JLG 3369LE, 4069LE, M3369, M4069 Aerial Lift Operation and Safety Manual

ANSI

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Model

3369LE/4069LE

M3369/M4069

S/N-0200230092 to Present

P/N - 3121638

June 10, 2014

®

3121638

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.

IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD

PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS,

JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DIS-

TANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPO-

NENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY

SATURATION.

– JLG Lift –

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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 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.

INDIC ATES A POTENTIALIT Y HA ZARDOUS 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 POTENTIALIT Y HA ZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE AN ORANGE BACKGROUND.

NOTICE

INDICATES INFORMATION OR A COMPANY POLIC Y THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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– JLG Lift – 3121638

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFET Y-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

NOTICE

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE C URRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

NOTICE

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 PROP-

ERTY OR THE JLG PRODUCT.

FOREWORD

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding

Product Safety

• 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 manual rear cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 240-420-2661

E-mail: [email protected]

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FOREWORD

REVISION LOG

Original Issue. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 10, 2014

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– JLG Lift – 3121638

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2

PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . 1-1

Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . 1-8

1.4

TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . 1-9

1.5

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . .1-10

Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10

SECTION - 2 - USER RESPONSIBILITIES, MACHINE

PREPARATION AND INSPECTION

2.1

PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . 2-1


2.2

PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.3

PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . .2-4

Preparing the Machine for Operation. . . . . . . . . 2-5

Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.4

OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Limit Switch Locations . . . . . . . . . . . . . . . . . . . . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2

CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . .3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-1

Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-3

SECTION - 4 - MACHINE OPERATION

4.1

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2

POWER SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

Platform/Ground Select . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3

RAISING AND LOWERING. . . . . . . . . . . . . . . . . . . . . . . .4-1

Raising & Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.4

LEVELING JACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5

PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . .4-2

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4.6

PLATFORM HANDRAILS FOLD DOWN

PROCEDURE (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . .4-2

4.7

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Traveling Forward and Reverse. . . . . . . . . . . . . . . 4-4

4.8

SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9

SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.10 BATTERY CHARGING PROCEDURE . . . . . . . . . . . . . . .4-5

4.11 TIE DOWN/LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SECTION - 5 - EMERGENCY PROCEDURES

5.1

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2

INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3

EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . .5-1

5.4

MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . . . . . .5-2

5.5

EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . .5-2

Operator Unable to Control Machine . . . . . . . . . .5-2

Platform Caught Overhead . . . . . . . . . . . . . . . . . . .5-2


SECTION - 6 - GENERAL SPECIFICATIONS AND

OPERATOR MAINTENANCE

6.1

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2

SUPPLEMENTAL INFORMATION. . . . . . . . . . . . . . . . . 6-1

6.3

OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Batteries (Electric Machines) . . . . . . . . . . . . . . . . . . 6-7

Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-8

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.4

OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-12

6.5

TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

Wheel Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 6-15

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

SECTION - 7 - INSPECTION AND REPAIR LOG

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– JLG Lift – 3121638


LIST OF FIGURES

2-1.

Walk-Around Inspection (Sheet 1 of 3) . . . . . . . . . . 2-8

2-2.

Walk-Around Inspection (Sheet 2 of 3) . . . . . . . . . . 2-9

2-3.

Walk-Around Inspection (Sheet 3 of 3) . . . . . . . . .2-10

2-4.

Limit Switch Locations. . . . . . . . . . . . . . . . . . . . . . . . .2-11

3-1.

Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2.

Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . 3-6

3-3.

Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

3-4.

Decal Installation (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . 3-8

3-5.

Decal Installation (ANSI Export) . . . . . . . . . . . . . . . .3-11

3-6.

Decal Installation (CE/AUS) . . . . . . . . . . . . . . . . . . . .3-17

4-1.

Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2.

Lifting & Tie Down Chart - Sheet 1 of 2 . . . . . . . . . . 4-6

4-3.

Lifting & Tie Down Chart - Sheet 2 of 2 . . . . . . . . . . 4-7

6-1.

Engine Operating Temperature Specifications -

(Kubota) Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-2.

Engine Operating Temperature Specifications -

(Kubota) Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-3.

Operator Maintenance and

Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . .6-12



LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3

2-2 Drive Limits. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

2-3 Tilt vs. Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-1 Decal Location Legend (ANSI) . . . . . . . . . . . . . . . . . . 3-9

3-2 Decal Location Legend (ANSI Export) . . . . . . . . . . 3-12

3-3 Decal Location Legend (CE/AUS) . . . . . . . . . . . . . . 3-18

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-5 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-6 Engine Battery Specifications. . . . . . . . . . . . . . . . . . . 6-7

6-7 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-8 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-9 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-10 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . 6-11

6-11 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . 7-1

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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

This page left blank intentionally.

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– JLG Lift – 3121638

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1

GENERAL

This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to promote proper machine usage, 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 must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must 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.

These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation.If

there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MAN-

UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL

INJURY OR DEATH.

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1.2

PRE-OPERATION

Operator Training and Knowledge

• The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

• An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.

• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.

• Read, understand, and obey all DANGERS, WARNINGS, CAU-

TIONS, and operating instructions on the machine and in this manual.

• Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG.

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

• Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utilization and application of the machine.

Workplace Inspection

• Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.

• Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG.

• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.

• Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

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– JLG Lift – 3121272


• Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

• This machine can be operated in nominal ambient temperatures of 0 o

F to 104 o

F (-20 o

C to 40 o

C). Consult JLG to optimize operation outside of this temperature range.

Machine Inspection

• Do not operate this machine until the inspections and functional checks have been performed as specified in Section 2 of this manual.

• Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and

Maintenance Manual.

• Ensure all 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 PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.

• Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck.

1.3

OPERATION

General

• Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.

• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.

• Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.

• Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities.

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• Do not remove, modify, or disable any safety devices.

• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

• Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.

• Do not carry materials directly on platform railing unless approved by JLG.

• When two or more persons are in the platform, the operator shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leaving machine.

• Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.

• 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.

• 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 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.

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– JLG Lift – 3121272


Trip and Fall Hazards

• Prior to operation, ensure all gates and rails are fastened and secured in their proper position.

.

• JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc.

• Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. Attach only one

(1) lanyard per lanyard anchorage point.

• Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

• Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.

• Never use the scissor arm assembly to gain access to or leave the platform.

• Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

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Electrocution Hazards

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the

Minimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintain a clearance of at least 10 ft. (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.

• 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.

1-6

– JLG Lift – 3121272


DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).

ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-

ERWISE.

Table 1-1. Minimum Approach Distances (M.A.D.)

VOLTAGE RANGE

(Phase to Phase)

MINIMUM APPROACH DISTANCE in Feet (Meters)

0 to 50 KV

Over 50KV to 200 KV

Over 200 KV to 350 KV

Over 350 KV to 500 KV

10 (3)

15 (5)

20 (6)

25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where employer, local or governmental regulations are more stringent.

