Operation and Safety Manual - BlueLine Rental · Operation and Safety Manual ... 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2 ... THIS MANUAL COULD RESULT IN MACHINE DAMAGE,

Operation and Safety Manual

ANSI ®

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

Boom Lift ModelsE450AE450AJM450AM450AJ

3121210December 7, 2009

FOREWORD

a

l times.

lessors, and lessees with the precautions anderation for its intended purpose.

erves the right to make specification changesformation.

3121210 – JLG Lift –

FOREWORD

This manual is a very important tool! Keep it with the machine at al

The purpose of this manual is to provide owners, users, operators,operating procedures essential for the safe and proper machine op

Due to continuous product improvements, JLG Industries, Inc. reswithout prior notification. Contact JLG Industries, Inc. for updated in

FOREWORD

b 3121210

SIGNAL WORDS

INDIAVOWIL

INDAVODEC

OTENTIALLY HAZARDOUS SITUATION. IF NOTRESULT IN MINOR OR MODERATE INJURY. IT MAYAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEGROUND.

the potential personalmbol to avoid possible

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

L HAVE A RED BACKGROUND.

ICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOTIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A PAVOIDED, MAY ALSO ALERT AGA YELLOW BACK

This is the Safety Alert Symbol. It is used to alert you toinjury hazards. Obey all safety messages that follow this syinjury or death

FOREWORD

c

act:

duct Safety and Reliability Department Industries, Inc.24 Fountainhead Plazaerstown, MD 21742

our Local JLG Officee addresses on inside of manual cover)

A:

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

ide USA:

ne: 240-420-2661: 301-745-3713ail: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

tions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

3121210 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNELOR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONALPROPERTY OR THE JLG PRODUCT.

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FOREWORD

d 3121210

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– JLG Lift –

REVISION LOG

riginal Issue - June 21, 2005

riginal Issue - July 21, 2006

riginal Issue - December 7, 2009

TABLE OF CONTENTS

3121 i

SEC - PARAGRAPH, SUBJECT PAGE

SEC

SECPRE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

- 3 - MACHINE CONTROLS AND INDICATORS

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

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Platform Control Indicator Panel . . . . . . . . . . . . 3-11

- 4 - MACHINE OPERATION

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2Power/Emergency Stop . . . . . . . . . . . . . . . . . . . 4-2Platform/Ground Select Switch. . . . . . . . . . . . . . 4-5Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . 4-5Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Loading From Ground Level . . . . . . . . . . . . . . . . 4-6Loading From Positions Above Ground Level . . 4-6

210 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

TION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge. . . . . . . . . . . 1-1Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-81.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

TION - 2 - USER RESPONSIBILITIES, MACHINE PARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION

3.13.2

SECTION

4.14.2

4.3

4.4

4.54.6

TABLE OF CONTENTS

ii 3121210

SECTIO RAGRAPH, SUBJECT PAGE

4.7

4.8

4.94.104.114.124.13

SECTION

5.15.25.3

RGENCY TOWING PROCEDURES . . . . . . . . .5-2UAL DESCENT SYSTEM . . . . . . . . . . . . . . . . .5-2UAL SWING OVERRIDE. . . . . . . . . . . . . . . . . .5-3

GENERAL SPECIFICATIONS & OPERATOR E

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1RATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

apacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3imensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3rque Specifications. . . . . . . . . . . . . . . . . . . . . 6-4

ydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4brication Specifications . . . . . . . . . . . . . . . . . 6-5

ritical Stability Weights . . . . . . . . . . . . . . . . . . . 6-5rial Number Locations . . . . . . . . . . . . . . . . . . 6-6RATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-8TERY MAINTENANCE AND CHARGING. . . . .6-13attery Maintenance, Quarterly . . . . . . . . . . . . 6-13ptional On Board Generator . . . . . . . . . . . . . 6-14attery Charging (On Board Charger) . . . . . . . 6-14S & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-15

re Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15re Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15re Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-15

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9Raising and Lowering the Lower and Mid Boom 4-9Raising and Lowering the Upper Boom . . . . . . 4-9

GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9Automatic Operating Mode . . . . . . . . . . . . . . . . 4-9Battery Only Operating Mode . . . . . . . . . . . . . 4-10Manual (Charge) Operating Mode. . . . . . . . . . 4-10

INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10MACHINE FUNCTION SPEEDS . . . . . . . . . . . . . . 4-11BOOM SYNCHRONIZING PROCEDURE . . . . . . . 4-11SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-11MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1Platform or Boom Caught Overhead. . . . . . . . . 5-2

5.4 EME5.5 MAN5.6 MAN

SECTION - 6 - MAINTENANC

6.1 INTR6.2 OPE

CTiDToHLuCSe

6.3 OPE6.4 BAT

BOB

6.5 TIRETiTiTi

TABLE OF CONTENTS

3121 iii

SEC - PARAGRAPH, SUBJECT PAGE

SEC

LIST OF TABLES

Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10Inspection and Maintenance Table. . . . . . . . . . . . . 2-3Simultaneous Functions . . . . . . . . . . . . . . . . . . . . 3-10E450A/E450AJP Decal Legend . . . . . . . . . . . . . . 4-19M450A/M450AJ Decal Legend . . . . . . . . . . . . . . . 4-25Operating Specifications. . . . . . . . . . . . . . . . . . . . . 6-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . 6-4Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . 6-5Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-5Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-8Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-17Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

210 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-16Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-18

TION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-72-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-82-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-92-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-103-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-33-2. Ground Control Station w/ Function Enable . . . . . .3-43-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-73-4. Platform Control Indicator Panel . . . . . . . . . . . . . .3-124-1. Position of Least Forward Stability . . . . . . . . . . . . .4-34-2. Position of Least Backward Stability . . . . . . . . . . . .4-44-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-74-4. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-134-5. Chassis & Platform Tie Down - Sheet 1 of 2 . . . . .4-144-6. Chassis & Platform Tie Down - Sheet 2 of 2 . . . . .4-154-7. Decal Installation - Sheet 1 of 3 . . . . . . . . . . . . . . .4-164-8. Decal Installation - Sheet 2 of 3 . . . . . . . . . . . . . . .4-174-9. Decal Installation - Sheet 3 of 3 . . . . . . . . . . . . . . .4-186-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . .6-66-2. Operator Maintenance & Lubrication Diagram . . . .6-7

1-11-22-13-14-14-26-16-26-36-46-56-66-76-86-96-107-1

TABLE OF CONTENTS

iv 3121210

SECTIO RAGRAPH, SUBJECT PAGE

nally.

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

This page left blank intentio

SECTION 1 - SAFETY PRECAUTIONS

1-1

CAUTIONS

E-OPERATION

Training and Knowledged and understand this manual before operating thehine.

not operate this machine until complete training is per-ed by authorized persons.

y authorized and qualified personnel can operate thehine.

3121210 – JLG Lift –

SECTION 1. SAFETY PRE

1.1 GENERALThis section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of this manual. A maintenanceprogram, using the information provided in this manual andthe Service and Maintenance Manual, must also be estab-lished by a qualified person and followed to ensure themachine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not operate the machine until this manual has beenread, training is accomplished, and operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.

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

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-AGE, PERSONAL INJURY OR DEATH.

1.2 PR

Operator• Rea

mac

• Do form

• Onlmac


1-2 3121210

Wo

chine can be operated in temperatures of 0o F to-20o C to 40o C). Consult JLG for operation out- range.

pection achine operation, perform inspections and func-

hecks. Refer to Section 2 of this manual for instructions.

perate this machine until it has been serviced anded according to requirements specified in theand Maintenance Manual.

the footswitch and all other safety devices areg properly. Modification of these devices is aolation.

R ALTERATION OF AN AERIAL WORK PLATFORMONLY WITH WRITTEN PERMISSION FROM THE MANU-

perate any machine on which safety or instruction or decals are missing or illegible.

ny buildup of debris on the platform floor. Keep, grease, and other slippery substances from foot-d platform floor.

– JLG Lift –

• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

• Use the machine in a manner which is within the scope ofits intended application set by JLG.

• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain tooperation of the machine.

rkplace Inspection• The operator is to take safety measures to avoid all haz-

ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail-ers, railway cars, floating vessels, scaffolds or other equip-ment unless approved in writing by JLG.

• Do not operate the machine in hazardous environmentsunless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support themaximum load shown on the decals located on themachine.

• This ma104o F (side this

Machine Ins• Before m

tional cdetailed

• Do not omaintainService

• Be sureoperatinsafety vi

MODIFICATION OSHALL BE MADE FACTURER

• Do not oplacards

• Avoid amud, oilwear an


1-3

plies or tools which extend outside the platform arehibited unless approved by JLG.

n driving, always position boom over rear axle in line the direction of travel. Remember, if boom is over thet axle, steer and drive functions will be reversed.

not assist a stuck or disabled machine by pushing,ing, or by using boom functions. Only pull the unit the tie-down lugs on the chassis.

not place boom or platform against any structure tody the platform or to support the structure.

w boom and shut off all power before leaving machine.

Fall Hazards operation, occupants in the platform must wear a fullarness with a lanyard attached to an authorized lan-

nchorage point. Attach only one (1) lanyard per lan-nchorage point.

3121210 – JLG Lift –

1.3 OPERATION

General • Do not use the machine for any purpose other than posi-

tioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If amalfunctions occurs, shut down the machine.

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

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

• Do not carry materials directly on platform railing. ContactJLG for approved material handling accessories.

