Owner`s Manual - BlueLine Rental

Owner`s Manual - BlueLine Rental
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
E450A
E450AJ
M450A
M450AJ
ANSI
®
3121210
December 7, 2009
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
3121210
– JLG Lift –
a
FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE
A YELLOW BACKGROUND.
INDIC ATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
b
– JLG Lift –
3121210
FOREWORD
For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL
OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL
PROPERTY OR THE JLG PRODUCT.
• Standards and Regulations
Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free:
877-JLG-SAFE (877-554-7233)
Outside USA:
Phone:
Fax:
E-mail:
3121210
– JLG Lift –
240-420-2661
301-745-3713
ProductSafety@JLG.com
c
FOREWORD
REVISION LOG
d
Original Issue
- June 21, 2005
Original Issue
- July 21, 2006
Original Issue
- December 7, 2009
– JLG Lift –
3121210
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
PAGE
SECTION - PARAGRAPH, SUBJECT
SECTION - 1 - SAFETY PRECAUTIONS
1.1
1.2
1.3
1.4
1.5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . 1-1
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . 1-7
TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8
ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1
3.2
2.2
3121210
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Platform Control Indicator Panel . . . . . . . . . . . . 3-11
SECTION - 4 - MACHINE OPERATION
SECTION - 2 - USER RESPONSIBILITIES, MACHINE
PREPARATION, AND INSPECTION
2.1
PAGE
4.1
4.2
4.3
PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1
PREPARATION, INSPECTION, AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
– JLG Lift –
4.4
4.5
4.6
DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . .
Power/Emergency Stop . . . . . . . . . . . . . . . . . . .
Platform/Ground Select Switch . . . . . . . . . . . . . .
Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . .
TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . .
Traveling Forward and Reverse . . . . . . . . . . . . .
STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Loading From Ground Level . . . . . . . . . . . . . . . .
Loading From Positions Above Ground Level . .
4-1
4-1
4-1
4-2
4-2
4-2
4-5
4-5
4-5
4-6
4-6
4-6
4-6
4-6
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
4.7
4.8
4.9
4.10
4.11
4.12
4.13
PAGE
Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8
BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9
Raising and Lowering the Lower and Mid Boom 4-9
Raising and Lowering the Upper Boom . . . . . . 4-9
GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Automatic Operating Mode . . . . . . . . . . . . . . . . 4-9
Battery Only Operating Mode . . . . . . . . . . . . . 4-10
Manual (Charge) Operating Mode. . . . . . . . . . 4-10
INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
MACHINE FUNCTION SPEEDS . . . . . . . . . . . . . . 4-11
BOOM SYNCHRONIZING PROCEDURE . . . . . . . 4-11
SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-11
MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . 4-12
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
SECTION - PARAGRAPH, SUBJECT
5.4
5.5
5.6
ii
EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2
MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . .5-2
MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . .5-3
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
SECTION - 5 - EMERGENCY PROCEDURES
5.1
5.2
5.3
PAGE
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1
EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . 5-1
Operator Unable to Control Machine . . . . . . . . 5-1
Platform or Boom Caught Overhead . . . . . . . . . 5-2
– JLG Lift –
6.1
6.2
6.3
6.4
6.5
INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Torque Specifications . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Lubrication Specifications . . . . . . . . . . . . . . . . . 6-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . 6-5
Serial Number Locations . . . . . . . . . . . . . . . . . . 6-6
OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-8
BATTERY MAINTENANCE AND CHARGING. . . . .6-13
Battery Maintenance, Quarterly . . . . . . . . . . . . 6-13
Optional On Board Generator . . . . . . . . . . . . . 6-14
Battery Charging (On Board Charger) . . . . . . . 6-14
TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-15
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
6.6
PAGE
SECTION - PARAGRAPH, SUBJECT
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-16
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-16
SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-18
LIST OF TABLES
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1.
2-2.
2-3.
2-4.
3-1.
3-2.
3-3.
3-4.
4-1.
4-2.
4-3.
4-4.
4-5.
4-6.
4-7.
4-8.
4-9.
6-1.
6-2.
3121210
Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7
Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-8
Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-9
Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10
Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-3
Ground Control Station w/ Function Enable . . . . . .3-4
Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-7
Platform Control Indicator Panel . . . . . . . . . . . . . .3-12
Position of Least Forward Stability . . . . . . . . . . . . .4-3
Position of Least Backward Stability . . . . . . . . . . . .4-4
Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-7
Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Chassis & Platform Tie Down - Sheet 1 of 2 . . . . .4-14
Chassis & Platform Tie Down - Sheet 2 of 2 . . . . .4-15
Decal Installation - Sheet 1 of 3 . . . . . . . . . . . . . . .4-16
Decal Installation - Sheet 2 of 3 . . . . . . . . . . . . . . .4-17
Decal Installation - Sheet 3 of 3 . . . . . . . . . . . . . . .4-18
Serial Number Locations . . . . . . . . . . . . . . . . . . . . .6-6
Operator Maintenance & Lubrication Diagram . . . .6-7
– JLG Lift –
1-1
1-2
2-1
3-1
4-1
4-2
6-1
6-2
6-3
6-4
6-5
6-6
6-7
6-8
6-9
6-10
7-1
PAGE
Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5
Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10
Inspection and Maintenance Table. . . . . . . . . . . . . 2-3
Simultaneous Functions . . . . . . . . . . . . . . . . . . . . 3-10
E450A/E450AJP Decal Legend . . . . . . . . . . . . . . 4-19
M450A/M450AJ Decal Legend . . . . . . . . . . . . . . . 4-25
Operating Specifications. . . . . . . . . . . . . . . . . . . . . 6-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . 6-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-8
Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-17
Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
PAGE
SECTION - PARAGRAPH, SUBJECT
PAGE
This page left blank intentionally.
iv
– JLG Lift –
3121210
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
1.1
GENERAL
1.2
This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance
program, using the information provided in this manual and
the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the
machine is safe to operate.
PRE-OPERATION
Operator Training and Knowledge
• Read and understand this manual before operating the
machine.
The owner/user/operator/lessor/lessee of the machine
should not operate the machine until this manual has been
read, training is accomplished, and operation of the machine
has been completed under the supervision of an experienced and qualified operator.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.
3121210
– JLG Lift –
• Do not operate this machine until complete training is performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
1-1
SECTION 1 - SAFETY PRECAUTIONS
• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, and operating instructions on the machine
and in this manual.
• Use the machine in a manner which is within the scope of
its intended application set by JLG.
Machine Inspection
• All operating personnel must be familiar with the emergency controls and emergency operation of the machine
as specified in this manual.
• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for
detailed instructions.
• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
operation of the machine.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the
Service and Maintenance Manual.
Workplace Inspection
• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.
1-2
• This machine can be operated in temperatures of 0o F to
104o F (-20o C to 40o C). Consult JLG for operation outside this range.
• Be sure the footswitch and all other safety devices are
operating properly. Modification of these devices is a
safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from footwear and platform floor.
– JLG Lift –
3121210
SECTION 1 - SAFETY PRECAUTIONS
1.3
OPERATION
• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.
General
• When driving, always position boom over rear axle in line
with the direction of travel. Remember, if boom is over the
front axle, steer and drive functions will be reversed.
• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.
• Never operate a machine that is not working properly. If a
malfunctions occurs, shut down the machine.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and
stop before moving the switch to the next function. Operate controls with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
• Do not place boom or platform against any structure to
steady the platform or to support the structure.
• Stow boom and shut off all power before leaving machine.
Trip and Fall Hazards
• Do not carry materials directly on platform railing. Contact
JLG for approved material handling accessories.
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.
• When two or more persons are in the platform, the operator shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
3121210
– JLG Lift –
1-3
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all gates are
closed and fastened in their proper position.
• Use extreme caution when entering or leaving platform.
Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.
Electrocution Hazards
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the boom assembly to enter or leave the platform.
1-4
– JLG Lift –
3121210
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
0 to 50 KV
10 (3)
Over 50KV to 200 KV
15 (5)
Over 200 KV to 350 KV
20 (6)
Over 350 KV to 500 KV
25 (8)
Over 500 KV to 750 KV
35 (11)
Over 750 KV to 1000 KV
45 (14)
NOTE:
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 11.
• Allow for machine movement and electrical line swaying.
3121210
– JLG Lift –
MINIMUM APPROACH DISTANCE
in Feet (Meters)
This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up
to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
1-5
SECTION 1 - SAFETY PRECAUTIONS
• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers
are rated for the voltage of the line being guarded. These
barriers shall not be part of (or attached to) the machine. The
minimum approach distance shall be reduced to a distance
within the designed working dimensions of the insulating
barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental
requirements for work practices near energized equipment
Tipping Hazards
• The user must be familiar with the surface before driving.
Do not exceed the allowable sideslope and grade while
driving.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
1-6
– JLG Lift –
3121210
SECTION 1 - SAFETY PRECAUTIONS
• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.
• If boom assembly or platform is in a position that one or
more wheels are off the ground, all persons must be
removed before attempting to stabilize the machine. Use
cranes, forklift trucks, or other appropriate equipment to
stabilize machine.
• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
Crushing and Collision Hazards
• Do not raise the platform or drive from an elevated position unless the machine is on firm, level and smooth surfaces.
• Keep the chassis of the machine at least 2 ft. (0.6m) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and
bottom of platform when lifting or lowering platform, and
driving.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure.
• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For
Reference Only).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
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– JLG Lift –
• During operation, keep all body parts inside platform railing.
1-7
SECTION 1 - SAFETY PRECAUTIONS
• Use the boom functions, not the drive function, to position
the platform close to obstacles.
• Always post a lookout when driving in areas where vision
is obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away
from machine during all driving and swing operations.
• Limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel,
and other factors which may cause collision or injury to
personnel.
• Be aware of stopping distances in all drive speeds. When
driving in high speed, switch to low speed before stopping. Travel grades in low speed only.
• Do not use high speed drive in restricted or close quarters
or when driving in reverse.
1.4
TOWING, LIFTING, AND HAULING
• Never allow personnel in platform while towing, lifting, or
hauling.
• This machine should not be towed, except in the event of
emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this
manual for emergency towing procedures.
• Ensure boom is in the stowed position and the turntable
locked prior to towing, lifting or hauling. The platform must
be completely empty of tools.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for
lifting information.
• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and persons in the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if necessary.
1-8
– JLG Lift –
3121210
SECTION 1 - SAFETY PRECAUTIONS
1.5
ADDITIONAL HAZARDS / SAFETY
• Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.
• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations,
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.
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• Charge batteries only in a well ventilated area.
1-9
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28
MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
1-10
Wind Speed
Beaufort
Number
mph
m/s
0
0
0-0.2
Description
Land Conditions
Calm
Calm. Smoke rises vertically
1
1-3
0.3-1.5
Light air
Wind motion visible in smoke
2
4-7
1.6-3.3
Light breeze
Wind felt on exposed skin. Leaves rustle
3
8-12
3.4-5.4
Gentle breeze
Leaves and smaller twigs in constant motion
4
13-18
5.5-7.9
Moderate breeze
Dust and loose paper raised. Small branches begin to move.
5
19-24
8.0-10.7
Fresh breeze
Smaller trees sway.
6
25-31
10.8-13.8
Strong breeze
Large branches in motion. Whistling heard in overhead wires.
Umbrella use becomes difficult.
7
32-38
13.9-17.1
Near Gale/Moderate Gale
Whole trees in motion. Effort needed to walk against the wind.
8
39-46
17.2-20.7
Fresh Gale
Twigs broken from trees. Cars veer on road.
9
47-54
20.8-24.4
Strong Gale
Light structure damage.
– JLG Lift –
3121210
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.
The aerial platform is a personnel handling device; so it is
necessary that it be operated and maintained only by trained
personnel.
Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.
Training Supervision
Operator Training
Training must be done under the supervision of a qualified
person in an open area free of obstructions until the trainee
has developed the ability to safely control and operate the
machine.
Operator training must cover:
1. Use and limitations of the controls in the platform and at
the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
Operator Responsibility
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a
malfunction or other unsafe condition of either the machine
or the job site.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunction.
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2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.2
PREPARATION, INSPECTION, AND
MAINTENANCE
The following table covers the periodic machine inspections
and maintenance recommended by JLG Industries, Inc.
Consult local regulations for further requirements for aerial
work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is
used in a harsh or hostile environment, if the machine is
used with increased frequency, or if the machine is used in a
severe manner.
2-2
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT
MODEL.
– JLG Lift –
3121210
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type
Primary
Responsibility
Frequency
Service
Qualification
Reference
Pre-Start Inspection
Before using each day; or
whenever there’s an Operator change.
User or Operator
User or Operator
Operator and Safety Manual
Pre-Delivery Inspection
(See Note)
Before each sale, lease, or rental delivery.
Owner, Dealer, or User
Qualified JLG
Mechanic
Service and Maintenance
Manual and applicable JLG
inspection form
Frequent Inspection
In service for 3 months or 150 hours, whichever Owner, Dealer, or User
comes first;
or
Out of service for a period of more than 3 months;
or
Purchased used.
Qualified JLG
Mechanic
Service and Maintenance
Manual and applicable JLG
inspection form
Annual Machine Inspection Annually, no later than 13 months from the date of Owner, Dealer, or User
prior inspection.
Factory Qualified
Service Technician
(Recommended)
Service and Maintenance
Manual and applicable JLG
inspection form
Preventative Maintenance
Qualified JLG
Mechanic
Service and Maintenance
Manual
At intervals as specified in the Service and Main- Owner, Dealer, or User
tenance Manual.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
3121210
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2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Pre-Start Inspection
(Domestic only) is enclosed in the weather resistant
storage container.
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel,
or battery fluid) or foreign objects. Report any leakage to
the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents,
damage, weld or parent metal cracks or other discrepancies.
5. “Walk-Around” Inspection – Refer to Figure 2-2. thru
Figure 2-4.
6. Battery – Charge as required.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Hydraulic Oil – Check the hydraulic oil level. Ensure
hydraulic oil is added as required.
9. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems in
an area free of overhead and ground level obstructions.
Refer to Section 4 for more specific instructions.
Parent Metal Crack
Weld Crack
3. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible decals and placards are
cleaned or replaced.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE
MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER
MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT
IS DECLARED SAFE FOR OPERATION.
4. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, EMI Safety Manual
(Domestic only), and ANSI Manual of Responsibilities
2-4
– JLG Lift –
3121210
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Function Check
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.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM
MOVEMENTS DO NOT RETURN TO THE OFF POSITION WHEN
RELEASED.
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP
WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT
FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE.
1. Check boom limit switches. Raise and lower the Lower
Boom. Check for smooth operation.
NOTE:
Perform checks from ground controls first, then from platform controls.
3121210
– JLG Lift –
2. Raise, extend, retract, and lower the Upper Boom.
Check for smooth operation.
3. If tower boom does not rest on stop with machine in the
stowed position, this indicates upright is out of plumb.
4. Telescope boom IN and OUT several cycles at various
degrees of elevation lengths. Check for smooth telescope operation.
5. Swing turntable to LEFT and RIGHT a minimum of 45
degrees. Check for smooth motion.
6. Check the chassis out of level indicator located on the
platform control console by driving, with the machine in
level position, up a suitable ramp of at least 6° slope.
Check the out of level alarm, with the machine on the
ramp, raise the upper boom until it is parallel with the
chassis. DO NOT RAISE ABOVE THE PARALLEL POSITION. If the light does not illuminate, return the machine
to a level surface, shut down the machine, and contact a
qualified technician before resuming operation.
For units equipped with optional tilt cutout, verify that the
drive function is cutout when the boom is elevated and
tilt alarm is activated.
2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITY
OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO
NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
7. Check that platform self-leveling system functions properly during raising and lowering of boom.
8. Check rotator for smooth operation and assure platform
will rotate 75 degrees in both directions from centerline
of boom.
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 qualified service technician.
12. Place the GROUND/PLATFORM SELECT switch to
GROUND. Platform controls should not operate.
13. Place GROUND/PLATFORM SELECT switch to OFF.
Platform/Ground controls should not operate.
9. Drive forward and reverse; check for proper operation.
10. Steer left and right; check for proper operation.
11. Footswitch.
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" (6 MM) OF TRAVEL, TOP OR
BOTTOM, IT SHOULD BE ADJUSTED.
FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION CONTROL, OTHERWISE THE FUNCTION WILL NOT WORK.
2-6
– JLG Lift –
3121210
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
1. Platform Control Console
2. Platform
3. Upper Boom
4. Telescope Cylinder
5. Master Cylinder
6. Upper Upright
7. Upper Lift Cylinder
8. Mid Lift Cylinder
9. Lower Boom
10. Turntable
11. Frame
12. Steer Wheels
13. Drive Wheels
14. Battery Box
15. Lower Lift Cylinder
16. Lower Link
17. Lower Upright
18. Upper Link
19. Mid Boom
20. Slave Cylinder
21. Footswitch
Figure 2-1. Basic Nomenclature
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2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3
2-8
– JLG Lift –
3121210
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
General
Begin the “Walk-Around Inspection” at Item 1, as noted on
the diagram. Continue to the right (counterclockwise
viewed from top) checking each item in sequence for the
conditions listed in the “Walk-Around Inspection Checklist”.
TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING "WALK-AROUND INSPECTION".
1. Platform and Gate Assembly - Platform mounting pins
secure. Footswitch in good working order; not modified, disabled or blocked; Bar slides freely.
2. Platform & Ground Control Console - Switches and
levers return to neutral and are properly secured,
decals/placards secure and legible, control marking
legible.
3. Rotator - See Note.
4. Jib - See Note.
5. Jib Rotator - See Note.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.
CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS
WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.
NOTE:
On each item, make sure there are no loose or missing
parts, that they are securely fastened and that no visible
damage exists in addition to any other criteria mentioned.
6. Boom Sections - See Note.
7. All Hydraulic Cylinders - No visible damage; pivot pins
and hydraulic hoses undamaged, not leaking.
8. Limit Switches - See Note.
Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 3
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2-9
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
15. Cowling and Latches - See Note.
9. Drive Axle and Motor - See Note.
10. Wheel/Tire Assembly - No loose or missing lug nuts.
Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.
11. Swing Motor and Worm Gear - See Note.
12. Hydraulic Pump and Reservoir - Properly secured; no
visible damage or hydraulic leaks. Recommended
hydraulic fluid level on dipstick (system shut down,
boom in stowed position). Breather cap/dipstick
secure and working.
13. Turntable Bearing - No loose or missing hardware; no
visible damage; evidence of proper lubrication. No
loose bolts or looseness between bearing and structure.
