Operation and Safety Manual

Operation and Safety Manual
Operation and Safety Manual
Model
80HX
80HX+6
P/N - 3120890
August 21, 2007
FOREWORD
FOREWORD
The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.
REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS.
THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these
areas. They are defined as follows:
DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR
DEATH.]
WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
OR DEATH.
CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE
PRACTICES
IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES
ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED, MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
MACHINE.
JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT
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.
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FOREWORD
This page left blank intentionally.
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FOREWORD
5. All personnel in the platform shall, at all times,
wear approved fall protection devices and
other safety gear as required.
All procedures herein are based on the use of the
machine under proper operating conditions, with no
deviations from original design intent... as per OSHA
regulations.
6. Load limits specified by the manufacturer shall
not be exceeded.
7. Instruction and warning placards must be legible.
READ & HEED!
The ownership, use, service, and/or maintenance of
this machine is subject to various governmental and
local laws and regulations. It is the responsibility of
the owner/user to be knowledgeable of these laws
and regulations and to comply with them. The most
prevalent regulations of this type in the United States
are the Federal OSHA Safety Regulations*. Listed
below, in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the
date of publication of this handbook.
The listing of these requirements shall not relieve
the owner/user of the responsibility and obligation
to determine all applicable laws and regulations and
their exact wording and requirements, and to comply with the requirements. Nor shall the listing of
these requirements constitute an assumption of
responsibility of liability on the part of JLG Industries, Inc.
1. Only trained and authorized operators shall be
permitted to operate the aerial lift.
2. A malfunctioning lift shall be shut down until
repaired.
8. Aerial lifts may be field modified for uses other
than those intended by the manufacturer only if
certified in writing by the manufacturer to be in
conformity to JLG requirements and to be at
least as safe as it was prior to modification.
9. Aerial lifts shall not be used near electric power
lines unless the lines have been de energized
or adequate clearance is maintained.
10. Employees using aerial lifts shall be instructed
on how to recognize and avoid unsafe conditions and hazards.
11. Ground controls shall not be operated unless
permission has been obtained from personnel
in the platform, except in case of an emergency.
12. Regular inspection of the job site and aerial lift
shall be performed by competent persons.
13. Personnel shall always stand on the floor of the
platform, not on boxes, planks, railing or other
devices, for a work position.
*Applicable Federal OSHA regulations for the
United States, as of the date of publication of this
manual, include, but are not limited to, 29 CFR
1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR
1926.28, and 29 CFR 1926.453.
3. The controls shall be plainly marked as to their
function.
4. The controls shall be tested each day prior to
use to determine that they are in safe operating
condition.
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FOREWORD
REVISON LOG
Original Issue
Revised
d
-
May 1, 1999
August 21, 2007
– JLG Lift –
3120890
TABLE OF CONTENTS
SECTION
- FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1
1.2
1.3
1.4
1.5
1.6
1.7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
SECTION 2 - PREPARATION AND INSPECTION
2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Delivery and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Turntable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Extend-A-Reach (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1
3.2
3.3
3.4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Platform Station - May 1994 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Platform Station - September 1991 to May 1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Platform Station - Hydraulic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Steer/Axle Selector Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
SECTION 4 - MACHINE OPERATION
4.1
4.2
4.3
4.4
4.5
4.6
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Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Traveling Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
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TABLE OF CONTENTS (Continued)
4.7
4.8
4.9
4.10
4.11
4.12
4.13
4.14
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Loading From Ground Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Loading From Positions Above Ground
Level 4-4
Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Raising and Lowering the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shut Down and Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Axles, Extending and Retracting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Machines Without Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Machines With Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Oscillating Axle Lockout Test (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Steer/tow Selector (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Towing (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Prior to towing the machine, complete the following:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
After towing the machine, complete the following: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
SECTION 5 - OPTIONAL EQUIPMENT
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8
5.9
5.10
5.11
5.12
5.13
5.14
5.15
5.16
Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Dual Fuel System (Gas Engine Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Changing From Gasoline to LP Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Tow Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Four Wheel Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Travel Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Electric Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Foam Filled Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Cylinder Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Boom Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Hostile Environment Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Four Wheel Steer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Soft Touch Proximity System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION 6 - EMERGENCY PROCEDURES
6.1
6.2
6.3
6.4
6.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power/Emergency Stop Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Use of Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Platform or Boom Caught Overhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Post Incident Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
SECTION 7 - INSPECTION AND REPAIR LOG
ii
– JLG Lift –
3120890
TABLE OF CONTENTS
LIST OF FIGURES
2-1.
2-2.
2-3.
2-4.
2-5.
2-6.
2-7.
3-1.
3-2.
3-3.
3-4.
3-5.
3-6.
3-7.
3-8.
3-9.
3-10.
3-11.
3-12.
3-13.
3-14.
4-1.
4-2.
4-3.
6-1.
Machine Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Daily Walk-Around Inspection - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Daily Walk-Around Inspection - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
Daily Walk-Around Inspection - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Position of Least Backward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
Ground Control Station - May 1994 to Present with Hydraulic Controls . . . . . . . . . . . . . . . . . . . .3-6
Ground Control Station - May 1994 to Present without Hydraulic Controls. . . . . . . . . . . . . . . . . .3-7
Ground Control Station - Prior to May 1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
Control Console - May 1994 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Control Console - Sept. 91 to May 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Control Console - Hydraulic Controls May 1994 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
Control Console - Hydraulic Controls Prior to May 1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Caution, Danger, Warning Decal Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Common Symbols - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
Common Symbols - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Common Symbols - Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
Common Symbols - Sheet 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Manual Descent Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
LIST OF TABLES
1-1
2-1
7-1
3120890
Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated)
power lines and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Lubrication Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
– JLG Lift –
iii
TABLE OF CONTENTS (Continued)
This page left blank intentionally.
iv
– JLG Lift –
3120890
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
1.1
GENERAL
1.2
DRIVING/TOWING
This section prescribes the proper and safe practices for
major areas of machine usage. In order to promote proper
usage of the machine, it is mandatory that a daily routine
be established based on instructions given in this section.
A maintenance program must be also be established by a
qualified person and must be followed to ensure that the
machine is safe to operate.
Before driving the machine, the user must be familiar with
the drive, steer and stopping characteristics. This is especially important when driving in close quarters.
The owner/user/operator of the machine should not
accept operating responsibility until this manual has been
read and understood, and operation of the machine,
under the supervision of an experienced and qualified person, has been completed. If there is a question on application and or operation, JLG Industries Inc., should be
consulted.
NOTE: Remember that the key to safe and proper usage is
common sense and its careful application.
MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF
THE MANUFACTURER.
3120890
The user should be familiar with the driving surface before
driving. The surface should be firm and level and grades
should not exceed the allowable grade for the machine.
The machine is not equipped with provisions for towing.
Refer to Section 6 for emergency towing procedures.
SPECIAL NOTE:
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION AND ON THE MACHINE COULD RESULT IN
MACHINE DAMAGE, PERSONNEL INJURY OR DEATH, AND IS A
SAFETY VIOLATION.
– JLG Lift –
1-1
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts
Voltage Range
(Phase to Phase)
MINIMUM SAFE APPROACH DISTANCE
in Meters
0 to 300V
AVOID CONTACT
Over 300V to 50 KV
3
Over 50KV to 200 KV
5
Over 200 KV to 350 KV
6
Over 350 KV to 500 KV
8
Over 500 KV to 750 KV
11
Over 750 KV to 1000 KV
14
DANGER: DO NOT maneuver machine or personnel inside PROHIBITED ZONE. ASSUME all electrical parts and wiring
are ENERGIZED unless known otherwise.
1.3
FROM CONTACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED CONDUCTOR.
ELECTROCUTION HAZARD
• MAINTAIN A CLEARANCE OF AT LEAST 3 M (10
FEET) BETWEEN ANY PART OF THE MACHINE OR
ITS LOAD AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. 30.5 cm ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY
ADDITIONAL 30,000 VOLTS OR LESS.
1.4
PRE-OPERATIONAL
• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.
• MAINTAIN SAFE CLEARANCE FROM ELECTRICAL
LINES AND APPARATUS. ALLOW FOR BOOM SWAY,
ROCK OR SAG AND ELECTRICAL LINE SWAYING.
THE MACHINE DOES NOT PROVIDE PROTECTION
1-2
• ALLOW ONLY AUTHORIZED AND QUALIFIED PERSONNEL TO OPERATE MACHINE WHO HAVE DEMONSTRATED THAT THEY UNDERSTAND SAFE AND
PROPER OPERATION AND MAINTENANCE OF THE
UNIT.
– JLG Lift –
3120890
SECTION 1 - SAFETY PRECAUTIONS
• AN OPERATOR MUST NOT ACCEPT OPERATING
RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS
BEEN GIVEN BY COMPETENT AND AUTHORIZED
PERSONS.
• NEVER DISABLE OR MODIFY THE FOOTSWITCH OR
ANY OTHER SAFETY DEVICE. UNAUTHORIZED MODIFICATION OF THE MACHINE IS A SAFETY VIOLATION.
• BEFORE OPERATION, CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES, MACHINE TRAFFIC
SUCH AS BRIDGE CRANES, HIGHWAY, RAILWAY AND
CONSTRUCTION EQUIPMENT.
• DO NOT OPERATE MACHINE WHEN WIND CONDITIONS EXCEED 12.5 M/S (30MPH).
• NEVER OPERATE BOOM FUNCTIONS (TELE, SWING,
LIFT) WHEN MACHINE IS ON A TRUCK, OTHER VEHICLE, OR ABOVE GROUND STRUCTURE.
• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN
THE WORK AREA MUST BE TAKEN BY THE OPERATOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.
• THIS MACHINE CAN BE OPERATED IN NOMINAL
AMBIENT TEMPERATURES OF -20° C TO 40° C (0° F
TO 104°F). CONSULT FACTORY TO OPTIMIZE
OPERATION OUTSIDE THIS RANGE.
• DO NOT OPERATE THIS MACHINE UNLESS IT HAS
BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.
• ENSURE DAILY INSPECTION AND FUNCTION CHECK
IS PERFORMED PRIOR TO PLACING MACHINE INTO
OPERATION.
• APPROVED HEAD GEAR MUST BE WORN BY ALL
OPERATING AND GROUND PERSONNEL.
3120890
– JLG Lift –
1-3
SECTION 1 - SAFETY PRECAUTIONS
• ALWAYS POSITION BOOM OVER REAR (DRIVE) AXLE
IN LINE WITH DIRECTION OF TRAVEL. REMEMBER,
IF BOOM IS OVER FRONT (STEER) AXLE, DIRECTION
OF STEER AND DRIVE MOVEMENT WILL BE OPPOSITE FROM NORMAL OPERATION.
.
• READ AND OBEY ALL DANGERS, WARNINGS, CAUT I O N S A N D O P E R AT I N G I N S T R U C T I O N S O N
MACHINE AND IN THIS MANUAL.
• BE FAMILIAR WITH LOCATION AND OPERATION OF
GROUND STATION CONTROLS.
• DO NOT USE DRIVE FUNCTION TO POSITION PLATFORM CLOSE TO OBSTACLES. USE BOOM FUNCTION INSTEAD.
• ALWAYS USE THREE POINT CONTACT WHEN
ENTERING OR EXITING THE MACHINE. FACE THE
MACHINE WHEN YOU ENTER OR LEAVE. THREE
POINT CONTACT MEANS THAT TWO HANDS AND
ONE FOOT OR ONE HAND AND TWO FEET ARE IN
CONTACT WITH THE MACHINE AT ALL TIMES DURING MOUNT AND DISMOUNT.
1.5
DRIVING
• WHEN DRIVING IN HIGH SPEED, SWITCH TO LOW
SPEED BEFORE STOPPING. TRAVEL GRADES IN
LOW DRIVE, HIGH ENGINE ONLY.
• DO NOT USE HIGH SPEED DRIVE WHEN IN
RESTRICTED OR CLOSE QUARTERS, OR WHEN
DRIVING IN REVERSE.
• BE AWARE OF STOPPING DISTANCES WHEN TRAVELING IN HIGH AND LOW SPEEDS.
• ALWAYS POST A LOOKOUT AND SOUND HORN
WHEN DRIVING IN AREAS WHERE VISION IS
OBSTRUCTED.
• KEEP NON-OPERATING PERSONNEL AT LEAST 2 M
(6 FEET) AWAY FROM MACHINE DURING DRIVING
OPERATIONS.
• WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN DRIVING.
1-4
– JLG Lift –
3120890
SECTION 1 - SAFETY PRECAUTIONS
1.6
OPERATION.
• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.
• CHECK TRAVEL PATH FOR PERSONS, HOLES,
BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS,
AND COVERINGS WHICH MAY CONCEAL HOLES
AND OTHER HAZARDS.
• TRAVEL IS PERMITTED ON GRADES AND SIDESLOPES NO GREATER THAN THOSE INDICATED IN
WARNING PLACARD AT MACHINE PLATFORM.
• OPERATION WITH BOOM RAISED IS RESTRICTED
TO FIRM, LEVEL AND UNIFORM SURFACE.
• DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES,
AS TIPPING WILL OCCUR.
• DO NOT DRIVE MACHINE NEAR PITS, LOADING
DOCKS OR OTHER DROP-OFFS.
• PRIOR TO ENTERING AND EXITING PLATFORM AT
G R O U N D L E V E L , F U L LY LO W E R T H E B O O M .
EXTEND BOOM UNTIL END OF FLY BOOM CONTACTS GROUND. WITH BOOM LIFT IN THIS CONFIGU R AT I O N , E N T E R A N D / O R E X I T P L AT F O R M
THROUGH GATE OPENING.
• JLG RECOMMENDS ALL PERSONS IN THE PLATFORM TO WEAR LANYARDS WITH AN APPROVED
FALL PROTECTION DEVICE. SECURE LANYARD TO
DESIGNATED LANYARD ATTACH POINT ON PLATFORM. KEEP GATE CLOSED AT ALL TIMES.
• TO AVOID FALLING - USE EXTREME CAUTION WHEN
E N T E R I N G O R L E A V I N G P L AT F O R M A B O V E
GROUND. ENTER OR EXIT THRU GATE ONLY. PLATFORM FLOOR MUST BE WITHIN 30CM (1 FOOT) OF
ADJACENT - SAFE AND SECURE - STRUCTURE.
ALLOW FOR PLATFORM VERTICAL MOVEMENT AS
WEIGHT IS TRANSFERRED TO OR FROM PLATFORM.
3120890
– JLG Lift –
1-5
SECTION 1 - SAFETY PRECAUTIONS
• TRANSFERS BETWEEN A STRUCTURE AND THE
AERIAL PLATFORM EXPOSE OPERATORS TO FALL
HAZARDS. THIS PRACTICE SHOULD BE DISCOURAGED WHEREVER POSSIBLE. WHERE TRANSFER
MUST BE ACCOMPLISHED TO PERFORM THE JOB
TWO LANYARDS WITH AN APPROVED FALL PROTECTION DEVICE WILL BE USED. ONE LANYARD
SHOULD BE ATTACHED TO THE AERIAL PLATFORM.
THE OTHER TO THE STRUCTURE. THE LANYARD
THAT IS ATTACHED TO THE AERIAL PLATFORM
SHOULD NOT BE DISCONNECTED UNTIL SUCH
TIME AS THE TRANSFER TO THE STRUCTURE IS
COMPLETE. OTHERWISE, DO NOT STEP OUTSIDE
OF PLATFORM.
• IF PLATFORM OR BOOM IS CAUGHT SO THAT ONE
OR MORE WHEELS ARE OFF THE FLOOR, ALL PERSONNEL MUST BE REMOVED FROM PLATFORM
BEFORE ATTEMPTING TO FREE MACHINE. USE
CRANES, FORKLIFT TRUCKS OR OTHER EQUIPMENT TO REMOVE PERSONNEL AND STABILIZE
MACHINE MOTION, IF NECESSARY.
• DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS
TO THE PLATFORM. ADDITION OF SUCH ITEMS
INCREASES THE EXPOSED WIND AREA OF THE
MACHINE.
• NEVER POSITION LADDERS, STEPS, OR SIMILAR
ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE.
• WHEN RIDING IN OR WORKING FROM PLATFORM,
BOTH FEET MUST BE FIRMLY POSITIONED ON THE
FLOOR.
• KEEP OIL, MUD AND SLIPPERY SUBSTANCES
CLEANED FROM FOOTWEAR AND PLATFORM
FLOOR.
• NEVER "WALK" THE BOOM TO GAIN ACCESS TO OR
LEAVE PLATFORM.
• NEVER PLACE HANDS OR ARMS IN TOWER BOOM
OR UPRIGHT MECHANISM.
• KEEP ALL NON-OPERATING PERSONNEL AT LEAST
2 METERS AWAY FROM THE MACHINE AT ALL
TIMES.
1-6
• THE OPERATOR IS RESPONSIBLE TO AVOID OPERATING MACHINE OVER GROUND PERSONNEL AND
TO WARN THEM NOT TO WORK, WALK OR STAND
UNDER A RAISED BOOM OR PLATFORM. POSITION
BARRICADES ON FLOOR IF NECESSARY.
– JLG Lift –
3120890
SECTION 1 - SAFETY PRECAUTIONS
FERING WITH OPERATING CONTROLS AND PERSONS IN PLATFORM.
.
• ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR MACHINES ARE AWARE OF THE AERIAL
PLATFORMS PRESENCE. DISCONNECT POWER TO
OVERHEAD CRANES. POSITION BARRICADES ON
FLOOR IF NECESSARY.
• NEVER "SLAM" A CONTROL SWITCH OR LEVER
THROUGH NEUTRAL TO THE OPPOSITE DIRECTION.
ALWAYS RETURN SWITCH TO NEUTRAL AND STOP;
THEN MOVE SWITCH TO THE DESIRED POSITION.
OPERATE LEVERS WITH SLOW, EVEN PRESSURE.
• DO NOT CARRY MATERIALS ON PLATFORM RAILING
UNLESS APPROVED BY JLG INDUSTRIES INC.
• NEVER PUSH OR PULL THE MACHINE OR OTHER
OBJECTS BY TELESCOPING THE BOOM.
• NEVER USE BOOM FOR ANY PURPOSE OTHER
THAN POSITIONING PERSONNEL, THEIR TOOLS
AND EQUIPMENT.
• ENSURE MACHINE IS POSITIONED ON A FIRM,
LEVEL AND UNIFORM SUPPORTING SURFACE
BEFORE RAISING OR EXTENDING BOOM.
• NEVER EXCEED MANUFACTURERS RATED PLATFORM CAPACITY - REFER TO CAPACITY DECAL ON
MACHINE. DISTRIBUTE LOADS EVENLY ON PLATFORM FLOOR.
• NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE , RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.
• DO NOT REMOVE, MODIFY, OR DISABLE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
• DO NOT ASSIST A STUCK OR DISABLED MACHINE
BY PUSHING OR PULLING EXCEPT BY PULLING AT
CHASSIS TIE-DOWN LUGS.
• CHECK CLEARANCES ABOVE, ON SIDES AND BOTTOM OF PLATFORM WHEN RAISING, LOWERING,
SWINGING, AND TELESCOPING BOOM.
• EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER-
3120890
• NEVER ATTEMPT USING BOOM AS A CRANE.
STRUCTURAL DAMAGE OR TIPPING MAY OCCUR.
• STOW BOOM AND SHUT OFF ALL POWER BEFORE
LEAVING MACHINE.
• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.
– JLG Lift –
1-7
SECTION 1 - SAFETY PRECAUTIONS
• NEVER ATTEMPT TO FREE A MACHINE STUCK IN
SOFT GROUND OR ASSIST A MACHINE UP A STEEP
HILL OR RAMP BY USING BOOM "LIFT", "TELESCOPE", OR "SWING" FUNCTIONS.
• NEVER ATTACH WIRE, CABLE, OR ANY SIMILAR
ITEMS TO PLATFORM.
• DO NOT PLACE BOOM OR PLATFORM AGAINST ANY
STRUCTURE TO STEADY PLATFORM OR SUPPORT
STRUCTURES.
• DO NOT USE THE LIFT, SWING, OR TELESCOPE
FUNCTIONS FOR THE BOOM, TO MOVE EITHER THE
MACHINE OR OTHER OBJECTS.
• HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT
F U L LY E X T E N D E D O R R E T R A C T E D F O R A N Y
LENGTH OF TIME. ALWAYS "BUMP" CONTROL IN
OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION
BEING USED REACHES END OF TRAVEL. THIS
APPLIES TO MACHINES IN OPERATION OR IN
STOWED MODE.
• MACHINE MUST ALWAYS BE SHUT DOWN WHEN
REFUELING. NO SMOKING IS MANDATORY. NEVER
REFUEL DURING AN ELECTRICAL STORM. ENSURE
THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.
1.7
TOWING AND HAULING
• DO NOT TOW A MACHINE EXCEPT IN AN EMERGENCY. SEE SECTION 6 FOR EMERGENCY TOWING
PROCEDURES.
• LOCK TURNTABLE BEFORE TRAVELING LONG DISTANCES OR BEFORE HAULING MACHINE ON A
TRUCK OR TRAILER.
• DO NOT OPERATE ANY MACHINE ON WHICH DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE.
1-8
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
SECTION 2. PREPARATION AND INSPECTION
2.1
GENERAL
2.3
This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtaining maximum service life and safe operation.
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.
2.2
DELIVERY AND FREQUENT INSPECTION
NOTE: This machine requires periodic safety and maintenance inspections by an authorized JLG Dealer.
The following checklist provides a systematic inspection
to assist in detecting defective, damaged, or improperly
installed parts. The checklist denotes the items to be
inspected and conditions to examine.
Frequent inspection shall be performed every 3 months or
150 hours whichever comes first, or more often when
required by environment, severity, and frequency of
usage.
Chassis
1. Check front tire and wheel assemblies for loose or
worn spindles, components and hardware for security, tires for wear and damage.
2. Check steering assembly for loose or bent tie rod,
cylinder and hydraulic lines for leaks and security,
and hardware for proper installation.
PREPARATION FOR USE
Before a new machine is put into operation it must be
carefully inspected for any evidence of damage resulting
from shipment and inspected periodically thereafter, as
outlined in Delivery and Frequent Inspection (see section
2-3). During initial start-up and run, the unit should be
thoroughly checked for hydraulic leaks. A check of all
components should be made to ensure their security.
All preparation necessary to place the machine in operation readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate properly) coupled with a series of visual inspections. The mandatory requirements are given in the Daily Walk Around
Inspection (see section 2-4).
3. Check rear tire and wheel assemblies for security,
tires for wear and damage.
4. Check drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.
5. Check oil level in drive hub by removing pipe plug
on side and feeling for oil level. (Contact Service
Personnel for assistance if needed).
NOTE: Torque hubs should be one-half full of lubricant.
It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.
6. Check 4WS steering assembly (if equipped) for
loose or bent tie rod, cylinder and hydraulic lines for
leaks and security, and hardware for proper installation.
7. Check counterbalance, flow divider valves, hydraulic
swivel assembly and lines for visible damage, evidence of leakage, and security and electrical connections for corrosion and tightness.
8. Check extending axle assemblies for evidence of
leakage and security; pressure lines for abnormal
chafing drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.
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– JLG Lift –
2-1
SECTION 2 - PREPARATION AND INSPECTION
9. Check extending axles for visible damage and loose
or missing parts.
10. Check oscillating axle (if equipped) for loose, missing and worn parts, pivot pin and lockout cylinder
pins for security, lockout cylinders and hydraulic
hoses for damage and leaks.
Turntable
1. Check turntable and turntable lock for damage,
loose or missing parts, and security. Check swing
drive hub, hydraulic motor, and brake for damage,
loose or missing parts, hydraulic lines and component housings for evidence of leakage; pinion for
proper mesh with swing gear.
10. Check fuel tank for damage, leakage and filler cap
for security.
11. Check hydraulic reservoir and hydraulic lines for
damage, leakage and security.
NOTE: JLG recommends replacing the hydraulic filter element after the first 50 hours of operation and then
every 300 hours thereafter, unless system indicator
require earlier replacement.
12. Check all cylinder pin and shaft retaining hardware
for security and wear.
13. Check all electrical cables for defects, damage,
loose or corroded connections.
Boom
2. Check swing bearing for damage, wear, lubrication
and loose or missing bearing bolts.
1. Check all cylinder pin and shaft retaining hardware
for security and wear.
3. Check solenoid valves and hydraulic lines for damage, leakage, security and electrical connections for
tightness and evidence of corrosion.
2. Check hydraulic lines, electrical cable and track
assemblies for damage, missing parts and security.
3. Check lift cylinder and cross pins and hydraulic
lines for damage, wear, leakage and security.
4. Check ground controls for damage, loose or missing parts, security, electrical connections for evidence of corrosion and tightness and wiring for
insulation damage. Assure that all switches function
properly.
4. Check boom pivot pins for damage, wear, and security.
5. Check hydraulic line and electrical cable track
assembly for visible damage, loose or missing parts,
and security.
5. Check manual descent valves for visible damage,
evidence of leakage and security. Assure that valves
function properly.
6. Check boom for damage, missing parts and security.
6. Check battery for damage, loose or missing vent
caps, electrical connections for tightness, and evidence of corrosion, holddown brackets for tightness, and electrolyte for proper water level. Add only
clean distilled water to battery.
7. Check boom wear pads for damage, wear and security.
8. Check boom telescope cylinder and cross pins and
hydraulic lines for damage, wear, leakage and security.
7. Check engine and accessories for damage, loose or
missing parts, leakage and security. Check throttle
solenoid and linkage for damage, electrical connections for tightness, and evidence of corrosion and
wiring for insulation damage.
8. Check fuel lines for damage, leakage and security.
9. Check all access doors for damage, proper operation of latches, props and security.
2-2
9. Check platform leveling cylinder and cross pins and
hydraulic lines for damage, wear, leakage and security.
10. Check boom/platform pivot pin for damage, wear
and security.
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-1. Machine Nomenclature
3120890
– JLG Lift –
2-3
SECTION 2 - PREPARATION AND INSPECTION
11. Check horizontal and capacity limit switches
mounted on turntable for security of mounting, damage to switch arms and rollers; and for debris.
12. Check boom tape for correct length and tearing or
defacing at any point.
Extend-A-Reach (If Equipped)
1. Check the slave cylinder, weld link and cross pins,
and lines for visible damage, wear, lubrication, evidence of leakage, and security.
2. Check extend-a-reach for visible damage, loose or
missing parts, and security.
3. Check hydraulic lines and electrical cable for damage, missing parts and security.
Platform
1. Check platform and control console for damage,
loose or missing parts, and security.
2. Check control switches and levers for damage,
loose or missing parts and security. Assure that
levers function properly.
Torque Requirements
The Torque Chart (Figure 2-6.) consists of standard torque
values based on bolt diameter and grade, also specifying
dry and wet torque values in accordance with recommended shop practices. This chart is provided as an aid
to the operator in the event he/she notices a condition that
requires prompt attention during the walk-around inspection or during operation, until the proper service personnel
can be notified. The Service and Maintenance manual
provides specific torque values and periodic maintenance
procedures with a listing of individual components. Utilizing this Torque Chart in conjunction with the preventive
maintenance section in the Service and Maintenance
manual will enhance safety, reliability, and performance of
the machine.
2.4
DAILY WALK-AROUND INSPECTION
It is the operator’s responsibility to inspect the machine
before the start of each workday. It is recommended that
each operator inspect the machine before operation, even
if the machine has already been put into service under
another operator. This Daily Walk-Around Inspection is the
preferred method of inspection.
(See Figure 2-2.)
In addition to the Daily Walk-Around Inspection, be sure to
include the following as part of the daily inspection:
3. Check control switches, levers and electrical connections for tightness and evidence of corrosion,
and wiring for defects and chafing damage. Assure
that switches function properly.
4. Check capacity indicator for correct operation, any
damage and that decals are not defaced. Ensure
indicator dial is zeroed with boom at horizontal and
indicator dial moves in accordance with boom
angle.
5. Check access gate hinges and latch for proper
operation, damage and security.
6. Check platform rotator mechanism for proper operation, damage, security. Check hydraulic lines for
leakage, damage and security.
1. Overall cleanliness.
Check all standing surfaces for oil, fuel and hydraulic oil spillage and foreign objects. Ensure overall
cleanliness.
2.
Placards.
Keep all information and operating placards clean
and unobstructed. Cover when spray painting or
shot blasting to protect legibility.
3. Operator’s and Safety Manual.
Ensure a copy of this manual is enclosed in the
manual storage box.
NOTE: Check all DANGER, WARNING, CAUTION and
INSTRUCTION placards for legibility and security on
the entire machine.
2-4
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
4.
4.
Machine Log.
Ensure a machine operating record or log is kept,
check to see that it is current and that no entries
have been left uncleared, leaving machine in an
unsafe condition for operation.
NOTE: Check boom horizontal limit switch for proper operation and security, both visually and manually. Switch
must shut down high engine and high drive speed
when boom is raised above horizontal:
6. Check platform footswitch for proper operation.
Switch must be released to start engine and
depressed to operate machine.
5. Start each day with a full fuel tank.
TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS
“OFF” DURING WALK-AROUND INSPECTION.
7. Check that drive brakes hold when machine is
driven up a grade and stopped.
NOTE: On new machines, those recently overhauled, or
after changing hydraulic oil, operate all systems a
minimum of two complete cycles and recheck oil
level in reservoir.
8. Assure that all items requiring lubrication are serviced. Refer to Table 2-1, Lubrication Chart, for specific requirements.
3120890
– JLG Lift –
2-5
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 4
2-6
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
GENERAL
NOTE: Begin the “Walk-Around Inspection” at Item 1, as
noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in
sequence for the conditions listed in the “WalkAround Inspection Checklist”.
TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNCTIONING MACHINE IS A SAFETY VIOLATION. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DURING
WALK-AROUND INSPECTION.
NOTE: Do not overlook visual inspection of chassis underside. Checking this area often results in discovery of
conditions which could cause extensive machine
damage.
1. Platform Assembly - No loose or missing parts, no
visible damage. Lock bolts in place. Footswitch in
good working order, not modified, disabled or
blocked. Check area of fly boom nose section
above and under platform slave level cylinder for
accumulation of foreign material. Remove any foreign material present.
2. Platform Control Console - Switches and levers
return to neutral and are properly secured, no loose
or missing parts, no visible damage, decals/placards secure and legible, control marking legible.
3. Rotator - Properly secured, no visible damage, no
evidence of leakage.
4. Rotator and Motor - Properly secured, no visible
damage, no evidence of leakage.
5. Slave Leveling Cylinder, Extend-A-Reach - Properly secured, no visible damage, no evidence of
leakage. (If equipped on Extend-A-Reach)
7. Extend-A-Reach Pivot - No loose, damaged, or
missing parts, evidence of proper lubrication. (If
equipped on Extend-A-Reach)
8. Hose and Cable Guards/Clamps - Properly
secured, no visible damage.
9. Power Track - No loose, damaged or missing parts,
no visible damage.
