Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
NOTES:
SECTION - 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.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS 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.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS For: • Accident Reporting 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. • 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.
SECTION - REVISION LOG REVISION LOG Original Issue of Manual. . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . B Contact: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C Outside USA:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE Key Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Platform Lift/Lower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 MDI-Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Overload Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 3.8 SCISSOR ARM - SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Lubrication Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF FIGURES 2-1. 2-2. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. 3-7. 3-8. 3-9. 3-10. 3-11. 3-12. 3-13. 3-14. 3-15. 3-16. 4-1. 5-1. 5-2. 5-3. 5-4. iv PAGE LIST OF TABLES Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Machine Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . . 2-9 R6 - Location of Machine Controls. . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation.If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”). GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance.
SECTION 1 - SAFETY PRECAUTIONS 1.2 • 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 • The Operation and Safety 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 • Do not operate any machine on which the safety or instruction placards or decals are missing or illegible. • 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.
SECTION 1 - SAFETY PRECAUTIONS • Do not remove, modify, or disable any safety devices. • Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure. • Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.
SECTION 1 - SAFETY PRECAUTIONS Trip and Fall Hazards . • Prior to operation, ensure all gates and rails are fastened and secured in their proper position. • JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact 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. • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1. • Allow for machine movement and electrical line swaying. • Maintain a clearance of at least 10 ft.
SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. Table 1-1. Minimum Approach Distances (M.A.D.
SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 5, TABLE 5-2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLATFORM BILLBOARD. Table 1-2. Beaufort Scale (For Reference Only) 1-8 WIND SPEED BEAUFORT NUMBER mph m/s 0 0 0-0.2 Calm Calm. Smoke rises vertically. 1 1-3 0.3-1.5 Light air Wind motion visible in smoke. 2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle. 3 8-12 3.4-5.
SECTION 1 - SAFETY PRECAUTIONS • Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. • Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine. • Do not increase the platform size with unauthorized deck extensions or attachments.
SECTION 1 - SAFETY PRECAUTIONS • During operation, keep all body parts inside platform railing. • 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. • Do not use high speed drive in restricted or close quarters or when driving in reverse. • Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.
SECTION 1 - SAFETY PRECAUTIONS 1.4 must be established by a qualified person and must be followed to ensure that the machine is safe. TOWING, LIFTING, AND HAULING • Never allow personnel in platform while towing, lifting, or hauling. Maintenance Hazards • This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to emergency towing procedures.
SECTION 1 - SAFETY PRECAUTIONS • Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine. Battery Hazards • Always disconnect batteries when servicing electrical components or when performing welding on the machine. • Use only approved non-flammable cleaning solvents.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.1 PERSONNEL TRAINING Operator Training The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel. Operator training must cover: • Use and limitations of the controls in the platform and at the ground, emergency controls and safety features.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.2 Training Supervision Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine. Operator Responsibility The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Table 2-1. Inspection and Maintenance Table TYPE PRIMARY RESPONSIBILITY FREQUENCY SERVICE QUALIFICATION User or Operator REFERENCE Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator Operation and Safety Manual Pre-Delivery Inspection (see note below) 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 or battery fluid) or foreign objects. Report this to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. Report this to the proper maintenance personnel. .
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 10. Platform Gate - Keep gate and surrounding area clean and unobstructed. Check that gate closes and latches securely and is not bent or damaged. During operation keep gate closed. 11. Lanyard Anchorage Points - JLG Industries, Inc. recommends personnel in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point (1).