14. Battery Compartment Right Side - Batteries have
proper electrolyte level; cables tight; no visible damage or corrosion.
16. Battery Charger - See Note.
17. Valve - See Note.
18. Boom/Upright - No visible damage; All pins properly
secured. Upright in vertical position. If Upright does
not rest on stop with machine in the stowed position,
this indicates upright is out of plumb.
19. Counterweight - See Note.
20. Tie Rod Ends and Steering Spindles - See Note. Tie
rod end stubs locked.
21. Manual Descent Valve - See Note.
22. Control Valve - See Note.
23. Frame - See Note.
24. Platform Pivot Pins - Properly secured.
Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 3
2-10
– JLG Lift –
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
SECTION 3. MACHINE CONTROLS AND INDICATORS
3.1
GENERAL
Ground Control Station
(See Figure 3-1. and Figure 3-2.)
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE
APPLICATION AND OPERATION. THE USER AND OPERATOR ARE
RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.
NOTE:
When machine is shut down the Platform/Ground Select
switch and Emergency Stop must be positioned to OFF.
NOTE:
If equipped, the Function Enable switch must be held
down in order to operate Telescope, Lower Lift, Swing,
Main Lift, Jib Lift, Platform Level Override, and Platform
Rotate functions.
This section provides the necessary information needed to
understand control functions.
3.2
NOTE:
CONTROLS AND INDICATORS
1. System Distress Indicator
This machines is equipped with control panels that use
symbols to indicate control functions. On ANSI machines,
refer to decal located on the control box guard in front of
the control box or by the ground controls for these symbols and the corresponding functions.
The system distress indicator lights to signify an abnormal condition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an
electrical system fault.
NOTE:
The engine will automatically shut down under the following conditions:
High Oil Temperature
Low Oil Pressure
Engine Overspeed
Overvoltage
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3-1
SECTION 3 - MACHINE CONTROLS AND INDICATORS
2. Platform Overload (If equipped)
5. Telescope
Indicates the platform has been overloaded.
Provides for extension and retraction of Upper Boom
when positioned to IN or OUT.
3. Generator/Engine Start Button
6. Swing
The generator/engine start push-button switch allows
the generator to be started manually to top-off the battery charge. The generator will start automatically when
the batteries reach a low-charge state and the Generator
Enable switch on the platform console is in the on position.
NOTE:
The engine will not start if the batteries are fully charged
or if the Generator Enable switch on the platform console
is not in the on position.
The SWING control switch provides 360 degrees noncontinuous turntable rotation. To activate SWING, position switch to LEFT or RIGHT.
7. Circuit Breakers
The circuit breakers open (pop out) to indicate a short or
overload somewhere on the machine.
8. Power/Emergency Stop Switch
4. Battery Indicator and Hourmeter
An hourmeter, installed in the upper portion of the
Ground Control Box, registers the amount of machine
operating time. The hourmeter registers up to 9,999.9
hours and cannot be reset.
3-2
– JLG Lift –
A two-position red mushroom shaped switch furnishes
power to PLATFORM/GROUND SELECT switch when
pulled out (on). When pushed in (off), power is shut off
to the PLATFORM/GROUND SELECT switch.
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
System Distress Indicator
Platform Overload Indicator
Engine/Generator Start Button
Battery Condition Indicator & Hourmeter
Telescope
Swing
Circuit Breakers
Emergency Stop
Platform/Ground Select
Lower/Mid Lift
Upper Boom Lift
Jib
Platform Leveling
Rotate
Figure 3-1. Ground Control Station
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– JLG Lift –
3-3
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
System Distress Indicator
Platform Overload Indicator
Engine/Generator Start Button
Battery Condition Indicator & Hourmeter
Telescope
Swing
Circuit Breakers
Emergency Stop
Platform/Ground Select
Lower/Mid Lift
Upper Boom Lift
Jib
Platform Leveling
Rotate
Function Enable
Figure 3-2. Ground Control Station w/ Function Enable
3-4
– JLG Lift –
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
12. Articulating Jib Boom (If equipped)
9. Platform/Ground Select Switch
A three position, key operated switch supplies power to
the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground
controls are operable. When released from GROUND
position the switch spring returns to the (off) position.
NOTE:
With PLATFORM/GROUND SELECT switch in the center
position, power is shut off to controls at both operating
stations.
The Articulating Jib Boom control switch provides raising and lowering of the jib when positioned up or down.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.
13. Platform Leveling Override
10. Lower/Mid Boom Lift
Provides for raising and lowering of Lower Boom when
positioned to UP or DOWN.
11. Upper Boom Lift
A three position switch allows the operator to adjust the
automatic self leveling system. This switch is used to
adjust platform level in situations such as ascending/
descending a grade.
14. Rotate
Provides for raising and lowering of Upper Boom when
positioned to UP or DOWN.
A three position ROTATE control switch permits rotation
of the platform when positioned to left or right.
15. Function Enable (If Equipped)
If equipped, the enable switch must be held "DOWN" to
enable all boom controls when the engine is running.
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3-5
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Platform Station
3. Horn
A push-type HORN switch supplies electrical power to
an audible warning device when pressed.
(See Figure 3-3.)
1. Posi-Track Control
4. Power/Emergency Stop
Activating the Posi-Track switch allows the operator to
engage positive traction for the time period pre-set in the
controller. Posi-traction occurs by changing the drive
motors from a series to parallel arrangement, causing
available power to be distributed evenly between the
two drive wheels. The control system may also engage
the posi-track function automatically.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.
A two-position red mushroom shaped switch furnishes
power to PLATFORM Controls when pulled out (on).
When pushed in (off), power is shut off to the platform
functions.
Within about 2 seconds of pulling the switch out, the
machine will perform a diagnostic check of the various
electrical circuits, and if everything is OK, the platform
alarm will beep once. During this time the lights on the
indicator panel will also blink once as a bulb check.
5. Generator Enable Control
2. Platform Leveling Override
A three position switch allows the operator to adjust the
automatic self leveling system. This switch is used to
adjust platform level in situations such as ascending/
descending a grade.
3-6
– JLG Lift –
The Generator Enable control switch, when in the off
position, allows the operator to prevent the generator
engine from starting when using the machine indoors.
When in the on position (and the ground Emergency
Stop Switch on [pulled out]), the generator is enabled to
automatically start when the batteries need charged.
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1.
2.
3.
4.
Posi-Track
Platform Leveling Override
Horn
Power/Emergency Stop
5. Generator Enable
6. Lights
7. Drive/Steer
8. Telescope
11. Platform Rotate
9. Jib
12. Function Speed
10. Lower Boom Lift 13. Main Lift/Swing
Figure 3-3. Platform Control Console
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3-7
SECTION 3 - MACHINE CONTROLS AND INDICATORS
6. Lights (If Equipped)
This switch operates control console panel lights and
head lights if the machine is so equipped.
7. Drive/Steer
The DRIVE controller provides for driving either forward
or backward when positioned to FORWARD or
REVERSE. The controller is ‘ramped’ to allow infinitely
variable drive speed between fast and slow.
Positioning the steer control thumb operated switch
RIGHT or LEFT enables steering the machine to the
right or left respectively.
NOTE:
NOTE:
When lower boom is raised above horizontal, or the upper
boom is raised approximately 16 inches (40.64 cm) above
boom rest, the high drive function will automatically
switch to low drive. This also occurs when Function
Speed Control is clicked on creep.
DRIVE control lever is spring-loaded and will automatically return to neutral (OFF) position when released.
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.
8. Telescope Control
The TELESCOPE control switch affords extension and
retraction of the main boom when positioned to IN or
OUT.
9. Jib (If Equipped)
Push forward to lift up, pull back to lift down. Variable lift
speed is using the Function Speed Control.
10. Lower Boom Lift
Provides for raising and lowering of Lower and Mid
Boom when positioned to UP or DOWN. Upper lift will
not function when operating lower lift.
11. Platform Rotate
The PLATFORM ROTATE control switch allows the operator to rotate the basket to the left or right when positioned to the desired direction.
3-8
– JLG Lift –
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
12. Function Speed Control
13. Main Lift/Swing
Adjusts speed of Boom and Swing Functions. Rotate
CCW for slower speed and CW for faster speed. To
adjust Drive, Swing, and Main Lift to creep, turn knob
fully CCW until it clicks.
NOTE:
Main Lift, Swing, and Drive control levers are springloaded and will automatically return to neutral (off) position when released.
The dual axis joystick is provided for main lift and swing.
Push forward to lift up, pull backward to lift down. Move
right to swing right, move left to swing left. Moving the
joystick activates switches to provide the functions
selected. Proportional control of these functions can be
attained by using the Function Speed knob.
NOTE:
Main lift and swing functions may be selected in combination. The handle features a round gate so that maximum
speed is reduced when multiple functions are selected.
Lower lift will not function when operating upper lift.
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3-9
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Table 3-1. Simultaneous Functions
If This Function is Selected:
These Functions Will Also Work at the Same Time:
Swing
Drive and Steer
Lower Lift**
Upper Lift**
Telescope
Lower Lift**
Upper Lift**
Telescope
No
Telescope*
Swing
Drive and Steer
Lower Lift
Drive and Steer
Swing*
Upper Lift
Drive and Steer
Swing
No
Telescope
Drive and Steer
Swing*
Lower Lift**
Upper Lift**
Jib
Drive and Steer
Swing*
Lower Lift**
Upper Lift**
Telescope
Platform Rotate
Drive and Steer
No
No
No
No
Telescope
Note: Boom functions may be slower when selected with another function than when operated individually, due to sharing of oil.
