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ANSI
®
AS/NZS
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Models
AM Series
25AM
30AM
38AM
PVC 2002
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31215807
February 10, 2020 - Rev B
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WARNING
Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of
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vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing. For more information go to www.P65Warnings.ca.gov.
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31215807
FOREWORD
FOREWARD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed various compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject
MEWP for specific standard compliance information.
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.
Refer to www.JLG.com for Warranty, Production Registration, and other machine-related documentation.
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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 possi ble injury or death b
DANGER CAUTION
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
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ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A
YELLOW BACKGROUND.
NOTICE
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE AN ORANGE BACKGROUND.
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INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO
-
TECTION OF PROPERTY.
31215807
FOREWORD
For :
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE
-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
• Accident Reporting
• Product Safety Publi cations
• Standards and Regula tions Compliance Infor mation
• Current Owner
Updates
• Questions Regarding Spe cial Product Applications
NOTICE
• Questions Regarding
Product Safety
• Questions Regarding
Product Modifications
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.
WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP
ERTY OR THE JLG PRODUCT.
NOTICE
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-
Contact :
Product Safety and Reliability Department
JLG Industries, Inc.
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DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
order
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: [email protected]
31215807 c
d
FOREWORD
Original Issue A - October 3, 2019
Revised B - February 10, 2020
REVISION LOG
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31215807
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
SECTION - - REVISION LOG
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
To
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Familiarization. . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 DAILY WALK-AROUND INSPECTION. . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-1
Manual Descent Valve . . . . . . . . . . . . . . . . . . . . . . . 3-3
Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARA -
31215807 i
ii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.3 DECAL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . .3-5
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 OPERATING CHARACTERISTICS AND LIMITATIONS
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 BATTERY CHARGING & MAINTENANCE - (DC MODELS
ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Battery Maintenance and Safety . . . . . . . . . . . . . 4-2
Battery Charger Operation . . . . . . . . . . . . . . . . . . . 4-3
Abnormal Cycle Indicator LED. . . . . . . . . . . . . . . . 4-4
4.4 MACHINE SET-UP AND OPERATION. . . . . . . . . . . . . .4-5
Caster Brake Operation . . . . . . . . . . . . . . . . . . . . . . 4-5
Outrigger Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 MACHINE SHUT DOWN AND PARK . . . . . . . . . . . . 4-10
Transporting by Pushing. . . . . . . . . . . . . . . . . . . . 4-11
Tilt-Back Assembly Set-up (AM38) . . . . . . . . . . 4-12
Pickup Truck Loading Device (Option) . . . . . . . 4-16
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
SECTION - 5 - OPTIONAL EQUIPMENT
5.1 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . 5-1
22" x 22" Quick-Change Platform (Not Available in
26" x 26" Quick-Change Platform (Not Available in
28" x 26" Quick-Change Platform (Not Available in
Fluorescent Tube Caddy . . . . . . . . . . . . . . . . . . . . . 5-1
Crane Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Extra Power Pack (Battery, Charger & Case) . . . 5-1
Platform Auxiliary Power Lowering Device . . . . 5-1
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine . . . . . . . . . 6-1
31215807
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Platform Caught Overhead . . . . . . . . . . . . . . . . . . 6-1
Righting of Tipped Machine . . . . . . . . . . . . . . . . . 6-2
6.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 6-2
SECTION - 7 - GENERAL SPECIFICATIONS AND OPERATOR
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . 7-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . 7-3
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . 7-3
Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
LIST OF FIGURES
7.3 OPERATOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . 7-6
Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . .7-10
Daily Walk-Around inspection. . . . . . . . . . . . . . . . . . 2-7
Ground Control Station.. . . . . . . . . . . . . . . . . . . . . . . . 3-2
Manual Descent Valve Location.. . . . . . . . . . . . . . . . 3-3
Platform Control Station.. . . . . . . . . . . . . . . . . . . . . . . 3-4
Decal Installation. (ANSI/CSA) . . . . . . . . . . . . . . . . . . 3-5
Decal Installation (CE and AUS). . . . . . . . . . . . . . . . . 3-8
Battery Fluid Level.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Box and Charger Assembly.
(D.C. Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Dual Voltage Charger - Front Panel. . . . . . . . . . . . . 4-4
Setting & Releasing Caster Brake . . . . . . . . . . . . . . . 4-5
Outrigger Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Quick Change Platform Mount.. . . . . . . . . . . . . . . . . 4-9
Tilt-Back Assembly Set-Up . . . . . . . . . . . . . . . . . . . . 4-13
Tilt-Back Assembly Set-Up . . . . . . . . . . . . . . . . . . . . 4-14
Tilt-Back Assembly Set-Up . . . . . . . . . . . . . . . . . . . . 4-15
4-10. Loading Machine onto Bed of Pick-Up Truck. . . 4-17
Hour Meter Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
To
31215807 iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT
LIST OF TABLES
PAGE SECTION - PARAGRAPH, SUBJECT
1-1 Minimum Approach Distance (M.A.D.) . . . . . . . . . . 1-6
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
3-1 Decal Installation Chart (ANSI and CSA) (See Figure
3-4.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-2 Decal Installation Chart (CE and AUS Specification)
(See Figure 3-5.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
4-1 Maximum Platform Capacity.. . . . . . . . . . . . . . . . . . . 4-8
4-2 AM Machine Gross Weights . . . . . . . . . . . . . . . . . . . 4-20
7-1 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . 7-6
7-2 Lubrication Intervals for Various Components . . 7-9
8-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . 8-1 Discount-Equipment.com
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PAGE
31215807
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL 1.2 TRANSPORTING
This section outlines the necessary precautions for proper and safe machine usage 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 Main tenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
AND ON MACHINE MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY
OR DEATH AND IS A SAFETY VIOLATION.
Transport
The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility 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, inspec tion, maintenance, application and operation, please contact
JLG Industries, Inc. ("JLG").
to
-
• The platform must be completely empty of tools and debris.
• Ensure platform is fully lowered. Remove and stow outrig -
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• To move machine use handles provided on the mast cross bar.
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PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
31215807 1-1
SECTION 1 - SAFETY PRECAUTIONS
Tipping Hazards
FAILURE TO COMPLY WITH THE FOLLOWING TIPPING HAZARD INSTRUCTIONS
COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING
MOVED, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.
1-2
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• On a level surface, always travel with the platform end lead ing the way.
• Watch for obstructions around machine and overhead.
• Check travel path for persons, holes, bumps, drop-offs, obstructions, debris, and coverings which may conceal other hazards.
• Before placing machine on floors, trucks and other surfaces, check allowable capacity of surfaces.
31215807
SECTION 1 - SAFETY PRECAUTIONS go to
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• Two persons are required on slopes up to 5°. A forklift must be used when moving units on slopes greater than 5°.
• Do not elevate the platform or move the machine on a soft surface.
•
• Always travel up or down a slope with the platform end of the machine positioned towards the low side of the slope.
the operator and assistant must walk beside to guide the machine.