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.4 DAILY WALK-AROUND INSPECTION Begin the “Walk-Around Inspection” at item 1, see Figure 2-1. on page 2-7. Continue checking each item in sequence for the conditions listed in the following checklist. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF”. DO NOT OPERATE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED. NOTICE DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.5 FUNCTION CHECK . Perform the Function Check as follows: 1. From the Ground Control Panel with no load in the platform: a. Ensure that the key selector switch and the platform lift switch operates properly. b. Ensure that all machine functions are disabled when the Emergency Stop Button is depressed. c.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION drive with the platform above elevation unless the pot-hole-protection system is fully lowered. e. With the platform elevated on a smooth, firm, level surface with no overhead obstructions, drive the machine to check if the high drive cutout speed-limit is engaged at the height indicated in Table 2-2. Ensure drive speed is reduced from a higher speed to a slower speed. Limit switch locations shown in Figure 2-2. on page 2-10. b.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 1. Platform Elevation Switch 2-10 Figure 2-2. Machine Switch Locations 2. LSS Scissor Arm - Rotary Angle Switch 3.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION 3.1 GENERAL 3.2 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 controls and their functions. DO NOT RAISE PLATFORM EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.3 OPERATING CHARACTERISTICS AND LIMITATIONS 3.4 General A thorough knowledge of the operating characteristics and limitations of the machine is always the first requirement for any user, regardless of user’s experience with similar types of equipment. Placards Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, NOTICE, and INSTRUCTION placards.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.5 MACHINE CONTROL LOCATIONS 1. 2. 3. 4. 5. Ground Control Station Platform Control Station Platform Manual Descent Control AC Plug - To Platform AC Receptacle Outlet Box AC Plug - Battery Charger Input Plug Figure 3-1. R6 - Location of Machine Controls.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.6 through the opening on the rear panel where the charger AC cord is accessed. 4. The batteries are fully charged when the green light on the battery charger status panel is illuminated. BATTERY CHARGING NOTE: Be sure that machine is parked in a well ventilated area before charging begins. ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Battery Charger Fault (LED Flash) If a fault has occurred during battery charging, the (AMBER or RED) LED on the charger LED indicator (See Figure 3-2.) will flash corresponding to the fault which occurred. Refer to Table 3-1 following for the charger LED flash codes and their meaning. If required, further general and troubleshooting information about the battery charger can be found in the charger manufacturers Owner’s Guide. Table 3-1.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.7 GROUND CONTROL STATION 1 DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. 2 PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE. 3 1001132360A 5 4 1001146979A Figure 3-3. Ground Control Station 1. Platform Lift/Lower Switch 2. Key Selector Switch 3. Ground Emergency Stop Button 3-6 – JLG Lift – 4. MDI - Indicator 5.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Ground Emergency Stop Switch - (Item 3 - Figure 3-3.) Platform Lift/Lower Switch - (Item 1 - Figure 3-3.) Power is turned on by pulling the switch out, and is turned off by depressing switch. A two-position, red, mushroom-shaped emergency stop switch, when positioned to ON with the key selector switch positioned to ground, furnishes operating power to the ground control station key switch.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION NOTE: When more than one DTC exists, each DTC will be displayed on the LCD for 3 seconds before changing to the next DTC. Once the last active DTC is displayed, the display will recycle indefinitely until the DTC’s are corrected. For DTC’s and descriptions, refer to Section 5.9. 7 6 Also located on the MDI are Battery Discharge Indicators (BDI) (items 4 thru 7). (4) GREEN LEDs indicate the level of charge (voltage) remaining in the batteries.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform Manual Descent Control The platform manual descent control is used in the event of total power failure to lower the platform using gravity. The manual descent control T-handle is located on the right rear of the machine, just in front of the drive wheel. The lowering procedure is as follows: 1. Locate the manual descent control T-handle. (See Figure 3-5.) KEEP HANDS AND ARMS OUT OF THE PATH OF THE SCISSOR ARMS AND PLATFORM WHILE LOWERING. 2.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.8 To release the safety prop: SCISSOR ARM - SAFETY PROP NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT WITH THE SAFETY PROP, BLOCKING OR OVERHEAD SLING. The safety prop is located at the rear of the machine on the rod end of the lift cylinder, located between the scissor arms. 1. Raise the platform enough to release the safety prop off the head of the cylinder. 2.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Prop Released and Locked Figure 3-6.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.9 PLATFORM CONTROL STATION 1 2 3 4 11 2 1 5 62 23 13 01 10 6 B 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Steer Control Switch Drive and Lift Joystick Control Trigger Switch Forward/Reverse/Lift/Lower Direction Decal Alarm Overload Indicator Machine Tilt Indicator Emergency Stop Switch Horn Button Drive and Lift Select Switch Low Battery Charge and System Fault Indicator 7 8 10 9 Figure 3-7. Platform Control Station.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform Emergency Stop Switch - (Item 8 - Figure 3-7.) NOTE: Both the ground and platform emergency stop buttons must be set to ON in order to operate the machine. When power is directed to the platform from the ground control station, the platform emergency stop switch is turned on by pulling the switch out (on), and is turned off by pushing the switch in (off ).