* These functions may move very slowly (or not at all) if the first function selected (Lower Lift or Swing) is being operated at full speed, due to sharing
of oil.
** Lower Lift and Upper Lift will not function simultaneously. Upper Lift always prevails.
3-10
– JLG Lift –
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Platform Control Indicator Panel
1. Tilt Alarm Warning Light and Alarm
This orange illuminator indicates that the chassis is on a
slope. An alarm will also sound when the chassis is on a
slope and the boom is above horizontal. If lit when boom
is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before
continuing operation. If the boom is above horizontal
and the machine is on a slope, the tilt alarm warning
light will illuminate and an alarm will sound and CREEP
is automatically activated.
(See Figure 3-4., Platform Control Indicator Panel)
NOTE:
The platform control indicator panel uses different shaped
symbols to alert the operator to different types of operational situations that could arise. The meaning of those
symbols are explained below.
Indicates a potentially hazardous situation, which
if not corrected, could result in serious injury or
death. This indicator will be red.
Indicates an abnormal operating condition,
which if not corrected, may result in machine
interruption or damage. This indicator will be yellow.
Indicates important information regarding the
operating condition, i.e. procedures essential for
safe operation. This indicator will be green with
the exception of the capacity indicator which will
be green or yellow depending upon platform
position.
3121210
IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR
EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN
REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING BOOM ABOVE HORIZONTAL.
– JLG Lift –
3-11
SECTION 3 - MACHINE CONTROLS AND INDICATORS
2. Platform Overload (If equipped)
Indicates the platform has been overloaded.
3. System Distress Indicator
The system distress indicator lights to signify an abnormal condition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an
electrical system fault.
The four likely causes of a system fault are:
1.
2.
3.
4.
a. The seven second enable time has been allowed to
lapse or a function was selected before depressing
the footswitch. The system reads this condition as a
fault, just as it would if the footswitch were jammed
in the depressed position or a function switch were
stuck in the on position. Re-depress the footswitch
to power the controls and extinguish the light.
Tilt
5. Enable
Platform Overload 6. Low Battery
System Distress 7. Creep
Posi-Track
Figure 3-4. Platform Control Indicator Panel
b. The maximum power limit has been reached and
the machine is not moving. This could happen
when the machine is stuck or when attempting to
travel over rough terrain or on steep grades which
exceed the rated gradeability of the machine. This
condition is comparable to stalling the engine by
asking it to provide more power than it was
designed to do.
3-12
– JLG Lift –
3121210
SECTION 3 - MACHINE CONTROLS AND INDICATORS
c. The batteries are nearly depleted, and should be
charged very soon to prevent having the machine
stop at an inconvenient place.
5. Enable Indicator/Footswitch
To operate any function, the footswitch must be
depressed and the function selected within seven seconds. The enable indicator shows that the controls are
enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one
function and beginning the next function, the enable
light will go out and the footswitch must be released and
depressed again to enable the controls.
d. There is some other fault in one of the circuits. If so
determine the cause by counting the flash code, a
number of flashes followed by a pause followed by
another number of flashes, and refer to the service
manual.
NOTE:
The engine will automatically shut down under the following conditions:
Releasing the footswitch removes power from all controls and applies the drive brakes.
High Engine Oil Temperature
Low Engine Oil Pressure
Engine Overspeed
Generator Overvoltage
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE
THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
4. Posi-Track Indicator
This indicator lights to show that posi-traction is operating.
3121210
FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN
SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.
– JLG Lift –
3-13
SECTION 3 - MACHINE CONTROLS AND INDICATORS
6. Low Battery Indicator
7. Creep Speed Indicator
Indicates the batteries are low and need to be charged.
3-14
– JLG Lift –
When the Function Speed Control is turned to the creep
position, the indicator acts as a reminder that all functions are set to the slowest speed.
3121210
SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION
4.1
DESCRIPTION
4.2
This machine is a self-propelled hydraulic personnel lift
equipped with a work platform on the end of an elevating
and rotating boom.
Capacities
The primary operator control station is in the platform. From
this control station, the operator can drive and steer the
machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the
boom to the left or right. Standard boom swing is 360 degree
non-continuous left and right of the stowed position. The
machine has a Ground Control Station which will override
the Platform Control Station. Ground Controls operate Upper
and Lower Boom Lift and Swing, and are to be used in an
emergency to lower the platform to the ground should the
operator in the platform be unable to do so.
3121210
OPERATING CHARACTERISTICS AND
LIMITATIONS
– JLG Lift –
The boom can be raised above horizontal with or without any
load in platform, if:
1. Machine is positioned on a smooth, firm and level surface.
2. Load is within manufacturers rated design capacity.
3. All machine systems are functioning properly.
4. Proper tire pressure.
5. Machine is as originally equipped from JLG.
4-1
SECTION 4 - MACHINE OPERATION
Stability
4.3
Machine stability is based on two positions which are called
FORWARD and BACKWARD stability. The machines position
of least FORWARD stability is shown in Figure 4-1., Position
of Least Forward Stability, and its position of least BACKWARD stability is shown in Figure 4-2., Position of Least
Backward Stability.
MOTOR OPERATION
Power/Emergency Stop
The Power/Emergency Stop switch, when pulled out (on),
provides battery power for all machine functions. The switch
should be pushed in (off) when recharging the batteries or
parking the machine overnight.
NOTE:
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD
MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.
If equipped with the optional on-board generator, the
Emergency Stop switch must be left on (pulled out) to
allow for automatic charging of the batteries.
Within about 2 seconds of pulling the switch out, the
machine will perform a diagnostic check of the various electrical circuits, and if everything is OK, the platform alarm will
beep once. During this time the lights on the indicator panel
will also blink once as a bulb check.
4-2
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
UPPER BOOM
HORIZONTAL
FLY BOOM
FULLY EXTENDED
MACHINE WILL "TIP OVER" IN THIS
DIRECTION IF OPERATED ON AN
OUT-OF-LEVEL SURFACE
TOWER AND MID
BOOM AT
33 DEGREES
Figure 4-1. Position of Least Forward Stability
3121210
– JLG Lift –
4-3
4-4
– JLG Lift –
LOWER BOOM
FULLY ELEVATED
MID BOOM
FULLY ELEVATED
UPPER BOOM
FULLY ELEVATED
AND RETRACTED
Figure 4-2. Position of Least Backward Stability
MACHINE WILL "TIP OVER" IN THIS
DIRECTION IF OPERATED ON AN
OUT-OF-LEVEL SURFACE
PLATFORM
ROTATED
90 DEGREES
SECTION 4 - MACHINE OPERATION
3121210
SECTION 4 - MACHINE OPERATION
Platform/Ground Select Switch
4.4
The Platform/Ground Select switch directs battery power to
the desired control station when the POWER/EMERGENCY
STOP switch is pulled out (on). With the switch held in the
GROUND position battery power is supplied to the ground
control station. When the switch is in the PLATFORM position, battery power is supplied to the platform control station.
NOTE:
For units equipped with optional tilt cutout, verify that the
drive function is cutout when the boom is elevated and tilt
alarm is activated.
NOTE:
When lower boom is raised above horizontal, or the upper
boom is raised approximately 16 inches (40.6 cm) above
boom rest, the high drive function will automatically be in
low drive.
Motor Activation
FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION, OTHERWISE FUNCTION WILL NOT OPERATE.
The motor becomes activated and operates the desired
function when the Emergency Stop switch is pulled out (on),
the Platform/Ground select switch is in the appropriate position and the Footswitch is depressed.
TRAVELING (DRIVING)
IF THE MACHINE IS OPERATED AT A VERY SLOW SPEED OR STALLED
WHEN CLIMBING A GRADE OF 20% OR GREATER, DRIVE FUNCTION
WILL STOP. REMOVE FOOT FROM FOOT-SWITCH, AND DEPRESS FOOTSWITCH TO RESET.
DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A
SMOOTH, FIRM AND LEVEL SURFACE.
IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY
OPERATION.
TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER” ON GRADES AND
SIDE SLOPES, DO NOT DRIVE MACHINE ON GRADES EXCEEDING
THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
3121210
– JLG Lift –
4-5
SECTION 4 - MACHINE OPERATION
AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE
TO TIPOVER.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL
TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUCTION.
BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR
DRIVE AXLE. IF BOOM IS OVER STEER WHEELS, STEER AND DRIVE
CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE
MOTION.
Traveling Forward and Reverse
4.5
STEERING
Depress footswitch, position thumb switch on Drive/Steer
controller to RIGHT for steering right, or to LEFT for steering
left.
4.6
PLATFORM
Loading From Ground Level
1. Position chassis on a smooth, firm and level surface.
2. If total load (personnel, tools and supplies) is 500 LB.
(227 kg) or less, distribute load uniformly on platform
floor and proceed to work position.
FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNCTION, OTHERWISE FUNCTION WILL NOT OPERATE.
1. If machine is shut down, pull out Emergency Stop at
Ground Controls and place Platform/Ground Select
switch to PLATFORM.
2. At Platform Controls, pull out Emergency Stop switch
and activate footswitch.
4-6
3. Position Drive controller to FORWARD or REVERSE as
desired. Angle of controller will determine travel speed.