10. Steer Cylinder Assembly, Right Rear - Properly
secured, no visible damage or signs of leakage. (4
Wheel Steer)
11. Tie Rod and Steering Linkage - No loose or missing parts, no visible damage. Tie rod end studs
locked. (4 Wheel Steer)
12. Drive Motor and Brake, Right Rear - No visible
damage, no evidence of leakage.
13. Spindle, Right Rear - No loose or missing parts, no
visible damage, evidence of proper lubrication. (4
Wheel Steer)
14. Drive Hub, Right Rear - No visible damage, no evidence of leakage.
15. Wheel/Tire Assembly, Right Rear - Properly
secured, no loose or missing lug nuts, no visible
damage.
16. Turntable Bearing and Pinion - No loose or missing hardware; no visible damage, evidence of
proper lubrication. No evidence of loose bolts or
looseness between bearing and structure.
17. Swing Drive Motor and Brake - No visible damage,
no evidence of leakage.
18. Fuel Supply - Fuel filler cap secure. Tank - no visible
damage; no evidence of leaks.
19. Extend-A-Reach Control valves (Tank Compartment) No visible damage, no evidence of leakage,
no unsupported wires or hoses, no damaged wires.
6. Extend-A-Reach Lift Cylinder - Properly secured,
no visible damage, or signs of leakage, evidence of
proper lubrication. (If equipped on Extend-A-Reach)
Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 4
3120890
– JLG Lift –
2-7
SECTION 2 - PREPARATION AND INSPECTION
20. Control Valves (Tank Compartment) - No loose or
missing parts, no evidence of leakage, no damaged
wires.
21. Hydraulic Oil Supply - Recommended oil level in
sight gauge. (Check level with cold oil, systems shut
down, machine in stowed position) Cap in place
and secure.
22. Steer Cylinder Assembly - Properly secured, no
visible damage or signs of leakage.
23. Cowling and Latches, Right Side - All cowling and
latches in working condition, properly secured, no
loose or missing part.
24. Spindle, Right Front - Properly secured, no loose
or missing parts, no visible damage.
25. Drive Hub, Right Front - No visible damage, no evidence of leakage. (4 Wheel Drive)
26. Wheel/Tire Assembly, Right Front - Properly
secured, no loose or missing lug nuts, no visible
damage.
27. Tie Rod and Steering Linkage, Right Front - No
loose or missing parts, no visible damage. Tie rod
end studs locked.
28. Axle Lock Pin, Right Front - No loose or missing
parts, no visible damage. Installed in proper location.
29. Oscillating Axle Cylinder, Right Front - Properly
secured, no visible damage or signs of leakage. (If
Equipped)
30. Ground Controls - Switches operable, no visible
damage, decals secure and legible.
31. Manual Descent - No evidence of leakage, no visible damage.
32. Oscillating Axle - Properly secured, no loose or
missing parts, no visible damage. (If Equipped)
33. Towing Package - No loose, damaged or missing
parts, no visible damage. (If Equipped)
34. Master Cylinder - Properly secured, evidence of
lubrication.
35. Lift Cylinder - Properly secured, evidence of lubrication.
36. Oscillating Axle Cylinder, Left Front - Properly
secured, no visible damage or signs of leakage. (If
Equipped)
37. Axle Lock Pin, Left Front - No loose or missing
parts, no visible damage. Installed in proper location.
38. Tie Rod and Steering Linkage, Left Front - No
loose or missing parts, no visible damage. Tie rod
end studs locked.
39. Auxiliary Power Pump - No loose or missing parts,
no evidence of leakage, no damaged wires.
40. Wheel/Tire Assembly, Left Front - Properly
secured, no loose or missing lug nuts, no visible
damage.
41. Spindle, Left Front - Properly secured, no loose or
missing parts, no visible damage.
42. Drive Hub, Right Front - No visible damage, no evidence of leakage. (4 Wheel Drive)
43. Hydraulic Pump - No loose or missing parts, no evidence of leakage.
44. Muffler and Exhaust System - Properly secured,
no evidence of leakage
45. Engine Oil Supply - Full mark on dipstick; filler cap
secure.
46. Cowling and Latches, Left Side - All cowling and
latches in working condition, properly secured, no
loose or missing part.
47. Engine Air Filter - No loose or missing parts; no visible damage; element clean.
48. Battery - Proper electrolyte levels; cables tight, no
visible damage or corrosion.
49. Turntable Lock - Operable; No missing parts, no
visible damage.
50. Wheel/Tire Assembly, Left Rear - Properly
secured, no loose or missing lug nuts, no visible
damage.
Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 4
2-8
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
51. Drive Hub, Left Rear - No visible damage, no evidence of leakage.
52. Drive Motor and Brake, Left Rear - No visible damage, no evidence of leakage.
53. Spindle, Left Rear - Properly secured, no loose or
missing parts, no visible damage. (4 Wheel Steer)
54. Tie Rod and Steering Linkage, Left Rear - No
loose or missing parts, no visible damage. Tie rod
end studs locked. (4 Wheel Steer)
55. Steer Cylinder Assembly, Left Rear - Properly
secured, no visible damage or signs of leakage, evidence of proper lubrication.
56. Frame - No visible damage, no loose or missing
hardware (top and underside).
57. Boom Sections - No visible damage; wear pads
secure. All cylinders - rod end shafts and barrel-end
shafts properly secured.
Figure 2-5. Daily Walk-Around Inspection - Sheet 4 of 4
3120890
– JLG Lift –
2-9
SECTION 2 - PREPARATION AND INSPECTION
2.5
Machines Without Jacks
DAILY FUNCTIONAL CHECK
a. Position the boom over the drive wheel end of
machine. Position STEER/AXLES valve, located
adjacent to the right front wheel, to AXLES.
Remove axle lock pins.
PROPER AXLE EXTENSION MUST BE CHECKED AND VERIFIED
PRIOR TO ANY OTHER SYSTEMS AND/OR FUNCTIONS.
A functional check of all systems should be performed,
once the walk-around inspection is complete, in an area
free of overhead and ground level obstructions. First,
using the ground controls, check all functions controlled
by the ground controls. Next, using the platform controls,
check all functions controlled by the platform controls.
D O N O T U S E E X T E N D - A - R E A C H ( I F E Q U I P P E D ) TO L I FT
MACHINE WHEN EXTENDING AND RETRACTING AXLES.
NOTE: On machines equipped with Soft Touch Proximity
System, the operator must press and hold the override button on the front of the control box in order to
lift the drive wheels from the ground.
b. Position LIFT control to DOWN and hold until
drive wheels rise from the ground; it may be necessary to feather the lift control to maintain drive
wheel elevation.
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.
c. With the aid of an assistant, position the
EXTENDABLE AXLE/STEER switch located on
the platform control console to LEFT until axles
are fully extended. On machines with fixed axles,
install axle lock pins.
TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT
STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED,
REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP
TO STOP THE MACHINE.
d. Position LIFT control to UP to lower the
machine; elevate the boom sufficiently and reposition the boom over the steer wheel end of the
machine.
NOTE: Perform checks from the ground controls first, where
applicable, then from the platform controls.
e. Repeat steps b thru d for the steer axle. On
machines with fixed axles, remove the tie rod
lock pins, steer cylinder lock pin, and axle lock
pins.
1. Extendable Axles.
Prior to extending the axles, verify that the boom will
not elevate above horizontal and that it will not
extend more than 10 feet (3.0 m). For machines
equipped with red Axles Set or red Axles Not Set
indicator lamps, at the platform and/or the ground
controls, verify the lamps illuminate until the axles
are properly extended and locked. For machines
equipped with green Axles Set indicator lamps at the
platform and/or the ground controls, the lamps
should not illuminate until the axles are extended
and locked.
f. Position STEER/AXLES valve to STEER.
g. On machines with fixed axles, cycle steer system in both directions to ensure tie rod and steer
cylinder are properly locked.
h. For machines equipped with a green Axles Set
Indicator lamp, verify proper operation of the
lamp at the platform and ground controls.
Machines With Jacks
NOTE: For machines equipped with a front jack only,
refer to the instructions under Machines Without
Jacks to extend the rear axle.
DO NOT OPERATE THE MACHINE IF THE BOOM ELEVATES
ABOVE HORIZONTAL OR EXTENDS BEYOND TEN FEET WITHOUT FULLY EXTENDING AND LOCKING THE AXLES.
b. Position Jack/Steer/Axles select switch
the platform control console to JACK.
Check axle operation as follows:
NOTE: Fixed axle machines have retaining pins for the
axles, steer cylinders, and tie rods. Machines
equipped with oscillating axles do not have these
retaining pins and all extending and retracting operations are performed from the platform without aid of
an assistant.
2-10
a. Position STEER/AXLES valve, located adjacent
to the right front wheel, to AXLES.
– JLG Lift –
on
c. On machines with fixed axles, remove the axle
lock pins on the applicable axle. If extending
the steer axle, also remove the tie rod lock pins
and steer cylinder lock pin.
d. Position the Jack Select Switch to either FRONT
JACK or REAR JACK and position the JACK
3120890
SECTION 2 - PREPARATION AND INSPECTION
control switch to down and hold until the wheels
on the selected axle rise from the ground.
e. Position the Jack/Steer/Axles select switch to
AXLES. Then, position the Steer/Axles/Jack
control switch to left until the axles are fully
extended. On machines with fixed axles, install
axle lock pins. If extending the steer axle, also
install the tie rod lock pins and steer cylinder
lock pin.
f. Position the JACK control to the up position to
lower the machine. Ensure the jack is fully
retracted before operating the machine.
ENSURE THE JACK IS FULLY RETRACTED BEFORE OPERATING
THE MACHINE. FAILURE TO DO SO COULD RESULT IN DAMAGE
TO THE MACHINE.
g. Repeat steps b thru f to extend the opposite
axle.
h. Position the STEER/AXLES valve to STEER.
i. On machines with fixed axles, cycle the steer
system in both directions to ensure the tie rod
and steer cylinder are properly locked.
j. For machines equipped with a green Axles Set
Indicator lamp, verify proper operation of the
lamp at the platform and ground controls.
2. Drive forward and reverse; check for proper operation.
3. Steer left and right; check for proper operation.
4. If equipped with 4 wheel steer, check rear steer left
and right for proper operation.
9. Check that platform automatic self-leveling system
functions properly during raising and lowering of the
boom.
10. Check platform level adjustment system for proper
operation.
NOTE: Turntable lock is on turntable facing platform. To disengage lock, pull snap pin from lock pin, lift lock pin
up to unlock turntable. Return snap pin to lock pin to
hold lock pin in the disengaged position. Reverse
procedure to engage turntable lock.
11. Swing turntable to LEFT and RIGHT a minimum of
45 degrees. Check for smooth motion.
12. With the aid of an assistant to monitor the CHASSIS
OUT OF LEVEL indicator light on the platform control console, manually activate the indicator light by
compressing any one of the three tilt indicator
mounting springs. If the light does not illuminate,
shut down machine and contact a qualified service
technician before continuing operation.
13.
FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL
OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF
TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL,
TOP OR BOTTOM, IT SHOULD BE ADJUSTED.
5. If equipped, check platform rotator for smooth operation and assure platform will rotate 90 degrees in
both directions from centerline of boom.
6. Raise, lower, and swing boom to LEFT and RIGHT a
minimum of 45 degrees (Cycle function several
times.) Check for smooth elevation and swing
motion.
7. If equipped with Extend-A-Reach, raise and lower
and swing Extend-A-Reach (Cycle functions several
times). check for smooth elevation and swing
motion.
8. Telescope boom in and out several cycles at various
degrees of elevation lengths. Check for smooth telescope operation.
3120890
Footswitch.
– JLG Lift –
a. Activate hydraulic system. By depressing footswitch. Operate TELESCOPE and hold control.
Remove foot from footswitch, motion should
stop. If it does not, shut down machine and contact a certified JLG service technician.
b. With footswitch depressed, operate LIFT and
hold control. Remove foot from footswitch,
motion should stop. If it does not, shut down
machine and contact a certified JLG service
technician.
c. With engine power shut down, depress the footswitch. Attempt to start engine. Engine should
not attempt to start when footswitch is
depressed. If starter engages or engine turns
over, shut down machine and contact a certified
JLG service technician.
2-11
SECTION 2 - PREPARATION AND INSPECTION
14. Auxiliary Power.
2.7
Operate each function control switch (e.g. TELE,
LIFT and SWING) to assure that they function in
both directions using auxiliary power instead of
engine power.
15. Ground Controls.
Place GROUND/PLATFORM SELECT switch to
GROUND. Start engine. Platform controls should
not operate.
2.6
BATTERY MAINTENANCE
TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR
ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVICING.
Battery Maintenance
1. The battery is maintenance free except for occasional battery terminal cleaning, as noted in the following.
TORQUE REQUIREMENTS
2. Remove battery cables from each battery post one
at a time, negative first. Clean cables with acid neutralizing solution (e.g. baking soda and water or
ammonia) and wire brush. Replace cables and/or
cable clamp bolts as required.
The Torque Chart (Figure 2-7.) consists of standard torque
values based on bolt diameter and grade, also specifying
dry and wet torque values in accordance with recommended shop practices. This chart is provided as an aid
to the operator in the event a condition is noticed that
requires prompt attention during the walk-around inspection or during operation until the proper service personnel
can be notified. The Service and Maintenance manual
provides specific torque values and periodic maintenance
procedures with a listing of individual components. Utilizing this Torque Chart in conjunction with the preventive
maintenance section in the Service and Maintenance
manual, will enhance safety, reliability and performance of
the machine.
3. Clean battery post with wire brush then re-connect
cable to post. Coat non-contact surfaces with mineral grease or petroleum jelly (Vaseline).
4. When all cables and terminal posts have been
cleaned, ensure all cables are properly positioned
and are not pinched. Close battery compartment
cover.
2.8
LUBRICATION
NOTE: The lubrication intervals in the following lubrication
diagram and chart are equivalent to the following:
150 hours = 3 months
300 hours = 6 months
600 hours = 1 year
1200 hours = 2 years
2-12
– JLG Lift –
3120890
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-6. Lubrication Diagram
3120890
– JLG Lift –
2-13
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1. Lubrication Chart
Components
Interval
Number/Type
Lube Points
Capacity
Lube
Level/Fill Plug
1.3 liters (1/2 full)
EPGL
(SAE90)
3 Months
150 hrs
Hours
6 Months
300 hrs
1 Year
600 hrs
Comments
2 Years
1200 hrs
1
Wheel Drive Hubs
2
Slave Cylinder (Rod)
1 Grease Fitting
A/R
MPG
X
3
Slave Cylinder (Barrel )
1 Grease Fitting
A/R
MPG
X
4
Platform Pivot
1 Grease Fitting
A/R
MPG
X
5
Rotating Column
(Optional)
2 Grease Fittings
A/R
MPG
6
Rotary Worm Gear
(Optional)
N/A
A/R
MPG
X
7
Platform Hinges
2 Grease Fittings
A/R
MPG
X
8
Platform Latch
N/A
A/R
EO
X
9
Boom Chain Extension
Sheave
1 Grease Fitting
A/R
MPG
X
Align access holes in mid and fly boom.
10
Swing Bearing
2 Grease Fittings
A/R
MPG
X
Remote Access
11
Lift Cylinder (Barrel End)
1 Grease Fitting
A/R
MPG
X
Remote Access
12
Master Cylinder (Barrel
End)
1 Grease Fitting
A/R
MPG
X
Remote Access
13
Master Cylinder (Rod
End)
1 Grease Fitting
A/R
MPG
X
2-14
X
Check level every 150 hours; change @ 1200
hours
Gain access through boom fly section.
X
– JLG Lift –
Brush on.