To
• Use caution and check clearances when moving machine in restricted or close quarters.
• Always use an assistant when moving machine in areas where vision is obstructed.
• Keep non-operating personnel at least 6 feet (1.8 m) away from machine during moving operations.
31215807 1-3
SECTION 1 - SAFETY PRECAUTIONS
Tilt Back Procedure
(AM38 Machines Only)
• The platform must be completely empty of tools and debris.
• Ensure platform is fully lowered. Remove and stow outrig gers.
• Tilt machine back only on a flat, firm and level surface.
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1-4 31215807
SECTION 1 - SAFETY PRECAUTIONS
1.3 PRE-OPERATION
General
• Read, understand, and study the Operation and Safety
Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.
• Before operation check work area for machine traffic such as forklifts, cranes, and other construction equipment.
• Set-up machine for operation only on a smooth, firm sur face on which the machine is capable of being leveled.
• Be sure that operators of other overhead and floor level machines are aware of the MEWP’s presence. Disconnect power to overhead cranes.
• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
• Do not operate this machine until it has been serviced and maintained according to requirements specified in the Ser vice and Maintenance manual.
•
•
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Only personnel who have received proper training regard ing the inspection, application and operation of MEWPs
(including recognition and avoiding hazards associated with their operation) shall be authorized to operate a
MEWP.
Only properly trained personnel who have received unitdetermine if personnel are qualified to operate the MEWP prior to operation.
-
• Do not operate this machine until the inspections and func -
• Approved head gear must be worn by all operating and ground personnel.
• Read, understand, and obey all DANGERS, WARNINGS, CAU -
TIONS, and operating instructions on the machine and in this manual.
• All operating personnel must be familiar with emergency controls and emergency operation of the machine as speci fied in this manual.
31215807 1-5
SECTION 1 - SAFETY PRECAUTIONS
Electrocution Hazard
1-6
Table 1-1. Minimum Approach Distance (M.A.D.)
•
•
•
•
Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor, if necessary.
Be sure all safety devices are operating properly. Modifica tion of these devices is a safety violation.
order ers, railway cars, floating vessels, scaffolds or other equip ment unless approved by JLG.
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-
-
-
VOLTAGE RANGE
Over 50KV to 200KV
Over 200KV to 350KV
Over 350KV to 500KV
Over 500KV to 750KV
Over 750KV to 1000KV
MINIMUM APPROACH
DISTANCE - Feet (m)
10 (3)
15 (5)
20 (6)
25 (8)
35 (11)
45 (14)
NOTE: This Minimum Approach Distance shall apply except where employer, local, or governmental regulations are more stringent.
31215807
SECTION 1 - SAFETY PRECAUTIONS
Maintain a clearance of at least 10 ft (3m) between any part of the machine and its occupants, their tools, and their equip ment from any electrical line or apparatus carrying up to
50,000 volts. One foot (0.3m) additional clearance is required for every additional 30,000 volts or less.
The minimum approach distance may be reduced if insulat ing barriers are installed to prevent contact, and if the barriers are rated for the voltage of the line being guarded. These bar riers shall not be part of (or attached to) the machine. The min imum 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 employer, local, or governmental require ments for work practices near energized equipment.
1.4 OPERATION
• Do not operate any machine on which instruction placards or decals are missing or illegible.
• Never exceed the maximum platform capacity.
• Operate AC units with an extension cord rated at a mini mum of 15 amps.
• Prior to entering the platform ensure all leveling jacks have been properly installed and the unit’s base frame is level according to the bubble leveling indicator on base frame, and all wheels are completely off the ground.
• While operating the machine, always look in the direction of machine movement.
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• When applicable by reason of local regulations or job-site/ employer safety rules, personnel in the platform shall at all times wear approved fall protection devices. The autho rized lanyard attachment is on the side of the machine’s mast.
31215807 1-7
SECTION 1 - SAFETY PRECAUTIONS
1-8
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• Check work area for clearance overhead, on sides, and bot tom of platform when lifting and lowering platform.
• Never use the mast assembly to enter or leave the platform.
• Do not increase the platform size with unauthorized deck extensions or attachments, increasing the area exposed to wind will decrease stability.
31215807
SECTION 1 - SAFETY PRECAUTIONS
• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform
• Platform to structure transfers at elevated positions are dis couraged. Where transfer is necessary, enter and exit through the gate only with the platform within 1 foot (0.3
m) of the adjacent safe and secure structure. 100% tie-off is also required in this situation using (2) lanyards. One lan yard must be attached to the platform, the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until the transfer to the structure is complete.
• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.
• Avoid any build up of debris on the platform floor. keep mud, oil, grease and other slippery substances from foot wear and platform floor.
• Do not allow personnel to tamper with, or operate the machine from the ground with personnel in the platform, except in an emergency.
• During operation, keep all body parts inside platform rail ing.
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• Never position ladders, steps, or similar items on unit to provide additional reach for any purpose.
•
• When working from platform both feet must be firmly posi tioned on deck.
To order force or create a swaying motion of the platform.
• Do not operate machine from platform without the gate in place and properly closed.
31215807 1-9
SECTION 1 - SAFETY PRECAUTIONS
1.5 MAINTENANCE SAFETY PRECAUTIONS
• Keep standing surfaces and hand holds free of oil, grease, water, etc.
FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION
COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS
A SAFETY VIOLATION.
• Never work under an elevated platform until platform has been safely restrained from any movement by blocking or overhead sling.
• Before making adjustments, lubricating or performing any other maintenance, shut off all power controls.
• Remove all rings, watches, and jewelry when performing any maintenance.
• Do not wear long hair unrestrained, or loose fitting clothing and neckties which are apt to become caught on or entan gled in equipment.
• Battery should always be disconnected during replacement of electrical components.
• Keep all support equipment and attachments stowed in their proper place.
• Observe and obey all danger, warning, caution and other instructions on machine.
• Use only approved, nonflammable cleaning solvents.
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1-10 31215807
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING
The Mobile Elevating Work Platform (MEWP) is a personnel han dling device; so it is necessary that it be operated and main tained only by trained personnel.
Persons under the influence of drugs or alcohol or who are sub ject to seizures, dizziness or loss of physical control must not operate this machine.
Operator Training
Operator training must cover:
6.
Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.
7.
The safest means to operate the machine where over head obstructions, other moving equipment, and obstacles, depressions, holes, and drop-offs exist.
8.
Selection of the appropriate MEWP and available options for the work to be performed considering spe cific job requirements, with involvement from the
MEWP owner, user, and/or supervisor.
1.
Reading and understanding the Operation and Safety
2.
Manual.
Thorough understanding of the intended purpose go to
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-
9.
The responsibility of the operator to ensure all plat cable regulations, standards, and safety rules.
10.
The requirement for familiarization in addition to training.
-
3.
Control labels, instructions, and warnings on the
4.
5.
machine.
