Operation and Safety Manual

Operation and Safety Manual
Operation and Safety Manual
Keep this manual with the machine at all times.
Boom Lift Models
450A Series II
450AJ Series II
510AJ
ANSI
3121179
®
May 22, 2006
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.
3121179
– JLG Lift –
a
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, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE
A YELLOW BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
b
– JLG Lift –
3121179
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
IMPORTANT
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
IMPORTANT
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL
OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL
PROPERTY OR THE JLG PRODUCT.
• Standards and Regulations
Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free:
877-JLG-SAFE (877-554-7233)
Outside USA:
Phone:
E-mail:
3121179
– JLG Lift –
717-485-5161
ProductSafety@JLG.com
c
FOREWORD
REVISION LOG
d
Original Issue
- January 1, 2003
Revised
- April 24, 2003
Revised
- August 26, 2003
Revised
- June 15, 2004
Revised
- May 4, 2005
Revised
- February 8, 2006
Revised
- May 22, 2006
– JLG Lift –
3121179
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . 1-7
TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8
ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9
2.3
2.2
3121179
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1
3.2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Indicator Panel . . . . . . . . . . . . . 3-5
Platform Control Station . . . . . . . . . . . . . . . . . . . 3-8
Platform Control Indicator Panel . . . . . . . . . . . . 3-11
SECTION - 4 - MACHINE OPERATION
SECTION - 2 - USER RESPONSIBILITIES, MACHINE
PREPARATION, AND INSPECTION
2.1
PAGE
PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1
PREPARATION, INSPECTION, AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
– JLG Lift –
4.1
4.2
4.3
4.4
4.5
4.6
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . .
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . .
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . .
TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . .
Traveling Forward and Reverse . . . . . . . . . . . . .
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-1
4-1
4-2
4-2
4-2
4-3
4-5
4-7
4-7
4-7
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
PAGE
Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8
Raising and Lowering the Lower and Mid Boom 4-8
Raising and Lowering the Main (Upper) Boom . 4-8
Telescoping the Main Boom . . . . . . . . . . . . . . . 4-8
FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-8
AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . 4-9
LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-10
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Prior to Towing. . . . . . . . . . . . . . . . . . . . . . . . . 4-12
DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-13
Changing From Gasoline to LP Gas . . . . . . . . 4-13
Changing From LP Gas to Gasoline . . . . . . . . 4-13
SECTION - PARAGRAPH, SUBJECT
5.4
ii
Operator Unable to Control Machine . . . . . . . . . 5-2
Platform or Boom Caught Overhead . . . . . . . . . 5-2
EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
SECTION - 5 - EMERGENCY PROCEDURES
5.1
5.2
5.3
PAGE
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1
EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . 5-2
– JLG Lift –
6.1
6.2
6.3
6.4
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
OPERATING SPECIFICATIONS AND
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . .6-1
Reach Specifications . . . . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Major Component Weights. . . . . . . . . . . . . . . . . 6-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Serial Number Location . . . . . . . . . . . . . . . . . . 6-11
OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21
TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-30
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-30
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-31
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-31
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
6.5
6.6
6.7
PAGE
SECTION - PARAGRAPH, SUBJECT
PAGE
DRAINING OIL BUILD UP FROM THE PROPANE
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33
PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-34
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35
PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-36
SECTION - 7 - INSPECTION AND REPAIR LOG
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– JLG Lift –
iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
PAGE
LIST OF FIGURES
2-1.
2-2.
2-3.
2-4.
2-5.
3-1.
3-1.
3-2.
3-3.
3-4.
3-5.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
4-10.
4-11.
6-1.
6-2.
iv
Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . . 2-6
Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . . 2-7
Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . 2-8
Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . 2-9
Daily Walk-Around Inspection - Sheet 3 of 3 . . . . 2-10
Ground Control Station - A Models. . . . . . . . . . . . . 3-2
Ground Control Station - AJ Models . . . . . . . . . . . . 3-3
Ground Control Indicator Panel . . . . . . . . . . . . . . . 3-6
Platform Control Console . . . . . . . . . . . . . . . . . . . . 3-9
Platform Control Indicator Panel - Sheet 1 of 2 . . 3-13
Platform Control Indicator Panel - Sheet 2 of 2 . . 3-14
Position of Least Forward Stability . . . . . . . . . . . . . 4-4
Position of Least Backward Stability . . . . . . . . . . . . 4-5
Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . 4-6
Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-11
Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . 4-12
Decal Installation - Sheet 1 of 6. . . . . . . . . . . . . . . 4-14
Decal Installation - Sheet 2 of 6. . . . . . . . . . . . . . . 4-15
Decal Installation - Sheet 3 of 6. . . . . . . . . . . . . . . 4-16
Decal Installation - Sheet 4 of 6. . . . . . . . . . . . . . . 4-17
Decal Installation - Sheet 5 of 6. . . . . . . . . . . . . . . 4-18
Decal Installation - Sheet 6 of 6. . . . . . . . . . . . . . . 4-19
Serial Number Locations. . . . . . . . . . . . . . . . . . . . 6-11
Engine Operating Temperature Specifications -
SECTION - PARAGRAPH, SUBJECT
PAGE
Deutz - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . .6-12
Engine Operating Temperature Specifications Deutz - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . .6-13
6-4. Engine Operating Temperature Specifications Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . .6-14
6-5. Engine Operating Temperature Specifications Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . .6-15
6-6. Engine Operating Temperature Specifications Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . .6-16
6-7. Engine Operating Temperature Specifications Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . .6-17
6-8. Engine Operating Temperature Specifications GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-18
6-9. Engine Operating Temperature Specifications GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-19
6-10. Operator Maintenance and Lubrication Diagram .6-20
6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . .6-34
6-3.
– JLG Lift –
3121179
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
PAGE
SECTION - PARAGRAPH, SUBJECT
LIST OF TABLES
1-1
2-1
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
6-19
6-20
6-21
6-22
3121179
Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5
Inspection and Maintenance Table . . . . . . . . . . . . 2-3
Operating Specifications - 450A/450AJ . . . . . . . . . 6-1
Operating Specifications - 510AJ. . . . . . . . . . . . . . 6-2
Reach Specifications - 450. . . . . . . . . . . . . . . . . . . 6-2
Reach Specifications - 510. . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data - 450 . . . . . . . . . . . . . . . . . . . . . 6-3
Dimensional Data - 510 . . . . . . . . . . . . . . . . . . . . . 6-3
Chassis Specifications - 450 . . . . . . . . . . . . . . . . . 6-3
Chassis Specifications - 510 . . . . . . . . . . . . . . . . . 6-4
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-5
Deutz F3M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Deutz F3M2011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Caterpillar 3024 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Component Weights - 450 . . . . . . . . . . . . . . . . . . . 6-7
Component Weights - 510 . . . . . . . . . . . . . . . . . . . 6-7
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-8
Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-9
UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-9
Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . 6-10
– JLG Lift –
6-23
6-24
6-25
7-1
PAGE
Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . 6-10
Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-21
Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-32
Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
v
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
PAGE
SECTION - PARAGRAPH, SUBJECT
PAGE
This page left blank intentionally.
vi
– JLG Lift –
3121179
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.
PRE-OPERATION
Operator Training and Knowledge
• Read and understand this manual before operating the
machine.
The owner/user/operator/lessor/lessee of the machine
should not operate the machine until this manual has been
read, training is accomplished, and operation of the machine
has been completed under the supervision of an experienced and qualified operator.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
3121179
– JLG Lift –
• Do not operate this machine until complete training is performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
1-1
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.
Machine Inspection
• All operating personnel must be familiar with the emergency controls and emergency operation of the machine
as specified in this manual.
• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for
detailed instructions.
• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
operation of the machine.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the
Service and Maintenance Manual.
Workplace Inspection
• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.
1-2
• This machine can be operated in temperatures of 0o F to
104o F (-20o C to 40o C). Consult JLG for operation outside this range.
• Be sure the footswitch and all other safety devices are
operating properly. Modification of these devices is a
safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from footwear and platform floor.
– JLG Lift –
3121179
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.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.
• Never operate a machine that is not working properly. If a
malfunctions occurs, shut down the machine.
• 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.
• Hydraulic cylinders should never be left fully extended or
fully retracted before shutdown or for long periods of time.
• Do not place boom or platform against any structure to
steady the platform or to support the structure.
• Stow boom and shut off all power before leaving machine.
Trip and Fall Hazards
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.
• Do not carry materials directly on platform railing unless
approved by JLG.
• When two or more persons are in the platform, the operator shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
3121179
– JLG Lift –
1-3
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.
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 use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the boom assembly to enter or leave the platform.
1-4
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3121179
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.
• Allow for machine movement and electrical line swaying.
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MINIMUM APPROACH DISTANCE
in Feet (Meters)
This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up
to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
1-5
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. This determination shall be made by a qualified person in accordance with the employer, local, or governmental
requirements for wok practices near energized equipment
Tipping Hazards
• The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade
while driving.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
1-6
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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 and remove personnel.
• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
Crushing and Collision Hazards
• Do not raise the platform or drive from an elevated position unless the machine is on firm, level and smooth surfaces.
• Keep the chassis of the machine at least 2 ft. (0.6m) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and
bottom of platform when lifting or lowering platform, and
driving.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure.
• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
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• During operation, keep all body parts inside platform railing.
1-7
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.
• 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.
1.4
TOWING, LIFTING, AND HAULING
• Never allow personnel in platform while towing, lifting, or
hauling.
• This machine should not be towed, except in the event of
emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this
manual for emergency towing procedures.
• Ensure boom is in the stowed position and the turntable
locked prior to towing, lifting or hauling. The platform must
be completely empty of tools.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for
lifting information.
• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and persons in the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if necessary.
1-8
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SECTION 1 - SAFETY PRECAUTIONS
1.5
ADDITIONAL HAZARDS / SAFETY
• 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.
• Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.
• Charge batteries only in a well ventilated area.
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SECTION 1 - SAFETY PRECAUTIONS
This page left blank intentionally.
1-10
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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.
Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.
Training Supervision
Operator Training
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 training must cover:
1. Use and limitations of the controls in the platform and at
the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
Operator Responsibility
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
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.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunction.
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2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.2
PREPARATION, INSPECTION, AND
MAINTENANCE
IMPORTANT
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. The frequency of inspections and maintenance must be increased as necessary when the machine is
used in a harsh or hostile environment, if the machine is
used with increased frequency, or if the machine is used in a
severe manner.
2-2
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
– JLG Lift –
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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.
Owner, Dealer, or User
Qualified JLG
Mechanic
Service and Maintenance
Manual and applicable JLG
inspection form
Frequent Inspection
(See Note)
In service for 3 months or 150 hours, whichever Owner, Dealer, or User
comes first; or
Out of service for a period of more than 3 months;
or
Purchased used.
Qualified JLG
Mechanic
Service and Maintenance
Manual and applicable JLG
inspection form
Factory-Certified
Service Technician
(Recommended)
Service and Maintenance
Manual and applicable JLG
inspection form
Qualified JLG
Mechanic
Service and Maintenance
Manual
Annual Machine Inspection Annually, no later than 13 months from the date
(See Note)
of prior inspection.
Preventative Maintenance
Owner, Dealer, or User
At intervals as specified in the Service and Main- Owner, Dealer, or User
tenance Manual.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
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2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Pre-Start Inspection
8. Hydraulic Oil – Check the hydraulic oil level. Ensure
hydraulic oil is added as required.
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. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible decals and placards are
cleaned or replaced.
3. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, EMI Safety Manual
(Domestic only), and ANSI Manual of Responsibilities
(Domestic only) is enclosed in the weather resistant
storage container.
9. Accessories/Attachments - Reference the Operator
and Safety Manual of each attachment for accessory
installed upon the machine for specific inspection, operation, and maintenance instructions.
10. 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.
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.
4. “Walk-Around” Inspection – Refer to Figure 2-3. and
Figure 2-4.
5. Battery – Charge as required.
6. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
7. Engine Oil Supply - Ensure the engine oil level is at the
Full mark on the dipstick and the filler cap is secure.
2-4
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Function Check
3. With the platform in the transport (stowed) position:
Perform the Function Check as follows:
1. From the ground control panel with no load in the platform:
a. Check that all guards protecting the switches or
locks are in place;
a. Drive the machine on a grade, not to exceed the
rated gradeability, and stop to ensure the brakes
hold;
b. Check the tilt sensor alarm to ensure proper operation.
b. Operate all functions and check boom limit
switches; drive speed should switch to creep mode
if lower boom is elevated or main boom is above
horizontal.
c. Check auxiliary power (or manual descent);
d. Ensure that all machine functions are disabled
when the Emergency Stop Button is activated.
2. From the platform control console:
a. Ensure that the control console is firmly secured in
the proper location;
b. Check that all guards protecting the switches or
locks are in place;
c. Operate all functions and check all limiting and cutout switches;
d. Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in.
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2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Figure 2-1. Basic Nomenclature - Sheet 1 of 2
2-6
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3121179
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.
19.
20.
Steer Wheels
Drive Wheels
Lower Lift Cylinder
Lower Upright
Mid Boom
Upper Lift Cylinder
Main Boom Assembly
Power Track
Level Cylinder
Jib Cylinder
Platform
Platform Console
Jib
Fly Boom
Base Boom
Master Cylinder
Tower or Lower Boom
Turntable
Frame
Tower Link
Figure 2-2. Basic Nomenclature - Sheet 2 of 2
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2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Figure 2-3. Daily Walk-Around Inspection - Sheet 1 of 3
2-8
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3121179
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. All Hydraulic Cylinders - No visible damage; pivot
pins and hydraulic hoses undamaged, not leaking.
4. Boom Sections/Uprights/Turntable - See Inspection
Note.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.
5. Boom Limit Switches - Switches operate properly.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN
CORRECTED.
6. Drive Motor, Brake, and Hub - No evidence of leakage.
INSPECTION NOTE: On all components, make sure there
are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear
exists in addition to any other criteria mentioned.
7. Wheel/Tire Assemblies - Properly secured, no missing lug nuts, proper inflation (pneumatic).
8. Hood Assemblies - See Inspection Note.
1. Platform Assembly and Gate - Lockbolts in place.
Footswitch works properly, not modified, disabled or
blocked. Latch, stop, and hinges in working condition.
Figure 2-4. Daily Walk-Around Inspection - Sheet 2 of 3
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
9. Oscillation Lockout Valve (If Equipped) (450 Models
Prior to S/N 0300077285, 510 Models Prior to S/N
1300000353) - Check the lockout valve plunger in the
depressed position. Swing the turntable until the axle
lockout bracket passes the plunger and make sure the
plunger is fully extended as shown below
10. Tie Rod Ends and Steering Spindles - See Inspection
Note.
11. Turntable Bearing - Evidence of proper lubrication. No
evidence of loose bolts or looseness between bearing
and machine.
12. Swing Motor and Worm Gear - Evidence of proper
lubrication; No evidence of damage.