3120890
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1. Lubrication Chart
Components
Interval
Number/Type
Lube Points
Capacity
Lube
3 Months
150 hrs
Hours
6 Months
300 hrs
1 Year
600 hrs
Comments
2 Years
1200 hrs
14
Boom Chain Retract
Sheave
1 Grease Fitting
A/R
MPG
X
15
Boom Pivot Bushings
2 Grease Fittings
A/R
MoS2
X
16
Engine Crankcase
Fill Cap
Refer to Engine Manual
EO
Check daily. Change in accordance wth
engine manual.
17
Engine Oil Filter
N/A
N/A
N/A
Change in accordance with engine manual.
18
Engine Coolant
Radiator Cap
Refer to Engine Manual
19
Hydraulic Oil
Fill Cap
56 gallons
HO
20
Hydraulic Oil Return
Filters
N/A
N/A
N/A
21
Hydraulic Reservoir
Suction Filter
N/A
N/A
N/A
22
Tie Rod Ends
2 Grease Fittings
A/R
MPG
X
23
King Pins
2 Grease Fittings
A/R
MPG
X
24
Steer Cylinder (Rod
End)
1 Grease Fitting
A/R
MPG
X
25
Steer Cylinder (Barrel
End)
1 Grease Fitting
A/R
MPG
X
26
Wheel Bearings
N/A
A/R
27
Swing Drive Hub
Fill Plug
28
Swing Bearing and
Pinion Gear Teeth
29
Refer to engine manual for coolant specifications. Check daily with engine cold.
X
Check daily. Change every 1200 hours.
Check filter gauges for element construction
daily. Replace as necessary.
X
Replace filter element every 600 hours; clean
mesh as necessary.
MPG
X
Repack
0.5 liters (1/2 Full)
EPGL
(SAE90)
X
Check oil level weekly; change every 600
hours
N/A
A/R
MPG
X
Apply by brush onto bearing and gear teeth
Axle Beam (Extendable
Axles)
N/A
A/R
MPG
30
Axle Lock Pin
(Extendable Axles)
N/A
A/R
MPG
X
31
Oscillating Axle Pivot
1 Grease Fitting
A/R
MPG
X
32
Oscillation Cylinder
2 Grease Fittings
A/R
MPG
X
33
Extend-A-Reach Pivot (If
Equipped)
2 Grease Fittings
A/R
MPG
X
34
Extend-A-Reach Lift
Cylinder (Barrel End)
1 Grease Fitting
A/R
MPG
X
35
Extend-A-Reach Lift
Cylinder (Rod End)
1 Grease Fitting
A/R
MPG
X
3120890
X
– JLG Lift –
Apply by brush
Apply by brush
2-15
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1. Lubrication Chart
Components
Interval
Number/Type
Lube Points
Capacity
Lube
3 Months
150 hrs
36
Extend-A-Reach - Boom
End (If Equipped)
2 Grease Fittings
A/R
MPG
X
37
Extend-A-Reach Platform End (if
Equipped)
1 Grease Fitting
A/R
MPG
X
38
Extend-A-Reach - Slave
Cylinder Rod End (If
Equipped)
1 Grease Fittings
A/R
MPG
X
39
Extend-A-Reach Link Slave Cylinder Pivot
Point (If Equipped)
1 Grease Fitting
A/R
MPG
X
40
Extend-A-Reach Link Slave Cylinder Pivot
Point (If Equipped)
1 Grease Fitting
A/R
MPG
X
6 Months
300 hrs
Hours
1 Year
600 hrs
2 Years
1200 hrs
NOTES:
KEY TO LUBRICANTS
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.
2-16
Comments
– JLG Lift –
EO
EPGL
HO
MPG
Engine Oil
Extreme Pressure Gear Lube
Hydraulic Fluid (Mobil #424 or equivalent)
Multi-Purpose Grease
3120890
UNPLATED
CAP SCREWS
3120890
– JLG Lift –
40
48
32
40
32
36
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
6
12
Note:
1-1/2
1-1/2
1-1/4
1-1/8
1
7/8
3/4
5/8
9/16
1/2
7/16
3/8
5/16
1/4
10
8
6
4
0.0153
0.0168
0.0232
0.0258
0.0356
0.0374
0.0445
0.0508
0.0808
0.0925
0.1331
0.1473
0.1969
0.2230
0.2700
0.3015
0.3604
0.4061
0.4623
0.5156
0.5740
0.6502
0.8484
0.9474
1.1735
1.2929
1.5392
1.6840
1.9380
2.1742
2.4613
2.7254
2.9337
3.3401
3.5687
4.0132
172
191
263
277
408
426
508
583
916
1052
1515
1678
2241
2540
3085
3425
4105
4854
5262
5874
6532
7394
9662
10796
13336
14697
17509
19142
19187
21546
24404
27035
29076
33113
35381
39781
1
1
2
2
4
4
5
6
11
14
23
26
41
48
68
75
102
122
149
163
204
231
353
407
583
637
868
949
1085
1193
1519
1681
1980
2278
2630
2983
1
1
2
2
3
3
4
4
9
10
18
19
31
34
48
68
75
88
109
122
149
176
271
298
434
475
651
719
814
895
1139
1247
1492
1708
1980
2224
22
23
38
43
61
68
92
108
133
148
183
207
325
363
523
576
785
858
968
1087
1368
1516
1792
2042
2379
2676
12
16
26
29
48
54
75
81
115
136
163
183
224
258
387
448
644
705
915
997
1139
1254
1593
1762
2068
2373
2746
3118
245
272
372
417
572
599
717
817
1297
1488
2141
2821
3175
3583
4332
4854
5783
6532
7539
8278
9231
10433
13653
15241
18870
20775
23360
27080
31162
34927
38554
43818
47174
53570
57380
142200
Figure 2-7. Torque Chart
These torque values do not apply to cadium plated fasteners.
3.8100
3.4925
3.1750
2.8575
2.5400
2.2225
1.9050
1.5875
1.4288
1.2700
1.1112
0.9525
0.7938
0.6350
0.4826
0.4166
0.3505
0.2845
2
2
3
3
5
5
7
8
16
19
34
34
61
68
95
109
149
163
204
231
298
326
515
570
814
895
1220
1356
1736
1953
2468
2712
3227
3688
4284
4827
30
34
54
61
85
95
130
146
188
209
244
277
408
456
658
724
931
1079
1396
1566
1970
2183
2586
2935
3430
3856
18
21
41
41
68
75
109
122
163
183
224
258
326
359
570
631
895
983
1342
1492
1898
2136
2712
2983
3559
4068
4712
5322
SAE GRADE 5
1
1
2
2
4
4
5
6
12
14
25
27
48
48
75
81
109
122
149
176
231
244
380
434
624
678
922
1003
1302
1464
1844
2034
2413
2766
3200
3607
18
19
34
37
61
68
95
102
149
156
210
224
285
298
495
542
793
861
1173
1241
1681
1871
2373
2549
3145
3308
4122
4433
SAE GRADE 8
1442
1651
2377
2631
3493
3983
4822
5384
6437
7253
8256
9208
10251
11612
15150
16919
20956
23088
27488
30074
34610
38828
43954
48671
52391
59648
63731
71669
UNBRAKO 1960 SERIES
SAE GRADE 5 BOLTS & GRADE 2 NUTS SAE GRADE 8 BOLTS & GRADE 8 NUTS
SOCKET HEAD CAP SCREW
BOLT THREAD
TORQUE
WITH LOC-WEL PATCH
TORQUE
SIZE THD DIA. STRESS CLAMP
CLAMP
AREA
LOAD (DRY OR (LUB.) (LOCTITE (LOCTITE LOAD (DRY OR (LUB.) (LOCTITE (LOCTITE CLAMP LOAD TORQUE
(CM)
(as received)
262) 242 OR 271)
262) 242 OR 271)
263)
263)
(SQ. CM)
(KG) LOC.
(KG) LOC.
(KG)
NM
NM
NM
NM
NM
NM
NM
NM
NM
VALUES FOR ZINC PLATED BOLTS ONLY
SECTION 2 - PREPARATION AND INSPECTION
2-17
SECTION 2 - PREPARATION AND INSPECTION
This page left blank intentionally.
2-18
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL
3.1
5. Sufficient knowledge of the mechanical operation of
the machine to recognize a malfunction or potential
malfunction.
GENERAL
SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER
MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH
GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITY OF THE USER AND HIS/HER OPERATING PERSONNEL.
This section provides the necessary information needed
to understand control functions. Included in this section
are the operating characteristics and limitations, and functions and purposes of controls and indicators. It is important that the user read and understand the proper
procedures before operating the machine. These procedures will aid in obtaining optimum lift service and safe
operation.
3.2
PERSONNEL TRAINING
The aerial platform is a personnel handling device; therefore it is essential that it be operated and maintained only
by authorized and qualified personnel who have demonstrated that they understand the proper use and maintenance of the machine. It is important that all personnel
who are assigned to and responsible for the operation
and maintenance of the machine undergo a thorough
training program and check out period in order to become
familiar with the characteristics prior to operating the
machine.
Persons under the influence of drugs or alcohol or who
are subject to seizures, dizziness or loss of physical control must not be permitted to operate the machine.
6. The safest means to operate the machine where
overhead obstructions, other moving equipment,
and obstacles, depressions, holes, drop-offs, etc. on
the supporting surface exist.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Any other requirements of a specific job or machine
application.
Training Supervision
Training must be done under the supervision of a qualified
person in an open area free of obstructions until the
trainee has developed the ability to safely control a
machine in congested work locations.
Operator Responsibility
The operator must be instructed that he/she has the
responsibility and authority to shut down the machine in
case of a malfunction or other unsafe condition of either
the machine or the job site and to request further information from his/her supervisor or an authorized JLG Distributor before proceeding.
NOTE: Manufacturer or distributor will provide qualified persons for training assistance with first unit(s) delivered
and thereafter as requested by the user or his/her
personnel.
Operator Training
Operator training must include instruction in the following
areas:
1. Use and limitations of the platform controls, ground
controls, emergency controls and safety systems.
2. Knowledge and understanding of this manual and of
the control markings, instructions and warnings on
the machine itself.
3. Knowledge and understanding of all safety work
rules of the employer and of Government, State and
local statutes, including training in the recognition
and avoidance of potential hazards in the work
place; with particular attention to the work to be performed.
4. Proper use of all required personnel safety equipment, in particular the wearing of a safety harness or
other approved fall protection devices with a lanyard
attached to the platform at all times.
3120890
– JLG Lift –
3-1
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.3
OPERATING CHARACTERISTICS AND
LIMITATIONS
General
A thorough knowledge of the operating characteristics
and limitations of the machine is always the first requirement for any user, regardless of the user’s experience with
similar types of equipment.
Placards
Machine stability is based on two positions which are
called FORWARD STABILITY and BACKWARD STABILITY.
The machines position of least forward stability is shown
in Figure 3-1., Position of Least Forward Stability and its
position of least backward stability is shown in Figure 3-2.,
Position of Least Backward Stability.
TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD THE MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE.
Important points to remember during operation are provided at the control stations by DANGER, WARNING,
CAUTION, IMPORTANT and INSTRUCTION placards. This
information is placed at various locations for the express
purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations
of the machine. See FOREWORD for definitions of the
above placards.
Capacities
Raising the boom above horizontal and/or the extension
of the boom beyond the retracted position with or without
any load in the platform, is based on the following criteria:
1. Machine is positioned on a smooth, firm and level
surface.
2. Load is within manufacturer’s rated design capacity.
3. All machine systems are functioning properly.
4. Proper tire pressure exists in the tires.
5. Machine is as originally equipped from JLG.
Stability
This machine as originally manufactured by JLG Industries Inc., when operated within its rated capacity on a
smooth, firm and level supporting surface, and in accordance with the instructions provided on the machine and
this manual, provides a stable machine for all platform
positions.
3-2
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-1. Position of Least Forward Stability
3120890
– JLG Lift –
3-3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-2. Position of Least Backward Stability
3-4
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.4
3. Ignition.
CONTROLS AND INDICATORS
The machine is equipped with an on-off ignition
switch and a separate start push button switch on
the ground control panel which supplies electrical
power to the start solenoid when the ignition switch
is placed in the ON position and the START button
is depressed.
Ground Controls
PERFORM PRE-OPERATIONAL CHECKS AND INSPECTIONS
FROM THE GROUND CONTROL STATION. WHEN PERSONNEL
ARE IN THE PLATFORM, OPERATION OF THE BOOM WILL ONLY
BE PERFORMED WITH THE PERMISSION OF THE PLATFORM
OCCUPANT(S).
NOTE: Lift, Swing, and Telescope control switches are
spring-loaded and will automatically return to neutral
(off) when released.
WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY
STOP SWITCH MUST BE POSITIONED TO THE “OFF” POSITION
TO PREVENT DRAINING THE BATTERY.
WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.
1. Master Switch.
A two-position key operated switch furnishes battery power to the platform to the platform or ground
control switches when station power is selected
from the ground control panel and the master
switch is turned “ON”.
4. Lift Control.
The three-position LIFT control switch provides raising and lowering of the main boom when positioned
to UP or DOWN.
2. Control Station Selector.
5. Telescope Control.
A three position, center off, key activated PLATFORM/GROUND SELECT switch supplies power to
the platform control console when positioned to
PLATFORM. With the switch in the GROUND position, power is shut off to the platform station, and
only the controls on the ground control panel are
operable.
NOTE: With the Platform/Ground Select Switch in the center
position, power is shut off to controls at both operating stations.
The three-position TELESCOPE control switch provides extension and retraction of the boom, when
positioned to IN or OUT.
6. Swing Control.
The three-position SWING control switch provides
360 degrees continuous turntable rotation when
positioned to RIGHT or LEFT.
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE
MORE THEN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
MOTOR.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
WHEN RELEASED.
7. Auxiliary Power Control.
A toggle type AUXILIARY POWER control switch
energizes the electrically operated auxiliary hydraulic pump, when actuated. The switch must be held
in the ON position for the duration of auxiliary pump
use.
8.
Glow Plug Switch (Deutz Diesel Engine Only).
The push-button switch relays power to the glow
plugs used to warm the air intake on cold start operations.
3120890
– JLG Lift –
3-5
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-3. Ground Control Station - May 1994 to Present with Hydraulic Controls
3-6
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-4. Ground Control Station - May 1994 to Present without Hydraulic Controls
3120890
– JLG Lift –
3-7
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-5. Ground Control Station - Prior to May 1994
3-8
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
are extended and the retaining pins are properly
installed.
9. L.P. Gas/Gasoline Select Switch.
An optional two position contact toggle switch supplies electrical power to open the gasoline shut-off
solenoid and closes the LP gas shut-off solenoid
when placed in the “GASOLINE” position. This
switch supplies electrical power to open the LP gas
shut-off solenoid and closes the gasoline shut-off
solenoid when positioned to the LP position.
17. Choke (If equipped).
This push-button switch, when depressed, supplies
power to the choke solenoid to enrich the fuel mixture for cold weather starting.
18. Manual Descent.
10. Circuit Breakers.
The manual descent valves should be used, in the
event of a total power failure, to lower the work platform in the event of an emergency. The valves permit the use of gravity to retract and lower the boom.
Refer to Section 6 for a complete description of the
manual descent systems, their application, and
their operation.
Four reset push-button circuit breakers return cont r o l p ow er to t he f o l l ow i n g f un c ti o n s wh e n
depressed.
a. 35 amp - Master
b. 10 amp - High Engine
c. 10 amp - Choke
19. Boom Lift Control Knobs (Hydraulic Controls Only).
d. 10 amp - Ground Controls
The boom LIFT control knobs provide raising and
lowering of the boom when pushed in.
11. Extend-A-Reach.
The extend-a-reach (ARTICULATE) control switch
allows the operator to raise or lower the extend-areach as needed.