To order
31215708 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Training Supervision
Training must be delivered by a qualified person in an open area, free of hazards until the trainee has demonstrated the abil ity to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsi bility and authority to shut down the machine in case of a mal function or other unsafe condition of either the machine or the job site.
Machine Familiarization
1.
Location of the manual storage compartment and the requirement to ensure the required manual(s) are present on the MEWP;
2.
Purpose and function of the machine controls and indicators at the platform and ground control stations;
3.
Purpose, location, and function of the emergency con trols;
4.
Operating characteristics and limitations;
5.
Features and devices;
6.
Accessories and optional equipment.
NOTE: Responsibilities for familiarization may vary by region.
Only properly trained personnel who have received unit-spe cific familiarization shall operate a MEWP. The user shall deter mine if personnel are qualified to operate the MEWP prior to operation. The user shall ensure that after familiarization, the operator operates the MEWP for a sufficient period of time to achieve proficiency. When authorized by the user, self-famil iarization can be achieved, if authorized, by a properly trained operator reading, understanding and following the manufac turer’s operator’s manual.
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2.2 PREPARATION, INSPECTION, AND MAINTENANCE
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local regulations for further requirements for MEWPs. Frequency of inspections and maintenance must be increased as necessary when machine is used in a harsh or hostile environment, if machine is used with increased frequency, or if machine is used in a severe manner.
Prior to users authorization of an operator to use a specific model of MEWP, the user shall ensure the operator is familiar ized on the following:
To order
2-2 31215708
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1. Inspection and Maintenance Table
TYPE FREQUENCY
PRIMARY
RESPONSIBILITY
SERVICE
QUALIFICATION
REFERENCE
Pre-Start
Inspection
Pre-Delivery Inspec tion
(See Note Below)
Before using each day; or whenever there’s an Operator change.
Before each sale, lease, or rental delivery.
User or Operator
Owner, Dealer, or User
User or Operator Operator and Safety Manual
Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form
Frequent
Inspection
In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of more than 3 months; or Purchased used.
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form
Annual Machine
Inspection
Preventative
Maintenance
NOTE:
Annually, no later than 13 months from the date of prior inspection.
At intervals as specified in the Service and Maintenance
Manual.
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Owner, Dealer, or User Factory-Trained
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Owner, Dealer, or User
Service and Maintenance Manual and applicable JLG inspection form
Qualified JLG Mechanic Service and Maintenance Manual
NOTICE
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COM -
To order
PLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
31215708 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.3 PRE-START INSPECTION
4. Walk-Around Inspection –
Refer to Figure 2-1. on page 2-7.
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.
2. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.
3. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual
(ANSI Markets Only), and ANSI Manual of Responsibili ties (ANSI Markets Only) is enclosed in the weather resistant storage container.
5. Battery – Charge as required.
6. Fuel – (Combustion Engine Powered Machines Only) –
Add proper fuel as necessary.
7. Hydraulic Oil – Check hydraulic oil level. Add hydrau lic oil as required.
8. Function Check – Once “Walk-Around” Inspection is complete, perform a function check of all systems in an area free of overhead and ground level obstruc tions. Refer to Section 3 for specific instructions.
IF MACHINE DOES NOT OPERATE PROPERLY, TURN OFF MACHINE IMMEDI -
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To order
2-4 31215708
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.4 FUNCTION CHECK 2.5 DAILY WALK-AROUND INSPECTION
The function check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a function check as follows:
1.
Set-up machine for operation according to instruc tions in Section 3. Install outriggers, level machine, make sure all wheels are off the ground, etc.
General
Begin Walk-Around Inspection at item 1
. Continue around machine checking each item in this check list.
CAUTION
2.
Enter platform, raise and lower platform 2 ft to 3 ft
(.61m to .92 m) several times. Check for smooth eleva tion and lowering of platform.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DURING
WALK-AROUND INSPECTION.
3.
With platform completely lowered, check hydraulic oil level in reservoir at ground control station. Maintain an oil level to "Fill to Line" indicator on side of reser voir. NEVER USE HYDRAULIC BRAKE FLUID.
NOTICE
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDER -
SIDE. CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CON -
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go to 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.
To order
1. Front Caster Wheels - Properly secured, wheels and casters turn freely. Brakes lock and release - prevent wheels from rolling when locked.
2. Rear Wheels - Properly secured. Wheels turn freely.
3. Tiltback Wheels - Properly secured. Wheels turn freely.
31215708 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
4. Base Frame - Components properly secured, no loose wires dangling below base; bubble level in place and functioning properly.
12. Ground Controls - Key switch operable, placards secure and legible; emergency stop switch, properly set for operation.
5. Tilt Back Assembly - (38AM Models Only) Properly secured; no parts missing i.e.. safety pins, gas spring cylinder(s), caster wheels, etc.
13. Mast Assembly - Inspect mast chains or cables as per note above.
6. Battery/Charger Box Assembly - (DC Voltage
Machines) Proper battery electrolyte level, no cable corrosion. Battery box pivots freely when machine is tilted for transporting.
14. Platform Rail Installation - Entry gate/bar in proper working order.
15. Platform Assembly - Secure to mast; Control and power cables properly tensioned and seated in control cable sheaves; control cable sheaves rotate freely.
7. Outrigger Interlock Indicator LED’s - See note above.
8. Outrigger Sockets - Outrigger lock/release pins in place and secure, no visible damage. Outrigger inter lock contacts (inside outrigger sockets) secure and clean.
16. Platform Controls - Placards secure and legible, emergency shut-off button set for operation. Opera tors manual enclosed in manual storage tube.
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9. Outrigger Beams - Outrigger interlock contacts prop go assembly, lubricated and functioning properly.
to
10. Motor/Pump/Reservoir Power Unit hydraulic leaks. Check that hydraulic reservoir fluid reservoir.
To
11. Manual Release Control Valve - See note above.
2-6 31215708
31215708
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
6
12
10
13
5
11
3
2
16 15
14
1.
Caster Wheels and Brakes
2.
Rear Wheel
3.
Tilt Back Wheel
4.
Base Frame
5.
Tilt-Back Assembly (Not Shown - 38AM only)
6.
Battery/Charger Box Assembly
7.
Outrigger Interlock Indicator LED’s
8.
Outrigger Sockets
9.
Outrigger Beams
10.
Motor/Pump/Reservoir Power Unit
11.
Manual Release Control Valve
4 go to 8
12.
Ground Controls
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15.
Platform Assembly
16.
Platform Controls
To 7 order
1
9
OAR00380
Figure 2-1. Daily Walk-Around inspection
2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2-8
To order go to
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31215708
SECTION 3 - MACHINE CONTROLS AND INDICATORS
SECTION 3. MACHINE CONTROLS AND INDICATORS
3.1 GENERAL 3.2 CONTROLS AND INDICATORS
NOTICE
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICA -
TION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR
CONFORMING WITH GOOD SAFETY PRACTICES.
This section provides the necessary information needed to understand control functions.