13. Auxiliary Hydraulic Pump - See Inspection Note.
14. Main Hydraulic Pump - See Inspection Note.
15. Platform Rotator - See Inspection Note.
Figure 2-5. Daily Walk-Around Inspection - Sheet 3 of 3
2-10
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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.
IMPORTANT
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY
TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER
SYSTEM OPERATION IS SUSPECTED.
NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test.
1. Place a 6 inches (15.2 cm) high block with ascension
ramp in front of left front wheel.
2. From platform control station, start engine.
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front
wheel is on top of block.
4. Carefully activate Swing control lever and position boom
over right side of machine.
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7. 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 to activate Drive to release
cylinders.
8. Place the 6 inches (15.2 cm) high block with ascension
ramp in front of right front wheel.
9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on
top of block.
10. With boom over left side of machine, place Drive control
lever to Reverse and drive machine off of block and
ramp.
2-11
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. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.
– JLG Lift –
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SECTION 3 - MACHINE CONTROLS AND INDICATORS
SECTION 3. MACHINE CONTROLS AND INDICATORS
3.1 GENERAL
DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM EXCEPT IN AN EMERGENCY.
IMPORTANT
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE
APPLICATION AND OPERATION. THE USER AND OPERATOR ARE
RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.
PERFORM AS MANY PRE-OPERATIONAL CHECK AND INSPECTIONS
FROM GROUND CONTROLS AS POSSIBLE.
This section provides the necessary information needed to
understand control functions.
A three position switch controls rotation of the platform.
3.2 CONTROLS AND INDICATORS
2. Platform Leveling Override
Ground Control Station
NOTE:
A three position switch allows the operator to adjust the
automatic self leveling system.
If equipped, the Function Enable switch must
be held down in order to operate Telescope,
Swing, Tower Lift, Main Lift, Jib Lift, Platform
Level Override, and Platform Rotate functions.
3121179
1. Platform Rotate
3. Articulating Jib Boom (If Equipped)
This switch provides raising and lowering of the jib.
– JLG Lift –
3-1
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
Platform Rotate
Platform Leveling Override
Not Used
Engine Start/Auxiliary Power
or
Engine Start/Auxiliary Power/Function Enable
5. Power/Emergency Stop
6. Platform/Ground Select
7. Hourmeter
8. Swing
9. Tower Lift
10. Main Lift
11. Telescope
12. Indicator Panel
Figure 3-1. Ground Control Station - A Models
3-2
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SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
Platform Rotate
Platform Leveling Override
Jib
Engine Start/Auxiliary Power
or
Engine Start/Auxiliary Power/Function Enable
5. Power/Emergency Stop
6. Platform/Ground Select
7. Hourmeter
8. Swing
9. Tower Lift
10. Main Lift
11. Telescope
12. Indicator Panel
Figure 3-1. Ground Control Station - AJ Models
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3-3
SECTION 3 - MACHINE CONTROLS AND INDICATORS
4. Engine Start/Auxiliary Power Switch
or
Engine Start/ Auxiliary Power Switch /Function Enable.
6. Platform/Ground Select
A three position, key operated switch supplies power to
the platform control console when positioned to Platform. With the switch key held in the Ground position,
power is shut off to platform and only ground controls
are operable.
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.
If equipped, the enable switch must be held
"DOWN" to enable all boom controls when the
engine is running.
NOTE: Auxiliary power only works if there is no oil pressure, and is
disabled if engine is running.
NOTE: When machine is shut down the Platform/Ground Select
switch and Emergency Stop must be positioned to OFF.
NOTE: With PLATFORM/GROUND SELECT switch in the center
position, power is shut off to controls at both operating
stations.
7. Hourmeter
The hourmeter registers up to 9,999.9 hours and cannot
be reset.
5. Power/Emergency Stop
A two-position red mushroom shaped switch furnishes
power to Platform/Ground Select switch when pulled out
(on). When pushed in (off), power is shut off to the Platform/Ground Select switch.
3-4
8. Swing Control
– JLG Lift –
The Swing control switch provides 360 degrees noncontinuous turntable rotation when positioned to the
right or left.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS
Ground Control Indicator Panel
9. Tower Lift
Provides for 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
Provides for raising and lowering of the Main Boom.
11. Telescope
Provides for extension and retraction of the Main Boom.
2. Engine Oil Pressure Indicator
Indicates that engine oil pressure is below normal and
service is required.
3. Engine Coolant Temperature Indicator (Ford)
Indicates that engine coolant temperature is abnormally
high and service is required.
4. Engine Oil Temperature Indicator (Deutz)
Indicates that the temperature of the engine oil, which
also serves as engine coolant, is abnormally high and
service is required.
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3-5
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
5.
Battery Charging
Low Engine Oil Pressure
Engine Coolant Temp.
Engine Oil Temp.
Engine Malfunction
6. Low Fuel
7. Glow Plug Wait
8.
Overload
9. Engine Air Filter By-Pass
Figure 3-2. Ground Control Indicator Panel
3-6
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3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
5. Engine Malfunction Indicator
7. Glow Plug Wait Indicator
The light indicates that the JLG Control System has
detected a malfunction 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 malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act
as a self test.
6. Low Fuel Level Indicator
Indicates that the fuel level is 1/8 full or less. Illuminates
when there are approximately four gallons of fuel
remaining.
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– JLG Lift –
Indicates the glow plugs are on. The glow plugs are
automatically turned on with the ignition circuit and
remain on for approximately seven seconds. Start the
engine only after the light goes out.
8. Overload Indicator. (If Equipped)
Indicates the platform has been overloaded.
9. Engine Air Filter Indicator
Indicates that the air filter is too restrictive and needs to
be replaced.
3-7
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Platform Control Station
4. Power/Emergency Stop
1. Drive Speed Switch
(4WD Machines) - The forward position gives maximum
drive speed by shifting the drive motors to minimum displacement and giving high engine when drive controller
is moved. The back position gives maximum torque for
rough terrain and climbing grades by shifting the wheel
motors to maximum displacement and giving high
engine speed when drive controller is moved. The center position allows the machine to be driven as quietly as
possible by leaving the engine at mid speed and the
drive motors in maximum displacement.
(2WD Machines) - The forward position selects maximum speed by operating at high engine rpm. The backward position selects mid engine rpm.
An on-off Power/Emergency Stop switch and a separate
Engine Start/Auxiliary Power toggle switch on the platform console supply electrical power to the starter solenoid, when the ignition switch is placed in the ON
position and the ENGINE START switch is push forward.
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.
5. Auxiliary Power
2. Platform Leveling Override
This switch adjusts the level of the platform.
The auxiliary pump functions to provide sufficient oil flow
to operate the basic machine functions should the main
pump or engine fail. The auxiliary pump will operate
tower boom lift, tower telescope, main boom lift, main
telescope and swing.
3. Horn
If pressed, this switch supplies power to the horn.
3-8
The Auxiliary Power control switch energizes the electrically operated hydraulic pump. (Switch must be held
ON for duration of auxiliary pump use.)
– JLG Lift –
3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
3121179
Drive Speed
5. Aux. Power 9. 9. Telescope
Platform Leveling Override 6. Fuel Select
10. Jib
Horn
7. Lights
11. Tower Lift
Power/Emergency Stop
8. Drive/Steer 12. Platform Rotate
Figure 3-3. Platform Control Console
– JLG Lift –
13. Function Speed
14. Main Lift/Swing
3-9
SECTION 3 - MACHINE CONTROLS AND INDICATORS
6. Fuel Select (Dual Fuel Engine Only) (If Equipped)
11. Tower or Lower Boom Lift
Moving the switch to the appropriate position selects
gasoline or liquid propane fuel.