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

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Suppro

• Whewithfron

• Do pullfrom

• Do stea

• Sto

Trip and Duringbody hyard ayard a


1-4 3121210

reme caution when entering or leaving platform. that the boom is fully lowered. It may be neces-elescope out to position the platform closer to thefor entry/exit. Face the machine, maintain “threentact” with the machine, using two hands and one

o feet and one hand during entry and exit.

n Hazardschine is not insulated and does not provide pro-rom contact or proximity to electrical current.

– JLG Lift –

• Before operating the machine, make sure all gates areclosed and fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at alltimes. Never use ladders, boxes, steps, planks, or similaritems on platform to provide additional reach.

• Never use the boom assembly to enter or leave the plat-form.

• Use extBe suresary to tground point cofoot or tw

Electrocutio• This ma

tection f


1-5

in a clearance of at least 10 ft. (3m) between any part machine and its occupants, their tools, and their

ent from any electrical line or apparatus carrying up00 volts. One foot additional clearance is required for

additional 30,000 volts or less.

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

oltage Rangease to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

r 50KV to 200 KV 15 (5)

200 KV to 350 KV 20 (6)

350 KV to 500 KV 25 (8)

500 KV to 750 KV 35 (11)

50 KV to 1000 KV 45 (14)

This requirement shall apply except whereemployer, local or governmental regulationsare more stringent.

3121210 – JLG Lift –

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintaof theequipmto 50,0every

Table

V(Ph

Ove

Over

Over

Over

Over 7

NOTE:


1-6 3121210

•

DO ZONENE

ardsr must be familiar with the surface before driving.exceed the allowable sideslope and grade while

– JLG Lift –

The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Theminimum approach distance shall be reduced to a distancewithin the designed working dimensions of the insulatingbarrier. This determination shall be made by a qualified per-son in accordance with the employer, local, or governmentalrequirements for work practices near energized equipment

NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARERGIZED UNLESS KNOWN OTHERWISE.

Tipping Haz• The use

Do not driving.


1-7

om assembly or platform is in a position that one ore wheels are off the ground, all persons must beoved before attempting to stabilize the machine. Usees, forklift trucks, or other appropriate equipment toilize machine.

and Collision Hazardsroved head gear must be worn by all operating and

und personnel.

ck work area for clearances overhead, on sides, andom of platform when lifting or lowering platform, anding.

ing operation, keep all body parts inside platform rail-

3121210 – JLG Lift –

• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft surface.

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

• Never exceed the maximum platform capacity. Distributeloads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi-tion unless the machine is on firm, level and smooth sur-faces.

• Keep the chassis of the machine at least 2 ft. (0.6m) fromholes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards on the floor/surface.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (ForReference Only).

• Do not increase the surface area of the platform or theload. Increase of the area exposed to the wind willdecrease stability.

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

• If bomorremcranstab

Crushing• App

gro

• Chebottdriv

• During.


1-8 3121210

G, LIFTING, AND HAULINGllow personnel in platform while towing, lifting, or

chine should not be towed, except in the event ofcy, malfunction, power failure, or loading/unload-

er to the Emergency Procedures section of thisfor emergency towing procedures.

boom is in the stowed position and the turntablerior to towing, lifting or hauling. The platform mustletely empty of tools.

ting machine, lift only at designated areas of the. Lift the unit with equipment of adequate capac-

the Machine Operation section of this manual forormation.

– JLG Lift –

• Use the boom functions, not the drive function, to positionthe platform close to obstacles.

• Always post a lookout when driving in areas where visionis obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) awayfrom machine during all driving and swing operations.

• Limit travel speed according to conditions of ground sur-face, congestion, visibility, slope, location of personnel,and other factors which may cause collision or injury topersonnel.

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

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

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Be sure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedboom or platform. Position barricades on floor if neces-sary.

1.4 TOWIN• Never a

hauling.

• This maemergening. Refmanual

• Ensure locked pbe comp

• When lifmachineity.

• Refer tolifting inf


1-9

not refuel the machine with the engine running.

tery fluid is highly corrosive. Avoid contact with skin clothing at all times.

rge batteries only in a well ventilated area.

3121210 – JLG Lift –

1.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations,precautions must be taken to protect the chassis fromdirect exposure to weld and metal cutting spatter.

• Do

• Batand

• Cha


1-1 3121210

DO NMPH

Only)

Land Conditions

ertically

n smoke

skin. Leaves rustle

wigs in constant motion

r raised. Small branches begin to move.

tion. Whistling heard in overhead wires. es difficult.

n. Effort needed to walk against the wind.

ees. Cars veer on road.

ge.

0 – JLG Lift –

OT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 (12.5 M/S).

Table 1-2. Beaufort Scale (For Reference

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises v

1 1-3 0.3-1.5 Light air Wind motion visible i

2 4-7 1.6-3.3 Light breeze Wind felt on exposed

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller t

4 13-18 5.5-7.9 Moderate breeze Dust and loose pape

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in moUmbrella use becom

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motio

8 39-46 17.2-20.7 Fresh Gale Twigs broken from tr

9 47-54 20.8-24.4 Strong Gale Light structure dama

CHINE PREPARATION, AND INSPECTION

2-1

PREPARATION, AND INSPECTION

e safest means to operate the machine where over-ad obstructions, other moving equipment, and obsta-

es, depressions, holes, drop-offs.

eans to avoid the hazards of unprotected electricalnductors.

ecific job requirements or machine application.

Supervisiong must be done under the supervision of a qualified in an open area free of obstructions until the traineeveloped the ability to safely control and operate the

ne.

Responsibilityerator must be instructed that he/she has the respon-

and authority to shut down the machine in case of action or other unsafe condition of either the machinejob site.

SECTION 2 - USER RESPONSIBILITIES, MA

3121210 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

Persons under the influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and atthe ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on themachine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of themachine to recognize a malfunction or potential mal-function.

6. Thhecl

7. Mco

8. Sp

Training Traininpersonhas demachi

OperatorThe opsibilitymalfunor the

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121210

2.2, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICEA PERSON WHO HAS SUCCESSFULLY COMPLETED TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance recommended by JLG Industries, Inc.Consult local regulations for further requirements for aerialwork platforms. The frequency of inspections and mainte-nance must be increased as necessary when the machine isused in a harsh or hostile environment, if the machine isused with increased frequency, or if the machine is used in asevere manner.

JLG INDUSTRIESTECHNICIAN AS THE JLG SERVICEMODEL.


2-3

nce Table

rybility

Service Qualification

Reference

or User or Operator Operator and Safety Manual

or User Qualified JLG Mechanic

Service and Maintenance Manual and applicable JLG inspection form



or User Factory Qualified Service Technician (Recommended)



Service and Maintenance Manual

ance Manual to perform inspections.


3121210 – JLG Lift –

Table 2-1.Inspection and Maintena

Type FrequencyPrima

Responsi

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operat

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer,

Frequent Inspection In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer,

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

Owner, Dealer,

Preventative Maintenance At intervals as specified in the Service and Main-tenance Manual.

Owner, Dealer,

NOTE: Inspection forms are available from JLG. Use the Service and Mainten


2-4 3121210

Pre stic only) is enclosed in the weather resistante container.

-Around” Inspection – Refer to Figure 2-2. thru 2-4.

y – Charge as required.

ombustion Engine Powered Machines) – Add the fuel as necessary.

ulic Oil – Check the hydraulic oil level. Ensurelic oil is added as required.

on Check – Once the “Walk-Around” Inspectionplete, perform a functional check of all systems ina free of overhead and ground level obstructions.o Section 4 for more specific instructions.

DOES NOT OPERATE PROPERLY, TURN OFF THEIATELY! REPORT THE PROBLEM TO THE PROPERRSONNEL. DO NOT OPERATE THE MACHINE UNTIL ITE FOR OPERATION.

– JLG Lift –

-Start InspectionThe Pre-Start Inspection should include each of the follow-ing:

1. Cleanliness – Check all surfaces for leakage (oil, fuel,or battery fluid) or foreign objects. Report any leakage tothe proper maintenance personnel.

2. Structure - Inspect the machine structure for dents,damage, weld or parent metal cracks or other discrep-ancies.

3. Decals and Placards – Check all for cleanliness andlegibility. Make sure none of the decals and placards aremissing. Make sure all illegible decals and placards arecleaned or replaced.

4. Operators and Safety Manuals – Make sure a copy ofthe Operator and Safety Manual, EMI Safety Manual(Domestic only), and ANSI Manual of Responsibilities

(Domestorag

5. “WalkFigure

6. Batter

7. Fuel (Cproper

8. Hydrahydrau

9. Functiis coman areRefer t

IF THE MACHINEMACHINE IMMEDMAINTENANCE PEIS DECLARED SAF

Parent Metal Crack Weld Crack


2-5

ise, extend, retract, and lower the Upper Boom.heck for smooth operation.

tower boom does not rest on stop with machine in theowed position, this indicates upright is out of plumb.

lescope boom IN and OUT several cycles at variousgrees of elevation lengths. Check for smooth tele-ope operation.

ing turntable to LEFT and RIGHT a minimum of 45grees. Check for smooth motion.

heck the chassis out of level indicator located on theatform control console by driving, with the machine invel position, up a suitable ramp of at least 6° slope.heck the out of level alarm, with the machine on themp, raise the upper boom until it is parallel with theassis. DO NOT RAISE ABOVE THE PARALLEL POSI-ON. If the light does not illuminate, return the machine a level surface, shut down the machine, and contact aalified technician before resuming operation.

r units equipped with optional tilt cutout, verify that theive function is cutout when the boom is elevated andt alarm is activated.