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 1. Trigger Switch - This switch is located on the front of the joystick controller. The trigger switch acts as an enable and must be depressed before operating the drive, steer and lift functions. When released, the function being operated will stop.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Steering And Traveling Steering (Item 2 - Figure 3-8.) DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES. TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED IN TABLE 5-1 ON PAGE 5-2. BEFORE DRIVING, LOCATE THE DECALS WITH THE BLACK/WHITE ORIENTATION ARROWS ON THE CHASSIS AND THE PLATFORM CONTROLS.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-9.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Raising And Lowering Platform Overload Indicator - 1. If the machine was shut down, place the key selector switch to the desired position (platform or ground). 2. Position emergency stop switches, one at the platform and one at the ground control station to the ON position. 3. Position the lift/drive select switch to lift. (Item 10 - Figure 3-7.) 4.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Horn Alarm (Item 9 - Figure 3-7.) (Item 5 - Figure 3-7.) This push-button switch, when pressed, permits the operator to warn job site personnel when the machine is operating in the area. This alarm mounted on the front of the platform control station will sound for various machine conditions or warnings such as, system ready chirp or if the machine tilt warning is activated. Low Battery Charge and System Fault Indicator (Item 11 - Figure 3-7.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION To retract the deck: 3.10 PLATFORM EXTENSION (See Figure 3-10.) This machine is equipped with an extension deck, giving the operator better access to certain work areas. The deck extension adds length to the front of the platform. 1. Pull up on the mid-rail locking pin (1) and turn the pin 90° to hold in up position. 2. Pull the extension deck all the way back into the main deck using the top handrail (2). 3.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.11 PARKING AND STOWING MACHINE 1. Drive the machine to a well-protected and well-ventilated area. 2. Ensure the platform is fully lowered. NOTICE WHEN THE MACHINE IS SHUT DOWN FOR OVERNIGHT PARKING OR BATTERY CHARGING, THE EMERGENCY STOP AND POWER SELECT SWITCHES MUST BE POSITIONED TO OFF TO PREVENT DRAINING THE BATTERIES. 2 3.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Anti-Vandalism Package - Option The anti-vandalism package adds hinged metal covers for the platform and ground control stations. These hinged metal cover are also provided with a lock tab for adding a lock to prevent unauthorized operation of the machine when parked and stored overnight, or for extended periods.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.12 MACHINE LIFTING AND TIE DOWN Lifting The machine may be lifted using a fork lift truck. Lift only from the rear of the machine and only with the platform in the stowed position. Adjust the width of the forklift truck, lifting tines (1) to properly fit the machine, see Figure 3-12. The machine can also be lifted using a spreader bar and four equal length straps or chains capable of supporting the full gross weight of the machine, see Figure 3-13.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-13. Lifting Using Spreader Bar and Lift Lug Locations 1. Four (4) equal length chains or lifting straps. 3121684 – JLG Lift – 2. Spreader Bar Assembly.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-14.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.13 TOWING It is not recommended that this machine be towed, except in the event of an emergency such as a machine malfunction or a total machine power failure. Electric Brake Release (See Figure 3-15.) NOTE: Electrical release of the brakes requires enough battery power to hold the brakes in released mode until destination is reached. 1. Chock wheels or secure machine with tow vehicle. 2.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Mechanical Brake Release (See Figure 3-16.) AFTER THE MACHINE IS TOWED THE COVER BOLTS (1) MUST BE REMOVED FROM THE BRAKE DISENGAGE HOLES (4). THE BRAKES CANNOT BE ENGAGED IF THE DISENGAGE BOLTS ARE LEFT IN THE DISENGAGE HOLES. THIS WILL CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE. CHOCK WHEELS OR SECURE MACHINE WITH TOW VEHICLE. 1. At the ground control station turn power off by pressing the Emergency Stop switch in. 2.
