secured in the proper location. b.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Limit Switch Checks Check that the following limit switches function properly by attempting to exceed the preset limits. 1. Lowered Position Limit Switch - Outriggers cannot be deployed beyond the height of 9.8 ft (3m). 2. Limit Switches for Drive Mode a. High Drive Speed Limit Switch - high drive speed is possible up to a platform height of 12.14 ft (3.7 m). When the platform exceeds this limit, only low drive speed is possible. b.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Table 2-2. Cutout Switch Limits Limit and Cutout Switch Lowered Position High Drive Speed Cutout * Maximum Drive Height/Maximum Height without Outriggers * Maximum Height:* Tilt * Oscillating Axle 3121324 9.8 ft (3.2 m) 12.14 ft (3.7 m) 65 ft (20 m) 80.4 ft (24.5 m) 3° Outrigger Interlock NOTE: Limit drive cut out when outriggers activated; lift cut out when not level >1° and 12.8 ft (3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 1. Lowered Position Limit Switch 1 2. High Drive Speed Limit Switch 2 3 5 4 3. Max Drive Height/Max Height without Outriggers Limit Switch 4. Max Height Limit Switch 5. Tilt Sensor 6. Outrigger Interlocks (all 4 outriggers) 7. Oscillating Axle Limit Switches (rear axle) 6 7 Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 4 5 18 6 4 8 7 3 2 1 19 15 14 4 12 13 4 11 10 9 Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION General 3. Outrigger - (right front) - See Note 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 “Walk-Around Inspection Checklist.” 4. Wheel and Tire Assembly - Properly secured, no missing lug nuts. Refer to Section 6. Inspect wheels for damage and corrosion. 5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 13. Hydraulic Reservoir - Recommended hydraulic fluid level on level indicator on tank. Breather cap secure and working. 18. Ground Controls - Placard secure and legible, control switches return to neutral position, emergency stop switch functions properly. 14. Tie Rod and Spindle - (left front) - See Note 16. Scissor Arms and Sliding Wear Pads (Not Shown) See Note 19.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION NOTES: 2-12 – JLG Lift – 3121324
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 GENERAL 3.2 NOTICE SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IT IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL. This section provides the necessary information needed to understand control functions.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Capacities 3.3 Raising the platform above the stowed position with or without any load on the platform, is based on the following criteria: CONTROLS AND INDICATORS Ground Control Station 1. Machine is level and positioned on a firm supporting surface. 1 2 3 2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 1. Engine Control Box 2. Main Terminal Box 3. Ground Control Console Figure 3-1.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Engine Control DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE. ehbelectronics ehbelectronics 4 4 1 1 Vertragshandler Vertragshandler or Air 3 2 3 2 Glow Temp. Oil Alt. Start Start OK 1. Start Assist 2. Engine Start 3. Hourmeter 4. Glow Plug LED Figure 3-2.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 1. Start Assist - This push button is used to help assist starting the machine in cold temperatures. 2. Engine Start - A push button switch that, when depressed, will start the engine 3. Hourmeter - A meter used to measure the amount of time the machine is in use. 4. Glow Plug LED - This Yellow LED is off under normal operating conditions. The LED is illuminated when the ignition is on and the temperature sensing requires preglow.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Main Terminal Box R +X -X +Y -Y 1 1. Tilt Right LED 2. Tilt Left LED 2 3. Tilt Forward LED 3 4. Tilt Backward LED 4 5. Drive Cutout LED 5 E900057 A Figure 3-3.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL NOTE: The following LED’s are part of the self leveling system and illuminate as the machine self levels. 1. Tilt Right LED - This LED will illuminate any time the machine is tilted to the right. 2. Tilt Left LED - This LED will illuminate any time the machine is tilted to the left. 3. Tilt Front LED - This LED will illuminate any time the machine is tilted toward the machine front. 4.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Ground Control Console . 1. Platform/ Ground Select (Key Switch) R 2. Engine Start Switch 6 3. Emergency Stop Button 4. Outrigger Select Switch 4 5 5. Platform Lift/Lower Switch 6. Deck Extend/Retract Switch 3 7 7. Glow Plug LED 8. Battery Disconnect Switch 2 1 E900034A Figure 3-4.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Ground Control Descriptions: 1. Platform/Ground Select - This three way keyswitch is used to select between platform controls or ground controls. When in the center position, the machine is disabled. 2. Engine Start Switch - Toggle Switch used to start engine. 3. Emergency Stop Button - Button, when depressed, will immediately shut the machine off. Cuts out all functions except emergency platform lowering. 6.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3.4 PLATFORM CONTROL CONSOLE 2 11 1 10 8 9 7 1. Engine Start Switch 2. Emergency Stop Button E900036A 3. Deck Extension/Drive/Lift Select Switch 4. Drive Speed Switch 5. Lift/Drive/Deck/Steer Controller 6. Horn Button 7. Drive Enabled LED 8. Glow Plug Active or Enabled LED 9. Lift Enabled LED 10. High Drive Speed Enabled LED 11. Tilt LED R E900030C 4 6 3 5 Figure 3-5.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Platform Control Descriptions: button on the front of the joystick is the enable button. This button must be held in to work all joystick controlled functions. When the Drive function is selected, moving the joystick forward and backwards operates the forward and reverse movement of the machine. The switch on top of the joystick controls the steering of the machine when the Drive function is selected.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 9. Lift Enabled LED - This Green LED is illuminated when the lift function is enabled. The light goes out when tilted above 12.14 ft (3.7 m), or when at maximum height 80.4 ft (24.5 m) with the outriggers deployed, or 65 ft (20 m) with the outriggers not deployed. 10. High Drive Speed Enabled LED - This Green LED is illuminated when high drive speed is enabled. The light goes out when the platform is above the high drive speed limit of 12.14 ft (3.7 m).