7. Lights (If Equipped)
Provides for raising and lowering of the lower and mid
booms when positioned up or down.
12. Platform Rotate
This switch operates control console panel lights and
head lights if the machine is so equipped.
8. Drive/Steer
This switch controls the rotation of the basket (left or
right).
13. Function Speed Control
The DRIVE joystick provides for driving either forward or
backward. The controller is ‘ramped’ to allow variable
drive speed.
Steering is controlled by a thumb operated switch on
top of the joystick.
Controls the speed of Boom functions to the right of the
knob. Rotate CCW for slower speed and CW for faster
speed. To adjust to creep, turn knob fully CCW until it
clicks.
14. Main Lift/Swing
9. Telescope Control
The dual axis joystick is provided for main lift and swing.
Push forward to lift up, pull backward to lower. Move
right to swing right, move left to swing left. Proportional
control of these functions can be attained by using the
Function Speed control.
This switch allows extension and retraction of the main
boom.
10. Articulating Jib Boom (if equipped)
This switch controls the raising or lowering of the jib.
3-10
NOTE: Main lift and swing functions may be selected at the same
time. Maximum speed is reduced when both functions are
selected.
– JLG Lift –
3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Platform Control Indicator Panel
2. Overload Indicator. (If equipped)
NOTE: The platform control indicator panel (S/N 0300065315 to
Present) uses different shaped symbols to alert the operator to different types of operational situations that could
arise. The meaning of those symbols are explained
below.
Indicates a potentially hazardous situation, which
if not corrected, could result in serious injury or
death. This indicator will be red.
Indicates the platform has been overloaded.
3. Tilt Alarm Warning
Indicates that the chassis is on a slope (over 4 degrees
CE/Australia, 5 degrees all other markets). If the boom is
above horizontal and the machine is on a 5 degree
slope, an alarm will sound and CREEP speed is automatically activated.
4. Glow Plug Indicator
Indicates an abnormal operating condition,
which if not corrected, may result in machine
interruption or damage. This indicator will be yellow.
Indicates important information regarding the
operating condition, i.e. procedures essential for
safe operation. This indicator will be green with
the exception of the capacity indicator which will
be green or yellow depending upon platform
position.
1. AC Generator (Green)
Indicates the generator is in operation.
3121179
– JLG Lift –
Indicates the glow plugs are operating. After turning on
ignition, wait until light goes out before cranking engine.
5. Footswitch/Enable Indicator
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. If a function is not selected within seven seconds, or if a seven second lapse between ending one
function and beginning the next function, the enable
light will go out and the footswitch must be released and
depressed again to enable the controls.
3-11
SECTION 3 - MACHINE CONTROLS AND INDICATORS
NOTE: For engine starting, the footswitch must be in the released
(up) position.
8. System Malfunction Indicator
The light indicates that the JLG Control System has
detected a malfunction 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.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE
THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN
SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.
The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act
as a self test.
9. Soft Touch Indicator (If Equipped)
6. Low Fuel Indicator (Yellow)
Indicates the fuel tank is 1/8 full or less. When the light
first illuminates, there are approximately four usable gallons of fuel remaining.
Illuminates when 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.
7. Creep Speed Indicator
Illuminates when the Function Speed Control is turned
to the creep position.
3-12
– JLG Lift –
3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
S/N 0300065315 & 1300000001 to Present
1. AC Generator
2. Overload
3. Tilt Alarm Warning
4. Glow Plug
5. Enable
6. Fuel Level
7. Creep Speed
8. System Malfunction
9. Soft Touch
Figure 3-4. Platform Control Indicator Panel - Sheet 1 of 2
3121179
– JLG Lift –
3-13
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Prior to S/N 0300065315
1. AC Generator
2. Overload
3. Tilt Alarm Warning
4. Glow Plug
5. Enable
6. Fuel Level
7. Creep Speed
8. System Malfunction
9. Soft Touch
Figure 3-5. Platform Control Indicator Panel - Sheet 2 of 2
3-14
– JLG Lift –
3121179
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. Vibrations emitted by these machines are not
hazardous to an operator in the work platform. The equivalent continuous A-Weighted sound pressure level at the work
platform is less than 70dB(A).
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. Standard boom swing is 357 degree non-continuous
left and right of the stowed position. The machine has a
Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing,
and are to be used in an emergency to lower the platform to
the ground should the operator in the platform be unable to
do so. The Ground Control is also to be used in Pre-Start
Inspection.
3121179
OPERATING CHARACTERISTICS AND
LIMITATIONS
– JLG Lift –
The boom can be raised above horizontal with or without any
load in platform, if:
1. Machine is positioned on a smooth, firm and level surface.
2. Load is within manufacturer’s rated capacity.
3. All machine systems are functioning properly.
4. Proper tire pressure.
5. Machine is as originally equipped from JLG.
4-1
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.
ENGINE OPERATION
NOTE: Initial starting should always be performed from the
Ground Control station.
Starting Procedure
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN
EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW
STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER
SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.
NOTE: Diesel engines only: After turning on ignition, operator
must wait until glow plug indicator light goes out before
cranking engine.
1. Turn key of SELECT switch to GROUND. Position
POWER/EMERGENCY STOP switch to ON, then push
the ENGINE START switch until engine starts.
ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED
BEFORE APPLYING ANY LOAD.
4-2
– JLG Lift –
3121179
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. If starter operates with footswitch in
the depressed position, DO NOT OPERATE MACHINE.
1. Remove all load and allow engine to operate at low
speed for 3-5 minutes; this allows further reduction of
internal engine temperature.
2. Push POWER/EMERGENCY STOP switch in.
3. Turn MASTER switch to Off.
Refer to Engine Manufacturer’s manual for detailed information.
3121179
– JLG Lift –
4-3
SECTION 4 - MACHINE OPERATION
Figure 4-1. Position of Least Forward Stability
4-4
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
4.4
.
TRAVELING (DRIVING)
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.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL
TIMES WHEN THE PLATFORM IS ELEVATED.
TRAVEL GRADES WITH DRIVE SPEED/TORQUE SELECT SWITCH IN
THE FORWARD POSITION. USE CAUTION WHEN DRIVING IN REVERSE
AND WHEN DRIVING WITH PLATFORM ELEVATED, ESPECIALLY WHEN
DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET (2 M) OF AN
OBSTRUCTION.
BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR
DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE
CONTROLS WILL BE REVERSED.
Figure 4-2. Position of Least Backward Stability
3121179
– JLG Lift –
4-5
SECTION 4 - MACHINE OPERATION
Figure 4-3. Grade and Side Slopes
4-6
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
Traveling Forward and Reverse
4.7
BOOM
1. With the engine running, activate footswitch.
2. Position Drive controller to FORWARD or REVERSE as
desired.
4.5
STEERING
Position thumb switch on Drive/Steer controller to RIGHT for
steering right, or to LEFT for steering left.
4.6
PLATFORM
Platform Level Adjustment
To Level Up or Down - Position the Platform/Level control
switch Up or Down and hold until the platform is level.
DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN
MACHINE IS OUT OF LEVEL.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE
CHASSIS.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN
RELEASED.
IF THE 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.
Platform Rotation
To rotate the platform to the left or right, use the Platform
Rotate control switch to select the direction and hold until
desired position is reached.
3121179
– JLG Lift –
4-7
SECTION 4 - MACHINE OPERATION
Swinging the Boom
4.8
This control affects the speed of all boom functions to the
right of the control and Platform Rotate. When in the CCW
maximum position, Drive is placed in creep speed.