Tipping Hazards

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.

• The user must be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving.

• Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.

• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

• Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

• Do not operate the machine when wind conditions exceed specifications shown in Section 6 of this manual or as shown on the capacity placard on the platform billboard.

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1-7


DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 5, TABLE 5-2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLAT-

FORM BILLBOARD.

Table 1-2. Beaufort Scale (For Reference Only)

5

6

3

4

0

1

2

BEAUFORT

NUMBER

7

8

9

WIND SPEED

DESCRIPTION LAND CONDITIONS mph m/s

0

1-3

4-7

8-12

13-18

19-24

0-0.2

Calm

0.3-1.5

Light air

1.6-3.3

Light breeze

3.4-5.4

Gentle breeze

5.5-7.9

Moderate breeze

8.0-10.7

Fresh breeze

25-31 10.8-13.8

Strong breeze

Calm. Smoke rises vertically.

Wind motion visible in smoke.

Wind felt on exposed skin. Leaves rustle.

Leaves and smaller twigs in constant motion.

Dust and loose paper raised. Small branches begin to move.

Smaller trees sway.

Large branches in motion. Flags waving near horizontal. Umbrella use becomes difficult.

32-38 13.9-17.1

Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.

39-46 17.2-20.7

Fresh Gale Twigs broken from trees. Cars veer on road.

47-54 20.8-24.4

Strong Gale Light structure damage.

1-8

– JLG Lift – 3121272

3121272


• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

• Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine.

• Do not increase the platform size with unauthorized deck extensions or attachments.

• If the scissor arm assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personnel.

• Keep hands and limbs out of the scissor arm assembly during operation and when elevated without safety prop engaged.

• Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.

– JLG Lift –

1-9


• During operation, keep all body parts inside platform railing.

• 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 operations.

• Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors.

1-10

– JLG Lift –

• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping.

Travel grades in low speed only.

• Do not use high speed drive in restricted or close quarters or when driving in reverse.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence.

Disconnect power to overhead cranes. Barricade floor area if necessary.

• Do not operate over ground personnel. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary.

3121272


1.4

1.5

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 emergency towing procedures.

• Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling.

• When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity.

• Refer to Section 3 for lifting information.

MAINTENANCE

This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.

• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

• Ensure replacement parts or components are identical or equivalent to original parts or components.

3121272 – JLG Lift –

1-11


• Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.

• Use only approved non-flammable cleaning solvents.

• Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification.

Do not modify unit in any way to affect stability.

• Reference the Service and Maintenance Manual for the weights of critical stability items.

Battery Hazards

• Always disconnect batteries when servicing electrical components or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery during charging or servicing.

• Do not contact tools or other metal objects across the battery terminals.

• Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE

MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND

CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH

CLEAN WATER AND SEEK MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.

1-12

– JLG Lift – 3121272

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.1

PERSONNEL TRAINING

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.

Operator Training

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.

3. Rules of the employer and government regulations.

4. Use of approved fall protection equipment.

5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.

6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

7. Means to avoid the hazards of unprotected electrical conductors.

8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

3121638 – JLG Lift –

2-1


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.

NOTICE

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNI-

CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE

TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

2-2

– JLG Lift – 3121638


Type

Pre-Start

Inspection

Pre-Delivery

Inspection (See Note)

Table 2-1.Inspection and Maintenance Table

Frequency

Primary

Responsibility

Service

Qualification

Before using each day; or whenever there’s an Operator change.

User or Operator User or Operator

Reference

Before each sale, lease, or rental delivery.

Owner, Dealer, or User Qualified JLG Mechanic

Operator and Safety Manual

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.

Annual Machine Inspection

(See Note)

Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or User

Factory Certified Service

Technician

(Recommended)


Preventative

Maintenance

At intervals as specified in the Service and Maintenance Manual.


Service and Maintenance Man-

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

ual

3121638 – JLG Lift –

2-3


2.3

PRE-START INSPECTION

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.

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.

4.

Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual is enclosed in the weather resistant storage container.

5.

“Walk-Around” Inspection – Refer to Figure 2-1.,

Walk-Around Inspection (Sheet 1 of 3).

6.

Battery – Charge as required.

7.

Fuel - (Combustion Engine Powered Machines) – Add the proper fuel as necessary.

8.

Engine Oil Supply - Ensure that the engine oil level is at the full mark on the dipstick and the filler cap is secure

9.

Fluid Levels - Be sure to check the engine oil and the hydraulic oil levels.

10.

Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

11.

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 on the operation of each function.

2-4

– JLG Lift – 3121638


Preparing the Machine for Operation

Emergency Ground Control Station

1. Turn key-switch to ground control select.

2. Pull emergency stop switch to the On position.

3. Check the function of the protective scissor cage.

Platform Control Box

1. Ensure the control box is connected at the platform.

2. Complete pre-operational checks:

a. Check all functions

b. Machine should not be drivable with outriggers extended.

c. Check all limit switches

d. Check the emergency-STOP button

e. Check the automatic self levelling

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE

IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PER-

SONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR

OPERATION.

Function Check

Perform the Function Check as follows:

1. From the ground emergency control panel with no load in the platform:

a. Check for proper lifting and lowering of the platform.

b. Check manual descent.

c. Ensure that all machine functions are disabled when the Emergency Stop Button is activated.

NOTE:

Be sure the platform extension is retracted before lowering.

2. From the platform control console:

a. Ensure that the control console is firmly secured in the proper location.

b. Check that all guards protecting the function control switches are in place.

c. Check the high drive cut out switch by raising the platform beyond the preset high drive speed cutout height (stowed) and ensure the high drive speed cuts out.

d. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in.

3121638 – JLG Lift –

2-5


e. Ensure that all LED’s in the control box are working properly.

f. Check that the platform extension extends and retracts properly.

3. With the platform in the stowed position:

a. Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold.

b. The red warning LED on the control panel indicates the chassis is on a slope beyond the rated limit from side to side and/or front to rear when the platform is in the stowed position.

Model

3369LE/M3369

4069LE/M4069

M4069 (AUS Full Drive

Height Model)

Table 2-2. Drive Limits

High Drive

Cutout

Above Stowed

Above Stowed

Above Stowed

Drive Cutout

N/A

30 ft (9.1 m)

N/A

Drive at Creep

Speed

N/A

N/A

28 ft - 30 ft

(8.5 m - 9.1 m)

Table 2-3. Tilt vs. Height

Tilt

Height

Left - Right Front - Back

< 25 ft (7.6 m)

< 30 ft (9.1 m)

Full Height

3369LE/M3369 (ANSI/CE/Australia/Japan)

5°

4°

3°

5°

5°

5°

Full Height

3369LE/M3369 (CSA)

3° 3°

3369LE/M3369 (CE) - 37 mph (16.7 m/s) wind-speed option

< 25 ft (7.6 m)

Full Height

4°

2°

4069LE/M4069 (ANSI/CE/Australia/Japan)

5°

4°

< 30 ft (9.1 m)

< 36 ft (11 m)

Full Height

Full Height

5°

4°

3°

4069LE/M4069 (CSA)

3°

5°

5°

5°

3°

NOTE:

When the limits are exceeded, drive and lift-up functions are cutout.