Loading From Positions Above Ground Level
Before loading weight to platform above ground level:
1. Determine what the total weight will be after additional
weight is loaded (personnel, tools and supplies).
2. If total weight in platform will be 500 LBS. (227 kg) or
less, proceed with adding weight.
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Figure 4-3. Grade and Side Slopes
3121210
– JLG Lift –
4-7
SECTION 4 - MACHINE OPERATION
Platform Level Adjustment
4.7
1. Leveling UP. Depress footswitch to raise platform, position PLATFORM/LEVEL control switch UP and hold until
platform is level.
2. Leveling DOWN. Depress footswitch to lower platform,
position PLATFORM/LEVEL control switch to DOWN
and hold until platform is level.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD
CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO
COULD RESULT IN DEATH OR SERIOUS INJURY.
Platform Rotation
1. Depress footswitch to rotate platform to the left, PLATFORM ROTATE control switch is positioned to the LEFT
and held until desired position is reached.
2. Depress footswitch to rotate platform to the right, PLATFORM ROTATE control switch is positioned to the
RIGHT and held until desired position is reached.
4-8
BOOM
A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE
WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER
SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN
LIGHT IS LIT OR AUDIBLE ALARM SOUNDS.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE
CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5
DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING,
OR RAISING BOOM ABOVE HORIZONTAL.
TO AVOID UPSET IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS
RAISED ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL.
THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE
RAISING BOOM.
TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON
GRADES NOT EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER
PLATE.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY
CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM
MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION
WHEN RELEASED.
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP
WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT
FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE
MACHINE.
4.8
GENERATOR
Swinging the Boom
Automatic Operating Mode
The machine is equipped with an engine powered DC generator
connected in parallel to the 48V DC battery bank.
Depress footswitch to swing boom, with footswitch activated,
position SWING control switch to RIGHT or LEFT for direction desired.
The generator will operate in automatic mode always when
the following two conditions apply.
1. Ground Control EMS is pulled out (on), and:
WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR
THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.
Raising and Lowering the Lower and Mid Boom
2. The Generator Enable switch on the platform control
console is in the On or Enable position.
When the above conditions apply, the generator’s controller
will monitor status of the batteries, will turn on automatically
when the battery voltage drops as a result of discharge and
will turn off when batteries are fully charged.
Depress footswitch to raise or lower the Lower and Mid
Boom, with footswitch activated, position Lower Boom Lift
switch to UP or DOWN as desired.
Raising and Lowering the Upper Boom
Depress footswitch to raise or lower the Upper Boom, with
footswitch activated, position Upper Boom Lift switch to UP
or DOWN until desired height is reached.
3121210
– JLG Lift –
4-9
SECTION 4 - MACHINE OPERATION
Battery Only Operating Mode
Activation of the Manual Charge button will start the engine
and initiate the charging cycle even if the batteries are
charged above the level of automatic start. The operator can
initiate the charge cycle to charge the batteries to the maximum level. The charging cycle will include finishing phase
similar to conventional chargers.
The machine will operate in the battery only mode when the
following two conditions apply:
1. Ground Control EMS is pulled out, and:
2. The switch on the platform control console is in the Off
or Disable position.
In this mode the machine will operate as a conventional battery operated unit. The batteries can be used until they are
fully discharged.
Manual (Charge) Operating Mode
The generator will operate in manual mode always when the
following three conditions apply.
1. Ground Control EMS is pulled out, and:
2. The switch on the platform control console is in the On
or Enable position and:
3. The Manual Charge push button is activated.
4.9
INVERTER
The inverter converts 48 VDC to 110 VAC to allow operation
of power tools from the machine’s batteries.
• The inverter is operational when the emergency stop
switch is pulled out.
• The machine and inverter can be operated at the same
time.
• The inverter will shut off at approximately 42 VDC and stay
off until the emergency stop switch is recycled. It will operate again until voltage drops to 42 VDC.
• The machine will operate down to 36 VDC.
• The inverter will shut down if the high temperature light
indicated overheating. It will automatically turn back on
when cooled.
• The overload light indicates an output wiring short circuit
or a load that is too large for the rating of the inverter.
4-10
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
4.10 MACHINE FUNCTION SPEEDS
4.12 SHUT DOWN AND PARK
The Function Speed Control affects the speed of boom functions Lower Lift, Telescope, and Rotate. Turn the control CW
to increase function speed or CCW to decrease function
speed. When in the CCW maximum position, Drive is placed
in creep speed.
NOTE:
When parking battery powered units overnight, batteries
should be charged in accordance with instructions in
Section 2 to ensure readiness for following workday.
NOTE:
Electric machines are equipped with a static strap due to
static electricity build-ups. Strap is located under rear of
machine chassis.
4.11 BOOM SYNCHRONIZING PROCEDURE
NOTE:
If the Lower Boom assembly does not fully lower:
To shut down and park the machine, the procedures are as
follows:
1. Remove all personnel from the platform.
2. Pull the red knob located beside the main control valve.
3. From Ground Control, activate the lift control switch,
raise Lower Boom 1.8 m (6 feet).
2. Ensure boom is lowered over rear drive axle.
3. Shut down Emergency Stop at Platform Controls.
4. Shut down Emergency Stop at Ground Controls. Position Platform/Ground Select switch to center OFF.
4. After raising Lower Boom, release the red knob.
5. Activate Lower Boom Down, fully lower boom.
5. If necessary, cover Platform Controls to protect instruction placards, warning decals and operating controls
from hostile environment.
6. Repeat step 1 thru 5 if necessary.
3121210
1. Drive machine to a reasonably well protected area.
– JLG Lift –
4-11
SECTION 4 - MACHINE OPERATION
4.13 MACHINE LIFTING AND TIE DOWN
Tie Down
1. Place the boom in the stowed position.
Lifting
1. Call JLG Industries, see machine’s serial number plate,
or weigh the individual unit to obtain GVW.
2. Place the boom in the stowed position.
2. Remove all loose items from the machine.
3. Secure the chassis and the platform using straps or
chains of adequate strength.
3. Remove all loose items from the machine.
4. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level.
4-12
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Figure 4-4. Lifting Chart
3121210
– JLG Lift –
4-13
SECTION 4 - MACHINE OPERATION
Figure 4-5. Chassis & Platform Tie Down - Sheet 1 of 2
4-14
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Figure 4-6. Chassis & Platform Tie Down - Sheet 2 of 2
3121210
– JLG Lift –
4-15
SECTION 4 - MACHINE OPERATION
Figure 4-7. Decal Installation - Sheet 1 of 3
4-16
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Figure 4-8. Decal Installation - Sheet 2 of 3
3121210
– JLG Lift –
4-17
SECTION 4 - MACHINE OPERATION
Figure 4-9. Decal Installation - Sheet 3 of 3
4-18
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
3121210
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
--
--
--
1703935
1703936
1703937
1703940
--
--
--
--
--
1703932
1703933
1703929
1703930
1703931
1703934
--
--
--
--
1705514
--
--
1700584
1700584
1700584
1700584
1700584
1700584
1700584
1700584
7
3252342
--
1706948
1706948
1706948
1706948
1706948
1706948
8
--
--
--
--
--
--
--
--
9
1701504
1701504
1701504
1701504
1701504
1701504
1701504
1701504
10
1701642
1701642
1701642
1701642
1701642
1701642
1701642
1701642
11
1703797
1705921
1703926
1703927
1703923
1703924
1703925
1703928
12
--
--
--
--
--
--
--
--
13
1701644
1701644
1701644
1701644
1701644
1701644
1701644
1701644
14
3251813
--
--
--
--
3251813
--
3251813
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
1
--
--
--
--
--
2
1703805
--
1703938
1703939
3
--
--
--
4
1703798
1705822
5
--
6
– JLG Lift –
4-19