To swing boom, use SWING control switch to select RIGHT
or LEFT direction.
IMPORTANT
4.9
WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM
FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND
EQUIPMENT.
Raising and Lowering the Lower and Mid Boom
To raise or lower the Lower Boom, use Lower Boom Lift
switch to select UP or DOWN movement.
Raising and Lowering the Main (Upper) Boom
To raise or lower the Upper Boom, use Upper Boom Lift
switch to select UP or DOWN movement.
Telescoping the Main Boom
AUXILIARY PUMP
IMPORTANT
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. Operate as follows:
1. Position Platform/Ground switch to Platform.
2. Position Power/Emergency Stop switch to the on position.
3. Depress and hold footswitch.
To extend or retract the main boom, use the Main Telescope
Control Switch to select IN or OUT movement.
4-8
FUNCTION SPEED CONTROL
4. Operate appropriate control switch or lever for desired
function and hold.
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
5. Position Auxiliary Power switch to the on position and
hold.
4.11 SHUT DOWN AND PARK
6. Release Auxiliary Power switch, selected control switch
or lever, and footswitch.
7. Position Power/Emergency Stop switch to the off position.
4.10 OSCILLATING AXLE LOCKOUT TEST (IF
EQUIPPED)
1. Drive machine to a reasonably well protected area.
2. Be sure the main boom is fully retracted and lowered
over rear drive axle.
3. Remove all load and allow engine to operate 3-5 minutes at LOW setting to permit reduction of internal
engine temperatures.
4. At Ground Controls, turn KEY SELECT switch to OFF.
Push in the Emergency Stop. Remove key.
IMPORTANT
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY
TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER
SYSTEM OPERATION IS SUSPECTED.
5. If necessary, cover Platform Control console to protect
instruction placards, warning decals and operating controls from hostile environment.
Refer to Section 2.3, Oscillating Axle Lockout Test (If
Equipped) for procedure.
3121179
– JLG Lift –
4-9
SECTION 4 - MACHINE OPERATION
4.12 LIFTING AND TIE DOWN
Tie Down
Lifting
IMPORTANT
1. Refer to the Serial Number Tag, call JLG Industries, or
weigh the individual unit to find out the Gross Vehicle
Weight.
WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY
LOWERED INTO THE BOOM REST.
1. Place the boom in the stowed position.
2. Place the boom in the stowed position.
2. Remove all loose items from the machine.
3. Remove all loose items from the machine.
4. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level.
4-10
3. Secure the chassis and the platform using straps or
chains of adequate strength.
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
Figure 4-4. Lifting and Tie Down Chart
3121179
– JLG Lift –
4-11
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.) FOR NO LONGER THAN
30-45 MINUTES.
MAXIMUM TOWING GRADE 25%.
Prior to Towing
Prior to towing the machine, complete the following:
DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS
ENGAGED.
1. Retract, lower and position boom over rear drive wheels
in line with direction of travel.
Figure 4-5. Drive Disconnect Hub
4-12
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY)
Changing From LP Gas to Gasoline
The dual fuel system enables the standard gasoline engine
to run on either gasoline or LP gas.
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER
WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE
TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.
1. With engine operating on LP under a no-load condition,
position FUEL SELECT switch at Platform Control Station to GASOLINE position.
2. Close hand valve on LP gas supply tank by turning
clockwise.
Changing From Gasoline to LP Gas
1. Start engine from Ground Control Station.
2. Open hand valve on LP gas supply tank by turning
counterclockwise.
3. While engine is operating on GASOLINE under a noload condition, place FUEL SELECT switch at Platform
Control to LP position.
3121179
– JLG Lift –
4-13
SECTION 4 - MACHINE OPERATION
Figure 4-6. Decal Installation - Sheet 1 of 6
4-14
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
Figure 4-7. Decal Installation - Sheet 2 of 6
3121179
– JLG Lift –
4-15
SECTION 4 - MACHINE OPERATION
Figure 4-8. Decal Installation - Sheet 3 of 6
4-16
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
Figure 4-9. Decal Installation - Sheet 4 of 6
3121179
– JLG Lift –
4-17
SECTION 4 - MACHINE OPERATION
Figure 4-10. Decal Installation - Sheet 5 of 6
4-18
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
Figure 4-11. Decal Installation - Sheet 6 of 6
3121179
– JLG Lift –
4-19
SECTION 4 - MACHINE OPERATION
4-20
Item #
ANSI
0272573-5
Australian
0272574-3
CE
0273452-2
Japan
0272575-4
Korean
0272576-4
French/
0272577-6
Chinese
0272578-4
Portuguese/
Spanish
0272579-5
1
1703797
1703992
1705821
1703926
1703927
1703924
1703925
1703928
2
1703798
1705332
1705822
1703932
1703933
1703930
1703931
1703934
3
1703805
--
--
1703938
1703939
1703936
1703937
1703940
4
1703804
1701518
1701518
1703950
1703951
1703948
1703949
1703952
5
1702784
--
--
--
--
1702784
--
--
6
1703808
--
--
--
--
1703808
--
--
7
--
--
--
--
--
--
--
--
8
--
--
--
--
--
--
--
--
9
--
--
--
--
--
--
--
--
10
--
--
--
--
--
--
--
--
11
1702868
--
--
--
--
1704000
--
1704002
12
1704277
1704277
1704277
1704277
1704277
1704277
1704277
1704277
13
1701645
--
--
1703996
1703996
1703996
1703996
1703996
14
1702688
--
--
--
--
1704112
--
1704112
15
--
--
1705084
--
--
--
--
--
16
1701502
1701502
1701502
1701502
1701502
1701502
1701502
1701502
17
1701503
1701503
1701503
1701503
1701503
1701503
1701503
1701503
18
1701504
1701504
1701504
1701504
1701504
1701504
1701504
1701504
– JLG Lift –
3121179
SECTION 4 - MACHINE OPERATION
3121179
Australian
0272574-3
CE
0273452-2
Japan
0272575-4
Korean
0272576-4
French/
0272577-6
Chinese
0272578-4
Portuguese/
Spanish
0272579-5
Item #
ANSI
0272573-5
19
1702153
--
--
--
--
1704006
--
1704008
20
1702631
1702631
1702631
1702631
1702631
1702631
1702631
1702631
21
--
--
--
--
--
--
--
--
22
--
1702958
--
--
--
--
--
--
23
1701509
1701509
1701509
1701509
1701509
1701509
1701509
1701509
24
1702300
1702300
1702300
1702300
1702300
1702300
1702300
1702300
25
1701500
1701500
1701500
1701500
1701500
1701500
1701500
1701500
26
1701529
1701529
1701529
1701529
1701529
1701529
1701529
1701529
27
--
--
--
--
--
--
--
--
28
--
--
--
--
--
--
--
--
29
--
--
--
--
--
--
--
--
30
--
--
--
--
--
--
--
--
31
--
--
--
--
--
--
--
--
32
--
--
--
--
--
--
--
--
33
--
--
--
--
--
--
--
--
34
--
--
1705828
1703980
1703981
1703984
1703982
1703985
35
--
--
--
--
--
--
--
--
36
--
--
--
--
--
--
--
--
37
--
--
--
--
--
--
--
--
– JLG Lift –
4-21
SECTION 4 - MACHINE OPERATION
4-22
ANSI
0272573-5
Australian
0272574-3
CE
0273452-2
Japan
0272575-4
Korean
0272576-4
38
--
--
--
--
--
--
--
--
39
--
--
--
--
--
1705514
--
--
40
--
--
--
--
--
--
--
--
41
--
--
--
--
--
--
--
--
42
--
--
--
--
--
--
--
--
43
--
--
--
--
--
--
--
--
44
3252768
3252768
3252768
3252768
3252768
3252768
3252768
3252768
45
1704885
1704885
1704885
1704885
1704885
1704885
1704885
1704885
46
--
--
--
--
--
--
--
--
47
--
--
--
--
--
--
--
--
48
--
--
--
--
--
--
--
--
49
--
--
--
--
--
--
--
--
– JLG Lift –
French/
0272577-6
Chinese
0272578-4
Portuguese/
Spanish
0272579-5
Item #
3121179
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
IMPORTANT
JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property
damage is evident, the factory should be contacted by telephone and provided with all necessary details.