2-6

– JLG Lift – 3121638

2.4

OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

NOTICE


LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYS-

TEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS

SUSPECTED.

NOTE:

Ensure platform is fully lowered prior to beginning lockout cylinder test.

1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left rear wheel.

2. From platform control station, select LOW drive speed.

3. Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until left rear wheel is on top of block.

4. Raise machine platform approximately 7 ft (2.1 m) on the 3369LE or 9 ft (2.7 m) on the 4069LE.

5. Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp.

6. Have an assistant check to see that the left rear wheel remains locked in position off the ground.

7. Lower the machine platform; the lockout cylinder should then release and allow wheel to rest on the ground. It may be necessary to activate DRIVE to release cylinders.

8. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right rear wheel.

9. From platform control station, select LOW drive speed.

10. Place DRIVE control switch to FORWARD position and carefully drive the machine up ascension ramp until right rear wheel is on top of block.

11. Raise machine platform approximately 7 ft (2.1 m) on the 3369LE or 9 ft (2.7 m) on the 4069LE.

12. Place DRIVE control switch to REVERSE position and carefully drive the machine off the block and ramp.

13. Have an assistant check to see that the right rear wheel remains locked in position off the ground.

14. Lower the machine platform; the lockout cylinder should then release and allow wheel to rest on the ground. It may be necessary to activate DRIVE to release cylinders.

15. If the lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3121638 – JLG Lift –

2-7


2-8

Figure 2-1. Walk-Around Inspection (Sheet 1 of 3)

– JLG Lift – 3121638


GENERAL

Begin the “Walk-Around Inspection” at Item 1, as noted on the diagram. Continue Left (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DURING

“WALK-AROUND INSPECTION”.

NOTICE

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECK-

ING THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDITIONS WHICH

COULD CAUSE EXTENSIVE MACHINE DAMAGE.

3. Spindle, Tie Rod and Steer Linkage (left front) - See

Note

4. Wheels and Tires -Properly secured, no missing lug nuts. Refer to section 6, Tires and Wheels. Inspect wheels for damage and corrosion

5. Steer Cylinder - See Note

6. Hydraulic Reservoir - Recommended hydraulic fluid level on level indicator on tank. Breather cap secure and working.

7. Hydraulic Pump - See Note

8. Hydraulic Motor - See Note

9. Battery Compartment - Proper electrolyte level.

10. Battery Disconnect - See Note

11. Oscillating Axle, Oscillation Cylinder - See Note

12. Drive Hubs - See Note

13. Brake, Left Rear - See Note

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.

1. Platform Control Console - Placard secure and legible, control lever and switches return to neutral, control lever lock and emergency stop switch function properly, manual in storage box.

2. Leveling Jacks - See Note


3121638 – JLG Lift –

2-9


14. Limit Switch - See Note

15. Ladder - See Note

16. Manual Descent - See Note

17. Limit Switch - See Note

18. Brake, Right Rear - See Note

19. Oscillation Cylinder - See Note

20. Battery Disconnect - See Note

21. Lift Cylinder - See Note

22. Generator Fuel Supply - See Note

23. Ground Controls - Placard secure and legible, control switches return to neutral position, emergency stop switch functions properly. Control markings legible.

24. Control Valve - No unsupported wires or hoses; no damaged or broken wires.

25. Sizzor Arms and Sliding Wear Pads - See Note

26. Spindle, Tie Rod and Steer Linkage (right front) - See

Note

27. Battery Charger or Generator - See Note

28. Platform/Handrail Installation (Not Shown) - See

Note


2-10

– JLG Lift – 3121638

Limit Switch Locations


1

1. Proximity Sensor Switch

2. Rotary Angle Sensor Switch

2

3121638

Figure 2-4. Limit Switch Locations

– JLG Lift –

2-11


NOTES:

2-12

– JLG Lift – 3121638

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1

GENERAL

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.

3.2

CONTROLS AND INDICATORS

Ground Control Station

(See Figure 3-1.)

DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN

PLATFORM EXCEPT IN AN EMERGENCY.

NOTE:

When machine is shut down, the ground control emergency stop switch must be positioned to OFF to prevent draining the batteries.

1. Power/Emergency Stop

A two-position red mushroom shaped switch furnishes power to Platform/Ground Select switch when pulled out (on). When pushed in (off ), power is shut off to the Platform/Ground Select switch.

2. Platform/Ground Select

A three position, key operated switch supplies power to platform control console when positioned to platform. With the key held in the ground position, power is shut off to platform and only ground controls are operable.

3121638 – JLG Lift –

3-1

.


PLATFORM/GROUND

SELECT SWITCH

CIRCUIT

BREAKER

EMERGENCY

STOP SWITCH

3-2

HOURMETER

PLATFORM

OVERLOAD

INDICATOR

GENERATOR

SWITCH

SYSTEM

FAULT

LIFT

SWITCH

Figure 3-1. Ground Control Station

– JLG Lift – 3121638


NOTE:

With Platform/Ground Select in center position, power is shut off to controls at both operating stations.

3. Lift/Lower

A three position, momentary contact lift control switch provides raising and lowering of the platform when positioned to up or down.

4. Generator Start Switch (Optional)

A momentary contact, push button switch is provided to manually start the optional generator

5. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded. An audible alarm will also signal when the platform is overloaded.

NOTE:

If the Overload Indicator is illuminated, all functions will be prevented from the platform controls. Using the ground controls or manual descent, fully lower the machine and reduce the weight in the platform to not exceed the rated workload indicated on the capacity decal.

6. Hourmeter

The hourmeter indicates the number of hours the machine has been operated.

7. Circuit Breaker

If the circuit breaker opens this indicates a short or overload on the machine.

8. System Fault

Illuminates when there is any type of fault in the electrical system.

3121638 – JLG Lift –

3-3


Platform Control Station

(See Figure 3-2. and Figure 3-3.)

1. Power/Emergency Stop

A two-position red mushroom shaped switch furnishes power to Platform/Ground Select switch when pulled out (on). When pushed in (off ), power is shut off to the Platform/Ground Select switch.

2. Controller (Joystick)

The Joystick controls four functions: drive, steer, lift and optional outriggers. The drive or the lift function switch must be selected before operating the joystick.

The controller is ‘ramped’ to allow variable speed.

3. Steer

Steering is controlled by a thumb-operated switch on top of the Joystick.

4. Low/High Speed

The two position speed switch controls high or low range travel speed.

NOTE:

Travel speed will automatically be reduced to low drive when the platform is raised above the stowed position.