Ground Control Station
NOTE: For overnight parking or battery charging, be sure the
POWER ON/OFF KEY SWITCH is positioned to OFF to pre vent battery drain.
1.
POWER ON/OFF Key Switch
A key switch located on the ground control station controls power to all functions on the machine.
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ground controls when RESET (ON). When pushed in (OFF), power is shut off to the platform and ground controls.
3.
RAISE/LOWER SWITCH
The two position switch allows the platform to be raised or lowered.
4.
HYDRAULIC RESERVOIR / CIRCUIT BREAKER / FUSE
(located inside the ground control station housing)
The hydraulic oil level can be checked through an access hole in the side of the cover.
31215807 3-1
SECTION 3 - MACHINE CONTROLS AND INDICATORS
NOTE: Check hydraulic oil only when platform is completely low ered and after cycling platform up/down a few times.
A 20 amp reset type circuit breaker is located on the cover of the electrical box on AM-AC Models.
On AM-DC Models, a 5 Amp fuse is located inside the ground control station cover.
3
2
1
3-2
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Figure 3-1. Ground Control Station.
1.
Power ON/OFF Key
2.
Power/Emergency Stop
3.
Raise/Lower Switch
4.
Hydraulic Reservoir/Circuit Breaker/Fuse
31215807
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Manual Descent Valve
Located at the rear and bottom of the base frame. This pull to release - spring loaded return valve (RED Knob), allows for lowering of the platform in an emergency or power failure.
Platform Control Station
1.
POWER/EMERGENCY STOP
A two position mushroomed shaped switch furnishes power to the platform and ground controls when RESET (ON).
When pushed in (OFF), power is shut off to the platform and ground controls.
2.
PLATFORM UP Button.
When depressed simultaneously with ENABLE button raises the platform.
2
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3
3.
FUNCTION ENABLE Button.
This (GREEN) button must be depressed for machine to operate.
order
4.
To
When depressed simultaneously with ENABLE button lowers the platform.
Figure 3-2. Manual Descent Valve Location.
1.
Manual Descent Valve
2.
Tie-Down Lugs
3.
Mast
31215807 3-3
SECTION 3 - MACHINE CONTROLS AND INDICATORS
3-4
1
2
3
4
Figure 3-3. Platform Control Station.
1.
Emergency Stop (RED)
2.
Platform UP (WHITE)
3.
Function Enable (GREEN)
4.
Platform DOWN (WHITE)
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31215807
SECTION 3 - MACHINE CONTROLS AND INDICATORS
3.3 DECAL INSTALLATIONS
30
27
29
23
25
28
24
26
4
20
13
10
31
32
15
22
14 go
1
3 to
12
21
To
12 order
21
16 2 19 16
Figure 3-4. Decal Installation. (ANSI/CSA)
8
OAR00420
31215807 3-5
Item
1
8
9
6
7
4
5
2
3
10
11
12
13 (3)
14
15
16
17
18
19
20
21
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Table 3-1. Decal Installation Chart (ANSI and CSA) (See Figure 3-4.)
ANSI
1001131273
ANSI
(LAT)
ANSI
(BRZ)
ANSI
(JPN)
ANSI
(CHI - SIMP)
ANSI
(CHI - TRAD)
1703784
1703785
1703786
1703787
1703789
1704030
1704031
1704032
1704033
1704034
To
1702300
Bar Code - Not Available
Model Designation - 25AM-1703903 / 30AM-1703904 / 38AM-1001256057 order
1704022
1704023
1704024
1704025 go
Not Used
Not Used
Not Used
Serial Number Plate - Not Available to
Not Used
1704088
1704089
1704090
1704078
1704079
1704081
1706696
1706697
1704091
1701509
1704092
1703817
Not Used
Not Used
1001115864
1703681 - JLG Logo
1001126700 - Manlift
1704082
1704083
1706695
1706699
3-6
CSA
(FRE)
1001131273
1703784
1703785
1703786
1703787
1703789
31215807
31215807
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Table 3-1. Decal Installation Chart (ANSI and CSA) (See Figure 3-4.)
Item
26
27
28
29
(1)
22
23
24
25
ANSI
1001223055
1001228370
1001231801
1703778
1703779
1703780
1703781
ANSI
(LAT)
1001224049
1704027
1704028
1704029
29 (2)
30
31
32
NOTE: (1) 30AM/38AM Only
(2) - 25AM Only go
ANSI
(BRZ)
1001224049
1704019
1704020
1704021
ANSI
(JPN)
1001224053
1704084
1704085
1704086
1001256055
1001256056
1001110242 - JLG Service
ANSI
(CHI - SIMP)
1001224051
1704075
1704076
1704077
ANSI
(CHI - TRAD)
1001224050
1706692
1706693
1706694
To order
CSA
(FRE)
1001223971
1001228370
1703778
1703780
1703781
3-7
SECTION 3 - MACHINE CONTROLS AND INDICATORS
4 3
24
25
10 OR
5
CE SPEC.
3
4
5
10
AUSTRALIAN
SPEC.
1
11
13
18
15
9
8
2
14 go
21
20
7
23 20
17 To
16
Figure 3-5. Decal Installation (CE and AUS)
12 19 16
OAR00440
3-8 31215807
31215807
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1
2
3
12
13
14
15
16
17
8
9
10
11
4
5
6
7
Table 3-2. Decal Installation Chart (CE and AUS Specification) (See Figure 3-5.)
Item
CE
(ENG)
CE
(DUT)
CE
(FRE)
CE
(GER)
CE
(ITA)
CE
(SPA)
1701509
Not Used
1704094
(1)
/ 1704095
(2)
1705801
1702802
1705803
1705805
To order go to
1705831
Discount-Equipment.com
1001098579
Not Used
1702300
Not Available - BarCode
1702928
1703681
1703817
4410051
(AUS)
—
—
1703780
1703781
1703785
1703786
1703784
1703787
1703778
3-9
SECTION 3 - MACHINE CONTROLS AND INDICATORS
Table 3-2. Decal Installation Chart (CE and AUS Specification) (See Figure 3-5.)
Item
CE
(ENG)
CE
(DUT)
CE
(FRE)
CE
(GER)
CE
(ITA)
CE
(SPA)
18
19
20
Model Designation - 25AM-1703903 / 30AM-1703904 / 38AM-1001256057
1001115864
1001126700
21
22
23
24
25
Serial Number Plate - Not Available
Not Used
Not Used
120V - AC - 3255761 / 220V-240V AC - 3255760
1703994 (Optional)
NOTE: (1) - 30AM/38AM
(2) - 25AM to
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(AUS)
1703789
1705796
To order go
3-10 31215807
TO PURCHASE THIS PRODUCT PLEASE CONTACT US
Equipment Financing and
Extended Warranties Available
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561-964-4949 visit us on line @ www.discount-equipment.com
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Wanco, Yanmar
SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION
4.1 DESCRIPTION 4.2 OPERATING CHARACTERISTICS AND LIMITATIONS
This machine is a manually propelled machine, with a work plat form mounted to an elevating aluminum mast mechanism. The personnel lift’s intended purpose is to provide personnel (with their tools and supplies) access to areas above ground level.