SECTION 4 - EMERGENCY PROCEDURES SECTION 4. EMERGENCY PROCEDURES 4.1 GENERAL INFORMATION Righting of Tipped Machine This section explains the steps to be taken in case of an emergency situation during operation. 4.2 EMERGENCY OPERATION A fork truck of suitable capacity or equivalent equipment should be placed under the elevated side of the chassis, with a crane or other suitable lifting equipment used to lift the platform while the chassis is lowered by the forklift or other equipment.
SECTION 4 - EMERGENCY PROCEDURES 4.4 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, JLG must be contacted by telephone and provided with all necessary details. USA: 877-JLG-SAFE (554-7233) EUROPE: (44) 1 698 811005 AUSTRALIA: (61) 2 65 811111 E-mail: productsafety@jlg.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE SECTION 5. GENERAL SPECIFICATIONS AND MAINTENANCE 5.1 INTRODUCTION Other Publications Available Specific to this Machine: This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine. Service and Maintenance Manual......................................3121685 Illustrated Parts Manual .........................................................
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.2 OPERATING SPECIFICATIONS Table 5-1. Operating Specifications DESCRIPTION PLATFORM Maximum Platform Height DRIVING Maximum Drive Speed R6 5.79 m (19 ft.) Stowed: Elevated: Maximum Stowed Travel Grade (Gradeability) (Reference Figure 3-9.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Platform Capacities Table 5-2. Platform Capacities SPECIFICATION AUSTRALIA MACHINE MODEL R6 MAXIMUM MAXIMUM CAPACITY PLATFORM ALLOWED ON CAPACITY (1) PLATFORM EXTENSION 230 Kg 120 Kg MAX. SIDE FORCE (Platform Fully Extended @ Max. Capacity) MAXIMUM OPERATING WIND SPEED Indoor - 2 Persons + 70 Kg 400 N 0 m/s Outdoor - 1 Person + 150 Kg 200 N 12.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Machine Dimensional Data Tires Table 5-4. Tire Specifications Table 5-3. Dimensions DESCRIPTION 5-4 DESCRIPTION R6 R6 Platform Height - Elevated (Ground to Platform Floor) 5.79 m (19 ft) Platform Height - Stowed (Ground to Platform Floor) 100 cm (39.5 in.) Working Height 7.47 m (24 ft. 6 in.) Rail Height (Platform Floor to Top of Rail) 101.6 cm (40 in.) Overall Machine Width 81.2 cm (32 in.) Overall Machine Length (w/ladder) 2.08 m (81.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Electrical System 5.3 CRITICAL STABILITY WEIGHTS Table 5-6. Electrical System Specifications DESCRIPTION SPECIFICATION Electrical System Voltage (DC) Battery Charger: Input: AC Input Voltage: Nominal AC Input Voltage: Input Frequency: Max. AC Input Current: Ingress Protection: Operating Temperature: Output: Nominal DC Output Voltage: Max. DC Output Voltage: Max DC Output Current: Max.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.4 LUBRICATION Lubrication Specifications Table 5-10. Lubrication Specifications Lubrication Capacities Table 5-8. Capacities COMPONENT R6 Hydraulic Reservoir 5 L (1.32 Gal.) Hydraulic System (Including Reservoir) 7 L (1.85 Gal.) KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-11. Hydraulic Oil Specifications SPECIFICATION MOBIL DTE 10 EXCEL 15 MOBIL EAL ENVIRONSYN H 32 MOBIL EAL HYDRAULIC OIL 32 ISO Viscosity Grade #15 #32 #32 Spec Gravity API 31.9 0.950 — Pour Point, Max -40° C (-40° F) -51° C (-59° F) -39° C (-38.2° F) Flash Point, Min. 166° C (330° F) 268° C (514.4° F) 248° C (478° F) VISCOSITY SPECIFICATIONS at 40° C 15 cSt 33.1 cSt 32 cSt at 100° C 4.1 cSt 6.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.5 NOTE: Care should be taken not to introduce any impurities (dirt, water, etc.) while cap is removed. MAINTENANCE Hydraulic Oil Check Procedure Lube Point(s) - Hydraulic Reservoir Reservoir Capacity - See Table 5-8 on page 5-6. Lube - Hydraulic Oil Interval - Check Daily NOTE: Check the hydraulic oil level with the platform in the stowed position ONLY.