For M4069 (AUS Full Drive Height Model), low drive speed is cut back to creep drive speed above 28 - 30 ft (8.5 - 9.1

m) up to the maximum height of 40 ft (12.2 m).

5. Drive Select

When selected, the drive function will be active for 3 seconds. The operator has 3 seconds to select the desired direction of travel.

DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLAT-

FORM IS RAISED ABOVE THE STOWED POSITION. FOR AUSTRALIAN FULL

DRIVE HEIGHT MODEL, DO NOT OPERATE IF LOW DRIVE SPEED IS NOT CUT

BACK TO CREEP DRIVE SPEED ONCE PLATFORM IS RAISED ABOVE 28 - 30 FT

(8.5 - 9.1 M)

6. Lift /Lower

When selected, the lift function will be active for 3 seconds. The operator has 3 seconds to select the desired direction of lift.

DO NOT LOWER WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTEN-

SION.

7. Leveling Jacks (Optional, Mandatory on M4069 AUS

Full Drive Height Model)

When selected, the leveling jack function will be active for 3 seconds in order to raise or lower the jacks. Indicator lights will illuminate signaling the leveling jacks

3-4

– JLG Lift – 3121638


are being set or retracted. See Figure 3-3., Indicator

Panel

8. Generator Enable Switch (Optional)

The Generator Enable 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.

9. All Wheel Drive (Optional)

Activating the All Wheel Drive switch allows the operator to engage the front drive motors for a pre-set time of 10 seconds. The control system may also engage the posi-track function automatically. This occurs when the rear wheels begin to slip and the joystick is engaged at 75%. This is pre-set to remain engaged for 10 seconds.

NOTE:

All Wheel Drive does not aid in climbing a grade.

10. Horn

If pressed, this switch supplies power to the horn.

11. Tilt Indicator Warning LED

The red warning LED on the control panel the illuminates when the chassis is on a slope greater than what the machine is programmed for.

12. Tilt Alarm Warning Horn

The Tilt Alarm Warning Horn is activated when the chassis is on a slope greater than what the machine is programmed for and the platform is elevated.

13. Battery Charge Indicator

This indicates the level of charge remaining in the batteries.

3121638 – JLG Lift –

3-5


3-6

ALL WHEEL

DRIVE

HORN

DRIVE

SELECTOR

POWER/

EMERGENCY

STOP

A

SPEED

SELECTOR

A

B

1705911B

PLATFORM

OVERLOAD

LED

ENABLE

TRIGGER

STEER

BUTTON

1705912B

LIFT

SELECTOR

JOYSTICK

Figure 3-2. Platform Control Station

– JLG Lift –

LEVELING

JACKS

GENERATOR

ENABLE SWITCH

3121638

3121638


DRIVE

LIFT

BATTERY CHARGE

INDICATOR

TILT

SYSTEM

FAULT

LEVELING

JACKS

(SET)

LEVELING

JACKS

(RETRACTED)

Figure 3-3. Indicator Panel

– JLG Lift –

3-7


3-8

Figure 3-4. Decal Installation (ANSI)

– JLG Lift – 3121638

3121638

Table 3-1. Decal Location Legend (ANSI)

Item

1-3

4

5

6

7

8

9

10

11

12

13

14

15

16-18

ANSI

0270591

--

1001131270

1701644

--

1702153

1702155

1702631

1703816

1704211

1704412

--

3251813

1001092250

--

– JLG Lift –



Item

ANSI

0270591

19

USA manufactured - Prior to S/N

0200101481

1703788

USA manufactured - S/N

0200101481to present

Belgium Manufactured - S/N

1200000398 to present

20

21

22

23

24

25

26 to 33

34

35

36

1701509

1701509

1703811

1703812

1703814

1704277

1703819

1703822

--

1703687

--

1704911

3-9



Item

37

38

39

40

41

101

102

103

(M3369/M4069

ANSI California Spec only)

104

105

3369LE & M3369

4069LE & M4069

106

(4WD only)

ANSI

0270591

1703818

1703821

1704903

1703813

1704248

--

1704174

1702962

--

1001125438

1001125437

1704998

3-10

– JLG Lift –


Item

ANSI

0270591

107

3369LE

4069LE

M3369

M4069

108

3369LE & M3369

4069LE & M4069

109

(M3369/M4069 only)

110

111

112

113

(M3369/M4069 only)

1704783

1704784

1704908

1704909

1703490

1704953

1704286

1702773

1704885

1704830

1701505

3121638


3121638

Figure 3-5. Decal Installation (ANSI Export)

– JLG Lift –

3-11


Item #

1-3

4

5

Brazilian

0270601

--

1700584

1701644

Table 3-2. Decal Location Legend (ANSI Export)

Chinese

0272005

--

1700584

1701644

CSA

0272653

--

1700584

1701644

Japanese

0270602

--

1700584

1701644

3252191 -3252191

6

USA manufactured - Prior to S/

N 0200108331



Belgium manufactured - Prior to S/N 1200000459



3252191

1705303

3252191

1705303

1705303

3252191

1705303

--

--

--

1705303

3252191

1705303

Latin American

0270600

--

1700584

1701644

3252191

1705303

3252191

1705303

Korea

0275688

--

1700584

1701644

3252191

1705303

3252191

1705303

3-12

– JLG Lift – 3121638

3121638

8

9

10

11

12

Item #

7


Brazilian

0270601


Chinese

0272005

CSA

0272653

1704007

(USA manufactured - Prior to S/N 0200108331)

Japanese

0270602

1704008

1704607

1704006

(USA manufactured - S/N

0200108331to present)

1704007

(Belgium manufactured -

Prior to S/N 1200000459)

1704006

(Belgium Manufactured - S/

N 1200000459 to present)