3121210 – JLG Lift –

Function Check

A functional check of all systems should be performed, oncethe walk-around inspection is complete, in an area free ofoverhead and ground level obstructions. First, using theground controls, check all functions controlled by the groundcontrols. Next, using the platform controls, check all func-tions controlled by the platform controls.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMMOVEMENTS DO NOT RETURN TO THE OFF POSITION WHENRELEASED.

TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOPWHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOTFROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE.

1. Check boom limit switches. Raise and lower the LowerBoom. Check for smooth operation.

NOTE: Perform checks from ground controls first, then from plat-form controls.

2. RaC

3. If st

4. Tedesc

5. Swde

6. CplleCrachTItoqu

Fodrtil


2-6 3121210

DO NOF TNOT

FOOATE SWIBOT

FOOTION

tswitch depressed, operate LIFT and hold control. foot from footswitch, motion should stop. If itt, shut down machine and contact a qualified ser-nician.

the GROUND/PLATFORM SELECT switch toND. Platform controls should not operate.

GROUND/PLATFORM SELECT switch to OFF.m/Ground controls should not operate.

– JLG Lift –

OT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITYHE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

7. Check that platform self-leveling system functions prop-erly during raising and lowering of boom.

8. Check rotator for smooth operation and assure platformwill rotate 75 degrees in both directions from centerlineof boom.

9. Drive forward and reverse; check for proper operation.

10. Steer left and right; check for proper operation.

11. Footswitch.

TSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER-WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IFTCH OPERATES WITHIN LAST 1/4" (6 MM) OF TRAVEL, TOP ORTOM, IT SHOULD BE ADJUSTED.

TSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC- CONTROL, OTHERWISE THE FUNCTION WILL NOT WORK.

With fooRemovedoes novice tech

12. Place GROU

13. Place Platfor


2-7

lature

1. Platform Control Console2. Platform3. Upper Boom4. Telescope Cylinder5. Master Cylinder6. Upper Upright7. Upper Lift Cylinder8. Mid Lift Cylinder9. Lower Boom10. Turntable11. Frame12. Steer Wheels13. Drive Wheels14. Battery Box15. Lower Lift Cylinder16. Lower Link17. Lower Upright18. Upper Link19. Mid Boom20. Slave Cylinder21. Footswitch


3121210 – JLG Lift –

Figure 2-1. Basic Nomenc


2-8 3121210

heet 1 of 3

– JLG Lift –

Figure 2-2. Daily Walk-Around Inspection - S


2-9

latform and Gate Assembly - Platform mounting pinsecure. Footswitch in good working order; not modi-ed, disabled or blocked; Bar slides freely.

latform & Ground Control Console - Switches andvers return to neutral and are properly secured,ecals/placards secure and legible, control markinggible.

otator - See Note.

ib - See Note.

ib Rotator - See Note.

oom Sections - See Note.

ll Hydraulic Cylinders - No visible damage; pivot pinsnd hydraulic hoses undamaged, not leaking.

imit Switches - See Note.

n - Sheet 2 of 3


3121210 – JLG Lift –

GeneralBegin the “Walk-Around Inspection” at Item 1, as noted onthe diagram. Continue to the right (counterclockwiseviewed from top) checking each item in sequence for theconditions listed in the “Walk-Around Inspection Checklist”.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR-ING "WALK-AROUND INSPECTION".

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONSWHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missingparts, that they are securely fastened and that no visibledamage exists in addition to any other criteria men-tioned.

1. Psfi

2. Pledle

3. R

4. J

5. J

6. B

7. Aa

8. L

Figure 2-3. Daily Walk-Around Inspectio


2-1 3121210

ng and Latches - See Note.

ry Charger - See Note.

- See Note.

/Upright - No visible damage; All pins properlyed. Upright in vertical position. If Upright doesst on stop with machine in the stowed position,dicates upright is out of plumb.

terweight - See Note.

od Ends and Steering Spindles - See Note. Tiend stubs locked.

al Descent Valve - See Note.

ol Valve - See Note.

- See Note.

rm Pivot Pins - Properly secured.

heet 3 of 3

0 – JLG Lift –

9. Drive Axle and Motor - See Note.

10. Wheel/Tire Assembly - No loose or missing lug nuts.Inspect for worn tread, cuts, tears or other discrepan-cies. Inspect wheels for damage and corrosion.

11. Swing Motor and Worm Gear - See Note.

12. Hydraulic Pump and Reservoir - Properly secured; novisible damage or hydraulic leaks. Recommendedhydraulic fluid level on dipstick (system shut down,boom in stowed position). Breather cap/dipsticksecure and working.

13. Turntable Bearing - No loose or missing hardware; novisible damage; evidence of proper lubrication. Noloose bolts or looseness between bearing and struc-ture.

14. Battery Compartment Right Side - Batteries haveproper electrolyte level; cables tight; no visible dam-age or corrosion.

15. Cowli

16. Batte

17. Valve

18. Boomsecurnot rethis in

19. Coun

20. Tie Rrod e

21. Manu

22. Contr

23. Frame

24. Platfo

Figure 2-4. Daily Walk-Around Inspection - S

MACHINE CONTROLS AND INDICATORS

3-1

AND INDICATORS

ontrol Station

re 3-1. and Figure 3-2.)

en machine is shut down the Platform/Ground Selectitch and Emergency Stop must be positioned to OFF.

quipped, the Function Enable switch must be heldwn in order to operate Telescope, Lower Lift, Swing,in Lift, Jib Lift, Platform Level Override, and Platformtate functions.

stem Distress Indicator

e system distress indicator lights to signify an abnor-al condition for the generator engine (high oil tempera-re or low oil pressure) or, on all electric machines, anectrical system fault.

e engine will automatically shut down under the follow- conditions:

h Oil Temperaturew Oil Pressuregine Overspeedervoltage

SECTION 3 -

3121210 – JLG Lift –

SECTION 3. MACHINE CONTROLS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that usesymbols to indicate control functions. On ANSI machines,refer to decal located on the control box guard in front ofthe control box or by the ground controls for these sym-bols and the corresponding functions.

Ground C

(See Figu

NOTE: Whsw

NOTE: If edoMaRo

1. Sy

Thmtuel

NOTE: Thing

HigLoEnOv

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121210

NOT

ope

es for extension and retraction of Upper Boompositioned to IN or OUT.

WING control switch provides 360 degrees non-uous turntable rotation. To activate SWING, posi-itch to LEFT or RIGHT.

Breakers

rcuit breakers open (pop out) to indicate a short orad somewhere on the machine.

/Emergency Stop Switch

position red mushroom shaped switch furnishes to PLATFORM/GROUND SELECT switch when out (on). When pushed in (off), power is shut offPLATFORM/GROUND SELECT switch.

– JLG Lift –

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. Generator/Engine Start Button

The generator/engine start push-button switch allowsthe generator to be started manually to top-off the bat-tery charge. The generator will start automatically whenthe batteries reach a low-charge state and the GeneratorEnable switch on the platform console is in the on posi-tion.

E: The engine will not start if the batteries are fully chargedor if the Generator Enable switch on the platform consoleis not in the on position.

4. Battery Indicator and Hourmeter

An hourmeter, installed in the upper portion of theGround Control Box, registers the amount of machineoperating time. The hourmeter registers up to 9,999.9hours and cannot be reset.

5. Telesc

Providwhen

6. Swing

The Scontintion sw

7. Circuit

The cioverlo

8. Power

A two-powerpulledto the


3-3

tation

1. System Distress Indicator2. Platform Overload Indicator3. Engine/Generator Start Button4. Battery Condition Indicator & Hourmeter5. Telescope6. Swing7. Circuit Breakers8. Emergency Stop9. Platform/Ground Select10. Lower/Mid Lift11. Upper Boom Lift12. Jib13. Platform Leveling14. Rotate

SECTION 3 -

3121210 – JLG Lift –

Figure 3-1. Ground Control S


3-4 3121210

tion Enable

1. System Distress Indicator2. Platform Overload Indicator3. Engine/Generator Start Button4. Battery Condition Indicator & Hourmeter5. Telescope6. Swing7. Circuit Breakers8. Emergency Stop9. Platform/Ground Select10. Lower/Mid Lift11. Upper Boom Lift12. Jib13. Platform Leveling14. Rotate15. Function Enable

– JLG Lift –

Figure 3-2. Ground Control Station w/ Func


3-5

ticulating Jib Boom (If equipped)

e Articulating Jib Boom control switch provides rais-g and lowering of the jib when positioned up or down.

THE PLATFORM LEVELING OVERRIDE FUNCTION FORLING OF THE PLATFORM. INCORRECT USE COULD CAUSE

CCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULDEATH OR SERIOUS INJURY.

atform Leveling Override

three position switch allows the operator to adjust thetomatic self leveling system. This switch is used tojust platform level in situations such as ascending/scending a grade.

tate

three position ROTATE control switch permits rotation the platform when positioned to left or right.

nction Enable (If Equipped)

equipped, the enable switch must be held "DOWN" toable all boom controls when the engine is running.

SECTION 3 -

3121210 – JLG Lift –

9. Platform/Ground Select Switch

A three position, key operated switch supplies power tothe platform control console when positioned to PLAT-FORM. With the switch key held in the GROUND posi-tion, power is shut off to platform and only groundcontrols are operable. When released from GROUNDposition the switch spring returns to the (off) position.