In USA:
JLG Phone:877-JLG-SAFE (554-7233)
(8am till 4:45pm EST)
FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE
AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS,
THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 10 FT.
(3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED,
IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.
Outside USA:
717-485-5161
E-mail:
ProductSafety@JLG.com
3121179
– JLG Lift –
5-1
SECTION 5 - EMERGENCY PROCEDURES
5.3
EMERGENCY OPERATION
Platform or Boom Caught Overhead
If the platform or boom becomes jammed or snagged in
overhead structures or equipment, rescue platform occupants prior to freeing the machine.
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from
ground controls only as required.
2. Other qualified personnel on the platform may use the
platform controls. DO NOT CONTINUE OPERATION IF
CONTROLS DO NOT FUNCTION PROPERLY.
5.4
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.
3. Cranes, forklift trucks or other equipment can be used to
remove platform occupants and stabilize motion of the
machine.
5-2
– JLG Lift –
3121179
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.
The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough
Preventive Maintenance and Inspection Schedule included
in the Service and Maintenance Manual.
Other Publications Available:
450A/450AJ Service and Maintenance Manual........ 3121180
510AJ Service and Maintenance Manual ................. 3121181
450A/450AJ Illustrated Parts Manual
(ANSI, CSA Spec) .................................................. 3121131
OPERATING SPECIFICATIONS AND
PERFORMANCE DATA
Table 6-1. Operating Specifications - 450A/450AJ
Unrestricted Rated Capacity
500lb. (230kg)
Maximum Capacity
500lb. (230 kg)
Maximum Travel Grade (Gradeability)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped).
2WD
4WD
Maximum Travel Grade (Sideslope)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped).
30%
45%
5°
450A/450AJ Illustrated Parts Manual (CE Spec) ...... 3121833
Maximum Drive Speed:
4.5 mph (2.0 m/s)
510AJ Illustrated Parts Manual ................................ 3121182
Maximum Hyd. Operating Pressure
4500 psi (310 Bar)
Electrical System Voltage
Gross Machine Weight
(450A)
(450AJ)
3121179
– JLG Lift –
12 volts
14,500 lb. (6577 kg)
16,500 lb. (7484 kg)
6-1
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Reach Specifications
Table 6-2. Operating Specifications - 510AJ
Unrestricted Rated Capacity
500lb. (230kg)
Maximum Capacity
500lb. (230 kg)
Maximum Travel Grade (Gradeability)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped).
45%
Maximum Travel Grade (Sideslope)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped).
5°
Table 6-3. Reach Specifications - 450
Max. Platform Height
Max. Horizontal Reach
Up & Over Height
-24°
Table 6-4. Reach Specifications - 510
Max. Platform Height
Platform Rotation
Maximum Hyd. Operating Pressure
4500 psi (310 Bar)
Max. Horizontal Reach
12 volts
16,104 lb. (7305 kg)
Up & Over Height
Jib Length
Jib Angle
6-2
75°
Main Boom Down Angle
4.5 mph (2.0 m/s)
Gross Machine Weight
24.5ft. (7.5 M)
25 ft. 2 in. (7.7 M)
Main Boom Up Angle
Maximum Drive Speed:
Electrical System Voltage
45ft. (13.7 M)
– JLG Lift –
51.8 ft. (15.81 m)
180°
31.1 ft. (9.48 m)
24.08 ft. (7.34 m)
4.5 ft. (1.37 m)
135° (+70°, -65°)
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Dimensional Data
Table 6-6. Dimensional Data - 510
Table 6-5. Dimensional Data - 450
Overall Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)
6 ft. 6 in. (1.98 m)
6 ft. 10 in. (2.08 m)
6 ft. 11 in. (2.11 m)
Tailswing
0
Stowed Height
7 ft. 4.4 in. (2.25 m)
Stowed Length
21 ft. 4 in. (6.5 m)
Wheel base
Ground Clearance
65.3 in. (1.66 m)
66.3 in. (1.69 m)
66.6 in. (1.69 m)
Ground Clearance
1.18 ft. (0.36 m)
Chassis
78 in. (1.98 m)
Track Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)
Track Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)
65.3 in. (1.66 m)
66.3 in. (1.69 m)
66.6 in. (1.69 m)
14 in. (0.36 m)
Table 6-7. Chassis Specifications - 450
Swing
Rated Gradeability
2WD
4WD
Overall Width
Tailswing
Stowed Height
7.4 ft. (2.26 m)
0
7.4 ft. (2.26 m)
Stowed Length
25.1 ft. (7.68 m)
Wheel base
7.67 ft. (2.34 m)
3121179
– JLG Lift –
30%
45%
Max. Tire Load
7900 lb. (3583 kg)
Axle Oscillation
8 in. (0.2 m)
System Voltage
Table 6-6. Dimensional Data - 510
357° non-continuous
Max. Hydraulic System Operating
Pressure
Gross Machine Weight
450A SII
450AJ SII
12 Volts
4500 psi
(310 bar)
14,500 lbs. (6577 kg)
16,500 lbs. (7484 kg)
6-3
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Capacities
Table 6-8. Chassis Specifications - 510
Swing
Gradeability (boom in stowed position)
Max. Tire Load
Max. Ground Bearing Pressure
12x16.5 Tire
33/1550x16.5 - Tire
Drive Speed
357° non-continuous
7900 lb. (3583 kg)
48 psi (3.37 kg/cm2)
36 psi (2.53 kg/cm2)
4.5 mph (7.2 kph)
Axle Oscillation
4 in. (0.1 m)
Turning Radius
Inside
Outside
6.5 ft. (2.0 m)
16.4 ft. (5.0 m)
System Voltage
12 Volts
Max. Hydraulic System Operating
Pressure
Gross Machine Weight
6-4
Table 6-9. Capacities
40%
4500 psi
(310 bar)
16,104 lbs. (7305 kg)
Fuel Tank
17 gallons (64.3 liters)
Hydraulic Tank
(machines to S/N 0300070586)
28 gallons (106 liters)
Hydraulic Tank
(S/N 0300070586 &
SN 1300000001to Present)
27 gallons (102 liters)
23.6 gal. (89 liters) to the Full line
on the sight gauge
Tires
Table 6-10. 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)
33/1550x16.5
Pneumatic
90 psi (6 Bar)
135 lbs. (61 kg)
33/1550x16.5
Foam-Filled
N/A
395 lbs. (179 kg)
14 x 16.1
Pneumatic
40 lbs. (3 bar)
91.5 lbs. (41.5 kg)
14 x 16.1
Foam-Filled
N/A
426 lbs. (193 kg)
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Engine
NOTE:
Table 6-12. Deutz F3M1011F
Fuel
RPM Tolerances are ± 100.