1701621

Latin American

0270600

1704006

Korea

0275688

1703962

1702155

1702631

1704699

1704211

1704412

1702155

1702631

1705195

1704211

1704412

1702155

1702631

1704684

1704211

1704412

1702155

1702631

1704278

1704211

1704412

1702155

1702631

1704691

1704211

1704412

1702155

1702631

1707021

1704211

1704412

– JLG Lift –

3-13


Item #

13

14

15

16-17

18

19

USA manufactured - Prior to S/

N 0200101481





Brazilian

0270601

--

3251813

3252645

--

2901912


Chinese

0272005

--

3251813

3252645

--

2901912

CSA

0272653

--

3251813

3252645

--

2901912

Japanese

0270602

--

3251813

3252645

--

2901912

1703788

1701509

1703788

1701509

1703788

1701509

1703788

1701509

20

21

22

23

1701509

1703811

1703812

1703814

1704277

1701509

1703811

1703812

1703814

1704277

1701509

1703811

1703812

1703814

1704277

1701509

1703811

1703812

1703814

1704277

Latin American

0270600

--

3251813

3252645

--

2901912

1703788

1701509

1701509

1703811

1703812

1703814

1704277

Korea

0275688

--

3251813

3252645

--

2901912

1703788

1701509

1701509

1703811

1703812

1703814

1704277

3-14

– JLG Lift – 3121638

3121638

Item #

24

25

26-33

34

35

36

37

38

39

40

41

101

102

103-104

105

3369LE & M3369

4069LE & M4069


Brazilian

0270601

1704702

1704916

1704341

1704330

--

1704174

--

1703819

1703822

--

1703687

--

1704915

1704701


Chinese

0272005

1705194

1705098

1704344

1704333

--

1704174

--

1703819

1703822

--

1703687

--

1705097

1705193

CSA

0272653

1703819

1703822

--

1703687

--

1704904

1704686

1704687

1704912

1704340

1704329

--

1704174

--

Japanese

0270602

1705398

1704918

1704342

1704331

--

1704174

--

1703819

1703822

--

1703687

--

1704917

1705394

Latin American

0270600

1704694

1704914

1704339

1704329

--

1704174

--

1703819

1703822

--

1703687

--

1704913

1704693

Korea

0275688

1703819

1703822

--

1703687

1707026

1707018

1707020

1707024

1707022

1707025

--

1704174

--

1001125438

1001125437

– JLG Lift –

3-15


Brazilian

0270601


Chinese

0272005

CSA

0272653

Japanese

0270602

Item #

106

(4WD only)

107

3369LE

4069LE

M3369

M4069

108

3369LE & M3369

4069LE & M4069

109

(M3369/M4069 only)

110

111

112

(M3369/M4069 only)

113

1704998

1704783

1704784

1704908

1704909

1703490

1704953

1704373

1702773

1704885

1704830

1701505

1704998

1704783

1704784

1704908

1704909

1703490

1704953

--

1702773

1704885

1704830

1701505

1704998

1704783

1704784

1704908

1704909

1703490

1704953

1704368

1702773

1704885

1704830

1701505

1704998

1704783

1704784

1704908

1704909

1703490

1704953

1704369

1702773

1704885

1704830

1701505

Latin American

0270600

1704998

1704783

1704784

1704908

1704909

1703490

1704953

1704371

1702773

1704885

1704830

1701505

Korea

0275688

1704998

1704783

1704784

1704908

1704909

1703490

1704953

--

1702773

1704885

1704830

1701505

3-16

– JLG Lift – 3121638


3121638

Figure 3-6. Decal Installation (CE/AUS)

– JLG Lift –

3-17


19

20

21

22

23

11

12

13 - 17

18

9

10

7

8

1 - 3

4

5

6

Item #

Table 3-3. Decal Location Legend (CE/AUS)

CE/AUS

0275084

3369LE/4069LE

1704211

1704412

--

2901912

1701509

1703811

1703812

1703814

1704277

--

1700584

1701644

1706338

--

1702155

1702631

--

CE/AUS

0275085

M3369/M4069

1704211

1704412

--

2901912

1701509

1703811

1703812

1703814

1704277

--

1700584

1701644

1706338

1705084

1702155

1702631

--

3-18

– JLG Lift – 3121638

3121638


Item #

24

25

26 - 32

33

34 - 35

36

37

38

39

40

41

42

Table 3-3. Decal Location Legend (CE/AUS)

CE/AUS

0275084

3369LE/4069LE

1703819

1703822

--

1703687

--

1706338

1705670

1706492

--

1704530

1706491 (3369LE - 37 mph (16.7 m/s) wind-speed option)

1703490 (3369LE)

1704953 (4069LE)

1704174

CE/AUS

0275085

M3369/M4069

1703819

1703822

--

1703687

--

1706338

1705670

1706492

--

1704530 (M3369)

1704580

1703490 ( M3369)

1704953 ( M4069)

1704174

– JLG Lift –

3-19


NOTES:

3-20

– JLG Lift – 3121638

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1

DESCRIPTION

This machine is a self-propelled hydraulic lift equipped with a work platform on an elevating scissor mechanism. Vibrations emitted by these machines are not hazardous to an operator in the work platform. The equivalent continuous A-Weighted sound pressure level at the work platform is less than 70 dB(A).

The 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 machine has a Ground Control Station which will override the Platform

Control Station. Ground Controls operate lift and lower 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. Ground

Control is also to be used in Pre-Start Inspection.

4.2

POWER SELECT

Platform/Ground Select

The Platform/Ground Select switch directs power to the Ground or Platform controls as selected. For power, the POWER/EMER-

GENCY STOP switch must also be pulled out (on).

4.3

RAISING AND LOWERING

Raising & Lowering

To raise or lower the platform, either use Lift or Lower function and hold switch until desired elevation is reached.

DO NOT LOWER WITHOUT COMPLETELY RETRACTING PLATFORM EXTENSION.

3121638 – JLG Lift –

4-1


4.4

LEVELING JACKS

Once the leveling jacks leave the stowed position (fully retracted) but are not fully extended, the lift and drive functions are cut out.

After all 4 jacks are extended and touch a solid surface only the drive function is cut out. Drive function is restored once the jacks are stowed (fully retracted) again.

4. Remove the two pins from rear handrail, lift up and fold gate down onto platform deck.

5. Lift up left handrail, fold handrail down onto platform deck.

6. Lift up right handrail, fold handrail down onto platform deck.

4.5

PLATFORM EXTENSION

The machine is equipped with a mechanically extendible deck.

To extend the deck, lift handle up on the left and right side of the platform to release the latch and use the handle to push the extendible deck out. When the deck reaches the end of its travel, push handle down to latch, this will lock and hold the deck in place. To retract the deck, reverse operation.

4.7

STEERING

Position thumb switch on drive/lift/steer controller to right for steering right, or to left for steering left.

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDE

SLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDE SLOPES EXCEEDING

THOSE SPECIFIED ON WARNING PLACARD AT PLATFORM.

4.6

PLATFORM HANDRAILS FOLD DOWN PROCEDURE (IF

EQUIPPED)

1. Remove the two pins from platform extension gate and fold gate to the left side handrail.

2. Remove the pin from extension left side handrail, lift up and fold down handrail onto platform deck.

3. Remove the pin from extension right side handrail, lift up and fold down onto platform deck.

4-2

– JLG Lift – 3121638


3121638

Figure 4-1. Grade and Sideslope

– JLG Lift –

4-3


Traveling Forward and Reverse

1. At platform controls, pull out emergency stop switch and select the drive switch.

2. Position drive controller to forward or reverse as desired.

DIRECTION OF DRIVE AND STEER MOVEMENT MAY BE OPPOSITE FROM NOR-

MAL OPERATION. BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTA-

TION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE

THE DRIVE CONTROLS IN A DIRECTION MATCHING THE ORIENTATION

ARROWS.

REV FWD

4.8

SHUT DOWN AND PARK

NOTE:

When parking overnight, batteries should be charged properly to ensure readiness for next workday.