12. Hourmeter.
20. Telescope Control Knobs (Hydraulic Controls Only).
The telescope (TELE) control knobs provide extension and retraction of the boom when pushed in.
21. Swing Control Knobs (Hydraulic Controls Only).
An hourmeter, installed on a bracket mounted
above the ground control box, registers the amount
of time the machine has been in use, with the
engine running. The hourmeter registers up to
9,999.9 hours and cannot be reset.
The SWING control knobs provide 360 degree continuous turntable rotation. To activate swing, push in
the appropriate knob.
22. Start Button.
13. Ammeter.
An ammeter, installed on a bracket mounted above
the ground control box, indicates battery condition
(i.e. charging or discharging).
14. Oil Pressure Gauge.
The START button is a momentary contact, push
button type switch that supplies electrical power to
the starter solenoid, when the key switch and ignition switch are in the ON position and the start button is depressed.
An oil pressure gauge, installed on the bracket
mounted above the ground control box, provides
an indication of the engine lubricating oil pressure.
Normal operating pressure at 2000 rpm is 40 to 60
psi.
15. Engine Coolant Temperature Gauge.
An engine coolant temperature gauge installed on a
bracket above the ground control box, provides a
visual indication of the temperature of the engine
coolant.
16. Axle Set Indicator (If equipped).
The AXLE SET INDICATOR provides a visual indication that the extendable axles are properly set.
Some machines built prior to 1994 will have a red
indicator that lights up until the axles are extended
and the retaining pins are installed. Some machines
built prior to 1994 and all machines built after 1994
have a green indicator that lights up when the axles
3120890
– JLG Lift –
3-9
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
2. Power/Emergency Stop.
An on-off POWER/EMERGENCY STOP switch and
a separate START push button on the platform console supply electrical power to the starter solenoid,
when the power switch is pulled out to the “on”
position and the START button is depressed.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
WHEN RELEASED.
23. Rotate (If equipped).
3. Start Button.
The three position PLATFORM ROTATE control
switch permits rotation of the platform when positioned to LEFT or RIGHT.
24.
The START button is a momentary contact, pushbutton switch. With the POWER/EMERGENCY
STOP switch pulled up and the START button
depressed, electrical power is supplied to the start
solenoid.
Level.
The three position PLATFORM LEVEL control
switch allows the operator to compensate for any
difference in the automatic self leveling system by
positioning the control switch to UP or DOWN.
4. Warning Horn.
A push-type HORN switch, when pressed, supplies
electrical power to activate the horn.
5. Chassis Out of Level Warning Light.
Platform Station - May 1994 to Present
This red indicator lights to indicate that the chassis
is on a slope (over 5 degrees). If illuminated when
boom is raised or extended, retract and lower to
below horizontal then reposition the machine so
that it is level before extending the boom or raising
the boom above horizontal.
NOTE: Some machines are equipped with control panels
that use symbols to indicate control functions. Refer
to Figure 3-11., Common Symbols - Sheet 1, Figure
3-12., Common Symbols - Sheet 2, Figure 3-13.,
Common Symbols - Sheet 3, and Figure 3-14., Common Symbols - Sheet 4 for these symbols and the
corresponding functions.
NOTE: For engine starting, the footswitch must be in the
released (up) position. Footswitch must be actuated
in order for controls to function.
1. Footswitch.
This feature makes it necessary to depress the footswitch to allow operation of the controls.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
IF THE CHASSIS OUT OF LEVEL WARNING LIGHT IS ILLUMINATED WHEN THE BOOM IS RAISED OR EXTENDED, RETRACT
AND LOWER THE PLATFORM TO BELOW HORIZONTAL THEN
REPOSITION THE MACHINE SO IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING THE BOOM ABOVE HORIZONTAL.
NOTE: LIFT, SWING, and DRIVE control levers or switches
are spring-loaded and will automatically return to the
neutral (OFF) position when released.
TO AVOID SERIOUS INJURY, DO NOT OPERATE THE MACHINE IF
ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
THE PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR
NEUTRAL POSITION WHEN RELEASED.
THE FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS
WILL OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS
CENTER OF TRAVEL. IF THE SWITCH OPERATES WITHIN LAST 1/
4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.
3-10
– JLG Lift –
6. Lift.
The MAIN LIFT controller (proportional controls) or
MAIN LIFT control lever (hydraulic controls) provides raising and lowering of the boom when positioned to up or down.
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-6. Control Console - May 1994 to Present
3120890
– JLG Lift –
3-11
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
7. Telescope.
11. Wheel Speed.
The two position WHEEL SPEED control switch
allows the operator to select high wheel motor
speed when in the high position. When used in conjunction with high ENGINE SPEED, it gives the
machine a faster drive speed.
The MAIN TELESCOPE control switch or MAIN
TELESCOPE control lever (hydraulic controls) provides extension and retraction or the boom when
positioned to in or out.
8. Steer/Axles/Jack.
On standard machines, positioning the STEER/
AXLES/JACK control switch right or left enables
steering the machine to the right or to the left.
On machines equipped with hydraulic jacks and/or
hydraulic extendable axles, the function the switch
controls is dependent upon the position of the
JACK/STEER/AXLES SELECT switch.
TO AVOID PERSONNEL INJURY OR MACHINE DAMAGE, USE
SLOW FUNCTION SPEED CONTROL WHEN POSITIONING THE
PLATFORM IN CLOSE QUARTERS.
12. Pump Volume.
The two-position PUMP VOLUME control switch
allows the operator to select high pump flow, providing additional speed to all functions when in the
high position. When used in conjunction with high
ENGINE SPEED and WHEEL MOTOR SPEED
switches, it gives the machine a faster drive speed
range.
NOTE: On machines equipped with four wheel steering, the
drive controller will have a thumb-rocker switch controlling rear wheel steering.
9. Swing.
The SWING controller provides 360 degrees continuous swing when positioned to left or right.
NOTE: When the boom is above horizontal and if either the
ENGINE SPEED, PUMP VOLUME, or WHEEL
SPEED are positioned to high, high speed functions
are automatically cut out and the machine continues
to operate at a lower speed.
DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED, HIGH
WHEEL MOTOR SPEED, OR HIGH PUMP VOLUME OPERATE
WHEN BOOM IS ABOVE HORIZONTAL.
10. Engine Speed.
13. Creep.
The CREEP control switch allows the operator to
select a lower speed for DRIVE, LIFT, SWING and
TELESCOPE, when in the on position.
14. Drive.
The DRIVE controller provides driving either forward
or backward when positioned to forward or reverse.
The controller is ramped to allow infinitely variable
driving speed between fast and slow.
NOTE: On machines with four wheel steering, the Drive controller will have a thumb-rocker switch controlling
steer of the rear wheels.
15. Platform Level.
The two position ENGINE SPEED control switch
allows the operator to select higher function speeds
or higher drive speed when in the high position.
3-12
– JLG Lift –
The platform LEVEL control switch allows the operator to compensate for any difference in the automatic self-leveling system by positioning the switch
up or down.
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
16. Platform Rotate (If Equipped).
The platform ROTATE control switch allows operator to rotate the basket to the left or right when positioned to the desired direction.
NOTE: The main function of the 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 qualified service
technician.
17. Extend-A-Reach (If Equipped).
The EXTEND-A-REACH control switch allows operator to raise or lower the extend-a-reach, as
required.
18. Choke (If Equipped).
NOTE: Auxiliary power is primarily intended for platform lowering in the event of primary power failure. However,
auxiliary power may be used for platform positioning
when operating in close quarters in the following
sequence:
A push-button switch supplies power to the choke
solenoid for cold weather starting.
a. Position PLATFORM/GROUND switch to PLATFORM.
b. Pull the POWER/EMERGENCY STOP switch out
to the on position.
19. Glow Plug (If Equipped).
This push-button switch when depressed supplies
power to the diesel engine glow plugs for cold
weather start. See diesel engine operator manual
for instructions.
c. Depress and hold footswitch.
d. Operate appropriate control switch or lever for
desired function and hold.
e. Position AUXILIARY POWER switch on and hold.
20. Engine Distress Light (Red).
f. Release AUXILIARY POWER switch, selected
control switch or lever, and footswitch.
This indicator lights to notify the operator that the
engine has no oil pressure, is overheating (water or
oil), or is not producing voltage. The light will also
come on if the engine has stalled.
g. Push the POWER/EMERGENCY STOP switch to
the off position.
22. Jack/Steer/Axles Select Switch (If equipped).
21. Auxiliary Power.
The AUXILIARY POWER control switch energizes
the electrically operated hydraulic pump, when
actuated. The switch must be held on for duration of
auxiliary pump use.
The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine system should
the main pump or engine fail. The auxiliary pump
will operator boom lift, telescope and swing.
It should be noted that the functions will operate at
a slower than normal rate because of lower hydraulic flow.
When the machine in equipped with the optional
hydraulic jacks and/or hydraulic extendable axles,
this switch is used to select the function operated
by the STEER/AXLES/JACK control switch.
23. Axles Set Indicator (If equipped).
The green AXLES SET indicator lights to inform the
operator that the axles are set and locked (pinned)
in position.
24. Jack Select Switch (If equipped).
When the machine in equipped with the optional
hydraulic jacks, this switch is used to select the jack
to be operated; FRONT JACK or REAR JACK.
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE
MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
MOTOR.
3120890
– JLG Lift –
3-13
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
25. Lights Switch (If equipped).
3. Start Button.
The LIGHTS switch allows the operator to turn the
installed light options on or off.
The START button is a momentary contact, pushbutton switch. With the POWER/EMERGENCY
STOP switch pulled up and the START button
depressed, electrical power is supplied to the start
solenoid.
26. Capacity Indicator (If equipped).
The CAPACITY INDICATOR GAUGE is mounted on
the left side of the platform console. The indicator
scale is visible through a lens and indicates the
maximum platform load allowable at any given
boom angle and extension based on the color
stripe visible at the point where the fly boom enters
the mid boom.
4. Warning Horn.
A push-type HORN switch, when pressed, supplies
electrical power to activate the horn.
5. Chassis Out of Level Warning Light.
This red indicator lights to indicate that the chassis
is on a slope (over 5 degrees). If illuminated when
boom is raised or extended, retract and lower to
below horizontal then reposition the machine so
that it is level before extending the boom or raising
the boom above horizontal.
Platform Station - September 1991 to May
1994
NOTE: Some machines are equipped with control panels
that use symbols to indicate control functions. Refer
to Figure 3-11., Common Symbols - Sheet 1, Figure
3-12., Common Symbols - Sheet 2, Figure 3-13.,
Common Symbols - Sheet 3, and Figure 3-14., Common Symbols - Sheet 4 for these symbols and the
corresponding functions.
NOTE: For engine starting, the footswitch must be in the
released (up) position. Footswitch must be actuated
in order for controls to function.
1. Footswitch.
IF THE CHASSIS OUT OF LEVEL WARNING LIGHT IS ILLUMINATED WHEN THE BOOM IS RAISED OR EXTENDED, RETRACT
AND LOWER THE PLATFORM TO BELOW HORIZONTAL THEN
REPOSITION THE MACHINE SO THAT IT IS LEVEL BEFORE
EXTENDING THE BOOM OR RAISING THE BOOM ABOVE HORIZONTAL.
NOTE: LIFT, SWING, and DRIVE control levers or switches
are spring-loaded and will automatically return to the
neutral (OFF) position when released.
This feature makes it necessary to depress the footswitch to allow operation of the controls.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
TO AVOID SERIOUS INJURY, DO NOT OPERATE THE MACHINE IF
ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
6. Lift.
THE FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS
WILL OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS
CENTER OF TRAVEL. IF THE SWITCH OPERATES WITHIN LAST 1/
4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.
2. Power/Emergency Stop.
The MAIN LIFT controller provides raising and lowering of the boom when positioned to up or down.
7. Telescope.
The MAIN TELESCOPE control switch provides
extension and retraction or the boom when positioned to in or out.
An on-off POWER/EMERGENCY STOP switch and
a separate START push button on the platform console supply electrical power to the starter solenoid,
when the power switch is pulled out to the “on”
position and the START button is depressed.
3-14
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
1.
2.
3.
4.
5.
6.
Footswitch
Power/Emergency Stop
Start Button
Warning Horn
Chassis Out of Level Warning Light
Lift
7.
8.
9.
10.
11.
12.
Telescope
Steer/Axles/Jack
Swing
Engine Speed
Wheel Speed
Pump Volume
13.
14.
15.
16.
17.
18.
Creep
Drive
Platform Level
Platform Rotate
Extend-A-Reach
Choke
19.
20.
21.
22.
23.
24.
Glow Plug
Engine Distress Light
Auxiliary Power
Axles Set Indicator
Lights Switch
Capacity Indicator
Figure 3-7. Control Console - Sept. 91 to May 94
3120890
– JLG Lift –
3-15
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
8. 3333Steer/Axles.
On standard machines, positioning the STEER/
AXLES control switch right or left enables steering
the machine to the right or the left.
On machines equipped with hydraulic extendable
axles, the function the switch controls is dependent
upon the position of the lever on the STEER/AXLES
SELECTOR valve.
TO AVOID PERSONNEL INJURY OR MACHINE DAMAGE, USE
SLOW FUNCTION SPEED CONTROL WHEN POSITIONING THE
PLATFORM IN CLOSE QUARTERS.
12. Pump Volume.
The two-position PUMP VOLUME control switch
allows the operator to select high pump flow, providing additional speed to all functions when in the
high position. When used in conjunction with high
ENGINE SPEED and WHEEL MOTOR SPEED
switches, it gives the machine a faster drive speed
range.
NOTE: On machines equipped with four wheel steering, the
drive controller will have a thumb-rocker switch controlling rear wheel steering.
9. Swing.
The SWING controller provides 360 degrees continuous swing when positioned to left or right.
NOTE: When the boom is above horizontal and if either the
ENGINE SPEED, PUMP VOLUME, or WHEEL
SPEED are positioned to high, high speed functions
are automatically cut out and the machine continues
to operate at a lower speed.
DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED, HIGH
WHEEL MOTOR SPEED, OR HIGH PUMP VOLUME OPERATE
WHEN BOOM IS ABOVE HORIZONTAL.
10. Engine Speed.
13. Creep.
The CREEP control switch allows the operator to
select a lower speed for DRIVE, LIFT, SWING and
TELESCOPE, when in the on position.
14. Drive.
The DRIVE controller (provides driving either forward or backward when positioned to forward or
reverse. The controller is ramped to allow infinitely
variable driving speed between fast and slow.
NOTE: On machines with four wheel steering, the Drive controller will have a thumb-rocker switch controlling
steer of the rear wheels.
15. Platform Level.
The two position ENGINE SPEED control switch
allows the operator to select higher function speeds
or higher drive speed when in the high position.
The platform LEVEL control switch allows the operator to compensate for any difference in the automatic self-leveling system by positioning the switch
to UP or DOWN.
11. Wheel Speed.
The two position WHEEL SPEED control switch
allows the operator to select high wheel motor
speed when in the high position. When used in conjunction with high ENGINE SPEED, it gives the
machine a faster drive speed.
16. Platform Rotate (If Equipped).
The platform ROTATE control switch allows operator to rotate the basket to the left or right when positioned to the desired direction.
17. Extend-A-Reach (If Equipped).
The EXTEND-A-REACH control switch allows operator to raise or lower the extend-a-reach, as
required.
3-16
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
18. Choke (If Equipped).
A push-button switch supplies power to the choke
solenoid for cold weather starting.
19. Glow Plug (If Equipped).
NOTE: Auxiliary power is primarily intended for platform lowering in the event of primary power failure. However,
auxiliary power may be used for platform positioning
when operating in close quarters in the following
sequence:
This push-button switch when depressed supplies
power to the diesel engine glow plugs for cold
weather start. See diesel engine operator manual
for instructions.
a. Position PLATFORM/GROUND switch to PLATFORM.
b. Pull the POWER/EMERGENCY STOP switch out
to the on position.