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
4-20
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
1703984
1703982
1703985
1704277
1704277
1704277
1704277
--
1704007
1704006
--
1704008
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
3251243
3251243
--
3251243
21
--
--
--
--
--
--
--
--
22
1701691
1701691
1701691
1701691
1701691
1701691
1701691
1701691
23
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
24
1702868
--
--
--
1704001
1704000
--
1704002
25
1704254
1704254
1704254
1704254
1704254
1704254
1704254
1704254
26
1704253
--
1704253
--
1704253
1704253
--
1704253
27
1704446
1706378
1704417
1704418
1704454
1704452
1704419
1704453
28
1704431
1704431
1704431
1704431
1704431
1704431
1704431
1704431
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
15
--
1705828
1703980
1703981
1703983
16
1704277
1704277
1704277
1704277
17
--
--
--
18
--
--
19
--
20
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
3121210
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
35
--
--
--
--
--
--
--
--
36
--
--
--
--
--
--
--
--
37
1701500
1703811
1701500
1701500
1701500
1701500
1701500
1701500
38
1701509
1701509
1701509
1701509
1701509
1701509
1701509
1701509
39
1703813
1705670
1704342
1704343
1704339
1704340
1704344
1704341
40
--
--
--
--
--
--
--
--
41
1703804
1701518
1703950
1703951
1703947
1703948
1703949
1703952
42
--
--
--
--
--
--
--
--
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
29
--
--
--
--
--
30
--
--
--
--
31
--
--
--
32
--
--
33
--
34
– JLG Lift –
4-21
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
4-22
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
1705977
1702271
1703987
1702265
1702265
1703988
1703991
--
--
--
--
--
--
--
--
49
--
--
--
--
--
--
--
--
50
1702300
1703814
1702300
1702300
1702300
1702300
1702300
1702300
51
--
--
--
--
--
--
--
--
52
1702631
1702631
1702631
1702631
1702631
1702631
1702631
1702631
53
1707013
1705978
1707054
1707042
1707049
1707047
1707044
1707133
54
--
--
--
--
--
--
--
--
55
--
--
--
--
--
--
--
--
56
--
--
--
--
--
--
--
--
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
43
--
--
--
--
--
44
--
--
--
--
45
--
--
--
46
--
--
47
1702265
48
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
3121210
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
63
--
--
--
--
--
--
--
--
64
1706950
--
--
--
1706950
1704252
--
1706950
65
1701645
1705978
1707059
1707058
1707056
1707055
1707060
1707134
66
1701502
1701502
1701502
1701502
1701502
1701502
1701502
1701502
67
1701503
1701503
1701503
1701503
1701503
1701503
1701503
1701503
68
--
--
--
--
--
--
--
--
69
--
--
--
--
--
--
--
--
70
--
--
--
--
--
--
--
--
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
57
--
--
--
--
--
58
--
--
--
--
59
--
--
--
60
--
--
61
--
62
– JLG Lift –
4-23
SECTION 4 - MACHINE OPERATION
Table 4-1. E450A/E450AJP Decal Legend
4-24
Eng/
Eng/
Lat. Spanish CSA French
0259497-13 0259495-13
Chinese
/Eng
0259540-11
Spa/
Portuguese
0259499-13
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
--
77
1704412
1704412
1704412
1704412
1704412
1704412
1704412
1704412
78
1704830
--
--
--
--
--
--
--
79
1704885
1704885
1704885
1704885
1704885
1704885
1704885
1704885
Item #
ANSI
0259301-16
CE/AusI
0275070-6
Japanese
0259536-11
Korean
0259538-11
71
--
--
--
--
--
72
--
--
--
--
73
--
--
--
74
--
--
75
--
76
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-2. M450A/M450AJ Decal Legend
Item #
3121210
Japanese
0259535-13
Korean
0259537-13
Eng/
Spanish
0259496-15
Eng/
French
0259494-15
Spa/
Portuguese
0259498-15
ANSI
0258973-18
CE/AusI
0275069-6
1
--
--
--
--
--
--
--
--
2
1703805
--
1703938
1703939
1703935
1703936
1703937
1703940
Chinese
0259539-13
3
--
--
--
--
--
--
--
--
4
1703798
1705822
1703932
1703933
1703929
1703930
1703931
1703934
5
--
--
--
--
--
1705514
--
--
6
1700584
1700584
1700584
1700584
1700584
1700584
1700584
1700584
7
1706948
--
1706948
1706948
1706948
1706948
1706948
1706948
8
--
--
--
--
--
--
--
--
9
1701504
1701504
1701504
1701504
1701504
1701504
1701504
1701504
10
1701642
1701642
1701642
1701642
1701642
1701642
1701642
1701642
11
1703797
1705921
1703926
1703927
1703923
1703924
1703925
1703928
12
--
--
--
--
--
--
--
--
13
1701644
1701644
1701644
1701644
1701644
1701644
1701644
1701644
14
3251813
--
--
--
3251813
3251813
--
3251813
15
--
1705828
1703980
1703981
1703983
1703984
1703982
1703985
16
1704277
1704277
1704277
1704277
1704277
1704277
1704277
1704277
17
--
--
--
--
1704007
1704006
--
1704008
– JLG Lift –
4-25
SECTION 4 - MACHINE OPERATION
Table 4-2. M450A/M450AJ Decal Legend
4-26
Item #
ANSI
0258973-18
CE/AusI
0275069-6
Japanese
0259535-13
Korean
0259537-13
Eng/
Spanish
0259496-15
Eng/
French
0259494-15
Chinese
0259539-13
Spa/
Portuguese
0259498-15
18
--
--
--
--
--
--
--
--
19
--
--
--
--
--
--
--
--
20
--
--
--
--
3251243
3251243
3251243
3251243
21
--
--
--
--
--
--
--
--
22
1701691
1701691
1701691
1701691
1701691
1701691
1701691
1701691
23
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
1001104864
24
1702868
--
--
--
1704001
1704000
1704000
1704002
25
1704254
1704254
1704254
1704254
1704254
1704254
1704254
1704254
26
1704253
--
--
--
1704253
1704253
--
1704253
27
1704446
1706378
1704417
1704418
1704454
1704452
1704419
1704453
28
1704431
1704431
1704431
1704431
1704431
1704431
1704431
1704431
29
--
--
--
--
--
--
--
--
30
--
--
--
--
--
--
--
--
31
--
--
--
--
--
--
--
--
32
--
--
--
--
--
--
--
--
33
--
--
--
--
--
--
--
--
34
--
--
--
--
--
--
--
--
35
--
--
--
--
--
--
--
--
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-2. M450A/M450AJ Decal Legend
3121210
Item #
ANSI
0258973-18
CE/AusI
0275069-6
Japanese
0259535-13
Korean
0259537-13
Eng/
Spanish
0259496-15
Eng/
French
0259494-15
Chinese
0259539-13
Spa/
Portuguese
0259498-15
36
--
--
--
--
--
--
--
--
37
1701500
1703811
1701500
1701500
1701500
1701500
1701500
1701500
38
1701509
1701509
1701509
1701509
1701509
1701509
1701509
1701509
39
1703813
1705670
1704342
1704343
1704339
1704340
1704344
1704341
40
--
--
--
--
--
--
--
--
41
1703804
1701518
1703950
1703951
1703947
1703948
1703949
1703952
42
--
--
--
--
--
--
--
--
43
--
--
--
--
--
--
--
--
44
--
--
--
--
--
--
--
--
45
--
--
--
--
--
--
--
--
46
--
--
--
--
--
--
--
--
47
1702265
1705977
1702271
1703987
1702265
1702265
1703988
1703991
48
--
--
--
--
--
--
--
--
49
--
--
--
--
--
--
--
--
50
1702300
1703814
1702300
1702300
1702300
1702300
1702300
1702300
51
--
--
--
--
--
--
--
--
52
1702631
1702631
1702631
1702631
1702631
1702631
1702631
1702631
53
1707013
1705978
1707054
1707042
1707049
1707047
1707044
1707133
– JLG Lift –
4-27
SECTION 4 - MACHINE OPERATION
Table 4-2. M450A/M450AJ Decal Legend
4-28
Item #
ANSI
0258973-18
CE/AusI
0275069-6
Japanese
0259535-13
Korean
0259537-13
Eng/
Spanish
0259496-15
Eng/
French
0259494-15
Chinese
0259539-13
Spa/
Portuguese
0259498-15
54
--
--
--
--
--
--
--
--
55
--
--
--
--
--
--
--
--
56
--
--
--
--
--
--
--
--
57
--
--
--
--
--
--
--
--
58
--
--
--
--
--
--
--
--
59
--
--
--
--
--
--
--
--
60
--
--
--
--
--
--
--
--
61
--
--
--
--
--
--
--
--
62
--
--
--
--
--
--
--
--
63
--
--
--
--
--
--
--
--
64
1706950
--
--
--
1706950
1706950
--
1706950
65
1701645
1705978
1707059
1707058
1707056
1707055
1707060
1707134
66
1701502
1701502
1701502
1701502
1701502
1701502
1701502
1701502
67
1701503
1701503
1701503
1701503
1701503
1701503
1701503
1701503
68
--
--
--
--
--
--
--
--
69
--
--
--
--
--
--
--
--
70
1704286
--
1001093687
1001093687
1001093687
1001093687
1001093687
1001093687
71
--
--
--
--
--
--
--
--
– JLG Lift –
3121210
SECTION 4 - MACHINE OPERATION
Table 4-2. M450A/M450AJ Decal Legend
3121210
Item #
ANSI
0258973-18
CE/AusI
0275069-6
Japanese
0259535-13
Korean
0259537-13
Eng/
Spanish
0259496-15
Eng/
French
0259494-15
Chinese
0259539-13
Spa/
Portuguese
0259498-15
72
--
--
--
--
--
--
--
--
73
1702962
--
--
--
--
--
--
--
74
--
--
--
--
--
--
--
--
75
--
--
1705084
1705084
--
--
--
--
76
--
--
--
--
--
--
--
--
77
1704412
1704412
1704412
1704412
1704412
1704412
1704412
1704412
78
1704830
1704830
1704830
1704830
1704830
1704830
1704830
1704830
79
1704885
1704885
1704885
1704885
1704885
1704885
1704885
1704885
– JLG Lift –
4-29
SECTION 4 - MACHINE OPERATION
NOTES:
4-30
– JLG Lift –
3121210
SECTION 5 - EMERGENCY PROCEDURES
SECTION 5. EMERGENCY PROCEDURES
5.1
GENERAL
This section explains the steps to be taken in case of an
emergency situation while operating.
5.2
INCIDENT NOTIFICATION
JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property
damage is evident, the factory should be contacted by telephone and provided with all necessary details.
In USA:
JLG Phone: 877-JLG-SAFE (554-7233)
(8am till 4:45pm EST)
FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE
AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS,
THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10
FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF
REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.
5.3
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from
ground controls only as required.