Capacities
The platform can be raised above the stowed position if:
• The machine is positioned on a smooth, firm surface on which the machine is capable of being leveled.
The primary operator control station is in the platform. From this control station, the operator can raise and lower the plat form. A ground control station is provided to lower the platform to the ground in an emergency if the operator in the platform is unable to do so, or if a power failure should occur.
Vibrations emitted by these machines are not hazardous to an operator in the work platform. The equivalent continuous A-
Weighted sound pressure level at the work platform is less than
70dB(A).
to
• Load is within manufacturer’s rated capacity.
• All machine systems are functioning properly.
• The machine is leveled and outriggers are properly installed as indicated by the outrigger interlock LED lights on the base frame.
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To order go
31215807 4-1
SECTION 4 - MACHINE OPERATION
4.3 BATTERY CHARGING & MAINTENANCE - (DC MODELS
ONLY)
AM-DC Models are equipped with a 12 volt, 10 amp output dual voltage (120/240V) input battery charger. The charger is microprocessor controlled featuring an automatic charge sens ing circuit which can determine cell voltage and regulate char ger output and terminate charging as required.
Battery Maintenance and Safety
BATTERY ACID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT
ALL TIMES.
1
1/8 "
(3mm)
4
2
BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO OPEN
FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE CHARGING
BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA.
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ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING DISTILLED WATER TO THE go to
The battery fluid level should be approximately 1/8" (3mm) below vent tubes.
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1.
Battery Filler Cap
2.
Vent Tube
3
3.
Fluid Level
4.
Cell Plates
4-2 31215807
SECTION 4 - MACHINE OPERATION
Battery Charger Operation
NOTICE
ALWAYS CHECK THE VOLTAGE SELECT SWITCH ON THE FACE OF THE BATTERY
CHARGER BEFORE OPERATION. IF NOT SET TO THE PROPER AC POWER INPUT
VOLTAGE, THE CHARGER MAY BE DAMAGED.
1.
Turn the ground control key switch to the OFF posi tion.
2.
Set the AC voltage switch on the face of the charger for the local AC line voltage.
4.
The charger runs through a self-diagnostic check. The
LED’s on the face of the charger flash in the following sequence; a.
First all five (5) LED’s flash three (3) times.
to
2
3.
Plug the battery charger AC power cable, stowed inside the battery/charger carrier (beside charger) into a properly grounded receptacle. Use a suitable exten sion cord, if necessary.
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3 b.
Next each LED lights in sequence.
c.
Finally all five (5) LED’s flash three (3) times again.
5.
When ready to charge, the CHARGER ON LED and the
To order go the charger will light up, the charger will then begin to charge the batteries.
Figure 4-2. Battery Box and Charger Assembly.
(D.C. Model Only)
1.
Battery Box/Charger Assembly
2.
DC Battery Charger
4
3.
Charger AC Power Cord
4.
DC - Battery to Machine Main
Power Connector
31215807 4-3
SECTION 4 - MACHINE OPERATION
6.
When the battery cell voltage reaches 2.37 V/cell the
80% CHARGE LED will light up. The charger then con tinues to monitor the increase in charge until it sees no increase, and then terminates the charging pro cess.
7.
The CHARGE COMPLETE (100%) LED will light when the batteries are fully charged.
8.
Unplug the charger AC power cord and stow the cord.
Abnormal Cycle Indicator LED
The ABNORMAL CYCLE indicator LED will light when;
• The AC input to the charger was interrupted.
• There is a dead cell or cells in the battery.
1
2
3
4
5
• One or more of the battery connectors are loose or cor roded.
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1.
% of Charge in Progress
LED’s (Green)
2.
Charger On LED (Green)
3.
Abnormal Cycle LED
(Yellow)
4.
Circuit AC Circuit Breakers
5.
AC Voltage Selection
Switch
To order
4-4 31215807
SECTION 4 - MACHINE OPERATION
4.4 MACHINE SET-UP AND OPERATION
Caster Brake Operation
To set-up machine for operation the operator must:
1.
Position machine in work area.
NOTE: If AC powered machine, connect machine to a grounded
AC receptacle with a heavy duty extension cord equipped with an equipment grounding conductor.
If DC powered machine, check battery box assembly is installed, battery is charged and connected to machine’s
DC receptacle.
1.
Press down on caster brake lever on both casters at front of machine to apply caster brakes.
2.
To disengage caster brake, apply pressure or lift up on caster brake lever.
2.
Set key switch to ON position at ground control sta tion.
3.
Check both emergency stop switches are in RESET position for operation.
4.
Check manual decent control valve (red knob) is closed.
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APPLY FRONT CASTER BRAKES SO MACHINE DOES NOT ROLL IN ANY DIREC -
TION. DO NOT INSTALL OUTRIGGERS OR ELEVATE PLATFORM UNTIL FRONT
CASTER BRAKES ARE LOCKED.
5.
Apply caster brakes.
6.
Install outriggers.
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Figure 4-4. Setting & Releasing Caster Brake
31215807 4-5
SECTION 4 - MACHINE OPERATION
Outrigger Installation
NOTICE
AS A SAFETY PRECAUTION, DUE TO DIFFERENT LENGTHS, OUTRIGGER BEAMS
ARE DESIGNED TO FIT A SPECIFIC MODEL AND ARE NOT INTERCHANGEABLE.
1.
Remove one outrigger beam from the stowage socket.
2.
Insert outrigger beam into an outrigger socket on the base frame with outrigger interlock contact on the bottom. Push outrigger beam in socket until locking pin on side of outrigger socket snaps into the outrig ger beam detent. Repeat for remaining outriggers.
3.
With all outriggers inserted, turn each outrigger jack down, lifting entire machine until all wheels are off the ground.
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4.
When all four (4) wheels are off the ground, use the bubble level on the base frame to level machine.
NOTICE go to
MACHINE WILL OPERATE ONLY IF ALL FOUR (4) INTERLOCK LED LIGHTS ARE
ILLUMINATED.
To order
4-6 31215807
SECTION 4 - MACHINE OPERATION
5
1
31215807
2
1.
2.
To
3.
Interlock LED’s to
3
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4
4.
Outrigger Beam Assembly
5.
Leveling Jack
4-7
SECTION 4 - MACHINE OPERATION
Platform Loading
platform maximum rated load capacity is shown on a placard located on the platform control panel. Applies to all available
AM model platforms.
Maximum capacity for each model is as follows:
Table 4-1. Maximum Platform Capacity.
MODEL
25AM -
DC/AC
30AM -
DC/AC
38AM -
DC/AC
Platform Operation
1.
Enter platform and close gate/slide bar.
2.
To raise platform, press FUNCTION ENABLE button and platform UP button simultaneously. Upon reaching desired elevation level, release UP and FUNCTION
ENABLE buttons.