To shut down and park the machine, the procedures are as follows:

1. Drive machine to a reasonably well protected area.

2. Ensure platform is fully lowered.

3. Push in the Emergency Stop at platform controls.

4. Push in the Emergency Stop at ground controls. Position platform/ground select switch to center off.

5. If necessary, cover Platform Controls to protect instruction placards, warning decals and operating controls from hostile environment.

6. Chock at least two wheels when parking machine for an extended period of time.

IF TILT ALARM IS ON WHEN PLATFORM IS RAISED, STOP DRIVING AND

LOWER PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO THAT IT IS

LEVEL BEFORE RAISING PLATFORM.

4-4

– JLG Lift – 3121638


4.9

SAFETY PROP

SAFETY PROP MUST BE USED WHEN MAINTENANCE REQUIRES SIZZOR ARMS

TO BE RAISED.

1. To engage safety prop, raise platform, pull ring to release safety prop, then rotate prop clockwise until it hangs vertically. Lower the platform until the safety prop rests between the two extended cross-shafts.

2. To store safety prop, reverse operation of step 1.

4.10 BATTERY CHARGING PROCEDURE

The battery charger receptacle is located at the front of the machine. The receptacle is located in the molded front panel.

1. Connect the charger receptacle to a 115 volt (220 volt) power outlet with a 15 amp minimum capacity.

2. The batteries are charged fully when the 100% LED is lit. At this time, the charger will shut off automatically.

NOTE:

Discharged batteries will take approximately 23 hours to charge.

4.11 TIE DOWN/LIFTING

Tie Down

1. Place platform in stowed position and retract deck extension.

2. Remove all loose items from machine.

3. Secure the chassis using straps or chains of adequate strength.

Lifting

NOTE:

See manufacturer’s nameplate for gross weight of machine as originally manufactured.

1. Place platform in stowed position and retract deck extension.

2. Remove all loose items from machine.

3. Properly adjust rigging to prevent damage to machine and so machine remains level.

NOTICE

DO NOT ATTEMPT TO LIFT MACHINE WITH A FORK TRUCK. FORK POCKETS

LOCATED UNDER BATTERY PACKS ARE PROVIDED FOR LIFTING BATTERIES

ONLY.

3121638 – JLG Lift –

4-5


4-6

MODEL

3369LE - ANSI

3369LE - CE/AUS

4069LE - ANSI

4069LE - CE/AUS

FRONT AXLE lb (kg)

4,860 (2204)

5,002 (2269)

5,300 (2404)

5,300 (2594)

REAR AXLE lb (kg)

4,900 (2223)

5,057 (2294)

5,260 (2386)

5,260 (2622)

GVW lb (kg)

9,760 (4427)

10,060 (4563)

10,560 (4790)

11,500 (5216,3)

WHEELBAE in (m)

91.5 (2,324)

91.5 (2,324)

91.5 (2,324)

91.5 (2,324)

Figure 4-2. Lifting & Tie Down Chart - Sheet 1 of 2

X in (m)

45.5 (1,156)

45.5 (1,156)

45.5 (1,156)

45.9 (1,166)

– JLG Lift –

Z in (m)

30 (0,762)

30 (0,762)

30 (0,762)

30 (0,762)

3121638


3121638

Figure 4-3. Lifting & Tie Down Chart - Sheet 2 of 2

– JLG Lift –

4-7


NOTES:

4-8

– JLG Lift – 3121638

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.

JLG Phone: 717-485-5161

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.

NOTICE

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST

ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE

PLATFORM CONTROLS.

5.3

EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited. However, provisions for moving the machine have been incorporated. The following procedures are to be used ONLY for emergency.

1. Chock wheels securely.

2. Engage the brake release on both drive hubs by loosening the bolts, completely reversing hub caps, and retightening the bolts.

3. Connect towing equipment and remove chocks.

After towing machine, complete the following procedure:

1. Position machine on a firm level surface.

2. Chock wheels securely.

3. Disengage the brake release on both drive hubs by loosening the bolts, completely reversing hub caps, and retightening the bolts.

4. Remove chocks.

3121638 – JLG Lift –

5-1

SECTION 5 - EMERGENCY PROCEDURES

5.4

MANUAL DESCENT SYSTEM

The manual descent system is used, in the event of total power failure, to lower the platform using gravity. Pull the handle located at the rear of the machine just behind the ladder.

MANUAL DESCENT ON THE 4069LE DOES NOT COMPLETELY LOWER THE

PLATFORM. TO LOWER COMPLETELY, USE THE LOWER FUNCTION AT THE

GROUND CONTROL. THE PLATFORM WILL LOWER THE LAST SEVERAL INCHES

(CM) AT GRAVITY SPEED. KEEP CLEAR OF DESCENDING PLATFORM.

5.5

EMERGENCY OPERATION

Operator Unable to Control Machine

NOTE:

If the platform operator is pinned, trapped or unable to operate or control machine:

1. Other personnel should operate the machine from ground controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF

CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine.

Platform Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine.

5-2

– JLG Lift – 3121638

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.1

INTRODUCTION

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 Specific to this Machine:

Service and Maintenance Manual (Domestic) ......... 3121639

Illustrated Parts Manual (Domestic)............................. 3121640

6.2

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 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.

3121638 – JLG Lift –

6-1


6.3

OPERATING SPECIFICATIONS

Description

Max. Number of Persons

Max. Workload (Capacity)

Extension Only:

Max. Platform Height

Max. Gradeability

Max. Slope (Left - Right)

Max. Slope (Front - Back)

Max. Slope (Left - Right)

(optional for CE machines with

37 mph (16.7 m/s) windspeed rating only)

Table 6-1. Operating Specifications

3369LE/M3369

ANSI CE/AUS

ANSI/CSA/Brazil:

CE/AUS:


CE/AUS:

2

1000 lbs (454kg)

1000 lbs (450kg)

250 lbs (113kg)

250 lbs (120kg)

33 ft (10.1m)

35%

5° Up to 25 ft (7.6 m)

4° Up to 30 ft (9.1 m)

3° Up to 33 ft (10 m)

CSA

3° Up to 33 ft

(10 m)

5° Up to 33 ft (10 m)

3° Up to 33 ft

(10 m)

NA

4° Up to 25 ft

(7.6 m)

2° Up to 33 ft

(10 m)

NA

4069LE/M4069

ANSI CE/AUS

2


800 lbs (363kg)

CE/AUS:

800 lbs (360kg)


250 lbs (113kg)

CE/AUS:

250 lbs (120kg)

40 ft (12.2 m)

CSA

35%

5° Up to 30 ft (9.1 m)

4° Up to 36 ft (11 m)

3° Up to 40 ft (12.2 m)

3° Up to 40 ft

(12.2 m)

5° Up to 40 ft (12.2 m)

3° Up to 40 ft

(12.2 m)

NA NA NA

6-2

– JLG Lift – 3121638

Description

ANSI

Max. Slope (Front - Back)