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.6 BATTERY MAINTENANCE BATTERY FILLER CAP FLUID LEVEL OF FULLY CHARGED BATTERY VENT TUBE Battery Maintenance and Safety Practices NOTE: These instructions are for unsealed (wet) batteries only. if machine is equipped with sealed batteries, no maintenance other than cleaning corroded battery terminals is required. ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING WITH BATTERIES.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.7 TIRES AND WHEELS Tire Wear and Damage The tire and rim assemblies installed on RS machines have been approved by the tire manufacturer for applications in which those products are intended to be used. The tire and rims installed on each product model have been designed for stability requirements, which consist of track width, tire compound, and load capacity.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Check torque every 3 months or 150 hours of operation. Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque. WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN LUG NUTS, AND POSSIBLE SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE LUG NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.8 DECAL INSTALLATION Figure 5-4. Machine Decal Installation (See Table 5-13.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE Table 5-13. Machine Decal Installation Chart ITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 3121684 AUSTRALIA (R6) 0860520 — 1701504 1701509 1705754 1703177 1705670 1703819 1703822 1704016 1704277 1704412 (on tank) 1705647 — — 1705673 1705671 — — Table 5-13.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.9 DIAGNOSTIC TROUBLE CODES (DTC) 5.10 DTC CHECK TABLE INDEX The DTC tables following are sorted in groups by the first two digits, these digits represent the number of flashes the system distress indicator lamp will flash on the platform indicator panel when a fault occurs. DTC TABLE For example: a “2-1 Power-Up” on page 16 would be indicated by 2 flashes, a pause, then 1 flash, a pause, then would keep repeating until the fault is cleared.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 5.11 DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 001 EVERYTHING OK The normal help message in platform mode. Displays on the analyzer only. 002 GROUND MODE OK The normal help message in ground mode. Displays on the analyzer only. 003 ALARM SOUNDING - TILTED & ABOVE ELEVATION Control system senses that the platform is ele- • Check that the machine is tilted.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 0-0 Help Comments DTC FAULT MESSAGE DESCRIPTION CHECK 005 DRIVE & LIFT UP PREVENTED - TILTED & Driving is not possible since the platform is ELEVATED elevated and the chassis is not level. • Check that the machine is tilted. If so, lower the platform and reposition the machine to a level surface. • Fully stow the platform. • Check that the tilt sensor is securely mounted.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 2-2 Platform Controls DTC FAULT MESSAGE DESCRIPTION CHECK 221 FUNCTION PROBLEM - HORN PERMA- The horn switch was closed during power-up • Check if the horn switch is damaged, obstructed or jammed. NENTLY SELECTED in platform mode. Refer problem to a qualified JLG mechanic. 223 FUNCTION PROBLEM - DRIVE & LIFT ACTIVE TOGETHER The drive and lift inputs are closed simultane- • Check drive/lift switch for visible damage. ously in platform mode.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 2-2 Platform Controls DTC FAULT MESSAGE 2232 FUNCTION PROBLEM - DRIVE & LIFT BOTH OPEN DESCRIPTION CHECK The drive and lift inputs are both de-energized • Check if either function is active, if Yes; in platform mode. Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 2-5 Function Prevented DTC FAULT MESSAGE DESCRIPTION CHECK 254 DRIVE & LIFT UP PREVENTED - CHARGER CONNECTED Drive or lift is not possible while the vehicle is • Check if the charger is connected to off board power source and disconnect if charging AND is configured to prevent all desired. motion. Refer problem to a qualified JLG mechanic. 