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 17 10 11 24 23 9 10 10 11 11 11 11 3 11 11 11 10 22 1 21 1 6 4 14 18 5 24 20 15 16 14 8 15 13 2 19 15 20 4 6 1 5 8 1 21 Figure 3-6.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 1 21 7 12 30 20 22 1 5 14 15 6 8 29 4 14 15 6 1 5 20 1 8 21 Figure 3-7.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 8 8 8 9 9 9 18 9 11 24 29 9 2 9 9 8 9 23 12 22 12 3 5 19 4 24 21 14 1 20 17 7 16 32 16 14 32 13 3 14 15 21 5 12 4 7 12 22 Figure 3-8.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 12 22 6 10 34 21 23 12 14 5 7 32 4 16 33 16 3 32 14 5 12 4 21 12 7 22 Figure 3-9.
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Table 3-1. Decal Legend Table 3-1.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 STARTING Ensure Battery Disconnect Switch is not cutting off the battery power. On the Ground Control Console, select the operating position (platform vs. ground). General Description of the Functions and Components The normal location to operate the machine is on the platform.
SECTION 4 - MACHINE OPERATION 4.3 LIFTING AND LOWERING trigger is released or the joystick is returned to the neutral position, the movement will stop. Lowering: DO NOT RAISE PLATFORM EXCEPT ON A FIRM UNIFORM SURFACE FREE OF OBSTRUCTIONS AND HOLES. 1. If operating from the ground control console: a. Press down on the Platform Lift/Lower Switch to achieve desired elevation. ENSURE SCISSOR ARM AREA IS FREE OF PERSONNEL PRIOR TO LOWERING PLATFORM. 2. If operating from the platform control console: a.
SECTION 4 - MACHINE OPERATION 4.4 AUTOMATIC SELF LEVELING CHASSIS The machine is equipped with an auto leveling feature that allows the operator to automatically level the machine. When the machine is leveled, the lift function is automatically enabled. The indicator LED’s on the Main Terminal Box will also indicate when the machine is level (See Figure 3-3 on page 3-4 and page 3-5 for an explanation of the LED’s). This function can be turned on or off at the ground control station.
SECTION 4 - MACHINE OPERATION 4.5 DRIVING THE MACHINE FROM THE PLATFORM To activate the drive function, the controller (joystick) has to be moved forward for forward-drive and back for reversedrive. The controller has a neutral zone of about ± 7% of the total possible moving distance. After reaching the end of the neutral zone, the drive, brake and motion alarm valves will be activated and the machine starts to move.
SECTION 4 - MACHINE OPERATION DE GRA SIDESLOPE HORIZONTAL Figure 4-1.
SECTION 4 - MACHINE OPERATION 4.6 STEERING 4.8 The steer function is operated by depressing the two positioned button on top of the joystick. Pressing and holding the button to the right will turn the wheels to the right. Release the button when desired direction is achieved. When the button is released, the wheels will remain in the turned position. To straighten and/or turn to the left, the button must be pushed and held in the opposite direction (left in this case).
SECTION 4 - MACHINE OPERATION 4.10 TIE DOWN/LIFT LUGS Tie Down When transporting the machine, the platform extension must be fully retracted and the platform fully lowered in the stowed position with the machine securely tied down to the truck or trailer deck. Refer to the tie down lugs in Figure 4-2., Lifting and Tie Down Points. If it becomes necessary to lift the machine, it is possible to do so from the lifting lugs located at the four corners of the machine.