20. Engine Distress Light (Red).
c. Depress and hold footswitch.
This indicator lights to notify the operator that the
engine has no oil pressure, is overheating (water or
oil), or is not producing voltage. The light will also
come on if the engine has stalled.
d. Operate appropriate control switch or lever for
desired function and hold.
e. Position AUXILIARY POWER switch on and hold.
f. Release AUXILIARY POWER switch, selected
control switch or lever, and footswitch.
21. Auxiliary Power.
The AUXILIARY POWER control switch energizes
the electrically operated hydraulic pump, when
actuated. The switch must be held on for duration of
auxiliary pump use.
The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine system should
the main pump or engine fail. The auxiliary pump
will operator boom lift, telescope and swing.
It should be noted that the functions will operate at
a slower than normal rate because of lower hydraulic flow.
g. Push the POWER/EMERGENCY STOP switch to
the off position.
22. Axles Set Indicator (If equipped).
The green AXLES SET indicator lights to inform the
operator that the axles are set and locked (pinned)
in position.
23. Lights Switch (If equipped).
The LIGHTS switch allows the operator to turn the
installed light options on or off.
24. Capacity Indicator (If equipped).
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE
MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
MOTOR.
NOTE: The main function of the 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 qualified service
technician.
3120890
– JLG Lift –
The CAPACITY INDICATOR GAUGE is mounted on
the left side of the platform console. The indicator
scale is visible through a lens and indicates the
maximum platform load allowable at any given
boom angle and extension based on the color
stripe visible at the point where the fly boom enters
the mid boom.
3-17
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Platform Station - Hydraulic Controls
3. Start Button.
The START button is a momentary contact, pushbutton switch. With the IGNITION/EMERGENCY
STOP switch pulled up and the START button
depressed, electrical power is supplied to the start
solenoid.
NOTE: For engine starting, the footswitch must be in the
released (up) position. Footswitch must be actuated
in order for controls to function.
1. Footswitch.
4. Warning Horn.
This feature makes it necessary to depress the footswitch to allow operation of the controls.
A push-type HORN switch, when pressed, supplies
electrical power to activate the horn.
5. Tilt Alarm Warning Light.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
THE FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS
WILL OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS
CENTER OF TRAVEL. IF THE SWITCH OPERATES WITHIN LAST 1/
4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.
2. Ignition/Emergency Stop.
An ON-OFF IGNITION/EMERGENCY STOP switch
and a separate START push button on the platform
console supply electrical power to the starter solenoid, when the ignition switch is pulled out to the
“IGNITION ON” position and the START button is
depressed.
3-18
This red indicator lights to indicate that the chassis
is on a slope (over 5 degrees). If illuminated when
boom is raised or extended, retract and lower to
below horizontal then reposition the machine so it is
level before extending boom or raising boom above
horizontal.
IF THE TILT ALARM IS ILLUMINATED WHEN BOOM IS RAISED OR
EXTENDED, RETRACT AND LOWER THE PLATFORM TO BELOW
HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL
BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-8. Control Console - Hydraulic Controls May 1994 to Present
3120890
– JLG Lift –
3-19
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-9. Control Console - Hydraulic Controls Prior to May 1994
3-20
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
NOTE: LIFT, SWING, and DRIVE control levers or switches
are spring-loaded and will automatically return to the
neutral (OFF) position when released.
10. Engine Speed.
TO AVOID SERIOUS INJURY, DO NOT OPERATE THE MACHINE IF
ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
11. Wheel Speed.
The two position HIGH ENGINE speed control
switch allows the operator to select higher function
speeds or higher drive speed when positioned to
HIGH.
The two position WHEEL SPEED control switch
allows the operator to select high wheel motor
speed when positioned to HIGH. When used in conjunction with HIGH ENGINE speed, it gives the
machine a faster drive speed.
6. Lift.
The LIFT control lever provides raising and lowering
of the boom when positioned to UP or DOWN.
7. Telescope.
The TELESCOPE control lever provides extension
and retraction or the boom when positioned to IN or
OUT.
TO AVOID PERSONNEL INJURY OR MACHINE DAMAGE, USE
SLOW FUNCTION SPEED CONTROL WHEN POSITIONING THE
PLATFORM IN CLOSE QUARTERS.
12. Pump Volume.
8. Steer/Axles.
The two-position PUMP VOLUME control switch
allows the operator to select high pump flow, providing additional speed to all functions when positioned to HIGH. When used in conjunction with high
HIGH ENGINE and WHEEL MOTOR SPEED
switches, it gives the machine a faster drive speed
range.
On standard machines, positioning the STEER/
AXLES control switch right or left enables steering
the machine to the right or to the left.
On machines equipped with hydraulic extendable
axles, the function the switch controls is dependent
upon the position of the lever on the STEER/AXLES
SELECTOR valve. Ignition/Emergency Stop.
13. Drive.
9. Swing.
The SWING control lever provides 360 degrees
continuous swing when positioned to LEFT or
RIGHT.
NOTE: When the boom is above horizontal and if either the
ENGINE SPEED, PUMP VOLUME, or WHEEL
MOTOR SPEED are positioned to HIGH, high speed
functions are automatically cut out and the machine
continues to operate at a lower speed.
The DRIVE control lever provides driving either forward or backward when positioned to FORWARD or
REVERSE.
14. Platform Level.
The PLATFORM LEVEL control switch allows the
operator to compensate for any difference in the
automatic self-leveling system by positioning the
switch to UP or DOWN.
15. Platform Rotate (If Equipped).
The PLATFORM ROTATE control switch allows
operator to rotate the basket to the left or right when
positioned to the desired direction.
DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED, HIGH
WHEEL MOTOR SPEED, OR HIGH PUMP VOLUME OPERATE
WHEN BOOM IS ABOVE HORIZONTAL.
3120890
16. Choke (If Equipped).
– JLG Lift –
A push-button switch supplies power to the choke
solenoid for cold weather starting.
3-21
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
17. Glo-Plug (If Equipped).
d. Operate appropriate control switch or lever for
desired function and hold.
This push-button switch when depressed supplies
power to the diesel engine glow plugs for cold
weather start. See diesel engine operator manual
for instructions.
e. Position AUXILIARY POWER switch to ON and
hold.
f. Release AUXILIARY POWER switch, selected
control switch or lever, and footswitch.
18. Auxiliary Power.
g.
The AUXILIARY POWER control switch energizes
the electrically operated hydraulic pump, when
actuated. The switch must be held ON for duration
of auxiliary pump use.
The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine system should
the main pump or engine fail. The auxiliary pump
will operator boom lift, telescope and swing.
Position IGNITION/EMERGENCY STOP switch
to OFF.
19. Lights Switch (If equipped).
The LIGHTS switch allows the operator to turn the
installed light options (except beacon light) on or
off.
20. Axles Set Indicator (If equipped).
The red Axles Set or red Axles Not Set indicator illuminates until the axles are properly extended and
locked. The green Axles Set indicator lamp illuminates when the axles are extended and locked.
It should be noted that the functions will operate at
a slower than normal rate because of lower hydraulic flow.
21. 2 Wheel Drive/4 Wheel Drive.
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 two position 2 WHL DRIVE/4 WHL DRIVE control switch allows the operator to select high speed
(2 WHEEL DRIVE) or low speed (4 WHEEL DRIVE).
22. Beacon Switch (If equipped).
NOTE: The main function of the 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 qualified service
technician.
NOTE: Auxiliary power is primarily intended for platform lowering in the event of primary power failure. However,
auxiliary power may be used for platform positioning
when operating in close quarters in the following
sequence:
The BEACON switch allows the operator to turn the
beacon light on or off.
23. Capacity Indicator (If equipped).
The CAPACITY INDICATOR GAUGE is on the left
side of the platform console. The indicator scale is
visible through a lens and indicates the maximum
platform load allowable at any given boom angle
and extension based on the color stripe visible at
the point where the fly boom enters the mid boom.
Steer/Axle Selector Valve
a. Position PLATFORM/GROUND switch to PLATFORM.
b. Position IGNITION/EMERGENCY STOP switch
to ON.
A two-position selector valve, located on the frame
adjacent to the right front wheel, regulates oil flow
for the steer and axle circuit. The valve handle must
be positioned to AXLE for axle extension and to
STEER for normal operation.
c. Depress and hold footswitch.
3-22
– JLG Lift –
3120890
Figure 3-10. Caution, Danger, Warning Decal Location
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3120890
– JLG Lift –
3-23
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
!
CAUTION
THIS MACHINE MUST ONLY BE
OPERATED BY TRAINED PERSONNEL.
SWL=230KG
REFERENCES SHOULD BE MADE TO THE
OPERATORS HANDBOOK TO ENSURE
SAFE OPERATION OF THE MACHINE.
2 PERSONS + 70KG
DAILY CHECK LIST
MAX FORCE= 400N
1. CHECK TYRES - PRESSURE AND CONDITION.
2. CHECK BOOM AND AXLE CUT-OUT SWITCHES.
3. CHECK SAFETY BELTS.
1690697 B
4. CHECK ALL OPERATIONS FOR MALFUNCTION.
MAX. : 12.5 m/s
5. CHECK BRAKES
6. CHECK OPERATORS HANDBOOK IS WITH MACHINE.
7. DO NOT OPERATE MALFUNCTIONING MACHINE.
P/N 1690697 B
8. CHECK ENGINE AND DRIVE SPEED CUT-OUT SWITCHES.
9. MAXIMUM OPERATING SLOPE: 3°
BEWARE LIVE ELECTRICAL
CONDUCTORS. CONTACT
LOCAL ELECTRICITY
AUTHORITIES TO ENSURE
ADEQUATE CLEARANCES.
THIS MACHINE IS NOT ELECTRICALLY
INSULATED.
1691483
1701518
P/N 1691483 C
P/N 1701518
DAILY CHECK LIST
1. CHECK TYRES - PRESSURE AND CONDITION.
2. CHECK BOOM AND AXLE CUT-OUT SWITCHES.
CAUTION
3. CHECK SAFETY BELTS.
4. CHECK ALL OPERATIONS FOR MALFUNCTION.
5. CHECK BRAKES
6. CHECK OPERATORS HANDBOOK IS WITH MACHINE.
7. DO NOT OPERATE MALFUNCTIONING MACHINE.
8. CHECK ENGINE AND DRIVE SPEED CUT-OUT SWITCHES.
THIS MACHINE MUST ONLY BE
OPERATED BY TRAINED PERSONNEL.
REFERENCES SHOULD BE MADE TO THE
OPERATORS HANDBOOK TO ENSURE
SAFE OPERATION OF THE MACHINE.
9. MAXIMUM OPERATING SLOPE: 3°
BEWARE LIVE ELECTRICAL
CONDUCTORS. CONTACT
LOCAL ELECTRICITY
AUTHORITIES TO ENSURE
ADEQUATE CLEARANCES.
THIS MACHINE IS NOT ELECTRICALLY
INSULATED.
1690696
P/N 1690696 C
3-24
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-11. Common Symbols - Sheet 1
3120890
– JLG Lift –
3-25
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-12. Common Symbols - Sheet 2
3-26
– JLG Lift –
3120890
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-13. Common Symbols - Sheet 3
3120890
– JLG Lift –
3-27
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-14. Common Symbols - Sheet 4
3-28
– JLG Lift –
3120890
SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION
4.1
DESCRIPTION
This machine is a self-propelled aerial work platform on
the end of an elevating, telescoping and rotating boom.
The JLG Lift’s intended purpose is to position personnel
with their tools and supplies at positions above ground
level. The machine can be used to reach work areas
located above and over machinery or equipment.
The JLG Lift has a primary operator Control Station 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, lower, extend or retract the
boom; swing the boom to the left or right; and when
equipped with a platform rotator, can rotate the platform
around the boom end. Standard boom swing is 360° 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,
telescope and swing and are to be used only in an emergency to lower the platform to the ground should the
operator in the platform be unable to do so.
Instruction and hazard warnings are posted adjacent to
both operator control stations and at other places on the
machine. It is extremely important that operators know
what instructions and warnings are placed on the
machine, and review these periodically so that they are
fresh in their minds. 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 70 dB(A).
The JLG Lift is designed to provide efficient and safe operation when maintained and operated in accordance with
warnings on the machine, in the Operators and Safety
Manual, and all jobsite and government rules and regulations. As with any type of machinery, the operator is very
important to efficient and safe operation. It is absolutely
necessary that the JLG Lift be regularly maintained in
accordance with this manual and the machine Service
and Maintenance manual, and that any evidence of lack of
maintenance, malfunction, excessive wear, damage or
modification to the machine be reported immediately to
the machine owner or the jobsite supervisor or safety
manager and that the machine be taken out of service
until all discrepancies are corrected.
3120890
The JLG Lift is not intended to be used to lift material other
than supplies which personnel in the platform require to
do their job. Supplies or tools which extend outside the
platform are prohibited. It must not be used as a forklift,
crane, support for overhead structure, or to push or pull
another object.
The machine is equipped with an auxiliary battery operated power unit which will provide hydraulic power in the
event of a primary engine power loss. Auxiliary power can
be controlled from either the Platform Control Station or
the Ground Control Station. Follow the instructions placed
at the control stations.
The JLG Lift is hydraulically powered using hydraulic
motors and cylinders for various machine motions. The
hydraulic components are controlled by electrically activated hydraulic valves using switches and control levers.
The speeds of functions controlled by control levers are
variable from zero to maximum speed depending upon
the position of the control lever. Functions controlled by
toggle switches are either on or off and higher or lower
speed is possible when the Function Speed control switch
is used in conjunction with the function toggle switch. A
foot operated switch in the platform must be depressed
before any controls will function and provides a means of
emergency stop when the operator’s foot is removed from
the footswitch.
The JLG Lift is a two wheel drive (four wheel drive available) machine with drive power being supplied by a
hydraulic motor for each drive wheel. Each drive wheel is
supplied with a hydraulically released, spring-applied
brake. The swing drive is also equipped with such a
brake. These brakes are automatically applied any time
the Drive or Swing Control lever are returned to the neutral
position.
The unrestricted capacity of the JLG Lift is 230 kg. This
means that with a platform load of 230 kg or less, the platform may be positioned anywhere the boom will reach.
4.2
GENERAL
This section provides the necessary information needed
to operate the machine. Included in this section are the
procedures for starting, stopping, traveling, steering, parking, platform loading and transporting. It is important that
the user read and understand the proper procedures
before operating the machine.
– JLG Lift –
4-1
SECTION 4 - MACHINE OPERATION
4.3
Shutdown Procedure
ENGINE OPERATION
NOTE: Initial starting should always be performed from the
Ground Control station.
Starting Procedure
IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED
SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE
RESUMING ANY OPERATION.
1. Check engine oil. If necessary, add oil in accor-
1. Remove all load and allow engine to operate at
dance with the Engine Manufacturer’s manual.
low speed setting for 3-5 minutes; this allows
for further reduction of internal engine temperature.
2. Check fuel level. Add fuel if necessary.
3. Check that air cleaner components are in place
2. Position IGNITION switch to OFF .
and securely fastened.
3. Turn key of MASTER Switch to OFF position.
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN
EXTENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE
AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF
ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE
MAINTENANCE MANUAL.
NOTE: Refer to Engine Manufacturer’s manual for detailed
information.
4.4
TRAVELING (DRIVING)
4. Place ENGINE SPEED control switch on plat-
form console to LOW position.
5. Turn key of CONTROL SELECTION switch to
GROUND. Position IGNITION switch to ON,
then push the START switch to the upward
position until engine starts.
ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW
SPEED BEFORE APPLYING ANY LOAD.
6. After engine has had sufficient time to warm
up, shut engine off.
7. Turn key of CONTROL SELECTION switch to
PLATFORM.
8. From Platform position IGNITION
switch to
ON, then push the START switch to the forward
position until engine starts.
DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL
EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.
TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES
AND SIDE SLOPES, DO NOT DRIVE MACHINE ON GRADES OR
SIDE SLOPES EXCEEDING THOSE SPECIFIED ON THE SERIAL
NUMBER NAME PLATE.
ASSURE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGINNING ANY EXTENDED TRAVELING. AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE TO UPSET.
TRAVEL GRADES IN “LOW” WHEEL MOTOR SPEED AND “HIGH”
ENGINE SPEED ONLY. USE EXTREME CAUTION WHEN DRIVING
IN REVERSE AT ALL TIMES WHEN DRIVING WITH PLATFORM
ELEVATED AND ESPECIALLY WHEN DRIVING WITH ANY PART OF
MACHINE WITHIN 2 M OF AN OBSTRUCTION. DO NOT USE DRIVE
TO MANEUVER PLATFORM CLOSE TO AN OBSTRUCTION....USE
ONE OF THE BOOM FUNCTIONS.
NOTE: The footswitch must be in released (up) position
before starter will operate. If starter operates with
footswitch in the depressed position, DO NOT
OPERATE THE MACHINE.
4-2
– JLG Lift –
3120890
SECTION 4 - MACHINE OPERATION
BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER
REAR AXLE. IF BOOM IS OVER FRONT AXLE (STEER WHEELS),
STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE CONTROLS.
NOTE: For smoother operation when driving with fully
extended boom, place DRIVE control to SLOW
before stopping.
4.5
STEERING
Depress footswitch to steer machine, push on the left side
of the switch to steer left, on the right side to steer right.
Traveling Forward or Reverse
1. With engine running, depress footswitch and
position DRIVE control to FORWARD and hold
for the duration of forward travel desired.
NOTE: When DRIVE or STEER functions are being operated there is an interlock which prevents operation of
boom functions.
2. Depress footswitch and position DRIVE control
to REVERSE and hold for duration of reverse
travel desired.
NOTE: On machines with four wheel steering, the drive controller will have a thumb-rocker switch controlling the
rear drive wheels.
BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSITIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE
(STEER WHEELS), STEER AND DRIVE CONTROLS WILL MOVE IN
OPPOSITE DIRECTION THAN INDICATED ON MACHINE PLACARDS.
3. Depress footswitch and position STEER con-
trol to RIGHT for traveling right and LEFT for
traveling left.
4.6
Park and stow machine as follows:
4. To obtain maximum travel speed, position the
1. Park machine in travel position; boom lowered
DRIVE controller to FAST and activate the following switches:
over rear, all access panels and doors closed
and secured, ignition off, turntable locked.
a. Position ENGINE SPEED switch to HIGH.
2. Check that brakes hold machine in position.
b. Position WHEEL SPEED switch to HIGH.
3. Chock wheels front and rear.
c. Position PUMP VOLUME switch to HIGH.
5. Prior
to stopping
switches as follows:
the
machine,
4. Turn off SELECT switch and remove key.
position
4.7
a. Position ENGINE SPEED switch to LOW.
b. Position WHEEL SPEED switch to LOW.
PLATFORM
Loading From Ground Level
c. Position PUMP VOLUME switch to LOW.
1. Position chassis on a smooth, firm and level
6. 6. For traveling up grades, position switches as
follows:
a. Position ENGINE SPEED switch to HIGH.
b. Position WHEEL SPEED switch to LOW.
c. Position PUMP VOLUME switch to LOW.
3120890
PARKING AND STOWING
– JLG Lift –
surface.
2. If total load (personnel, tools and supplies) is
less then rated capacity, distribute load uniformly on platform floor and proceed to work
position.
4-3
SECTION 4 - MACHINE OPERATION
Figure 4-1. Grade and Side Slope
Loading From Positions Above Ground
Level
Platform Level Adjustment
1. Leveling UP. Depress footswitch to raise plat-
Before loading weight to platform above ground level:
1. Determine what the total rated capacity weight
form, position PLATFORM LEVEL control
switch UP and hold until platform is level.
will be after additional weight is loaded (personnel, tools and supplies).
2. Leveling DOWN. Depress footswitch to lower
platform, position PLATFORM LEVEL control
switch to DOWN and hold until platform is
level.
2. If total weight in platform will be less then rated
capacity, proceed with adding weight.
Platform Rotation
1. Depress footswitch to rotate platform to the left,
PLATFORM ROTATE control is positioned to the
LEFT and held until desired position is reached.
2. Depress footswitch to rotate platform to the
right, PLATFORM ROTATE control is positioned to the RIGHT and held until desired
position is reached.
4-4
– JLG Lift –
3120890
SECTION 4 - MACHINE OPERATION
4.8
Swinging the Boom
BOOM
A RED TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE
SLOPE (3 DEGREES OR GREATER). DO NOT SWING, EXTEND OR
RAISE BOOM ABOVE HORIZONTAL WHEN LIT.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR
THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A
SEVERE SLOPE (3 DEGREES OR GREATER). CHASSIS MUST BE
LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM
ABOVE HORIZONTAL.
ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE
STARTING ANY SWING OPERATION.
Depress footswitch to swing boom, position SWING control switch or controller to RIGHT or LEFT for direction
desired.
NOTE: When boom functions are being operated there is an
interlock that prevents the use of DRIVE and STEER
functions.
Raising and Lowering the Main Boom
TO AVOID UPSET, IF RED TILT ALARM WARNING LIGHT LIGHTS
WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND
LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS
LEVEL BEFORE EXTENDING OR RAISING BOOM.
TRAVELING WITH BOOM RETRACTED AND BELOW HORIZONTAL
IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON
CAUTION PLACARD AT PLATFORM.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF
ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
To raise and lower Boom, position LIFT control switch or
controller to UP OR DOWN and hold until desired height is
reached.
Telescoping the Main Boom
To extend or retract Boom, position TELESCOPE control
switch to IN or OUT and hold until platform reaches
desired position.
4.9
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT
STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED,
REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP
TO STOP THE MACHINE.
SHUT DOWN AND PARK
1. Drive machine to a protected area.
2. Position HIGH ENGINE speed control switch
on Platform Control Console to LOW.
3. Assure main boom is fully retracted and low-
ered over rear (Drive) axle; all access panels
and doors closed and secured.
4. Remove all load and allow engine to operate 3-
5 minutes at LOW setting to permit reduction of
engine internal temperatures.
5. At Ground Controls, turn MASTER SWITCH to
(center) OFF. Position, the IGNITION switch
(down) to OFF.
6. Cover the Platform Control Console to protect
instruction placards, warning decals and operating controls from hostile environment.
3120890
– JLG Lift –
4-5
SECTION 4 - MACHINE OPERATION
4. Position LIFT control to DOWN and hold until
4.10 TIE DOWN AND LIFTING
drive wheels rise from the ground; it may be
necessary to feather the lift control to maintain
drive wheel elevation.
When transporting machine, boom must be in the stowed
mode with turntable lock pin engaged and machine
securely tied down to truck or trailer deck. Four tie down
eyes are provided in the frame slab, one at each corner of
the machine.
5. With the aid of an assistant, position EXTEND-
ABLE AXLE/STEER switch located on platform
control console to LEFT until axles are fully
extended. On machines with fixed axles, install
axle lock pins.
If it becomes necessary to lift the machine using an overhead or mobile crane, it is very important that the lifting
devices are attached only to the designated lifting eyes,
and that the turntable lock pin is engaged. See Figure 42, Lifting Chart.
6. Position LIFT control to UP to lower the
machine; elevate the boom sufficiently and
reposition the boom over the steer wheel end
of the machine.
NOTE: Lifting eyes are provided at the front of the frame
slab and rear of the turntable. Each of the four
chains or slings used for lifting machine must be
adjusted individually so machine remains level when
elevated.
SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/
TRAILER.
7. On machines with fixed axles, remove the tie
rod lock pins, steer cylinder lock pin, and axle
lock pins.
NOTE: On machines equipped with Soft Touch Proximity
System, the operator must press and hold the override button on the front of the control box in order to
lift the steer wheels from the ground.
8. Position LIFT control to DOWN and hold until
the steer wheels rise from the ground; it may
be necessary to feather the LIFT control to
maintain wheel elevation.
4.11 AXLES, EXTENDING AND RETRACTING
NOTE: Throughout the text, there are references made to
fixed axle machines. Fixed axle machines have
retaining pins for the axles, steer cylinders, and tie
rods. Machines equipped with oscillating axles do
not have these retaining pins and all extending and
retracting operations are performed from the platform without the aid of an assistant.
9. With the aid of an assistant, position EXTEND-
ABLE AXLE/STEER switch on platform console
to LEFT until axles are fully extended.
10. On machines with fixed axles, align steer
wheels and insert tie rod lock pin, axle lock
pins, and steer cylinder lock pins.
Machines Without Jacks
11. Position LIFT control to UP to lower the
1. From ground control, activate the machine
hydraulic system. Raise the boom and extend
the boom no more than 2.4 meters.
2. Position STEER/AXLES valve, located adjacent
to right front wheel, to AXLES.
3. Position
boom over drive wheel end of
machine. On machines with fixed axles,
remove axle lock pins.
machine steer wheels; position STEER/AXLES
valve to STEER.
12. On machines with fixed axles, cycle steer system in both directions to ensure tie rod and
steer cylinder are properly locked. You are now
ready to operate all machine functions.
D O N O T U S E E X T E N D - A - R E A C H ( I F E Q U I P P E D ) TO LI FT
MACHINE WHEN EXTENDING AND RETRACTING AXLES.
NOTE: On machines equipped with Soft Touch Proximity
System, the operator must press and hold the override button on the front of the control box in order to
lift the drive wheels from the ground.
4-6
– JLG Lift –
3120890
Figure 4-2. Lifting Chart
SECTION 4 - MACHINE OPERATION
3120890
– JLG Lift –
4-7
SECTION 4 - MACHINE OPERATION
13. To retract extendable axles:
k. On machines with fixed axles, cycle the steer
system in both directions to ensure the tie rods
are properly locked.
a. Position STEER/AXLES valve located adjacent
to right front wheel to AXLES.
b. Activate the machine hydraulic system and raise
the boom and extend the boom no more than
2.4 meters.
c. Position the boom over the steer wheel end of
the machine; on machines with fixed axles,
remove tie rod lock pins, steer cylinder pin and
axle lock pins.
Machines With Jacks
NOTE: For machines equipped with a front jack only, refer to
the instructions under Machines Without Jacks to
extend the rear axle.
1. Position STEER/AXLES valve, located adjacent to
right front wheel, to AXLES.
NOTE: It may be necessary to elevate the wheels and jog
the steer control for removal of lock pins.
2. Position the Jack/Steer/Axles Select switch on the
Platform control console to JACK.
NOTE: On machines equipped with Soft Touch Proximity
System, the operator must press and hold the override button on the front of the control box in order to
lift the steer wheels from the ground.
3. On machines with fixed axles, remove the axle lock
pins on the applicable axle. If extending the steer
axle, also remove the tie rod lock pins and steer cylinder lock pin.
4. Position the Jack Select Switch to either FRONT
JACK or REAR JACK and position the JACK control
switch to down and hold until the wheels on the
selected axle rise from the ground.
d. Position the LIFT control to DOWN and hold until
the steer wheels rise from the ground; it may be
necessary to feather the LIFT control to maintain
wheel elevation.
5. Position the Jack/Steer/Axles Select switch to
AXLES. Then, position the Steer/Axles/Jack control
switch to left until the axles are fully extended. On
machines with fixed axles, install axle lock pins. If
extending the steer axle, also install the tie rod lock
pins and steer cylinder lock pin.
e. Position EXTENDABLE AXLE/STEER switch
located on platform control console to RIGHT,
until axles are fully retracted.
f. On machines with fixed axles, align steer wheels
and insert tie rod lock pins and steer cylinder
pin. Install axle lock pins.
g. Position LIFT control to UP to lower the
machine; elevate the boom sufficiently and reposition the boom over the drive wheel end of the
machine.
ENSURE THE JACK IS FULLY RETRACTED BEFORE OPERATING
THE MACHINE. FAILURE TO DO SO COULD RESULT IN DAMAGE
TO THE MACHINE.
NOTE: On machines equipped with Soft Touch Proximity
System, the operator must press and hold the override button on the front of the control box in order to
lift the drive wheels from the ground.
6. Position the JACK control to the up position to lower
the machine. Ensure the jack is fully retracted before
operating the machine.
7. Repeat steps 2 thru 6 and extend the opposite axle.
h. Position LIFT control to DOWN and hold until the
drive wheels rise from the ground; it may be necessary to feather the LIFT control to maintain
drive wheel elevation.
i. Position EXTENDABLE AXLES/STEER switch,
on platform control console, to RIGHT, until axles
are fully retracted. On machines with fixed axles,
install axle lock pins.
8. Position the STEER/AXLES valve to STEER.
9. On machines with fixed axles, cycle the steer system
in both directions to ensure the tie rod and steer cylinder are properly locked.
j. Position LIFT control to UP to lower the machine
drive wheels; position STEER/AXLES valve to
STEER.
4-8
– JLG Lift –
3120890
SECTION 4 - MACHINE OPERATION
4. Place DRIVE control lever to FORWARD position
and carefully drive machine up ascension ramp until
left front wheel is on top of block.
10. You are now ready to operate all machine functions.
11. To retract extendable axles:
a. Position STEER/AXLES valve located adjacent
to right front wheel to AXLES.
5. Carefully activate SWING control lever and position
boom over right side of machine.
b. On machines with fixed axles, if retracting the
drive axles, remove the axle lock pins. If retracting the steer axles, remove the tie rod lock pins,
steer cylinder pin and axle lock pins.
6. With boom over right side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.
NOTE: It may be necessary to elevate the wheels and jog
the steer control for removal of lock pins.
7. Have an assistant check to see that left front wheel
remains locked in position off of ground.
c. Position the Jack Select Switch to either FRONT
JACK or REAR JACK and position the JACK
control switch to down and hold until the wheels
on the selected axle rise from the ground.
8. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). After boom reaches stowed position, activate DRIVE and lockout cylinders should release
and allow wheel to rest on ground.
d. Position Steer/Axles/Jack control switch located
on platform control console to the right, until
axles are fully retracted.
e. On machines with fixed axles, if retracting the
steer axles, align the steer wheels and insert the
tie rod lock pins and steer cylinder pin. Install
axle lock pins.
9. Place the 15 cm high block with ascension ramp in
front of right front wheel.
10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right
front wheel is on top of block.
ENSURE THE JACK IS FULLY RETRACTED BEFORE OPERATING
THE MACHINE. FAILURE TO DO SO COULD RESULT IN DAMAGE
TO THE MACHINE.
11. Carefully activate SWING control lever and position
boom over left side of machine.
f. Position the JACK control switch to the UP position to lower the machine. Ensure the jack is fully
retracted before operating the machine.
12. With boom over left side of machine, place DRIVE
control lever to REVERSE and drive machine off of
block and ramp.
g. Repeat steps b thru f and retract the axles at the
opposite end of the machine.
4.12 OSCILLATING AXLE LOCKOUT TEST (IF
EQUIPPED)
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY,
ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN
IMPROPER SYSTEM OPERATION IS SUSPECTED.
13. Have an assistant check to see that right front wheel
remains locked in position off of ground.
14. Carefully activate SWING control lever and return
boom to stowed position (centered between drive
wheels). After boom reaches stowed position, activate DRIVE and lockout cylinders should release
and allow wheel to rest on ground.