PLATFORM CAPACITY
FOR MACHINES BUILT TO
SPECIFICATION
ANSI
350 lb.
(160 kg)
300 lb.
(136 kg)
300 lb.
(136 kg)
CHECK AREA BENEATH PLATFORM IS FREE OF PERSONNEL AND OBSTRUC -
TIONS PRIOR TO LOWERING PLATFORM.
CE
3.
To lower platform, press FUNCTION ENABLE button and platform DOWN button on control panel simulta neously.
350 lb.
(160 kg)
300 lb.
(136 kg)
300 lb.
(136kg)
To order go to
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4-8 31215807
SECTION 4 - MACHINE OPERATION
4.5 QUICK-CHANGE PLATFORM MOUNTS
1
The AM model is equipped with platform mounting for quick and simple exchange of platforms.
Platform Removal
1.
Remove both pins holding lower platform support rail to platform lower mount.
2.
Remove both pins holding upper platform support rail to platform upper mount.
3.
Using suitable lifting equipment or another person, swing lower platform support rail forward, away from mast to clear platform lower mount, then lift upper platform support rail up and out of platform upper mount.
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4
2
Figure 4-6. Quick Change Platform Mount.
1.
Platform Upper Mount
2.
Upper Mount Attach Pins
3.
4.
Platform Lower Mount
Lower Mount Attach Pins
31215807 4-9
SECTION 4 - MACHINE OPERATION
Platform Installation
1.
Using two people or suitable lifting equipment, lift platform and set platform upper support rail into the upper platform mount on the mast.
2.
Swing platform lower support rail into lower platform mount on the mast.
3.
Secure platform support rails with two (2) platform upper mount pins, and two (2) lower platform mount pins.
4.6 MACHINE SHUT DOWN AND PARK
1.
Ensure platform is fully lowered, turn key switch to
OFF position.
2.
Store outrigger beams in stowage sockets.
3.
Move machine to a well-protected and well-ventilated area. In a hostile environment, cover machine for pro tection.
4.
Apply caster brakes and chock at least two wheels when parking machine for extended time.
5.
Remove key switch to disable machine from unautho rized use.
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4-10 31215807
SECTION 4 - MACHINE OPERATION
4.7 TRANSPORT, LIFTING AND TIE DOWN
General
To move machine from work area to work area the operator may:
• Push machine on its base wheels.
• Push machine in Tilt-Back mode.
(38AM only)
• Move machine using a forklift.
• Load machine on back of a pickup truck, using the built-in load bar.
NOTE: 38AM machines are equipped with a permanently attached tilt-back assembly to allow machine to fit through standard size doorways.
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Transporting by Pushing
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The standard machine’s base frame is equipped with load bear ing wheels mounted on a straight axle at the mast end of the machine; and a pair of heavy duty swivel caster wheels order
REFER TO SECTION 1.2, TRANSPORTING SAFETY PRECAUTIONS BEFORE
TRANSPORTING MACHINE.
CAUTION
31215807 4-11
SECTION 4 - MACHINE OPERATION
Tilt-Back Assembly Set-up (AM38)
(See Figure 4-7., Figure 4-8. and Figure 4-9.)
3.
NOTICE
CAUTION
Lower the tilt-back assembly as far as it will go onto it’s rubber bumpers.
to
NOTE: If moving machine in other than a straight line forward, unlock tilt-back swivel wheels by pulling the swivel wheel lock pins out then turning pins 90° to the unlock position.
This will allow the tilt-back swivel wheels to rotate freely and steer machine while moving.
PLATFORM MUST BE FULLY LOWERED, AND OUTRIGGER BEAMS MUST BE
STOWED. ON DC MODELS ENSURE BATTERY BOX/CHARGER ASSEMBLY IS NOT
OBSTRUCTED AND IS CLEAR TO SWING ONCE MACHINE IS TILTED.
5.
(Step 3) Fully extend the T-handle lifting bar located under the front of the machine by pulling down on the release/lock pin located under the bar. Fully extend the lifting bar until the release/lock pin snaps back in, locking the bar in place. Push or pull bar to be certain it is secure before lifting machine.
REFER TO SECTION 1.2, TRANSPORTING SAFETY PRECAUTIONS BEFORE
TRANSPORTING MACHINE.
1.
Move machine to an area that is level, clear and free of obstacles.
2.
(Step 1) Hold the tilt-back assembly in place and remove the release pin securing the tilt-back assembly to the gas spring cylinder.
6.
(Step 4) With both hands on the grips of the T-handle lifting bar, carefully lift the front of the machine and
7.
tilt the machine back onto the tilt-back assembly and the gas spring cylinder.
Push machine around using the loop grips just behind the front swivel wheel assemblies under the base frame.
4.
(Step 2) Pull the gas spring cylinder out of it’s retaining clip on the back of the mast assembly. Lower and extend or retract the cylinder to guide the groove pins
To order go back crossbar assembly bracket. Secure the cylinder to the tilt-back crossbar bracket by replacing the pin removed in step 1 to lower the tilt-back assembly.
4-12 31215807
SECTION 4 - MACHINE OPERATION
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Step 1
Figure 4-7. Tilt-Back Assembly Set-Up
4-13
SECTION 4 - MACHINE OPERATION
4-14
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Figure 4-8. Tilt-Back Assembly Set-Up
Step 3
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SECTION 4 - MACHINE OPERATION
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Step 4
Figure 4-9. Tilt-Back Assembly Set-Up
4-15
SECTION 4 - MACHINE OPERATION
Pickup Truck Loading Device (Option)
NOTE: The stowed mast height of the 38AM exceeds the length of most pick-up truck beds. JLG does not recommend trans porting those models by pick-up truck.
AM model machines can be transported in a standard full size pickup truck. If the machine is equipped with the loading device option, it can be loaded and unloaded by one person.
3.
Begin lifting the machine onto the tailgate of the truck with the T-handle lifting bar. As machine begins to pivot be certain the load pivot bar is engaging the truck tailgate.
4.
Continue lifting and pushing machine onto the truck bed, firmly grasp the machine by the base frame pushing it all the way into truck bed.
5.
Secure machine to the truck bed with rope or tie down hooks to limit any machine movement while trans porting.
To unload machine from truck bed, reverse loading instructions above.
NOTE: For a smooth rolling surface and even weight distribution, it is recommended that 3/4" to 1" (2 to 2.5cm) thick ply wood be placed in the truck bed and out onto the tailgate.
This should avoid tailgate damage.
Park truck on a firm, smooth, level surface with the tailgate open. Remove the battery/charger storage box from DC model machines.
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1.
Set load pivot bar on back of mast so bar is set approx go to the spring loaded locking pin to raise or lower the load pivot bar. Once bar is locked in place, push machine against the tailgate.
2.
At front of the machine, extend the T-handle lifting bar from the base frame.