NOTE: With PLATFORM/GROUND SELECT switch in the centerposition, power is shut off to controls at both operatingstations.

10. Lower/Mid Boom Lift

Provides for raising and lowering of Lower Boom whenpositioned to UP or DOWN.

11. Upper Boom Lift

Provides for raising and lowering of Upper Boom whenpositioned to UP or DOWN.

12. Ar

Thin

ONLY USE SLIGHT LEVETHE LOAD/ORESULT IN D

13. Pl

A auadde

14. Ro

A of

15. Fu

If en


3-6 3121210

Pla

(S

ONLSLIGTHERES

h-type HORN switch supplies electrical power toible warning device when pressed.

/Emergency Stop

position red mushroom shaped switch furnishes to PLATFORM Controls when pulled out (on).pushed in (off), power is shut off to the platformns.

about 2 seconds of pulling the switch out, thene will perform a diagnostic check of the variouscal circuits, and if everything is OK, the platformwill beep once. During this time the lights on theor panel will also blink once as a bulb check.

ator Enable Control

enerator Enable control switch, when in the offn, allows the operator to prevent the generator from starting when using the machine indoors.in the on position (and the ground Emergencywitch on [pulled out]), the generator is enabled toatically start when the batteries need charged.

– JLG Lift –

tform Station

ee Figure 3-3.)

1. Posi-Track Control

Activating the Posi-Track switch allows the operator toengage positive traction for the time period pre-set in thecontroller. Posi-traction occurs by changing the drivemotors from a series to parallel arrangement, causingavailable power to be distributed evenly between thetwo drive wheels. The control system may also engagethe posi-track function automatically.

Y USE THE PLATFORM LEVELING OVERRIDE FUNCTION FORHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE

LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULDULT IN DEATH OR SERIOUS INJURY.

2. Platform Leveling Override

A three position switch allows the operator to adjust theautomatic self leveling system. This switch is used toadjust platform level in situations such as ascending/descending a grade.

3. Horn

A pusan aud

4. Power

A two-powerWhen functio

Withinmachielectrialarm indicat

5. Gener

The GpositioengineWhen Stop Sautom


3-7

elescopeibower Boom Lift

11. Platform Rotate12. Function Speed13. Main Lift/Swing

onsole

SECTION 3 -

3121210 – JLG Lift –

1. Posi-Track2. Platform Leveling Override3. Horn4. Power/Emergency Stop

5. Generator Enable6. Lights7. Drive/Steer

8. T9. J10. L

Figure 3-3. Platform Control C


3-8 3121210

NOT

NOT

S INJURY, DO NOT OPERATE MACHINE IF ANY CON-R TOGGLE SWITCHES CONTROLLING PLATFORM

NOT RETURN TO THE OFF OR NEUTRAL POSITION.

ope Control

ELESCOPE control switch affords extension andion of the main boom when positioned to IN or

Equipped)

orward to lift up, pull back to lift down. Variable lift is using the Function Speed Control.

Boom Lift

es for raising and lowering of Lower and Mid when positioned to UP or DOWN. Upper lift willction when operating lower lift.

m Rotate

ATFORM ROTATE control switch allows the oper- rotate the basket to the left or right when posi- to the desired direction.

– JLG Lift –

6. Lights (If Equipped)

This switch operates control console panel lights andhead lights if the machine is so equipped.

7. Drive/Steer

The DRIVE controller provides for driving either forwardor backward when positioned to FORWARD orREVERSE. The controller is ‘ramped’ to allow infinitelyvariable drive speed between fast and slow.

Positioning the steer control thumb operated switchRIGHT or LEFT enables steering the machine to theright or left respectively.

E: When lower boom is raised above horizontal, or the upperboom is raised approximately 16 inches (40.64 cm) aboveboom rest, the high drive function will automaticallyswitch to low drive. This also occurs when FunctionSpeed Control is clicked on creep.

E: DRIVE control lever is spring-loaded and will automati-cally return to neutral (OFF) position when released.

TO AVOID SERIOUTROL LEVERS OMOVEMENT DO WHEN RELEASED

8. Telesc

The TretractOUT.

9. Jib (If

Push fspeed

10. Lower

ProvidBoomnot fun

11. Platfor

The PLator totioned


3-9

ain Lift/Swing

e dual axis joystick is provided for main lift and swing.sh forward to lift up, pull backward to lift down. Moveht to swing right, move left to swing left. Moving the

ystick activates switches to provide the functionslected. Proportional control of these functions can betained by using the Function Speed knob.

in lift and swing functions may be selected in combina-. The handle features a round gate so that maximum

eed is reduced when multiple functions are selected.

wer lift will not function when operating upper lift.

SECTION 3 -

3121210 – JLG Lift –

12. Function Speed Control

Adjusts speed of Boom and Swing Functions. RotateCCW for slower speed and CW for faster speed. Toadjust Drive, Swing, and Main Lift to creep, turn knobfully CCW until it clicks.

NOTE: Main Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) posi-tion when released.

13. M

ThPurigjoseat

NOTE: Mationsp

Lo


3-1 3121210

s

o Work at the Same Time:

Lift** Upper Lift** Telescope


No Telescope*

o Telescope

Lift** Upper Lift**


o No No

dividually, due to sharing of oil.

Swing) is being operated at full speed, due to sharing

0 – JLG Lift –

Table 3-1. Simultaneous Function

If This Function is Selected: These Functions Will Als

Drive and Steer Swing Lower

Swing Drive and Steer Lower

Lower Lift Drive and Steer Swing*

Upper Lift Drive and Steer Swing N

Telescope Drive and Steer Swing* Lower

Jib Drive and Steer Swing* Lower

Platform Rotate Drive and Steer No N

Note: Boom functions may be slower when selected with another function than when operated in

* These functions may move very slowly (or not at all) if the first function selected (Lower Lift or of oil.

** Lower Lift and Upper Lift will not function simultaneously. Upper Lift always prevails.


3-11

lt Alarm Warning Light and Alarm

is orange illuminator indicates that the chassis is on aope. An alarm will also sound when the chassis is on aope and the boom is above horizontal. If lit when boom raised or extended, retract and lower to below hori-ntal then reposition machine so that it is level beforentinuing operation. If the boom is above horizontald the machine is on a slope, the tilt alarm warninght will illuminate and an alarm will sound and CREEP

automatically activated.

NING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED ORRETRACT AND LOWER TO BELOW HORIZONTAL THEN MACHINE SO THAT IT IS LEVEL BEFORE EXTENDINGISING BOOM ABOVE HORIZONTAL.

SECTION 3 -

3121210 – JLG Lift –

Platform Control Indicator Panel

(See Figure 3-4., Platform Control Indicator Panel)

NOTE: The platform control indicator panel uses different shapedsymbols to alert the operator to different types of opera-tional situations that could arise. The meaning of thosesymbols are explained below.

1. Ti

Thslsliszocoanligis

IF TILT WAREXTENDED, REPOSITIONBOOM OR RA

Indicates a potentially hazardous situation, whichif not corrected, could result in serious injury ordeath. This indicator will be red.

Indicates an abnormal operating condition,which if not corrected, may result in machineinterruption or damage. This indicator will be yel-low.

Indicates important information regarding theoperating condition, i.e. procedures essential forsafe operation. This indicator will be green withthe exception of the capacity indicator which willbe green or yellow depending upon platformposition.


3-1 3121210

m Overload (If equipped)

tes the platform has been overloaded.

Distress Indicator

stem distress indicator lights to signify an abnor-ndition for the generator engine (high oil tempera- low oil pressure) or, on all electric machines, an

cal system fault.

ur likely causes of a system fault are:

e seven second enable time has been allowed topse or a function was selected before depressinge footswitch. The system reads this condition as ault, just as it would if the footswitch were jammed the depressed position or a function switch wereuck in the on position. Re-depress the footswitch power the controls and extinguish the light.

e maximum power limit has been reached ande machine is not moving. This could happenhen the machine is stuck or when attempting tovel over rough terrain or on steep grades whichceed the rated gradeability of the machine. Thisndition is comparable to stalling the engine byking it to provide more power than it wassigned to do.

2 – JLG Lift –

2. Platfor

Indica

3. System

The symal coture orelectri

The fo

a. Thlathfainstto

b. Ththwtraexcoasde

1. Tilt2. Platform Overload3. System Distress4. Posi-Track

5. Enable6. Low Battery7. Creep

Figure 3-4. Platform Control Indicator Panel


3-13

able Indicator/Footswitch

operate any function, the footswitch must bepressed and the function selected within seven sec-ds. The enable indicator shows that the controls areabled. If a function is not selected within seven sec-ds, or if a seven second lapse between ending one

nction and beginning the next function, the enableht will go out and the footswitch must be released andpressed again to enable the controls.

leasing the footswitch removes power from all con-ls and applies the drive brakes.

ERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLEITCH BY BLOCKING OR ANY OTHER MEANS.

MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHENY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT-

SECTION 3 -

3121210 – JLG Lift –

c. The batteries are nearly depleted, and should becharged very soon to prevent having the machinestop at an inconvenient place.

d. There is some other fault in one of the circuits. If sodetermine the cause by counting the flash code, anumber of flashes followed by a pause followed byanother number of flashes, and refer to the servicemanual.