Outside USA:
240-420-2661
2. Other qualified personnel on the platform may use the
platform controls. DO NOT CONTINUE OPERATION IF
CONTROLS DO NOT FUNCTION PROPERLY.
E-mail:
ProductSafety@JLG.com
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.
3121210
EMERGENCY OPERATION
– JLG Lift –
3. Cranes, forklift trucks or other equipment can be used to
remove platform occupants and stabilize motion of the
machine.
5-1
SECTION 5 - EMERGENCY PROCEDURES
Platform or Boom Caught Overhead
5.5
If the platform or boom becomes jammed or snagged in
overhead structures or equipment, rescue platform occupants prior to freeing the machine.
5.4
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.
The manual descent system is used, in the event of total power
failure, to lower the upper and lower booms using gravity. To
operate the manual descent system, proceed as follows:
Machines prior to S/N 0300062850 and from S/N
0300127572 to Present:
1. Locate manual descent knob on main valve and turn
CW (clockwise). Install handle into manual descent
pump and lower the Mid and Lower Booms by pumping
the handle until they are completely lowered.
3. Connect suitable equipment, remove chocks, and move
machine.
2. Turn manual descent knob CCW (counterclockwise) and
lower the Upper (or main) Boom by pumping the handle
until it is completely lowered. Return manual descent
knob to center position and stow handle in bracket provided.
After moving machine, complete the following procedures:
S/N 0300062850 to S/N 0300127572:
1. Position machine on a firm and level surface.
1. Locate manual descent knob on main valve and turn
CCW (counterclockwise). Install handle into manual
descent pump and lower the Mid and Lower Booms by
pumping the handle until they are completely lowered.
2. Disengage drive hubs by reversing disconnect caps.
2. Chock wheels securely.
3. Engage drive hubs by reversing disconnect caps on
hubs.
4. Remove chocks from wheels as needed.
5-2
MANUAL DESCENT SYSTEM
2. Turn manual descent knob CW (clockwise) and lower
the Upper (or main) Boom by pumping the handle until it
– JLG Lift –
3121210
SECTION 5 - EMERGENCY PROCEDURES
is completely lowered. Return manual descent knob to
center position and stow handle in bracket provided.
5.6
MANUAL SWING OVERRIDE
The manual swing override is used to manually swing boom
and turntable assembly in the event of a total power failure when
the platform is positioned over a structure or obstacle. To operate the manual swing override, proceed as follows:
1. Using a 7/8 inch socket and ratchet wrench, locate nut
on swing worm gear on left side of machine.
2. Install wrench on nut and ratchet in the direction
desired.
3121210
– JLG Lift –
5-3
SECTION 5 - EMERGENCY PROCEDURES
NOTES:
5-4
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.1
INTRODUCTION
6.2
OPERATING SPECIFICATIONS
This section of the manual provides additional necessary
information to the operator for proper operation and maintenance of this machine.
The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough
Preventive Maintenance and Inspection Schedule included
in the Service and Maintenance Manual.
Other Publications Available:
Service and Maintenance Manual ANSI, CSA Spec ............................................... 3121127
Service and Maintenance Manual - CE Spec........... 3121829
Illustrated Parts Manual - ANSI, CSA Spec .............. 3121128
Illustrated Parts Manual - CE Spec ........................... 3121830
Table 6-1. Operating Specifications
Maximum Work Load (Capacity)
Unrestricted:
Travel Speed
Maximum Travel Grade (Gradeablility
Maximum Travel Grade (Side Slope)
– JLG Lift –
3.2 mph (5.2 kph)
30%
5°
Maximum Height: (stowed)
E450A/M450A
E450AJ/M450AJ
6 ft. 6.25 in. (1.9 m)
6 ft. 7 in. (2.0 m)
Maximum Horizontal Platform Reach
E450A
E450AJ
23 ft. 1in.(7.0 m)
23 ft. 9 in. (7.24 m)
Turning Radius (Curb to Curb)
15 ft. 3 in. (4.65 m)
Turning Radius (inside)
Maximum Tire Load:
M450A, E450A
M450AJ, E450AJ
3121210
500 lb. (230 kg)
2 ft. (0.61 m)
6100 lbs. (2,767 kg)
6900 lbs. (3,130 kg)
6-1
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Capacities
Table 6-1. Operating Specifications
Ground Bearing Pressure
M450A, E450A
M450AJ, E450AJ
System Voltage
48 volts
Battery Life per Charge
7 hours continuous
Battery Recharge Time
Charger
Generator
17 hours from full discharge
6.2 hours
Gross Machine Weight (Platform Empty)
E450A/M450A
E450AJ/M450AJ
6-2
Table 6-2. Capacities
64 psi (4.5 kg/cm2)
75 psi (5.2 kg/cm2)
Generator Fuel Tank
Hydraulic Oil Tank
4 Gallons (15.1 L)
5 Gallons (19 L) w/ 10% air space
Hydraulic System (Including Tank)
Torque Hub, Drive*
37.2 Gallons (140.8 L)
17 ounces (0.50 L)
*Torque hubs should be one half full of lubricant.
13,100 lb. (5942 kg)
15,100 lb. (6804 kg)
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Tires
Table 6-4. Dimensional Data
Table 6-3. Tire Specifications
Size
IN240/55-17.5 IN240/55-17.5
Load Range
E
E
Ply Rating
10
10
90 psi (6.2 Bar)
Foam-Filled
Tire Pressure
Wheel Base
6 ft. 7.0 in. (2.00 m)
Working Height
51 ft. 0 in. (15.54 m)
Platform Height
45 ft. 0 in. (13.72 m)
Track Width
Tail Swing (Any Position)
Dimensional Data
Ground Clearance
M450, E450
M450AJ, E450AJ
Table 6-4. Dimensional Data
Machine Length (stowed)
M450A, E450A
M450AJ, E450AJ
24 ft. 7 in. (7.49 m)
25 ft. 3 in. (7.7 m)
Horizontal Reach @ Maximum
Up and Over
M450 A, E450A
M450AJ, E450AJ
23 ft. 1 in. (7.0 m)
23 ft. 9 in. (7.24 m)
3121210
0
8.5 in. (0.22 m)
8 in. (0.20 m)
18 ft. 8.0 in. (5.69 m)
21 ft. 2 in. (6.45 m)
Up and Over Platform Height
M450A, E450A
M450AJ, E450AJ
Machine Width
5 ft. 0 in. (1.51 m)
5 ft. 9 in. (1.75 m)
– JLG Lift –
6-3
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Torque Specifications
Hydraulic Oil
Table 6-5. Torque Requirements
Table 6-6. Hydraulic Oil
Description
Torque Value
Interval Hours
Wheel Lugs
170 ft. lbs.
(230 Nm)
150
Hydraulic System
Operating
Temperature Range
Swing Bearing
(Dry)
220 ft. lbs.
(298 Nm)
50/600*
+0° to + 180° F
(-18° to +83° C)
10W
Swing Bearing
((Loctite)
240 ft. lbs.
(326 Nm)
50/600*
+0° to + 210° F
(-18° to +99° C)
10W-20, 10W30
+50° to + 210° F
(+10° to +99° C
20W-20
* Check swing bearing bolts for security after
first 50 hours of operation and every 600 hours
thereafter.
NOTE:
S.A.E. Viscosity
Grade
Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service.
Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobil DTE 11M
is desired, contact JLG Industries for proper recommendations.
6-4
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Lubrication Specifications
NOTE:
Critical Stability Weights
Table 6-8. Critical Stability Weights
Refer to Figure 6-2., Operator Maintenance & Lubrication
Diagram, for specific lubrication procedures.
Component
Table 6-7. Mobil DTE 11M Specs
ISO Viscosity Grade
#15
Gravity API
31.9
Pour Point, Max
-40°F (-40°C)
Flash Point, Min.
330°F (166°C)
LB.
KG.
Counterweight
3850
1746
Tire & Wheel (foam-filled)
207
94
Platform (4ft [1.2 m])
90
41
Platform (5 ft [1.5 m])
100
45
Battery (each)
120
54
Viscosity
3121210
at 40° C
15 cSt
at 100° C
4.1 cSt
at 100° F
80 SUS
at 210° F
43 SUS
cp at -30° F
3.200
Viscosity Index
140
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES,
FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.
– JLG Lift –
6-5
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Serial Number Locations
stamped on top of the end of the upper boom, mid boom,
and lower boom at the left rear of the booms.
For machine identification, a serial number plate is affixed to
the left rear of frame, in front of left rear wheel. If the serial
number plate is damaged or missing, the machine serial
number is stamped on the top left side of the frame and the
top left side of the turntable. In addition, the serial number is
SERIAL NUMBER
TURNTABLE
SERIAL NUMBER FRAME
SERIAL NUMBER PLATE
Figure 6-1. Serial Number Locations
6-6
– JLG Lift –
3121210
Figure 6-2. Operator Maintenance & Lubrication Diagram
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
3121210
– JLG Lift –
6-7
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.3
OPERATOR MAINTENANCE
NOTE:
The following numbers correspond to those in Figure 62., Operator Maintenance & Lubrication Diagram.
Table 6-9. Lubrication Specifications.
KEY
SPECIFICATIONS
MPG
Multipurpose Grease having a minimum dripping point of
350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40
pounds minimum).
EPGL
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.
1. Swing Bearing
Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access
Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L-2105.
HO
Hydraulic Oil. Mobil DTE-11M
OG*
Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG Part No. 3020027)
BG*
Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.