No. of Cylinders
Table 6-11. Ford LRG-425 (Gas or Dual Fuel)
Bore
Type
4 cylinder, 4 stroke, spark ignition
Fuel
Gasoline or Gasoline/LP Gas
Bore
3 in. (96 mm)
Stroke
3.4 in. (86.4 mm)
Displacement
153 cu. in. (2.5 L)
Firing Order
BHP at Max. RPM
Oil Capacity
1-3-4-2
82
4.5 quarts (4.26 L)
Low RPM
1000
Mid RPM
Tower Lift, Upper Lift, Tele
Swing, Basket Level, Basket
Rotate, Jib Lift
1800
1500
High RPM
3000
Spark Plug
Spark Plug Gap
3121179
Stroke
Displacement
BHP at Max. RPM
Oil Capacity
crankcase
cooler
total capacity
Diesel
3s
3.6 in. (91 mm)
4.4 in. (112 mm)
133 cu. in. (2184 cm³)
48
6.3 quarts (6 L)
4.75 quarts (4.5 L)
11 quarts (10.5 L)
Low RPM
1200
Mid RPM
Tower Lift, Upper Lift, Tele
Swing, Basket Level, Basket
Rotate, Jib Lift
1800
1500
High RPM
2800
AWSF-52-C
0.044 in. (1.117 mm)
– JLG Lift –
6-5
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-13. Deutz F3M2011F
Fuel
No. of Cylinders
Bore
Stroke
Displacement
Oil Capacity
crankcase
cooler
total capacity
Low RPM
Table 6-14. Caterpillar 3024
Diesel
3s
No. of Cylinders
Diesel
4
3.7 in. (94 mm)
BHP
46.5 hp (34 kW)
4.4 in. (112 mm)
Bore
3.307 in. (84 mm)
142 cu. in. (2331 cm³)
Stroke
Displacement
6.3 quarts (6 L)
4.75 quarts (4.5 L)
11 quarts (10.5 L)
1200
Oil Capacity
Compression Ratio
Firing Order
Max. RPM
Mid RPM
Tower Lift, Upper Lift, Tele
Swing, Basket Level, Basket
Rotate, Jib Lift
1800
1500
High RPM
2800
6-6
Fuel
– JLG Lift –
3.9370 in. (112 mm)
134.3 cu. in. (2.2L)
3.8 quarts (3.6 L) crankcase only
19:1
1-3-4-2
2800
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Major Component Weights
Table 6-15. GM 3.0L
Fuel
No. of Cylinders
4
BHP
Gasoline
LP
83 hp @ 3000 rpm
75 hp @ 3000 rpm
Bore
4.0 in. (101.6 mm)
Stroke
3.6 in. (91.44 mm)
Displacement
Oil Capacity w/filter
Minimum Oil Pressure
at idle
Hot
Compression Ratio
Firing Order
Max. RPM
Table 6-16. Component Weights - 450
Gasoline or Gasoline/LP Gas
181 cu.in. (3.0 L, 2966 cc)
4.5 qts. (4.25 L)
Pounds
Kilograms
Frame (Bare)
Component
2325
1055
Turntable (Bare)
1500
680
Boom Link
180
82
Boom Timing Link
30
14
Upper Upright
217
98
Lower Upright
115
52
Lower Boom
497
225
Mid Boom
385
175
Upper Boom
1065
484
9.2:1
4 Wheel Drive Axle
200
91
1-3-4-2
2 Wheel Drive Axle
235
107
6 psi (0.4 Bar) @ 1000 rpm
18 psi (1.2 Bar) @ 2000 rpm
2800
Table 6-17. Component Weights - 510
Component
3121179
– JLG Lift –
Pounds
Kilograms
Engine Only
440
200
Upper Boom
1257
570
Frame (Bare)
2105
955
Turntable (Bare)
1533
695.5
6-7
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 6-18. Hydraulic Oil
NOTE:
NOTE:
6-8
Hydraulic System Operating
Temperature Range
S.A.E. Viscosity
Grade
+0° to + 180° F
(-18° to +83° C)
10W
+0° to + 210° F
(-18° to +99° C)
10W-20, 10W30
+50° to + 210° F
(+10° to +99° C
20W-20
Table 6-19. Mobilfluid 424 Specs
Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity index of 152.
When temperatures remain consistently below 20
degrees F. (-7 degrees C.), JLG Industries recommends
the use of Mobil DTE13.
– JLG Lift –
SAE Grade
10W30
Gravity, API
29.0
Density, Lb/Gal. 60°F
7.35
Pour Point, Max
-46°F (-43°C)
Flash Point, Min.
442°F (228°C)
Viscosity
Brookfield, cP at -18°C
2700
at 40° C
55 cSt
at 100° C
9.3 cSt
Viscosity Index
152
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-20. Mobil DTE 13M Specs
Table 6-21. UCon Hydrolube HP-5046
ISO Viscosity Grade
#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
33cSt
at 0° C (32° F)
340 cSt (1600SUS)
at 100° C
6.6 cSt
at 40° C (104° F)
46 cSt (215SUS)
at 100° F
169 SUS
at 65° C (150° F)
22 cSt (106SUS)
Viscosity Index
170
Viscosity
at 40° C
3121179
Viscosity
at 210° F
48 SUS
cp at -20° F
6,200
Viscosity Index
140
– JLG Lift –
6-9
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-22. Mobil EAL H 46 Specs
Type
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)
7.64 lb. per gal.
(0.9 kg per liter)
Weight
Viscosity
6-10
Table 6-23. Exxon Univis HVI 26 Specs
at 40° C
45 cSt
at 100° C
8.0 cSt
Viscosity Index
153
Viscosity
at 40° C
25.8 cSt
at 100° C
9.3 cSt
Viscosity Index
376
NOTE: Mobil/Exxon recommends that this oil be checked
on a yearly basis for viscosity.
– JLG Lift –
3121179
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.
Figure 6-1. Serial Number Locations
3121179
– JLG Lift –
6-11
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2
6-12
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
4150548-C
Figure 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2
3121179
– JLG Lift –
6-13
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Figure 6-4. Engine Operating Temperature Specifications - Ford - Sheet 1 of 2
6-14
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
4150548-C
Figure 6-5. Engine Operating Temperature Specifications - Ford - Sheet 2 of 2
3121179
– JLG Lift –
6-15
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Figure 6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2
6-16
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
4150548-C
Figure 6-7. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2
3121179
– JLG Lift –
6-17
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Figure 6-8. Engine Operating Temperature Specifications - GM - Sheet 1 of 2
6-18
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
4150548-C
Figure 6-9. Engine Operating Temperature Specifications - GM - Sheet 2 of 2
3121179
– JLG Lift –
6-19
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Figure 6-10. Operator Maintenance and Lubrication Diagram
6-20
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.3
NOTE:
OPERATOR MAINTENANCE
IMPORTANT
The following numbers correspond to those in Figure 610., Operator Maintenance and Lubrication Diagram.
Table 6-24. Lubrication Specifications
KEY
MPG
EPGL
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.)
NOTE:
Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105
HO
Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO
Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104.
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
OGL
Open Gear Lubricant - Mobiltac 375 or equivalent.
3121179
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION
UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT
OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR
CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED
ACCORDINGLY.
– JLG Lift –
It is recommended as a good practice to replace all filters
at the same time.
1. Swing Bearing - Internal Ball Bearing
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
6-21
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
2. A. Swing Bearing - Teeth
3. Wheel Bearings (2WD Only)
Lube Point(s) - Spray On
Capacity - A/R
Lube - OGL
Interval - Every 3 months or 150 hrs of operation
Comments - More frequent lubrication intervals may be
required
B. End Bearings - Worm Gear*
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hrs of operation
Comments - Remove grease fittings and install plugs
after greasing
Lube Point(s) - Repack
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation
*If necessary install grease fittings into worm gear housing and grease bearings.