NOTE: The engine will automatically shut down under the follow-ing conditions:

High Engine Oil TemperatureLow Engine Oil PressureEngine OverspeedGenerator Overvoltage

4. Posi-Track Indicator

This indicator lights to show that posi-traction is operat-ing.

5. En

Todeonenonfuligde

Retro

TO AVOID STHE FOOTSW

FOOTSWITCHSWITCH ONLTOM.


3-1 3121210

Speed Indicator

the Function Speed Control is turned to the creepn, the indicator acts as a reminder that all func-re set to the slowest speed.

4 – JLG Lift –

6. Low Battery Indicator

Indicates the batteries are low and need to be charged.

7. Creep

When positiotions a

SECTION 4 - MACHINE OPERATION

4-1

PERATION

ERATING CHARACTERISTICS AND ITATIONS

esom can be raised above horizontal with or without any platform, if:

achine is positioned on a smooth, firm and level sur-ce.

ad is within manufacturers rated design capacity.

l machine systems are functioning properly.

oper tire pressure.

achine is as originally equipped from JLG.

3121210 – JLG Lift –

SECTION 4. MACHINE O

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic personnel liftequipped with a work platform on the end of an elevatingand rotating boom.

The primary operator control station is in the platform. Fromthis control station, the operator can drive and steer themachine in both forward and reverse directions. The opera-tor can raise or lower the upper or lower boom or swing theboom to the left or right. Standard boom swing is 360 degreenon-continuous left and right of the stowed position. Themachine has a Ground Control Station which will overridethe Platform Control Station. Ground Controls operate Upperand Lower Boom Lift and Swing, and are to be used in anemergency to lower the platform to the ground should theoperator in the platform be unable to do so.

4.2 OPLIM

CapacitiThe boload in

1. Mfa

2. Lo

3. Al

4. Pr

5. M


4-2 3121210

Sta

TO MAC

R OPERATION

gency Stop/Emergency Stop switch, when pulled out (on),attery power for all machine functions. The switchpushed in (off) when recharging the batteries or machine overnight.

ped with the optional on-board generator, thency Stop switch must be left on (pulled out) tor automatic charging of the batteries.

out 2 seconds of pulling the switch out, theill perform a diagnostic check of the various elec-ts, and if everything is OK, the platform alarm will. During this time the lights on the indicator panelnk once as a bulb check.

– JLG Lift –

bilityMachine stability is based on two positions which are calledFORWARD and BACKWARD stability. The machines positionof least FORWARD stability is shown in Figure 4-1., Positionof Least Forward Stability, and its position of least BACK-WARD stability is shown in Figure 4-2., Position of LeastBackward Stability.

AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOADHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

4.3 MOTO

Power/EmerThe Powerprovides bshould be parking the

NOTE: If equipEmergeallow fo

Within abmachine wtrical circuibeep oncewill also bli


4-3

ard Stability

MACHINE WILL "TIP OVER" IN THISDIRECTION IF OPERATED ON AN

OUT-OF-LEVEL SURFACE

BOOMEXTENDED

3121210 – JLG Lift –

Figure 4-1. Position of Least Forw

FLYFULLY

UPPER BOOMHORIZONTAL

TOWER AND MIDBOOM AT

33 DEGREES


4-4 3121210

Fig

ure

4-2.

Po

sitio

n o

f Le

ast B

ackw

ard

Sta

bili

ty

LOW

ER B

OOM

FULL

Y EL

EVAT

ED

– JLG Lift –

MID

BOO

MFU

LLY

ELEV

ATED

UPPE

R BO

OMFU

LLY

ELEV

ATED

AND

RETR

ACTE

D

PLAT

FORM

ROTA

TED

90 D

EGRE

ES

MAC

HINE

WIL

L "T

IP O

VER"

IN T

HIS

DIRE

CTIO

N IF

OPE

RATE

D ON

AN

OUT-

OF-L

EVEL

SUR

FACE


4-5

AVELING (DRIVING)

r units equipped with optional tilt cutout, verify that theve function is cutout when the boom is elevated and tiltrm is activated.

en lower boom is raised above horizontal, or the upperom is raised approximately 16 inches (40.6 cm) aboveom rest, the high drive function will automatically be in drive.

INE IS OPERATED AT A VERY SLOW SPEED OR STALLEDBING A GRADE OF 20% OR GREATER, DRIVE FUNCTIONEMOVE FOOT FROM FOOT-SWITCH, AND DEPRESS FOOT-ESET.

IVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON AM AND LEVEL SURFACE.

SS OF TRAVEL CONTROL OR “TIP OVER” ON GRADES ANDS, DO NOT DRIVE MACHINE ON GRADES EXCEEDINGIFIED ON THE SERIAL NUMBER PLATE.

E ON SIDESLOPES WHICH EXCEED 5 DEGREES.

3121210 – JLG Lift –

Platform/Ground Select SwitchThe Platform/Ground Select switch directs battery power tothe desired control station when the POWER/EMERGENCYSTOP switch is pulled out (on). With the switch held in theGROUND position battery power is supplied to the groundcontrol station. When the switch is in the PLATFORM posi-tion, battery power is supplied to the platform control station.

Motor Activation

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC-TION, OTHERWISE FUNCTION WILL NOT OPERATE.

The motor becomes activated and operates the desiredfunction when the Emergency Stop switch is pulled out (on),the Platform/Ground select switch is in the appropriate posi-tion and the Footswitch is depressed.

IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUT-DOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANYOPERATION.

4.4 TR

NOTE: Fodriala

NOTE: Whbobolow

IF THE MACHWHEN CLIMWILL STOP. RSWITCH TO R

DO NOT DRSMOOTH, FIR

TO AVOID LOSIDE SLOPETHOSE SPEC

DO NOT DRIV


4-6 3121210

AVOTO T

USETIMING TION

BEFDRIVCONMOT

Tra

FOOTION

n Drive controller to FORWARD or REVERSE asd. Angle of controller will determine travel speed.

INGotswitch, position thumb switch on Drive/Steer

o RIGHT for steering right, or to LEFT for steering

ORM

m Ground Leveln chassis on a smooth, firm and level surface.

load (personnel, tools and supplies) is 500 LB.g) or less, distribute load uniformly on platformnd proceed to work position.

m Positions Above Ground Leveling weight to platform above ground level:

ine what the total weight will be after additional is loaded (personnel, tools and supplies).

weight in platform will be 500 LBS. (227 kg) orroceed with adding weight.

– JLG Lift –

ID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINEIPOVER.

EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALLES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIV-WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUC-.

ORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REARE AXLE. IF BOOM IS OVER STEER WHEELS, STEER AND DRIVE

TROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINEION.

veling Forward and Reverse

TSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC-, OTHERWISE FUNCTION WILL NOT OPERATE.

1. If machine is shut down, pull out Emergency Stop atGround Controls and place Platform/Ground Selectswitch to PLATFORM.

2. At Platform Controls, pull out Emergency Stop switchand activate footswitch.

3. Positiodesire

4.5 STEERDepress focontroller tleft.

4.6 PLATF

Loading Fro1. Positio

2. If total(227 kfloor a

Loading FroBefore load

1. Determweight

2. If totalless, p


4-7

opes

3121210 – JLG Lift –

Figure 4-3. Grade and Side Sl


4-8 3121210

Pla

ONLSLIGCAUCOU

Pla

ING LIGHT IS LOCATED ON THE CONTROL CONSOLEHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER

SWING OR RAISE BOOM ABOVE HORIZONTAL WHENUDIBLE ALARM SOUNDS.

ON TILT ALARM AS A LEVEL INDICATOR FOR THEARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5TER). CHASSIS MUST BE LEVEL BEFORE SWINGING, ABOVE HORIZONTAL.

IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM ISORIZONTAL, LOWER PLATFORM TO GROUND LEVEL.N MACHINE SO THAT CHASSIS IS LEVEL BEFORE

BOOM BELOW HORIZONTAL IS PERMITTED ONEEDING THOSE SPECIFIED ON THE SERIAL NUMBER

US INJURY, DO NOT OPERATE MACHINERY IF ANY OR TOGGLE SWITCH CONTROLLING PLATFORM NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION

.

– JLG Lift –

tform Level Adjustment1. Leveling UP. Depress footswitch to raise platform, posi-

tion PLATFORM/LEVEL control switch UP and hold untilplatform is level.

2. Leveling DOWN. Depress footswitch to lower platform,position PLATFORM/LEVEL control switch to DOWNand hold until platform is level.

Y USE THE PLATFORM LEVELING OVERRIDE FUNCTION FORHT LEVELING OF THE PLATFORM. INCORRECT USE COULDSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SOLD RESULT IN DEATH OR SERIOUS INJURY.

tform Rotation

1. Depress footswitch to rotate platform to the left, PLAT-FORM ROTATE control switch is positioned to the LEFTand held until desired position is reached.

2. Depress footswitch to rotate platform to the right, PLAT-FORM ROTATE control switch is positioned to theRIGHT and held until desired position is reached.

4.7 BOOM

A RED TILT WARNWHICH LIGHTS WSLOPE. DO NOT LIGHT IS LIT OR A

DO NOT DEPENDCHASSIS. TILT ALDEGREE OR GREAOR RAISING BOOM

TO AVOID UPSET RAISED ABOVE HTHEN REPOSITIORAISING BOOM.

TRAVELING WITHGRADES NOT EXCPLATE.