(optional forCE machines with 37 mph (16.7 m/s) windspeed rating only)

Max. Tire Load

Max. Ground Bearing

Pressure

Max. Allowable Wind Speed

(Standard rating)

Maximum Horizontal Manual

Side Force

Max. Allowable Wind Speed

(16.7 m/s machines only)

(Optional rating for CE Specification only)

Turning Radius:

Inside

Outside

3121638

NA

667 N

(150 lb force))

NA



3369LE/M3369

CE

5° Up to 25 ft

(7.6 m)

4° Up to 33 ft

(10 m)

3200 lbs

(1452 kg)

57 psi

(4 kg/cm

2

)

28 mph

(12.5 m/s)

400 N

(90 lb force)

AUS

NA

ANSI

NA

534 N

(120 lb force)

4069LE/M4069

CE

NA

3700 lbs

(1680 kg)

61 psi

(4.3 kg/cm

2

)

28 mph

(12.5 m/s)

400N

(90 lb force)

AUS

NA

16.7m/s

(37 mph)

NA NA NA NA

7.5 ft (2.3 m)

16 ft (4.9 m)

– JLG Lift –

7.5 ft (2.3 m)

16 ft (4.9 m)

6-3


Description

Wheelbase

Gross Machine Weight (Approximate)

Maximum Drive Speed

Drive Speed - (reduced)

Drive Speed - (high)

Drive Speed - (creep)

(AUS Full drive height model)

Platform Lift Up Speed

(platform empty)

Platform Lowering Speed (platform empty)

Max Operating Hydraulic Pressure

Electrical System Voltage

Ground Clearance

ANSI

9,760 lbs

(4,427 kg)


3369LE/M3369

CE

91.5 in (2.3m)

10,060 lbs

(4563 kg)

3 mph (4.8 kmh)

16 - 24 sec/50 ft (15 m)

10.6 - 12 sec/50 ft (15 m)

AUS ANSI

10,560 lbs

(4,790 kg)

NA

4069LE/M4069

CE

91.5 in (2.3 m)

11,500 lbs

(5216.3 kg)

3 mph (4.8 kmh)

16 - 24 sec/50 ft (15 m)

10.6 - 12 sec/50 ft (15 m)

NA

AUS

142 -146 sec/25 ft

(7.6 m)

36 - 40 sec 52 - 60 sec

43 - 48 sec

3000 psi (207 bar)

48 volt

8 in (20 cm)

49 - 51 sec

3000 psi (207 bar)

48 volt

8 in (20 cm)

6-4

– JLG Lift – 3121638


Dimensional Data

Table 6-2. Dimensional Data

Transport Height (rails down)

Machine Length

Machine Width

3369LE/M3369 4069LE/M4069

76.5 in (1.9 m)

121 in (3.1 m)

69 in (1.75 m)

79 in (2 m)

Capacities

Table 6-3. Capacities

Fuel Tank - (M Models only)

Hydraulic Tank

Hydraulic System

Generator Crankcase

Approx. 0.9 gal (3.3 l)

8.25 gal (31.2 l)

8.5 gal(32.1 l)

1.37 qts(1.3 l)

3121638 – JLG Lift –

6-5


Tires

SIZE

Load Rating

Ply Rating

Wheel Nut Torque

Table 6-4. Tire Specifications

240/55 D17.5 R4 Tread

(Fill tire with high durometer polyurethane at 90 psi)

IN240/55-17.5 FF

7960 lbs @ 95 psi

(3611kg @ 655kPa)

7730 lbs @ 90 psi

(3506kg @ 621 kPa)

12 Ply

8550 lbs @ 105 psi

(3878kg @ 724kPa)

7960 lbs @ 95 psi

(3611kg @ 655kPa)

7730 lbs @ 90 psi

(3506kg @ 621 kPa)

10 Ply

170 ft lbs

(230 Nm)

27.2/10.5-15 FF Turf

4019 lbs @ 42 psi

(1823kg @ 290 kPa)

2180 lbs @ 32 psi

(989kg @ 221 kPa)

6 Ply

IN240/55-17.5

Non Marking

8550 lbs @ 105 psi

(3878kg @ 724kPa)

7960 lbs @ 95 psi

(3611kg @ 655kPa)

7730 lbs @ 90 psi

(3506kg @ 621 kPa)

10 Ply

6-6

– JLG Lift – 3121638


Batteries (Electric Machines)

TYPE

Voltage

Reserve Capacity

Amp Hour Rating

Table 6-5. Battery Specifications

706HD

6

810 minutes

@ 20 hour rate - 375

EVL16A-A (AGM)

6

841 min.

@ 20 hour rate - 390

NOTICE

JLG MACHINES EQUIPPED WITH DELTA Q BATTERY CHARGERS ARE DESIGNED

FOR THE BEST PERFORMANCE WITH OEM FACTORY APPROVED BATTERIES.

APPROVED JLG REPLACEMENT BATTERIES ARE AVAILABLE THROUGH JLG' S

AFTERMARKET PARTS DISTRIBUTION CENTERS OR JLG' S AFTERMARKET

PROGRAMS. FOR ASSISTANCE WITH PROPER BATTERY REPLACEMENT,

PLEASE CONTACT YOUR LOCAL JLG SUPPORT OFFICE.

BATTERIES APPROVED BY JLG HAVE BEEN TESTED FOR COMPATIBILITY WITH

THE ALGORITHM PROGRAMMING OF THE DELTA Q BATTERY CHARGER TO

OPTIMIZE BATTERY LIFE AND MACHINE CYCLE TIMES. THE USE OF NON

APPROVED BATTERIES IN YOUR JLG EQUIPMENT MAY RESULT IN PERFOR-

MANCE ISSUES OR BATTERY CHARGER FAULT CODES. JLG ASSUMES NO

RESPONSIBILITY FOR SERVICE OR PERFORMANCE ISSUES ARISING FROM

THE USE OF NON APPROVED BATTERIES.

Critical Stability Weights

Table 6-6. Critical Stability Weights

COMPONENT

Platform

Platform Extension

Foam Filled Tires

Batteries (Electric

Machines - Each)

lbs

780

360

207

111 50.3

kg

354

163

94

3121638 – JLG Lift –

6-7


Engine

Table 6-7. Engine Specifications (Generator - If Equipped)

TYPE

Displacement

Bore x Stroke

Number of cylinders

Horsepower

Fuel Type

Glow Plug

Weight

Air Cleaner

Air Cooled, 4 Cycle, Kubota Diesel

OC60-D (T4F)

16.85 cu. in

.