SECTION 4 - MACHINE OPERATION 4.11 TRANSPORT AND STORAGE OF THE MACHINE The control box must be unplugged during the transport of the machine. The socket at the platform must be closed, whenever the control box is not plugged in. This is the best way to prevent any damages due to moisture and transport to the electrical components of the machine. NOTICE DURING TRANSPORT THE BATTERY DISCONNECT SWITCH SHOULD BE DISCONNECTED.
SECTION 4 - MACHINE OPERATION Platform Rail Lowering Tool Procedure NOTE: Prior to lowering/raising rails, ensure deck surface is clean, dry, and free of debris. Maintain good footing during procedure. When transporting the machine, it may be necessary to lower the platform rails to meet traveling height requirements. A Rail Lowering Tool (Optional) is available to assist the operator with this procedure.
SECTION 4 - MACHINE OPERATION Main Platform Side Rails and Extension End Rail NOTE: b. Remove the Attach Pin. The following procedures apply to the Main Platform Side Rails and the Platform Extension End Rail. These rails fold outward. Stow these rails prior to stowing the extension side rails. 1. Remove the Rail/Platform Attach Pins from each rail leg (located on the sides of the platform where rails attach to platform). a. Remove the Safety Pin.
SECTION 4 - MACHINE OPERATION 2. While standing on the platform, place the Rail Lowering Tool on the Rail. (reference the illustration following) a. Place the Rail Clamp on the underside of the top rail near the center post. 5. Remove the Rail Corner Pin where the side rail connects to the end rail. While holding onto the side rail, remove the Safety Pin and pull out the Corner Pin. b. Lower the Tool handle so that the Rubber Stopper rests on the top of the rail locking the Tool in place on the rail. 1.
SECTION 4 - MACHINE OPERATION 7. Tightly grasp the top portion of the rope and begin to slowly lower the railing using hand-over-hand motions. FALL HAZARD. EXERCISE EXTREME CAUTION WHEN LOWERING RAILS, USER SHOULD STAND CLEAR OF THE PLATFORM EDGE AND MAINTAIN A STABLE FOOTING DURING THE LOWERING PROCEDURE. NOTE: 4-12 The extension side rails, in the upright position, can be used for extra footing support. 8.
SECTION 4 - MACHINE OPERATION 11. Secure Pins in place with Safety Pins. Main Platform End Rails/Gate and Extension Side Rails NOTE: The following procedures apply only to the Main Platform End Rails/Gate and Extension Side Rails. 12. Remove the Rail/Platform Attach Pins from each rail leg (located on the sides of the platform where rails attach to platform). a. Remove Safety Pin and pull out Main Pin. 1. Main Pin 3121324 – JLG Lift – 2.
SECTION 4 - MACHINE OPERATION 2. Carefully lower rails inward to the platform deck. Rail Raising Procedure 3. Secure rails by inserting Main Pins back into brackets and securing pin with Safety Pins. NOTE: Follow the Platform Rail Lowering Procedures in reverse order to raise rails to the working positions. Make certain to secure all rails with all pins and all safety pins. WHEN STANDING ON THE MAIN PLATFORM SURFACE LOWERING OR RAISING THE MAIN PLATFORM RAILS, JLG INDUSTRIES, INC.
SECTION 4 - MACHINE OPERATION FALL HAZARD. FAILURE TO PROPERLY SECURE ALL RAIL SECTIONS COULD RESULT IN RAIL COLLAPSE RESULTING IN DEATH OR SERIOUS INJURY. 1. Raise Main Platform End Rails/Gate and Extension Side Rails to the up-right position. Secure rails with all of the pins and all of the safety pins. 2. Attach the Rail Tool to raise Main Platform Side Rails to the up-right position. Secure with pins and safety pins. 3.
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SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL Platform Caught Overhead 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 5 - EMERGENCY PROCEDURES 5.2 EMERGENCY OPERATION malfunction when used prior to removing platform occupants. Use of Ground Controls Incident Notification NOTICE 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 5 - EMERGENCY PROCEDURES 5.3 MANUAL PROCEDURES 3. Locate the lever at the end of the valve bank near the back. Push lever down to engage valve. Manual Platform Deck Retraction NOTE: The platform deck extension should be retracted before the platform lowering begins. 1. Locate the valve block and handpump inside the hydraulic cover on the right side of the machine. 2. Turn valve knob on the manual handpump clockwise until tight. NOTE: Step 2 applies only to machines prior to S/N 1200021263.
SECTION 5 - EMERGENCY PROCEDURES 4. Locate separate valve handle and place handle on the valve as shown (first section from the left). the manual hand pump counterclockwise until fully open (if applicable). Push pump handle forward. Manual Descent NOTE: The manual descent system is provided as an emergency means to lower personnel from the platform. 1. Locate the valve block and hand pump inside the hydraulic cover on the right side of the machine. 2.