LL
Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part
No. 3020022)
EO
Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.
*MPG may be substituted for these lubricants, if necessary,
but service intervals will be reduced.
6-8
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
2. Swing Bearing/Worm Gear Teeth
DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL
RESULT IN BLOWING OUTER SEAL IN HOUSING.
Lube Point(s) - 2 Grease Fittings
Capacity - Spray On
Lube - OG or Mobiltac375NC
Interval - A/R
Comments - If necessary install grease fittings into worm
gear housing and grease bearings.
NOTE:
OG will allow better cycle times than Mobiltac375NC,
however Mobiltac375NC must be used in dusty environments. If the swing function becomes noisy and/or rough
lubricate the bearing teeth.
3121210
– JLG Lift –
6-9
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
3. Hydraulic Tank
4. Hydraulic Return Filter
Lube Point(s) - Fill Cap
Capacity - 4 Gal. (15.1 L)
Lube - HO
Interval - Check Level daily; Change every 2 years or 1200
hours of operation.
Comments - 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.
6-10
– JLG Lift –
Interval - Change after first 50 hrs. and every 6 months or
300 hrs. thereafter.
Comments - Under certain conditions, it may be necessary to replace the hydraulic filter on a more frequent
basis. A common symptom of a dirty filter is sluggishness
experienced in hydraulic functions.
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
5. Wheel Drive Hub
6. Wheel Bearings
Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation
Lube Point(s) - Repack
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation
7. Spindles/Bushing
Capacity - A/R
Lube - Lithium Lubricant
Interval - Every 2 years or 1200 hours of operation
Comments - At Spindle/Bushing Replacement; Coat I.D. of
bushings prior to installing king pins.
3121210
– JLG Lift –
6-11
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
8. Boom Pivot Pins/Bushing
Capacity - A/R
Lube - Lithium Lubricant
Interval - Every 2 years or 1200 hours of operation
Comments - At boom pivot pins/bushing replacement;
Coat I.D. of bushings prior to installing pivot pins.
9. Engine
Lube Point(s) - Fill Cap
Capacity - Refer to Engine Manual
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with
engine manual.
6-12
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.4
BATTERY MAINTENANCE AND CHARGING
Battery Maintenance, Quarterly
1. Open battery compartment cover to allow access to battery terminals and vent caps.
3. 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.
4. Clean battery post with wire brush then re-connect cable
to post. Coat non-contact surfaces with mineral grease
or petroleum jelly.
WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTROLYTE COVERS THE PLATES.
5. When all cables and terminal posts have been cleaned,
ensure all cables are properly positioned and do not get
pinched. Close battery compartment cover.
NOTE:
6. Start hydraulic system and ensure that it functions properly.
When adding distilled water to batteries, non-metallic
containers and/or funnels must be used.
To avoid electrolyte overflow, add distilled water to batteries after charging.
When adding water to the battery, fill only to level indicated.
2. Remove all vent caps and inspect electrolyte level of
each cell. Electrolyte level should be to the ring approximately one inch from top of battery. Fill batteries with
distilled water only. Replace and secure all vent caps.
3121210
– JLG Lift –
6-13
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Optional On Board Generator
Battery Charging (On Board Charger)
1. For maximum battery life:
a. Avoid completely discharging the batteries.
EXHAUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTILATED AREA ONLY.
b. Fully charge the batteries each day the machine is
used.
c. Charge the batteries at available times between
charging.
WHEN THE GENERATOR ENABLE CONTROL LOCATED IN THE PLATFORM CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMERGENCY STOP SWITCH IN ON (PULLED OUT), THE GENERATOR WILL
STAR T AUTOMATICALLY WHEN THE BATTERIES REACH A LOWCHARGE STATE AUTOMATICALLY CHARGING THE BATTERIES.
NOTE:
The engine will automatically shut down under the following conditions:
High Engine Oil Temperature
Low Engine Oil Pressure
Engine Overspeed
Generator Overvoltage
d. Be sure the battery fluid covers the battery plates
before charging, but to avoid overflow, do not top
off the fluid level until charging.
2. To charge the batteries, connect the charger to an
appropriate volt source with a 15 amp minimum capacity.
3. The Charger will shut off automatically when the batteries are fully charged.
4. The charge cycle is complete when the ammeter reads
0 amps. Any reading indicates the charge cycle is not
complete.
5. Depleted batteries will take approximately 17 hours to
charge.
TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOW
SPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYS
WEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.
6-14
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.5
TIRES & WHEELS
• any damage to the bead area cords of the tire
Tire Inflation
The air pressure for pneumatic tires must be equal to the air
pressure that is stenciled on the side of the JLG product or
rim decal for safe and proper operational characteristics.
Tire Damage
For pneumatic tires, JLG Industries, Inc. recommends that when
any cut, rip, or tear is discovered that exposes sidewall or tread
area cords in the tire, measures must be taken to remove the
JLG product from service immediately. Arrangements must be
made for replacement of the tire or tire assembly.
If a tire is damaged but is within the above noted criteria, the tire
must be inspected on a daily basis to insure the damage has
not propagated beyond the allowable criteria.
Tire Replacement
JLG recommends a replacement tire be the same size, ply and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for the part number of the approved tires for a
particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics:
• Equal or greater ply/load rating and size of original
For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures
must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the
tire or tire assembly.
• a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies
which exceeds 1 inch (2.5 cm) in any direction
• Tire tread contact width equal or greater than original
• Wheel diameter, width, and offset dimensions equal to
the original
• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to the pressure recommended
• any punctures which exceed 1 inch in diameter
3121210
– JLG Lift –
6-15
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
by JLG. Due to size variations between tire brands, both tires
on the same axle should be the same.
Wheel Installation
It is extremely important to apply and maintain proper wheel
mounting torque.
Wheel Replacement
The rims installed on each product model have been designed
for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written
factory recommendations, may result in an unsafe condition
regarding stability.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE
TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE
WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten the fasteners. If
you do not have a torque wrench, tighten the fasteners with a
lug wrench, then immediately have a service garage or dealer
tighten the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming the
mounting stud holes in the wheels. The proper procedure for
attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO NOT
use a lubricant on threads or nuts.
6-16
– JLG Lift –
3121210
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
2. Tighten nuts in the following sequence:
3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per
wheel torque chart.
Table 6-10. Wheel Torque Chart
TORQUE SEQUENCE
1st Stage
2nd Stage
3rd Stage
40 ft. lbs.
(55 Nm)
100 ft. lbs.
(130 Nm)
170 ft. lbs.
(255 Nm)
4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3
months or 150 hours of operation.
3121210
– JLG Lift –
6-17
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.6
SUPPLEMENTAL INFORMATION
The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/
EC and is only applicable to CE machines.
For electric powered machines, the equivalent continuous AWeighted sound pressure level at the work platform is less
than 70dB(A)
For combustion engine powered machines, guaranteed
Sound Power Level (LWA) per European Directive 2000/14/
EC (Noise Emission in the Environment by Equipment for
Use Outdoors) based on test methods in accordance with
Annex III, Part B, Method 1 and 0 of the directive, is 104 dB.
The vibration total value to which the hand-arm system is
subjected does not exceed 2,5 m/s2. The highest root mean
square value of weighted acceleration to which the whole
body is subjected does not exceed 0,5 m/s2.
6-18
– JLG Lift –
3121210
SECTION 7 - INSPECTION AND REPAIR LOG
SECTION 7. INSPECTION AND REPAIR LOG
Machine Serial Number _______________________________________
Table 7-1. Inspection and Repair Log
Date
3121210
Comments
– JLG Lift –
7-1
SECTION 7 - INSPECTION AND REPAIR LOG
Table 7-1. Inspection and Repair Log
Date
7-2
Comments
– JLG Lift –
3121210
TRANSFER OF OWNERSHIP
Title:____________________________________________________________________
Name: ___________________________________________________________________
Who in your organization should we notify?
Country: _________________________ Telephone: (_______) ____________________
_________________________________________________________________________
Address: _________________________________________________________________
Current Owner: ____________________________________________________________
Date of Transfer: _________________________________
Country: _________________________ Telephone: (_______) ____________________
_________________________________________________________________________
Address: _________________________________________________________________
Previous Owner: ___________________________________________________________
Serial Number: ____________________________________________________________
Mfg. Model: _______________________________________________________________
NOTE: Leased or rented units should not be included on this form.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. For the purpose of receiving safety-related
bulletins, it is very important to keep JLG Industries, Inc. updated with the current
ownership of all JLG products. JLG maintains owner information for each JLG product
and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
An Oshkosh Corporation Company
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
3121210
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
+61 2 65 811111
+55 19 3295 1025
+55 19 3295 0407
+44 (0)161 654 1000
+61 2 65 810122
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
+44 (0)161 654 1001
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
(852) 2639 5783
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
+39 029 359 5210
+39 029 359 5845
Oshkosh-JLG Singapore Technology
Equipment Pte Ltd
29 Tuas Ave 4,
Jurong Industrial Estate
Singapore, 639379
+65-6591 9030
(852) 2639 5797
+48 (0)914 320 245
JLG Industries (Scotland)
Wright Business Centre
1 Lonmay Road
Queenslie, Glasgow G33 4EL
Scotland
+48 (0)914 358 200
+44 (0)141 781 6700
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
+44 (0)141 773 1907
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762
www.jlg.com
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
+46 (0)850 659 500
+46 (0)850 659 534
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