(0.276L)

2.83 in x 2.68 in (72mm x 68mm)

1

5.6HP/3600 rpm (4.5 kw/3600rpm)

Diesel (SAE No. 2-D)

Preheater on @ 40° F (5° C)

38 lb. (17.24 kg)

Paper Element Type

Reserve Capacity

Weight

Table 6-8. Engine Battery Specifications

BCI Group Size

Cranking Performance

51R - 675

550 Amps @ 32° F (0° C)

450 Amps @ 0° F (-18° C)

80 minutes @ 80° F(27° C)

29 lb. (13.15 kg)

Kubota OC60-D Engine - Oil Dip Stick and Drain Location

6-8

– JLG Lift – 3121638


3121638

Figure 6-1. Engine Operating Temperature Specifications - (Kubota) Sheet 1 of 2

– JLG Lift –

6-9


6-10

Figure 6-2. Engine Operating Temperature Specifications - (Kubota) Sheet 2 of 2

– JLG Lift – 3121638


Lubrication

Hydraulic Oil

Table 6-9. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

0° to +23° F

(-18° to -5° C)

0° to +210° F

(-18° to +100° C)

+50° to +210° F

(+10° to +100° C)

SAE VISCOSITY GRADE

10W

10W-20, 10W-30

20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least to API

Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152.

NOTE:

When temperatures remain below 20° F (-7° C), JLG Industries recommends the use of Mobil DTE13.

NOTE:

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

Lubrication Specifications

KEY

MPG

EPGL

EO

HO

Table 6-10. Lubrication Specifications

SPECIFICATIONS

Multipurpose Grease having a minimum dripping point of

350° F. Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105.

Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

Hydraulic Oil. API service classification GL-3, e.g. Mobil

424.

3121638 – JLG Lift –

6-11


6.4

OPERATOR MAINTENANCE

1. Sliding Wear Pads

2. Engine Compartment

3. Wheel Bearings

4. Hydraulic Oil

5. Drive Hub

6-12

Figure 6-3. Operator Maintenance and Lubrication Diagram

– JLG Lift – 3121638


NOTE:

The following numbers correspond to those in Figure 6-3.,

Operator Maintenance and Lubrication Diagram.

1.

Sliding Wear Pads

Lube Points - 8 Sliding Wear Pads

Lube - MPG

Interval - Every month or 50 hours.

2.

Engine Compartment (Generator - If Equipped) - The engine compartment is mounted on a sliding tray that pulls out from the front of the machine.

a. Engine Oil Check/Fill

Capacity - See Engine Manual

Lube - See Engine Manual

Interval - Check level daily; change per manufacturer’s engine manual.

b. Air Cleaner

Lube Point - Filter Element

Interval - Check every 3 months or 150 hours; change every 6 months or 300 hours.

c. Fuel Filter

Lube Point - Filter Element

Interval - Clean every 3 months or 150 hours; change every 6 months or 300 hours.

3.

Wheel Bearings

Lube Points - Front Wheels (2)

Lube - MPG

Interval - Every 2 years or 1200 hours

4.

Hydraulic Oil

Lube Point - Fill Level/Drain Plug

Lube - HO

Interval - Check oil every 10 hours of operation; change oil every 2 years or 1200 hours of operation.

5.

Drive Hub

Lube Point - Fill Plug

Lube - EPGL

Interval - Every 2 years or 1200 hours

3121638 – JLG Lift –

6-13


6.5

TIRES AND WHEELS

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.

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 in. (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies which exceeds 1 in. (2.5 cm) in any direction

• any punctures which exceed 1 in. (2.5 cm) in diameter

• any damage to the bead area cords of the tire

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. lease refer to the

JLG Parts Manual for the part number of the approved tires for a particular machine and 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

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the original.

Unless specifically approved by JLG Industries Inc. do not replace a foam filled tire assembly with a pneumatic tire.

When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

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,

6-14

– JLG Lift – 3121638


etc., without written factory recommendations, may result in an unsafe condition regarding stability.

Wheel Installation

It is extremely important to apply and maintain proper wheel mounting torque.

.

5

3

1

7

9

8

2

6

4

9 LUG PATTERN

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER

TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DAN-

GEROUS 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.

2.

Tighten nuts in the following sequence:

3.

The tightening of the nuts should be done in stages. Following the recommended sequence, tighten the nuts

per wheel torque chart, Table 6-11 on page 6-16.

3121638 – JLG Lift –

6-15


1st Stage

40-50 ft lbs

(60-70 Nm)

Table 6-11. Wheel Torque Chart

TORQUE SEQUENCE

2nd Stage

90-105 ft lbs

(125-150 Nm)

3rd Stage

145-170 ft lbs

(200-240 Nm)

Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.

6-16

– JLG Lift – 3121638

Date

SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Comments

3121638 – JLG Lift –

7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Date

Table 7-1. Inspection and Repair Log

Comments

7-2

– JLG Lift – 3121638

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-

9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide Locations

JLG Industries (Australia)

P.O. Box 5119

11 Bolwarra Road

Port Macquarie

N.S.W. 2444

Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson,

80-Suite 71

13092-310 Campinas-SP

Brazil

+55 19 3295 0407

+55 19 3295 1025

JLG Deutschland GmbH

Max-Planck-Str. 21

D - 27721 Ritterhude - Ihlpohl

Germany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

Plataformas Elevadoras

JLG Iberica, S.L.

Trapadella, 2

P.I. Castellbisbal Sur

08755 Castellbisbal, Barcelona

Spain

+34 93 772 4700

+34 93 771 1762

JLG Equipment Services Ltd.

Rm 1107 Landmark North

39 Lung Sum Avenue

Sheung Shui N. T.

Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Sverige AB

Enkopingsvagen 150

Box 704

SE - 176 27 Jarfalla

Sweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

JLG Industries (UK) Ltd

Bentley House

Bentley Avenue

Middleton

Greater Manchester

M24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG Industries (Italia) s.r.l.

Via Po. 22

20010 Pregnana Milanese - MI

Italy

+39 029 359 5210

+39 029 359 5845

3121638

JLG France SAS

Z.I. de Baulieu

47400 Fauillet

France

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

Oshkosh - JLG Singapore T. E. P. Ltd.

29 Tuas Ave 4

Jurong Industrial Estate

639379

Singapore

+65-6591-9030

+65-6591-9031

JLG 3369LE, 4069LE, M3369, M4069 Aerial Lift Operation and Safety Manual

Assistant Bot

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDIC ATES A POTENTIALIT Y HA ZARDOUS 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 POTENTIALIT Y HA ZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE AN ORANGE BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLIC Y THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFET Y-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE C URRENT 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 PROP-

ERTY OR THE JLG PRODUCT.

For:

Contact:

In USA:

Outside USA:

REVISION LOG

This page left blank intentionally.

SECTION 1. SAFETY PRECAUTIONS

1.1

GENERAL

1.2

PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3

OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4

1.5

TOWING, LIFTING, AND HAULING

MAINTENANCE

Maintenance Hazards

Battery Hazards

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.1

PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2

PREPARATION, INSPECTION, AND MAINTENANCE

2.3

PRE-START INSPECTION

Preparing the Machine for Operation

Function Check

2.4

OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

GENERAL

Limit Switch Locations

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1

GENERAL

3.2