TO AVOID SERIOCONTROL LEVERMOVEMENT DOESWHEN RELEASED


4-9

NERATOR

ine is equipped with an engine powered DC generatord in parallel to the 48V DC battery bank.

ic Operating Modenerator will operate in automatic mode always when

lowing two conditions apply.

round Control EMS is pulled out (on), and:

e Generator Enable switch on the platform controlnsole is in the On or Enable position.

the above conditions apply, the generator’s controllernitor status of the batteries, will turn on automatically

the battery voltage drops as a result of discharge andn off when batteries are fully charged.

3121210 – JLG Lift –

TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOPWHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOTFROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THEMACHINE.

Swinging the BoomDepress footswitch to swing boom, with footswitch activated,position SWING control switch to RIGHT or LEFT for direc-tion desired.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FORTHE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIP-MENT.

Raising and Lowering the Lower and Mid BoomDepress footswitch to raise or lower the Lower and MidBoom, with footswitch activated, position Lower Boom Liftswitch to UP or DOWN as desired.

Raising and Lowering the Upper BoomDepress footswitch to raise or lower the Upper Boom, withfootswitch activated, position Upper Boom Lift switch to UPor DOWN until desired height is reached.

4.8 GE

The machconnecte

AutomatThe gethe fol

1. G

2. Thco

When will mowhen will tur


4-1 3121210

Ba

Ma

of the Manual Charge button will start the enginee the charging cycle even if the batteries areove the level of automatic start. The operator cancharge cycle to charge the batteries to the maxi-. The charging cycle will include finishing phaseonventional chargers.

TERr converts 48 VDC to 110 VAC to allow operationols from the machine’s batteries.

erter is operational when the emergency stop pulled out.

chine and inverter can be operated at the same

rter will shut off at approximately 42 VDC and staythe emergency stop switch is recycled. It will oper-n until voltage drops to 42 VDC.

hine will operate down to 36 VDC.

rter will shut down if the high temperature lightd overheating. It will automatically turn back onoled.

rload light indicates an output wiring short circuit that is too large for the rating of the inverter.

0 – JLG Lift –

ttery Only Operating ModeThe machine will operate in the battery only mode when thefollowing two conditions apply:

1. Ground Control EMS is pulled out, and:

2. The switch on the platform control console is in the Offor Disable position.

In this mode the machine will operate as a conventional bat-tery operated unit. The batteries can be used until they arefully discharged.

nual (Charge) Operating ModeThe generator will operate in manual mode always when thefollowing three conditions apply.

1. Ground Control EMS is pulled out, and:

2. The switch on the platform control console is in the Onor Enable position and:

3. The Manual Charge push button is activated.

Activation and initiatcharged abinitiate the mum levelsimilar to c

4.9 INVERThe inverteof power to

• The invswitch is

• The matime.

• The inveoff until ate agai

• The mac

• The inveindicatewhen co

• The oveor a load


4-11

UT DOWN AND PARK

en parking battery powered units overnight, batteriesuld be charged in accordance with instructions in

ction 2 to ensure readiness for following workday.

ctric machines are equipped with a static strap due totic electricity build-ups. Strap is located under rear ofchine chassis.

t down and park the machine, the procedures are as:

rive machine to a reasonably well protected area.

sure boom is lowered over rear drive axle.

ut down Emergency Stop at Platform Controls.

ut down Emergency Stop at Ground Controls. Posi-n Platform/Ground Select switch to center OFF.

necessary, cover Platform Controls to protect instruc-n placards, warning decals and operating controlsm hostile environment.

3121210 – JLG Lift –

4.10 MACHINE FUNCTION SPEEDSThe Function Speed Control affects the speed of boom func-tions Lower Lift, Telescope, and Rotate. Turn the control CWto increase function speed or CCW to decrease functionspeed. When in the CCW maximum position, Drive is placedin creep speed.

4.11 BOOM SYNCHRONIZING PROCEDURE

NOTE: If the Lower Boom assembly does not fully lower:

1. Remove all personnel from the platform.

2. Pull the red knob located beside the main control valve.

3. From Ground Control, activate the lift control switch,raise Lower Boom 1.8 m (6 feet).

4. After raising Lower Boom, release the red knob.

5. Activate Lower Boom Down, fully lower boom.

6. Repeat step 1 thru 5 if necessary.

4.12 SH

NOTE: WhshoSe

NOTE: Elestama

To shufollows

1. D

2. En

3. Sh

4. Shtio

5. If tiofro


4-1 3121210

4.1

Lif the boom in the stowed position.

e all loose items from the machine.

the chassis and the platform using straps or of adequate strength.

2 – JLG Lift –

3 MACHINE LIFTING AND TIE DOWN

ting1. Call JLG Industries, see machine’s serial number plate,

or weigh the individual unit to obtain GVW.

2. Place the boom in the stowed position.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to themachine and so the machine remains level.

Tie Down1. Place

2. Remov

3. Securechains


4-13
3121210 – JLG Lift –
Figure 4-4. Lifting Chart


4-1 3121210

eet 1 of 2

4 – JLG Lift –

Figure 4-5. Chassis & Platform Tie Down - Sh


4-15

- Sheet 2 of 2

3121210 – JLG Lift –

Figure 4-6. Chassis & Platform Tie Down


4-1 3121210

3

6 – JLG Lift –

Figure 4-7. Decal Installation - Sheet 1 of


4-17

of 3

3121210 – JLG Lift –

Figure 4-8. Decal Installation - Sheet 2


4-1 3121210

3

8 – JLG Lift –

Figure 4-9. Decal Installation - Sheet 3 of


4-19

Legend

/nish7-13

Eng/CSA French0259495-13

Chinese/Eng

0259540-11

Spa/Portuguese0259499-13

- - - - - -

35 1703936 1703937 1703940

- - - - - -

29 1703930 1703931 1703934

1705514 - - - -

84 1700584 1700584 1700584

48 1706948 1706948 1706948

- - - - - -

04 1701504 1701504 1701504

42 1701642 1701642 1701642

23 1703924 1703925 1703928

- - - - - -

44 1701644 1701644 1701644

3251813 - - 3251813

3121210 – JLG Lift –

Table 4-1. E450A/E450AJP Decal

Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11

EngLat. Spa025949

1 - - - - - - - - - -

2 1703805 - - 1703938 1703939 17039

3 - - - - - - - - - -

4 1703798 1705822 1703932 1703933 17039

5 - - - - - - - - - -

6 1700584 1700584 1700584 1700584 17005

7 3252342 - - 1706948 1706948 17069

8 - - - - - - - - - -

9 1701504 1701504 1701504 1701504 17015

10 1701642 1701642 1701642 1701642 17016

11 1703797 1705921 1703926 1703927 17039

12 - - - - - - - - - -

13 1701644 1701644 1701644 1701644 17016

14 3251813 - - - - - - - -


4-2 3121210

1703984 1703982 1703985

1704277 1704277 1704277

1704006 - - 1704008

- - - - - -

- - - - - -

3251243 - - 3251243

- - - - - -

1701691 1701691 1701691

1001104864 1001104864 1001104864

1704000 - - 1704002

1704254 1704254 1704254

1704253 - - 1704253

1704452 1704419 1704453

1704431 1704431 1704431

end


Chinese/Eng

0259540-11


0 – JLG Lift –

15 - - 1705828 1703980 1703981 1703983

16 1704277 1704277 1704277 1704277 1704277

17 - - - - - - - - 1704007

18 - - - - - - - - - -

19 - - - - - - - - - -

20 - - - - - - - - 3251243

21 - - - - - - - - - -

22 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702868 - - - - - - 1704001

25 1704254 1704254 1704254 1704254 1704254

26 1704253 - - 1704253 - - 1704253

27 1704446 1706378 1704417 1704418 1704454

28 1704431 1704431 1704431 1704431 1704431

Table 4-1. E450A/E450AJP Decal Leg

Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11

Eng/Lat. Spanish0259497-13


4-21

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

00 1701500 1701500 1701500

09 1701509 1701509 1701509

39 1704340 1704344 1704341

- - - - - -

47 1703948 1703949 1703952

- - - - - -

Legend

/nish7-13


Chinese/Eng

0259540-11


3121210 – JLG Lift –

29 - - - - - - - - - -

30 - - - - - - - - - -

31 - - - - - - - - - -

32 - - - - - - - - - -

33 - - - - - - - - - -

34 - - - - - - - - - -

35 - - - - - - - - - -

36 - - - - - - - - - -

37 1701500 1703811 1701500 1701500 17015

38 1701509 1701509 1701509 1701509 17015

39 1703813 1705670 1704342 1704343 17043

40 - - - - - - - - - -

41 1703804 1701518 1703950 1703951 17039

42 - - - - - - - - - -


Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11

EngLat. Spa025949


4-2 3121210

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1702265 1703988 1703991

- - - - - -

- - - - - -

1702300 1702300 1702300

- - - - - -

1702631 1702631 1702631

1707047 1707044 1707133

- - - - - -

- - - - - -

- - - - - -

end


Chinese/Eng

0259540-11


2 – JLG Lift –

43 - - - - - - - - - -

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 1702265 1705977 1702271 1703987 1702265