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4-16 31215807
SECTION 4 - MACHINE OPERATION
31215807 to
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Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
2
4-17
SECTION 4 - MACHINE OPERATION
4-18 go to
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3
To order
Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
4
31215807
SECTION 4 - MACHINE OPERATION
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5
Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
4-19
SECTION 4 - MACHINE OPERATION
Lifting
To lift the machine, use suitable lifting equipment capable of handling the weight of the machine.
NOTE: Fork lifts, cranes, chains, slings, etc. must be capable of handling the following weights:
Table 4-2. AM Machine Gross Weights
AM Model
25AM-AC
25AM-DC
30AM-AC
30AM-DC
38AM-AC
38AM-DC
NOTE: All AM models are equipped with forklift pockets at the mast end of frame for transporting the unit. An optional crane hook is available. Do not lift with a crane without the optional crane hook.
Machine Tie Down
Secure the machine to the transport vehicle using the tie down lug weldments provided on the rear and sides of the machine.
1.
Transport only with platform in the stowed position.
2.
Remove all loose items from machine.
Gross Weight
825 lb. (374kg)
905 lb. (411kg)
1030 lb.(467kg)
1110 lb.(503kg)
1265 lb.(574kg)
1395 lb. (633kg)
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4-20 31215807
SECTION 5 - OPTIONAL EQUIPMENT
SECTION 5. OPTIONAL EQUIPMENT
5.1 OPTIONAL EQUIPMENT
Crane Hook
The following optional equipment is available for AM model machines:
Attached at the top rear of the mast, the crane hook is used to lift the machine up or down to another level.
22" x 22" Quick-Change Platform
(Not Available in CE Markets)
Extra Power Pack
(Battery, Charger & Case)
The 22" (56cm) long by 22" (56cm) wide platform features a gull wing gate opening.
Includes the battery, charger and molded case.
Platform Auxiliary Power Lowering Device
26" x 26" Quick-Change Platform
(Not Available in CE Markets)
The 26" (66cm) long by 26" (66cm) wide platform features a side entry gate opening.
28" x 26" Quick-Change Platform
(Not Available in CE Markets)
The 28" (71cm) long by 26" (66cm) wide platform features a gull wing gate opening.
Tool Tray
The Platform Auxiliary Power Lowering device is a switch acti vated battery backed electrical circuit designed to provide power to the platform control box in the event of loss of the machines power supply.
(See Figure 5-1., Hour Meter Location.
The machine hour meter accumulates pump operation time during the platform LIFT UP cycle only. The reading indicates hours and tenths of an hour.
Platform attachment to hold hand tools or other small items placed in the tray.
Fluorescent Tube Caddy
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31215807 5-1
SECTION 5 - OPTIONAL EQUIPMENT
5-2
Figure 5-1. Hour Meter Location.
1. Hour Meter
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31215807
SECTION 6 - EMERGENCY PROCEDURES
SECTION 6. EMERGENCY PROCEDURES
6.1 GENERAL INFORMATION
Platform Caught Overhead
This section explains the steps to be taken in case of an emer gency situation while operating the machine.
6.2 EMERGENCY OPERATION
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE
TO OPERATE OR CONTROL THE MACHINE, USE THE FOLLOWING
INSTRUCTIONS AS A GUIDELINE.
1.
Other personnel should operate the machine from ground controls only as required.
2.
Only qualified personnel in the platform may use the platform controls. DO NOT CONTINUE OPERATION IF go to
3.
Cranes, forklift trucks or other equipment can be used to remove the platform occupant and stabilize motion of the machine.
To order
If the platform becomes jammed or snagged in overhead structures or equipment, do the following:
1.
Shut off the machine.
2.
Rescue all people in the platform before freeing the machine. Personnel must be out of the platform before operating any controls on the machine.
3.
Use cranes, forklifts or other equipment to stabilize motion of the machine to prevent a tip over as required.
4.
From the ground controls, carefully free the platform
5.
from the object.
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6.
Inspect the machine for damage. If the machine is damaged or 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.
-
31215807
SECTION 6 - EMERGENCY PROCEDURES
Righting of Tipped Machine
6.3 INCIDENT NOTIFICATION
Before righting a tipped machine, check machine for any dam age which may prevent it from setting properly on its base wheels once in a vertical position, (i.e. base wheels damaged, base frame distorted, etc.). Use a crane, forklift or other suitable lifting equipment and carefully lift the machine to an upright position.
JLG Industries, Inc. must be notified immediately of any inci dent involving a JLG product. Even if no injury or property damage is evident, JLG must be contacted by telephone and provided with all necessary details.
• USA: 877-JLG-SAFE (554-7233)
• EUROPE: (32) 0 89 84 82 20
• AUSTRALIA: (61) 2 65 811111 NOTICE
FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST
ALL FUNCTIONS. DO NOT LIFT ABOVE 10 FEET (3 METERS) UNTIL YOU ARE
SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND THAT ALL
CONTROLS ARE OPERATING CORRECTLY.
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• E-mail: [email protected]
NOTICE
FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE. DO NOT
ELEVATE THE PLATFORM UNTIL IT IS CERTAIN THAT ALL DAMAGE HAS BEEN
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6-2 31215807
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
SECTION 7. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
7.1 INTRODUCTION
This section of the manual provides additional necessary infor mation to the operator for proper operation and maintenance of this machine.
The maintenance portion of this section is intended as informa tion to assist the machine operator to perform daily mainte nance tasks only, and does not replace the more thorough
Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.
Other Publications Available Specific to this Machine:
Service and Maintenance Manual
ANSI . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . . . . 31215808
CE . . . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . . . . 31215808
Illustrated Parts Manual
ANSI . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . . . . 31215809
CE . . . . . .. . . .. . . .. . . .. . . . . . . . . . . .. . . .. . . .. . . . . . 31215809
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31215807 7-1
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
7.2 GENERAL SPECIFICATIONS
Machine Specifications
SPECIFICATION 25AM
30AM
(EXCEPT CE)
30AM
(CE ONLY)
38AM
Gross Machine Weight ( Platform Empty) : DC:
AC:
905 lb.
(411kg)
825 lb.
(374kg)
77.3 in.
(2m)
1110lb.
(503kg)
1030 lb.
(467kg)
77.3 in.
(2m)
1110lb.
(503kg)
1030 lb.
(467kg)
77.3 in.
(2m)
1395 lb.
(633kg)
1265 lb.
(574kg)
*77 in. (2m)
104.3 in. (2.64m)
Machine Height (Platform Stowed)
* Machine Height in Tilt-Back Mode
Maximum Outrigger Pad Load:
(per outrigger)
Outrigger Footprint: (Length x Width)
Machine Base - Overall : (Length x Width)
Maximum Wind Speed:
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Maximum Horizontal Manual Side Force:
(Platform fully extended with Maximum load) go to
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68x 62 in.
(1.72 x 1.57 m)
49 x 29 in.
(1.24m x 74cm)
79x 79 in.
(2.0 x 2.0 m)
52 x 29 in.