15. If lockout cylinders do not function properly, have
qualified personnel correct the malfunction prior to
any further operation.
NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test.
1. Place a 15 cm high block with ascension ramp in
front of left front wheel.
2. From platform control station, start engine .
3. Place ENGINE SPEED, WHEEL MOTOR SPEED,
and PUMP VOLUME control switches to their
respective LOW positions.
3120890
– JLG Lift –
4-9
SECTION 4 - MACHINE OPERATION
4.13 STEER/TOW SELECTOR (IF EQUIPPED)
After towing the machine, complete the
following:
DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH
COMPLETE TOW PACKAGE FROM MANUFACTURER.
A push-pull type selector valve located adjacent to the
steer cylinder assembly and linkage regulates oil flow in
the steer circuit for steering and towing applications.
When steering the unit (self-propelled operation) the valve
knob is pushed IN. When towing the unit the valve knob is
pulled OUT to the float position.
1. Actuate steer/tow selector valve for steering; push
valve knob IN to the actuated position.
2. Reconnect drive hubs by inverting disconnect cap.
(See Figure 4-2.)
3. Disconnect towbar from steering hitch and from towing vehicle. The machine is now in the driving mode.
4.14 TOWING (IF EQUIPPED)
DISCONNECT
CAP
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.
DRIVE
HUB
Drive Hub Engaged
MAXIMUM TOWING SPEED 8 K.M.H.
Prior to towing the machine, complete the
following:
DISCONNECT
CAP
(REVERSED)
DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE
HUBS ENGAGED.
DRIVE
HUB
Drive Hub Disconnected
1. Retract, lower and position boom over rear drive
wheels in line with direction of travel; lock turntable.
2. Connect towbar to front of frame with attach pins,
and towbar to towing vehicle.
Figure 4-3. Drive Disconnect Hub
3. Disconnect drive hubs by inverting disconnect cap.
(See Figure 4-2.)
4. Actuate steer/tow selector valve for towing; pull
valve knob OUT to float position. (This opens the
steer circuit to reservoir, allowing the steer cylinder
rod free travel.) The machine is now in the towing
mode.
4-10
– JLG Lift –
3120890
SECTION 5 - OPTIONAL EQUIPMENT
SECTION 5. OPTIONAL EQUIPMENT
5.1
Changing From LP Gas to Gasoline.
ROTATOR
1. With engine operating on LP under a no-load condition, position DUAL FUEL switch at Ground Control
Station to GASOLINE position.
A Platform rotator allows for platform rotation 90 degrees
from center in either direction. The rotator is designed to
give added jobsite versatility. The platform should be
returned to the center position for all other operations.
5.2
2. If engine stumbles because of lack of gasoline,
place the switch to LP position until engine regains
smoothness, then return switch to GASOLINE position. Repeat as necessary until engine runs
smoothly on gasoline.
DUAL FUEL SYSTEM (GAS ENGINE
ONLY)
3. Close hand valve on LP gas supply tank by turning
clockwise.
Description
The dual fuel system enables the standard gasoline
engine to run on either gasoline or LP gas. The system
includes pressurized cylinders mounted on the frame, and
the valves and switches needed to switch the fuel supply
from gasoline to LP gas or from LP gas to gasoline.
A two position, FUEL toggle switch at the ground control
station supplies electrical power to open the LP gas shutoff solenoid and close the LP gas shut off solenoid when
positioned to the GASOLINE position. This switch supplies electrical power to open the LP gas shut-off solenoid
and close the gasoline shut-off solenoid when positioned
to the LP position.
5.3
The oscillating front axle is attached to the frame by a
pivot pin which allows all four wheels to remain on the
ground when traveling on rough terrain. The oscillating
axle also incorporates two lockout cylinders connected
between the frame and each wheel end. The lockout cylinders permit axle oscillation when the boom is centered
over the rear, and lock and hold the axle when the boom is
moved off center.
5.4
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.
TOW PACKAGE
The tow package is required when it is necessary to move
the machine without use of the drive and steer system.
TOWING IS PERMITTED ONLY FOR EMERGENCY TRAVEL ON THE
JOBSITE. NO HIGHWAY TOWING IS PERMITTED.
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.
BE SURE GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP
GAS. SEE STEP (3) BELOW.
3. While engine is operating, place DUAL FUEL switch
at Ground Control to center OFF position. Allow
engine to operate without load, until engine begins
to stumble from lack of gasoline. As engine begins
to stumble, place the switch to LP position, allowing
LP gas to flow to the fuel regulator.
3120890
OSCILLATING AXLE
The towing package consists of the tow bar, attaching
hardware, a tow bar which connects to the eyes on front
of frame and the towing vehicle, and a tow/steer selector
valve which permits the steering system to ‘float free’
when towing the machine.
5.5
FOUR WHEEL DRIVE
Provides drive motors, brakes and torque hubs at each
wheel to give extra traction. The system is a full time four
wheel drive system and is available with either a fixed or
oscillating front axle.
– JLG Lift –
5-1
SECTION 5 - OPTIONAL EQUIPMENT
5.6
TRAVEL ALARM
5.12 BOOM WIPERS
A 12-volt alarm horn, mounted on the turntable, provides
an audible warning when the machine is in the travel
(DRIVE) mode. It will function in FORWARD or REVERSE
to warn jobsite personnel the machine is traveling.
5.7
TILT ALARM
Senses when the machine is out of level in any direction
approximately 3 degrees and illuminates a warning light at
the platform control station and sounds the machine’s
horn, signaling the operator. A second switch mounted on
the machine senses when the machine is out of level 5
degrees and will cut out two speed drive when activated.
5.8
ELECTRIC GENERATOR
An electric generator mounted on the machine functions
to supply electrical power to the platform. This device will
provide enough power to run assorted power tools.
5.9
A one piece U-shaped neoprene strip, be attached to the
front of the base boom section, wipes the top and both
sides of the fly section. The bottom side of the fly section
is protected by a straight neoprene strip which also
attaches to the base section.
5.13 HOSTILE ENVIRONMENT PACKAGE
The hostile environment package provides additional protection against the entry of dust, dirt, sand and other abrasive materials into the hydraulic system, control handles
and switches, cylinders, boom wire ropes and wear pads,
and the air inlet of the engine. The package is intended for
machines that will be exposed to painting, sandblasting or
other similar hostile conditions. The hostile environment
package includes boom wipers, cylinder bellows, heavy
duty reservoir breather, an engine air cleaner and control
console cover, as required.
5.14 MOTION ALARM
FOAM FILLED TIRES
Eliminates flats by filling tires with polyurethane foam. For
use where sharp objects are frequently encountered on
operating surface of jobsite.
5.10 ROTATING BEACON
An amber or red rotating beacon may be installed on the
hood or platform, and can be controlled by a two position
toggle switch mounted on the platform control console.
When the switch is placed in the ON position, the light is
activated and provides a visual warning to the machine’s
operation.
A motion alarm horn provides an audible warning when
the platform controls are selected at the PLATFORM/
GROUND SELECT switch, the POWER/EMERGENCY
STOP switch is ON, and the footswitch is depressed. The
alarm warns personnel in the jobsite area to avoid the
operating machine.
5.15 FOUR WHEEL STEER
Provides spindles at all wheels. Front wheels are steered
by a toggle switch as usual. Rear wheels are controlled by
a thumb-rocker on top of drive controller.
5.11 CYLINDER BELLOWS
A one piece accordion shaped rubber bellows may be
attached to the rod end of the cylinder barrel and to the
cylinder rod as close to the rod attach bushing as possible. The bellows affords protection to the cylinder rod in
either the extended or retracted position. The bellows are
installed on the lift cylinder, slave cylinder, master cylinder
and steer cylinder.
5-2
5.16 SOFT TOUCH PROXIMITY SYSTEM
The soft touch system incorporates a lower padded rail,
slightly larger than and encompassing the platform, suspended beneath the platform. A proximity switch is
attached to the center of the rail beneath the platform
floor. The proximity switch is set so that any time the lower
rail comes into contact with an object, electrical power is
cut off to the platform controls, shutting down all functions. To restore machine functions, the operator must
press and hold the PUSH TO OVERRIDE button, located
on the platform control console, and select the proper
function to move the platform clear of the object. In addition to the lower rail, all stationary outside platform rails
are padded.
– JLG Lift –
3120890
SECTION 6 - EMERGENCY PROCEDURES
SECTION 6. EMERGENCY PROCEDURES
6.1
This section provides information on the procedures to be
followed and on the systems and controls to be used in
the event an emergency situation is encountered during
machine operation. Prior to operation of the machine and
periodically thereafter, the entire operating manual, including this section, should be reviewed by all personnel
whose responsibilities include any work or contact with
the machine.
6.2
2. Installed on the Platform Console, this round red
switch is pulled up for normal machine functions. In
an emergency, push the button to the down position
with your palm and machine will immediately stop.
GENERAL
EMERGENCY TOWING PROCEDURES
Towing this machine is prohibited, unless properly
equipped. However, provisions for moving the machine, in
case of a malfunction or power failure, have been incorporated. The following procedures are to be used ONLY for
emergency movement to a suitable maintenance area.
1. Chock wheels securely.
2. Disengage drive hubs by reversing disconnect caps.
3. Connect suitable equipment, remove chocks, and
move machine.
Ground Control Station
The Ground Control Station is located on the right front
side of the turntable. The controls on this panel provide
the means for overriding the platform controls, and for
controlling the platform level, boom and swing functions
from the ground. Place the KEY SELECT switch to
GROUND position and operate the proper switch to lift,
swing, or telescope the boom, or level the platform.
Auxiliary Power
A toggle type auxiliary power control switch is located on
the platform control station and another is located on the
ground control station. Operation of either switch turns on
the electrically driven auxiliary hydraulic pump. This
should be used in case of failure of the main power plant.
The auxiliary pump will operate boom lift, telescope and
swing. To activate auxiliary power:
1. Position PLATFORM/GROUND
SWITCH to PLATFORM.
4. After moving machine, complete the following procedures:
KEY
2. Position POWER/EMERGENCY STOP switch to ON.
5. Position machine on a firm and level surface.
3. Depress and hold footswitch.
6. Chock wheels securely.
4. Operate appropriate control switch, lever or controller for desired function and hold.
7. Engage drive hubs by reversing disconnect caps on
hubs.
5. Position AUXILIARY POWER switch to ON and hold.
8. Remove chocks from wheels as needed.
6.3
SELECT
6. Release AUXILIARY POWER switch, selected control
switch, lever or controller, and footswitch.
EMERGENCY CONTROLS AND THEIR
LOCATIONS
7. Position POWER/EMERGENCY STOP switch to OFF.
To activate auxiliary power from the ground control station:
Power/Emergency Stop Switches
1. There is one of these red mushroom shaped
switches at both the Ground Controls and Platform
Controls. When depressed it will immediately stop
the machine.
1. Position PLATFORM/GROUND
SWITCH to GROUND.
SELECT
KEY
2. Position POWER/EMERGENCY STOP switch to ON.
CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP
SWITCH GUARD IS IN PLACE AND THAT GROUND CONTROL
INSTRUCTIONS ARE IN PLACE AND LEGIBLE.
3120890
– JLG Lift –
6-1
SECTION 6 - EMERGENCY PROCEDURES
3. Operate appropriate control switch or controller for
desired function and hold.
6.4
EMERGENCY OPERATION
4. Position AUXILIARY POWER switch to ON and hold.
Use of Ground Controls
5. Release AUXILIARY POWER switch, and appropriate
control switch or controller.
KNOW HOW TO USE THE GROUND CONTROLS IN AN
EMERGENCY SITUATION.
6. Position POWER/EMERGENCY STOP switch to OFF.
Ground personnel must be thoroughly familiar with the
machine operating characteristics and the ground control
functions. Training should include operation of the
machine, review and understanding of this section and
hands-on operation of the controls in simulated emergencies.
Manual Descent
The manual descent valves are used, in the event of total
power failure, to retract and lower the boom using gravity.
The manual descent valves are located on the right side of
the turntable (directly below the ground control box). This
system should be used if there is a total power failure
since the valves will permit use of gravity to retract and
lower the boom. The procedures for use of the valves for
descent and retraction are given adjacent to the valves.
Figure 6-1. Manual Descent Valves
6-2
– JLG Lift –
3120890
SECTION 6 - EMERGENCY PROCEDURES
Operator Unable to Control Machine
6.5
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL THE MACHINE:
DO NOT OPERATE WITH PRIMARY POWER SOURCE (ENGINE OR
ELECTRIC MOTOR) IF PERSONS ARE PINNED OR TRAPPED. USE
AUXILIARY POWER INSTEAD.
1. Operate the machine from ground controls ONLY
with the assistance of other personnel and equipment (cranes, overhead hoists, etc.) as may be be
required to safely remove the danger or emergency
condition.
INCIDENT NOTIFICATION
It is imperative that JLG Industries, Inc. 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.
Contact your local JLG office.
It should be noted that 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.
2. Other qualified personnel on the platform may use
the platform controls with regular or auxiliary power.
DO NOT CONTINUE OPERATION IF CONTROLS
DO NOT FUNCTION NORMALLY.
3. Cranes, forklift trucks or other equipment which may
be available are to be used to remove platform
occupants and stabilize motion of the machine in
case machine controls are inadequate or malfunction when used.
Platform or Boom Caught Overhead
If the platform or boom becomes jammed or snagged in
overhead structures or equipment, do not continue operation of the machine from either the platform or the ground
until the operator and all personnel are safely moved to a
secure location. Only then should an attempt be made to
free the platform using any necessary equipment and personnel. Do not operate controls to cause one or more
wheels to leave the ground.
Post Incident Inspection and Repair
Following any incident, thoroughly inspect the machine
and test all functions first from the ground controls, then
from the platform controls. Do not lift above 3 meters until
you are sure that all damage has been repaired, if
required, and that all controls are operating correctly.
3120890
– JLG Lift –
6-3
SECTION 6 - EMERGENCY PROCEDURES
This page left blank intentionally.
6-4
– JLG Lift –
3120890
SECTION 7 - INSPECTION AND REPAIR LOG
SECTION 7. INSPECTION AND REPAIR LOG
Table 7-1.Inspection and Repair Log
Date
3120890
Comments
– JLG Lift –
7-1
SECTION 7 - INSPECTION AND REPAIR LOG
Table 7-1.Inspection and Repair Log
Date
7-2
Comments
– JLG Lift –
3120890
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
Phone: (61) 2 65 811111
Fax: (61) 2 65 810122
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 Industries (UK)
Unit 4& 5
Bentley Avenue
M24 2GP Middleton
England
Phone: (44) 161 654 1000
Fax: (44) 161 654 1003
JLG EQS
Z. I. De Beaulieu
47400 Fauillet
France
Phone: (33) 553 848 584
Fax: (33) 553848588
JLG Deutschland GmbH
Max Planckstrasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: (49) 421 693 500
Fax: (49) 421 693 5035
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
Phone: (852) 2639 5783
Fax: (852) 2639 5797
JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: (39) 029 359 5210
Fax: (39) 029 359 5845
JLG Europe B.V.
Polaris Avenue 63
2132 JH Hoofddorp
The Netherlands
Phone: (31) 235 655 665
Fax: (31) 235 572 493
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 914 320 245
Fax: (48) 914 358 200
JLG Industries (Scotland)
Wright Business Centre
1 Lonmay Road
Queenslie,Glasgow G33 4EL
Scotland
Phone: (44) 141 781 6700
Fax: (44) 141 773 1907
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal, Barcelona
Spain
Phone: (34) 937 724 700
Fax: (34) 937 711 762
JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 17527 Jarfalla
Sweden
Phone: (46) 850 659 500
Fax: (46) 850 659 534
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