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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).
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• 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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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
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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.
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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
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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
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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
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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.
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SECTION 4 - MACHINE OPERATION
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1.
2.
To
3.
Interlock LED’s to
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4
4.
Outrigger Beam Assembly
5.
Leveling Jack
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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)
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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
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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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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
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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.
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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.
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SECTION 4 - MACHINE OPERATION
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Step 1
Figure 4-7. Tilt-Back Assembly Set-Up
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SECTION 4 - MACHINE OPERATION
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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
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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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SECTION 4 - MACHINE OPERATION
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Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
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SECTION 4 - MACHINE OPERATION
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Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
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SECTION 4 - MACHINE OPERATION
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Figure 4-10. Loading Machine onto Bed of Pick-Up Truck.
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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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