(1.32m x 74cm)
75x 72 in.
(1.90 x 1.83 m)
52 x 29 in.
(1.32m x 74cm)
510 lb.
(231kg)
86 x84 in.
(2.18 x 2.13m)
57.5 x 29 in.
(1.46m x 74cm)
0 mph (0kph) - Machine rated for indoor use only
45 Pound Force (200 Newtons)
Maximum Hydraulic System Pressure: Pressure Relief Set to 2800 PSI (193 bar) at Factory
7-2 31215807
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
Electrical Specifications
SPECIFICATION
System Voltage:
Battery Charger (DC Models)
25AM 30AM 38AM
DC Models:
AC Models:
12 Volts DC
100/120/240 Volts AC
Input: 120/240 Volts AC - 50/60 Hz - Voltage Selectable
Output: 12 Volt - 10 Amps DC - w/Auto Charge Sensing Circuit
Battery Specifications
Battery Type:
Voltage:
Amp Hour (AH) Rating:
Reserve Capacity:
Cold Cranking Amps:
Weight:
WET/DRY COMBO
105 Amp Hr. @ 20 Hr.
165 Min.
625 Amps @ 0° F to
AGM (VRLA)
100 Amp Hr. @ 20 Hr.
N/A
N/A
78 lb. (35kg)
To
31215807 7-3
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
Platform Data
SPECIFICATION 25AM 30AM
Occupants: (Persons allowed in Platform)
Platform Capacity : ANSI:
(U.S.A, Brazil, Japan, China, Latin America )
CE:
( Europe, Australia)
Platform Height - Mast Fully Extended - (Ground to Platform Floor ) :
350 lb.
(160 kg)
350 lb.
(160 kg)
25 ft.
(7.62 m)
300 lb.
(136 kg)
300 lb.
(136 kg)
30 ft.
(9.14 m)
Platform Working Height - (Average Size Person):
Platform Cycle Performance (in seconds) (w/max. rated load) go to
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Pump - Lift Up: 62 72
Lift Down:
31 ft.
(9.4 m)
32-42
36 ft.
(11 m)
32-42
To order
38AM
300 lb.
(136 kg)
300 lb.
(136 kg)
38 ft.
(11.58 m)
44ft.
(13.4 m)
120
45-55
7-4 31215807
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
Machine Component Weights
SPECIFICATION
Platform Weight :
DC Voltage Battery Pack: (Wet Cell)
Standard Platform:
25AM 30AM
55 lb. (25 kg)
70 lb. (32 kg)
38AM
Serial Number Locations
For machine identification, a serial number plate is affixed to the machine. The plate is located on the back of the mast, just above the mast support bracket.
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31215807 7-5
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
7.3 OPERATOR MAINTENANCE
Lubrication
Hydraulic Oil (HO) Table 7-1. - Lubrication Specifications
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
KEY SPECIFICATIONS
+0° F to +180° F (-18° C to -83° C)
SAE VISCOSITYGRADE
10W
MPG - Multipurpose Grease having a minimum dripping point of 350° F. Excel lent water resistance and adhesive qualities, and being of extreme pres sure type. (Timken OK 40 pounds minimum.)
+0° F to +210° F (-18° C to +99° C)
+50° F to +210° F (+10° C to +99° C)
10W-20, 10W-30
20W-20
EPGL - Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105.
Hydraulic oils must have anti-wear qualities at least to API Ser vice Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries, recommends standard UTTO hydraulic oil, which has an SAE viscosity of 10W-
30 and a viscosity index of 152.
For cold weather applications, i.e. when temperatures remain consistently below +20°F (–7°C) JLG recommends using Mobil
DTE 13 hydraulic oil.
To
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Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same
HO - Hydraulic Oil. ISO-Vg grade 32, 46.
CL - Chain Lube. Use a good quality chain lubricant
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7-6 31215807
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
Battery Maintenance
NOTE: This information applies to wet cell batteries only. Do not attempt to open a maintenance-free sealed battery.
Battery fluid level should be approximately 1/8" (3mm) below vent tubes. (See Illustration)
Keep cable connections clean and free of corrosion.
CAUTION
BATTERY ACID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
CLOTHING AT ALL TIMES.
1
1/8 "
(3mm)
4
2
3
BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO
OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA WHILE
CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED
AREA.
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ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING DISTILLED WATER
TO THE BATTERIES, A NON-METALLIC CONTAINER AND/OR FUNNEL MUST BE
USED.
Battery Fluid Level
1.
Battery Filler Cap
2.
Vent Tube
To order
3.
Fluid Level
4.
Cell Plates
31215807 7-7
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
4
1
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3
2
7-8 31215807
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
Table 7-2. - Lubrication Intervals for Various Components
INTERVAL HOURS
ITEM COMPONENT
NO/TYPE
LUBE POINTS
LUBE/METHOD
3
MONTHS
150 Hrs.
6
MONTHS
300 Hrs.
1
YEAR
600 Hrs.
1 Hydraulic Oil
Fill To Line on Reservoir
5 Qt. (4.3 L) Reservoir
HO/Check Hydraulic
Oil Level HO/Change Hydraulic
Oil
MPG - Pressure Gun 2 Swivel Raceways 2 - Front Casters X
3
Leveling Jack
Screws
4 - Jack Threads MPG - Brush
X
4 Mast Chains * 2 - Per Section
* Applies Only to Mast Sections with Chains.
Key to Lubricants: MPG - Multipurpose Grease
HO - Hydraulic Oil - ISO-Vg grade 32, 46.
to
CL - Chain Lube. Use a good quality chain lubricant
X
CL - Brush or Spray
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Notes:
2
YEARS
1200 Hrs.
X
Check oil level every day.
Change hydraulic oil every
2 years.
Inspect, lubricate if drying or rusting.
1. Be certain to lubricate like items on each side of the machine.
2. Recommended lubricating intervals are based on normal use. If machine is subjected to severe operating conditions, such as a high number of cycles, location, corrosive/dirty environment, etc., user must adjust lubricating requirements accordingly.
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4. Prior to checking hydraulic oil level, operate machine through one complete cycle of lift function (full up and down). Failure to do so will result in incorrect oil level reading on the hydraulic reservoir.
COMMENTS
31215807 7-9
SECTION 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
7.4 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 A-
Weighted 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 109 dB.
The vibration total value to which the hand-arm system is sub jected does not exceed 2,5 m/s2. The highest root mean square value of weighted acceleration to which the whole body is sub jected does not exceed 0,5 m/s2.
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7-10 31215807
31215807
DATE
SECTION 8 - INSPECTION AND REPAIR LOG
SECTION 8. INSPECTION AND REPAIR LOG
Machine Serial Number: _________________________
Table 8-1. Inspection and Repair Log
COMMENTS
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8-1
SECTION 8 - INSPECTION AND REPAIR LOG
DATE
Machine Serial Number: _________________________
Table 8-1. Inspection and Repair Log
COMMENTS
8-2
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31215807
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