48 - - - - - - - - - -

49 - - - - - - - - - -

50 1702300 1703814 1702300 1702300 1702300

51 - - - - - - - - - -

52 1702631 1702631 1702631 1702631 1702631

53 1707013 1705978 1707054 1707042 1707049

54 - - - - - - - - - -

55 - - - - - - - - - -

56 - - - - - - - - - -


Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11



4-23

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

50 1704252 - - 1706950

56 1707055 1707060 1707134

02 1701502 1701502 1701502

03 1701503 1701503 1701503

- - - - - -

- - - - - -

- - - - - -

Legend

/nish7-13


Chinese/Eng

0259540-11


3121210 – JLG Lift –

57 - - - - - - - - - -

58 - - - - - - - - - -

59 - - - - - - - - - -

60 - - - - - - - - - -

61 - - - - - - - - - -

62 - - - - - - - - - -

63 - - - - - - - - - -

64 1706950 - - - - - - 17069

65 1701645 1705978 1707059 1707058 17070

66 1701502 1701502 1701502 1701502 17015

67 1701503 1701503 1701503 1701503 17015

68 - - - - - - - - - -

69 - - - - - - - - - -

70 - - - - - - - - - -


Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11

EngLat. Spa025949


4-2 3121210

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1704412 1704412 1704412

- - - - - -

1704885 1704885 1704885

end


Chinese/Eng

0259540-11


4 – JLG Lift –

71 - - - - - - - - - -

72 - - - - - - - - - -

73 - - - - - - - - - -

74 - - - - - - - - - -

75 - - - - - - - - - -

76 - - - - - - - - - -

77 1704412 1704412 1704412 1704412 1704412

78 1704830 - - - - - - - -

79 1704885 1704885 1704885 1704885 1704885


Item # ANSI0259301-16

CE/AusI0275070-6

Japanese0259536-11

Korean0259538-11



4-25

Legend

/sh6-15

Eng/French

0259494-15

Chinese0259539-13


- - - - - -

35 1703936 1703937 1703940

- - - - - -

29 1703930 1703931 1703934

1705514 - - - -

84 1700584 1700584 1700584

48 1706948 1706948 1706948

- - - - - -

04 1701504 1701504 1701504

42 1701642 1701642 1701642

23 1703924 1703925 1703928

- - - - - -

44 1701644 1701644 1701644

13 3251813 - - 3251813

83 1703984 1703982 1703985

77 1704277 1704277 1704277

07 1704006 - - 1704008

3121210 – JLG Lift –

Table 4-2. M450A/M450AJ Decal

Item # ANSI0258973-18

CE/AusI0275069-6

Japanese0259535-13

Korean0259537-13

EngSpani

025949

1 - - - - - - - - - -

2 1703805 - - 1703938 1703939 17039

3 - - - - - - - - - -

4 1703798 1705822 1703932 1703933 17039

5 - - - - - - - - - -

6 1700584 1700584 1700584 1700584 17005

7 1706948 - - 1706948 1706948 17069

8 - - - - - - - - - -

9 1701504 1701504 1701504 1701504 17015

10 1701642 1701642 1701642 1701642 17016

11 1703797 1705921 1703926 1703927 17039

12 - - - - - - - - - -

13 1701644 1701644 1701644 1701644 17016

14 3251813 - - - - - - 32518

15 - - 1705828 1703980 1703981 17039

16 1704277 1704277 1704277 1704277 17042

17 - - - - - - - - 17040


4-2 3121210

- - - - - -

- - - - - -

3251243 3251243 3251243

- - - - - -

1701691 1701691 1701691

1001104864 1001104864 1001104864

1704000 1704000 1704002

1704254 1704254 1704254

1704253 - - 1704253

1704452 1704419 1704453

1704431 1704431 1704431

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

end

Eng/French

0259494-15

Chinese0259539-13


6 – JLG Lift –

18 - - - - - - - - - -

19 - - - - - - - - - -

20 - - - - - - - - 3251243

21 - - - - - - - - - -

22 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702868 - - - - - - 1704001

25 1704254 1704254 1704254 1704254 1704254

26 1704253 - - - - - - 1704253

27 1704446 1706378 1704417 1704418 1704454

28 1704431 1704431 1704431 1704431 1704431

29 - - - - - - - - - -

30 - - - - - - - - - -

31 - - - - - - - - - -

32 - - - - - - - - - -

33 - - - - - - - - - -

34 - - - - - - - - - -

35 - - - - - - - - - -

Table 4-2. M450A/M450AJ Decal Leg

Item # ANSI0258973-18

CE/AusI0275069-6

Japanese0259535-13

Korean0259537-13

Eng/Spanish

0259496-15


4-27

- - - - - -

00 1701500 1701500 1701500

09 1701509 1701509 1701509

39 1704340 1704344 1704341

- - - - - -

47 1703948 1703949 1703952

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

65 1702265 1703988 1703991

- - - - - -

- - - - - -

00 1702300 1702300 1702300

- - - - - -

31 1702631 1702631 1702631

49 1707047 1707044 1707133

Legend

/sh6-15

Eng/French

0259494-15

Chinese0259539-13


3121210 – JLG Lift –

36 - - - - - - - - - -

37 1701500 1703811 1701500 1701500 17015

38 1701509 1701509 1701509 1701509 17015

39 1703813 1705670 1704342 1704343 17043

40 - - - - - - - - - -

41 1703804 1701518 1703950 1703951 17039

42 - - - - - - - - - -

43 - - - - - - - - - -

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 1702265 1705977 1702271 1703987 17022

48 - - - - - - - - - -

49 - - - - - - - - - -

50 1702300 1703814 1702300 1702300 17023

51 - - - - - - - - - -

52 1702631 1702631 1702631 1702631 17026

53 1707013 1705978 1707054 1707042 17070


Item # ANSI0258973-18

CE/AusI0275069-6

Japanese0259535-13

Korean0259537-13

EngSpani

025949


4-2 3121210

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1706950 - - 1706950

1707055 1707060 1707134

1701502 1701502 1701502

1701503 1701503 1701503

- - - - - -

- - - - - -

1001093687 1001093687 1001093687

- - - - - -

end

Eng/French

0259494-15

Chinese0259539-13


8 – JLG Lift –

54 - - - - - - - - - -

55 - - - - - - - - - -

56 - - - - - - - - - -

57 - - - - - - - - - -

58 - - - - - - - - - -

59 - - - - - - - - - -

60 - - - - - - - - - -

61 - - - - - - - - - -

62 - - - - - - - - - -

63 - - - - - - - - - -

64 1706950 - - - - - - 1706950

65 1701645 1705978 1707059 1707058 1707056

66 1701502 1701502 1701502 1701502 1701502

67 1701503 1701503 1701503 1701503 1701503

68 - - - - - - - - - -

69 - - - - - - - - - -

70 1704286 - - 1001093687 1001093687 1001093687

71 - - - - - - - - - -

Table 4-2. M450A/M450AJ Decal Leg

Item # ANSI0258973-18

CE/AusI0275069-6

Japanese0259535-13

Korean0259537-13

Eng/Spanish

0259496-15


4-29

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

12 1704412 1704412 1704412

30 1704830 1704830 1704830

85 1704885 1704885 1704885

Legend

/sh6-15

Eng/French

0259494-15

Chinese0259539-13


3121210 – JLG Lift –

72 - - - - - - - - - -

73 1702962 - - - - - - - -

74 - - - - - - - - - -

75 - - - - 1705084 1705084 - -

76 - - - - - - - - - -

77 1704412 1704412 1704412 1704412 17044

78 1704830 1704830 1704830 1704830 17048

79 1704885 1704885 1704885 1704885 17048


Item # ANSI0258973-18

CE/AusI0275069-6

Japanese0259535-13

Korean0259537-13

EngSpani

025949


4-3 3121210
0 – JLG Lift –
NOTES:

SECTION 5 - EMERGENCY PROCEDURES

5-1

ROCEDURES

ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINELL FUNCTIONS FIRST FROM THE GROUND CONTROLS,THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10OU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IFND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

ERGENCY OPERATION

Unable to Control Machine PLATFORM OPERATOR IS PINNED, TRAPPED OR

LE TO OPERATE OR CONTROL MACHINE:

ther personnel should operate the machine fromound controls only as required.

ther qualified personnel on the platform may use theatform controls. DO NOT CONTINUE OPERATION IFONTROLS DO NOT FUNCTION PROPERLY.

ranes, forklift trucks or other equipment can be used tomove platform occupants and stabilize motion of theachine.

3121210 – JLG Lift –

SECTION 5. EMERGENCY P

5.1 GENERALThis section explains the steps to be taken in case of anemergency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any inci-dent involving a JLG product. Even if no injury or propertydamage is evident, the factory should be contacted by tele-phone and provided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving aJLG Industries product within 48 hours of such an occur-rence may void any warranty consideration on that particularmachine.

FOLLOWINGAND TEST ATHEN FROM FT.) UNTIL YREQUIRED, A

5.3 EM

OperatorIF THEUNAB

1. Ogr

2. OplC

3. Crem


5-2 3121210

Pla

5.4

AL DESCENT SYSTEM

escent system is used, in the event of total powerer the upper and lower booms using gravity. Toanual descent system, proceed as follows:

p r io r to S/N 0300062850 and f rom S/N2 to Present:

manual descent knob on main valve and turnlockwise). Install handle into manual descentand lower the Mid and Lower Booms by pumpingndle until they are completely lowered.

anual descent knob CCW (counterclockwise) andthe Upper (or main) Boom by pumping the handle is completely lowered. Return manual descento center position and stow handle in bracket pro-

62850 to S/N 0300127572:

manual descent knob on main valve and turn(counterclockwise). Install handle into manual

nt pump and lower the Mid and Lower Booms byng the handle until they are completely lowered.

anual descent knob CW (clockwise) and lowerper (or main) Boom by pumping the handle until it

– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged inoverhead structures or equipment, rescue platform occu-pants prior to freeing the machine.