255 PLATFORM OVERLOAD The Load Sensing System (LSS) measured platform load is excessive.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 2-5 Function Prevented DTC FAULT MESSAGE 2568 TEMPERATURE CUTOUT ACTIVE – AMBIENT TEMPERATURE TOO LOW DESCRIPTION CHECK Reported if the ambient temperature reading • If elevated, drive and steer shall be restricted to “creep”, lift down shall be allowed at normal speed and lift up shall not be allowed.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 3-2 Line Contactor Short Circuit DTC FAULT MESSAGE 321 LINE CONTACTOR MISWIRED ON OR WELDED DESCRIPTION There is a problem with the line contactor. CHECK Refer problem to a qualified JLG mechanic. 326 AUXILIARY RELAY - SHORT TO BATTERY There is a problem with the auxiliary relay con- Refer problem to a qualified JLG mechanic. tacts or wiring.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 3-3 Ground Output Driver DTC FAULT MESSAGE DESCRIPTION CHECK 3314 LEFT BRAKE OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 3315 RIGHT BRAKE OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic. 3349 LINE CONTACTOR COIL - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 4-2 Thermal Limit (SOA) DTC FAULT MESSAGE DESCRIPTION CHECK 421 POWER MODULE TOO HOT - PLEASE WAIT The power module has reached thermal cutout. • Power down and allow to cool. • Do not operate in ambients over 140° F (60° C). Refer problem to a qualified JLG mechanic. 422 DRIVING AT CUTBACK - POWER MODULE CURRENT LIMIT The drive portion of the power module has reached thermal limit. Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 6-6 Communication DTC FAULT MESSAGE 661 CANBUS FAILURE - POWER MODULE DESCRIPTION CHECK The control system failed to receive messages Refer problem to a qualified JLG mechanic. from the power module. 6643 CANBUS FAILURE - LSS ANGLE SENSOR The control system failed to receive messages Refer problem to a qualified JLG mechanic. from the angle sensor.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 7-7 Electric Motor DTC FAULT MESSAGE DESCRIPTION CHECK 774 SHORT CIRCUIT FIELD WIRING The power module detected a problem in the Refer problem to a qualified JLG mechanic. drive motors' power circuit wiring. 775 OPEN CIRCUIT FIELD WIRING The power module detected a problem in the Refer problem to a qualified JLG mechanic. drive motors' power circuit wiring.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 7-7 Electric Motor DTC FAULT MESSAGE 7742 FIELD VOLTAGE IMPROPER DESCRIPTION CHECK The power module detected a problem in the Recycle power on/off, if problem persists; drive motors' power circuit wiring. Refer problem to a qualified JLG mechanic. 8-2 LSS - Load Sensing System DTC FAULT MESSAGE DESCRIPTION CHECK 8212 LSS PRESSURE SENSOR DISAGREEMENT Pressure Sensor 1 and Pressure Sensor 2 do not Refer problem to a qualified JLG mechanic. agree.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 8-4 Elevation Switch DTC FAULT MESSAGE 84109 ELEVATION SWITCH CONTACTS DISAGREEMENT DESCRIPTION CHECK The elevation switch is repeating an incorrect Refer problem to a qualified JLG mechanic. value. 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 995 POWER MODULE FAILURE - PERSONAL- A problem has been detected with the power Refer problem to a qualified JLG mechanic. ITY RANGE ERROR module.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE 9-9 Hardware DTC FAULT MESSAGE DESCRIPTION CHECK 9950 POWER MODULE FAILURE - INTERNAL A problem has been detected with the power Cycle machine power on /off a few times if this doesn’t clear the DTC, 9951 ERROR module. refer problem to a qualified JLG mechanic.
SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 6-1.
SECTION 6 - INSPECTION AND REPAIR LOG Table 6-1.
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 172339533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65 813058 JLG Latino Americana Ltda. Rua Eng.