SECTION 5 - EMERGENCY PROCEDURES 3. Locate the lever at the end of the valve bank near the back. Lift lever to engage valve. . PLATFORM WILL CONTINUE TO DESCEND ONCE MOVEMENT IS STARTED. TO STOP PLATFORM DESCENT, RELEASE THE HANDLE ON THE MAIN VALVE. 4. Locate handle and place it on the third valve from the left. Press handle downward while activating the manual pump. NOTE: Valve handles are located in plastic storage bag within valve compartment. 3121324 – JLG Lift – 5.
SECTION 5 - EMERGENCY PROCEDURES 5.4 EMERGENCY TOWING a. Reconnect drive hubs by inverting disconnect cap. (See Figure 5-1.) 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. 1 2 MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) FOR NO LONGER THAN 30-45 MINUTES. MAXIMUM TOWING GRADE 25%.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.2 OPERATING SPECIFICATIONS Table 6-1. Operating Specifications Table 6-1. Operating Specifications Maximum Operating Wind Speed 28 mph (12.5 m/s) Gross Machine Weight (Approximate) 35,935 lbs (16,300 kg) Maximum Working Height: with outriggers deployed with outriggers stowed 87 ft (26.5 m) 72 ft (22 m) Maximum Platform Height: with outriggers deployed with outriggers stowed 80 ft (24.5 m) 65 ft (19.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Capacities Table 6-1. Operating Specifications Electrical System Voltage 24 V Table 6-3. Capacities 10.8 in. (27.4 cm) Ground Clearance Dimensional Data 14 ft (4.24 m) Platform Height (Stowed) 10.3 ft (3.14 m) Platform dimensions (extension retracted) Platform dimensions (extension extended) Transport Dimensions 3121324 23.8 gal (90 L) Hydraulic Tank 68.7 gal (260 L) Engine Crankcase with Filter without Filter Table 6-2.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Component Weights Table 6-5. Engine Specifications Table 6-7. Component Weights Type Deutz F4L 2011 Deutz D2011 L04 i Component # of Cylinders 4 Displacement 3108 cm³ Bore 3.7 in (94 mm) Stroke 4.4 in (112 mm) Fuel Type Diesel Weight Fixed Platform 2425 lbs (1100 kg) Chassis with Foam Filled Tires 12,787 lbs (5800 kg) Arm Assembly 15,653 lbs (7100 kg) Batteries Table 6-6.
SECTION 6 - GENERAL SPECIFICATIONS AND 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) SAE 20W-50 SAE 15W-40 SAE 10W-40 SAE 10W-30 SAE 5W-40 SAE 5W-30 SAE OW-40 SUMMER GRADE FUEL SAE OW-30 ENGINE SPECIFICATIONS 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 ENGINE WIL
SECTION 6 - GENERAL SPECIFICATIONS AND 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 AND OPERATOR MAINTENANCE Lubrication NOTE: Hydraulic Oil Table 6-8. Hydraulic Oil HYDRAULIC SYSTEM OPERATING TEMPERATURE RANGE SAE VISCOSITY GRADE 0° to +23°F (-18° to -5°C) 10W NOTE: 0° to +210°F (-18° to +100°C) 10W-20, 10W-30 +50° to +210°F (+10° to +100°C) 20W-20 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 AND OPERATOR MAINTENANCE 6.3 OPERATOR MAINTENANCE 1. Arm Pins 2. Outrigger Cylinders 3. Engine Compartment 4. Tie Rod End 5. Spindles 6. Oscillating Axle 7. Fuel Tank (electrical/hydraulic compartment) (not shown) Figure 6-3.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE NOTE: The following numbers correspond with those in Figure 63., Operator Maintenance and Lubrication Diagram. NOTE: Be sure to grease all like items on the opposite side of machine. 2. Outrigger Cylinders 1.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3. Engine Compartment a. b.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE c. Hydraulic Oil Check/Fill 4. Tie Rod End • Lube Points - 2 Grease Fittings • Lube Points - Fill Cap and Site Gage • Capacity - As Required • Capacity - 68.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 5. Spindles 6-12 6.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.4 7. Fuel Tank (Opposite Engine Compartment) TIRES AND WHEELS Tire Damage For pneumatic tires, JLG Industries, Inc. recommends that when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly. For polyurethane foam filled tires, JLG Industries, Inc.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Tire Replacement Wheel Replacement JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine and model.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque. 1 WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL. Tighten the lug nuts to the proper torque to prevent wheels from coming loose.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE NOTES: 6-16 – JLG Lift – 3121324
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG 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 3121324 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 +61 2 65 811111 +55 19 3295 1025 +55 19 3295 0407 +44 (0)161 654 1000 +61 2 65 810122 JLG Deutschland GmbH Max-Planck-Str.