4. Wheel Drive Hub
DO NOT OVERGREASE END BEARINGS. OVERGREASING BEARINGS
WILL RESULT IN BLOWING OUTER SEAL IN HOUSING.
6-22
– JLG Lift –
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
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
5. Hydraulic Return Filter
6. Hydraulic Charge Filter
Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter or as indicated by Condition
Indicator.
3121179
– JLG Lift –
Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter or as indicated by Condition
Indicator.
6-23
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
7. Hydraulic Tank
8. Suction Strainers
Lube Point(s) - Fill Cap
Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters) to
the Full line on the sight gauge
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
6-24
– JLG Lift –
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
9. Oil Change w/Filter - Ford
10. Oil Change w/Filter - Deutz
Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N
7014501)
Capacity - 4.5 Quarts (4.25 L)
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
3121179
– JLG Lift –
Fill Cap/Spin-on Element (JLG P/N
7016641)
Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts (4.7 L)
Cooler
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
6-25
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
11. Oil Change w/Filter - Caterpillar
12. Oil Change w/Filter - GM
Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N
7026855)
Capacity - 10.6 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
6-26
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
14. Fuel Filter - Deutz
13. Fuel Filter - Ford
Lube Point(s) - Replaceable Element
Interval - Every Year or 1200 hours of operation
Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
15. Fuel Filter - Caterpillar
Lube Point(s) - Replaceable Element
Interval - Every Year or 600 hours of operation
3121179
– JLG Lift –
6-27
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
16. Fuel Filter - GM
17. Air Filter
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
6-28
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
18. Electronic Pressure Regulator (LP only)
19. Fuel Filter (Propane) - GM Engine
Interval - 3 Months or 150 hours of operation
Comments - Drain oil build up. Refer to Section 6.5,
DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR
3121179
– JLG Lift –
Interval - 3 Months or 150 hours of operation
Comments - Replace filter. Refer to Section 6.6, Propane
Fuel Filter Replacement
6-29
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. 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.
If a tire is damaged but is within the above noted criteria, the tire
must be inspected on a daily basis to insure the damage has
not propagated beyond the allowable criteria.
Tire 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 model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original
For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures
must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the
tire or tire assembly.
• a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies
which exceeds 1 inch (2.5 cm) in any direction
• Tire tread contact width equal or greater than original
• Wheel diameter, width, and offset dimensions equal to
the original
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to the pressure recommended
• any punctures which exceed 1 inch in diameter
6-30
– JLG Lift –
3121179
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 Installation
It is extremely important to apply and maintain proper wheel
mounting torque.
Wheel 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., without written
factory recommendations, may result in an unsafe condition
regarding stability.
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. Use a torque wrench to tighten the fasteners. If
you do not have a torque wrench, tighten the fasteners with a
lug wrench, then immediately have a service garage or dealer
tighten the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming the
mounting stud holes in the wheels. The proper procedure for
attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
3121179
– JLG Lift –
6-31
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 6-25. 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. Check torque
every 3 months or 150 hours of operation.
6-32
– JLG Lift –
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.5
DRAINING OIL BUILD UP FROM THE
PROPANE REGULATOR
4. Push in the Emergency Switch once the engine stops.
5. Disconnect the electrical connection to the LPG fuel
temperature sensor in the auxiliary fuel port of the EPR.
During the course of normal operation oils may build inside
the primary and secondary chambers of the propane pressure regulator. These oils may be a result of poor fuel quality,
contamination of the fuel supply chain, or regional variation
in the make up of the fuel. If the build up of the oil is significant this can effect the operation of the fuel control system.
Refer to Section 6.3, Operator Maintenance for maintenance
intervals. More frequent draining may be required if the fuel
supply has been contaminated.
IMPORTANT
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERATURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO FLOW
FREELY FROM THE REGULATOR.
1. Move the equipment to a well ventilated area. Ensure
there are no external ignition sources.
2. Start the engine and bring to operating temperature.
3. With the engine running, close the manual tank valve
and run the engine out of fuel.
3121179
– JLG Lift –
6-33
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6. Remove the retainer clip for the LPG fuel temperature
sensor and remove the sensor from the regulator body.
NOTE:
6.6
Have a small container ready to collect oil that will drain
freely from the regulator at this point.
7. Once all of the oil has been drained, reinstall the LPG
fuel temperature sensor and reconnect the electrical
connector.
8. Open the fuel tank manual valve.
9. Start the engine and verify all connections are secure.
10. Dispose of any drained oil per local regulations in a safe
and proper fashion.
6-34
PROPANE FUEL FILTER REPLACEMENT
– JLG Lift –
1.
2.
3.
4.
5.
6.
Electric Lock Off Solenoid
Mounting Plate
Housing Seal
Filter Magnet
Filter Housing
Seal
7.
8.
9.
10.
11.
12.
Electrical Connector
Fuel Outlet
O-ring
Filter
Fuel Inlet
Retaining Bolt
Figure 6-11. Filter Lock Assembly
3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Removal
Installation
1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief.
IMPORTANT
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING
BEFORE INSTALLING NEW SEAL
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing retaining bolt and
remove it.
4. Pull the filter housing from the Electric lock off assembly.
1. Install the mounting plate to lock off O-ring seal.
2. Install the retaining bolt seal.
3. Install the housing seal.
5. Locate Filter magnet and remove it.
4. Drop the magnet into the bottom of the filter housing.
6. Remove the filter from the housing.
5. Install the filter into the housing.
7. Remove and discard the housing seal.
6. Install the retaining bolt into the filter housing.
8. Remove and discard the retaining bolt seal.
9. Remove and discard mounting plate to lock off O-ring
seal.
7. Install the filter up to the bottom of the electric lock off.
8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).
9. Open manual shut-off valve. Start the vehicle and leak
check the propane fuel system at each serviced fitting.
Refer to Propane Fuel System Leak Test.
3121179
– JLG Lift –
6-35
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.7
PROPANE FUEL SYSTEM PRESSURE RELIEF
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312
PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL
INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE
APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.
To relieve propane fuel system pressure:
1. Close the manual shut-off valve on the propane fuel
tank.
2. Start and run the vehicle until the engine stalls.
3. Turn the ignition switch OFF.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.
6-36
– JLG Lift –
3121179
SECTION 7 - INSPECTION AND REPAIR LOG
SECTION 7. INSPECTION AND REPAIR LOG
Machine Serial Number _______________________________________
Table 7-1. Inspection and Repair Log
Date
3121179
Comments
– JLG Lift –
7-1
SECTION 7 - INSPECTION AND REPAIR LOG
Table 7-1. Inspection and Repair Log
Date
7-2
Comments
– JLG Lift –
3121179
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: (44) 870 200 7700
Fax: (44) 870 200 7711
JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: (44) 1 698 811005
Fax: (44) 1 698 811055
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: (61) 2 65 811111
Fax: (61) 2 65 810122
JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: (27) 11 453 1334
Fax: (27) 11 453 1342
JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: (31) 23 565 5665
Fax: (31) 23 557 2493
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: (55) 19 3295 0407
Fax: (55) 19 3295 1025
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 91 4320 245
Fax: (48) 91 4358 200
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: (46) 8 506 59500
Fax: (46) 8 506 59534
JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: (49) 421 693 500
Fax: (49) 421 693 5035
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: (39) 02 9359 5210
Fax: (39) 02 9359 5845
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: (34) 93 77 24700
Fax: (34) 93 77 11762
www.jlg.com
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