EMERGENCY TOWING PROCEDURESTowing this machine is prohibited, unless properly equipped.However, provisions for moving the machine, in case of amalfunction or power failure, have been incorporated. Thefollowing procedures are to be used ONLY for emergencymovement to a suitable maintenance area.

1. Chock wheels securely.

2. Disengage drive hubs by reversing disconnect caps.

3. Connect suitable equipment, remove chocks, and movemachine.

After moving machine, complete the following procedures:

1. Position machine on a firm and level surface.

2. Chock wheels securely.

3. Engage drive hubs by reversing disconnect caps onhubs.

4. Remove chocks from wheels as needed.

5.5 MANU

The manual dfailure, to lowoperate the m

Mach ines030012757

1. LocateCW (cpump the ha

2. Turn mlower until itknob tvided.

S/N 03000

1. LocateCCW descepumpi

2. Turn mthe Up


5-3
3121210 – JLG Lift –
is completely lowered. Return manual descent knob tocenter position and stow handle in bracket provided.

5.6 MANUAL SWING OVERRIDE

The manual swing override is used to manually swing boomand turntable assembly in the event of a total power failure whenthe platform is positioned over a structure or obstacle. To oper-ate the manual swing override, proceed as follows:

1. Using a 7/8 inch socket and ratchet wrench, locate nuton swing worm gear on left side of machine.

2. Install wrench on nut and ratchet in the directiondesired.


5-4 3121210
– JLG Lift –
NOTES:

FICATIONS & OPERATOR MAINTENANCE

6-1

OPERATOR MAINTENANCE

ERATING SPECIFICATIONS

Table 6-1. Operating Specifications

Work Load (Capacity)tricted: 500 lb. (230 kg)

ed 3.2 mph (5.2 kph)

Travel Grade (Gradeablility 30%

Travel Grade (Side Slope) 5°

Height: (stowed)/M450AJ/M450AJ

6 ft. 6.25 in. (1.9 m)6 ft. 7 in. (2.0 m)

Horizontal Platform Reach

J 23 ft. 1in.(7.0 m)

23 ft. 9 in. (7.24 m)

adius (Curb to Curb) 15 ft. 3 in. (4.65 m)

adius (inside) 2 ft. (0.61 m)

Tire Load:, E450AJ, E450AJ

6100 lbs. (2,767 kg)6900 lbs. (3,130 kg)

SECTION 6 - GENERAL SPECI

3121210 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS &

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machine.

The maintenance portion of this section is intended as infor-mation to assist the machine operator to perform daily main-tenance tasks only, and does not replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual - ANSI, CSA Spec ............................................... 3121127

Service and Maintenance Manual - CE Spec........... 3121829

Illustrated Parts Manual - ANSI, CSA Spec .............. 3121128

Illustrated Parts Manual - CE Spec........................... 3121830

6.2 OP

Maximum Unres

Travel Spe

Maximum

Maximum

Maximum E450A E450A

Maximum E450A E450A

Turning R

Turning R

Maximum M450A M450A

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121210

Table 6-2. Capacities

ank 4 Gallons (15.1 L)

nk 5 Gallons (19 L) w/ 10% air space

m (Including Tank) 37.2 Gallons (140.8 L)

ve* 17 ounces (0.50 L)

hould be one half full of lubricant.

– JLG Lift –

CapacitiesGround Bearing Pressure M450A, E450A M450AJ, E450AJ

64 psi (4.5 kg/cm2)75 psi (5.2 kg/cm2)

System Voltage 48 volts

Battery Life per Charge 7 hours continuous

Battery Recharge Time Charger Generator

17 hours from full discharge6.2 hours

Gross Machine Weight (Platform Empty) E450A/M450A E450AJ/M450AJ

13,100 lb. (5942 kg)15,100 lb. (6804 kg)

Table 6-1. Operating Specifications

Generator Fuel T

Hydraulic Oil Ta

Hydraulic Syste

Torque Hub, Dri

*Torque hubs s


6-3

se 6 ft. 7.0 in. (2.00 m)

Height 51 ft. 0 in. (15.54 m)

Height 45 ft. 0 in. (13.72 m)

dth 5 ft. 0 in. (1.51 m)

g (Any Position) 0

learance E450J, E450AJ

8.5 in. (0.22 m)8 in. (0.20 m)

Table 6-4. Dimensional Data


3121210 – JLG Lift –

Tires

Dimensional Data

Table 6-3. Tire Specifications

Size IN240/55-17.5 IN240/55-17.5

Load Range E E

Ply Rating 10 10

Tire Pressure 90 psi (6.2 Bar) Foam-Filled

Table 6-4. Dimensional Data

Machine Length (stowed) M450A, E450A M450AJ, E450AJ

18 ft. 8.0 in. (5.69 m)21 ft. 2 in. (6.45 m)

Up and Over Platform Height M450A, E450A M450AJ, E450AJ

24 ft. 7 in. (7.49 m)25 ft. 3 in. (7.7 m)

Horizontal Reach @ Maximum Up and Over M450 A, E450A M450AJ, E450AJ

23 ft. 1 in. (7.0 m)23 ft. 9 in. (7.24 m)

Machine Width 5 ft. 9 in. (1.75 m)

Wheel Ba

Working

Platform

Track Wi

Tail Swin

Ground C M450, M450A


6-4 3121210

Tor l

lic oils must have anti-wear qualities at least to API Classification GL-3, and sufficient chemical stabil-obile hydraulic system service.

rom JLG recommendations, it is not advisable to of different brands or types, as they may not con- same required additives or be of comparable vis-. If use of hydraulic oil other than Mobil DTE 11Med, contact JLG Industries for proper recommen-.

Table 6-6. Hydraulic Oil

aulic Systemperating

erature Range

S.A.E. ViscosityGrade

° to + 180° F° to +83° C)

10W

° to + 210° F° to +99° C)

10W-20, 10W30

° to + 210° F0° to +99° C

20W-20

– JLG Lift –

que Specifications Hydraulic Oi

NOTE: HydrauServiceity for m

Aside fmix oilstain thecositiesis desirdations

Table 6-5. Torque Requirements

Description Torque Value Interval Hours

Wheel Lugs 170 ft. lbs.(230 Nm)

150

Swing Bearing(Dry)

220 ft. lbs.(298 Nm)

50/600*

Swing Bearing((Loctite)

240 ft. lbs.(326 Nm)

50/600*

* Check swing bearing bolts for security afterfirst 50 hours of operation and every 600 hoursthereafter.

HydrO

Temp

+0(-18

+0(-18

+50(+1


6-5

tability Weights

LACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF-IGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES,S, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TOBILITY.

Table 6-8. Critical Stability Weights

Component LB. KG.

weight 3850 1746

heel (foam-filled) 207 94

(4ft [1.2 m]) 90 41

(5 ft [1.5 m]) 100 45

(each) 120 54


3121210 – JLG Lift –

Lubrication Specifications

NOTE: Refer to Figure 6-2., Operator Maintenance & LubricationDiagram, for specific lubrication procedures.

Critical S

DO NOT REPFERENT WEFILLED TIREAFFECT STA

Table 6-7. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

Counter

Tire & W

Platform

Platform

Battery


6-6 3121210

Ser n top of the end of the upper boom, mid boom,oom at the left rear of the booms.

gure 6-1. Serial Number Locations

SERIAL NUMBER PLATE

SERIAL NUMBER FRAME

SERIAL NUMBERTURNTABLE

– JLG Lift –

ial Number LocationsFor machine identification, a serial number plate is affixed tothe left rear of frame, in front of left rear wheel. If the serialnumber plate is damaged or missing, the machine serialnumber is stamped on the top left side of the frame and thetop left side of the turntable. In addition, the serial number is

stamped oand lower b

Fi


6-7

Fig

ure

6-2.

Op

erat

or

Mai

nten

ance

& L

ubri

catio

n D

iagr

am


3121210 – JLG Lift –


6-8 3121210

6.3

NOT TERVALS ARE BASED ON MACHINE OPERATIONCONDITIONS. FOR MACHINES USED IN MULTI-SHIFT/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON-

ATION FREQUENCIES MUST BE INCREASED ACCORD-

Bearing

int(s) - 2 Grease Fittings - A/RPG Every 3 months or 150 hrs of operationnts - Remote Access

– JLG Lift –

OPERATOR MAINTENANCE

E: The following numbers correspond to those in Figure 6-2., Operator Maintenance & Lubrication Diagram.

LUBRICATION INUNDER NORMAL OPERATIONS ANDDITIONS, LUBRICINGLY.

1. Swing

Lube PoCapacityLube - MInterval -Comme

Table 6-9. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qual-ities; and being of extreme pressure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Clas-sification GL-5 or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Com-pound. (JLG Part No. 3020027)

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part No. 3020022)

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.


6-9

ERGREASE BEARINGS. OVERGREASING BEARINGS WILLLOWING OUTER SEAL IN HOUSING.


3121210 – JLG Lift –

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - 2 Grease FittingsCapacity - Spray OnLube - OG or Mobiltac375NCInterval - A/RComments - If necessary install grease fittings into wormgear housing and grease bearings.

NOTE: OG will allow better cycle times than Mobiltac375NC,however Mobiltac375NC must be used in dusty environ-ments. If the swing function becomes noisy and/or roughlubricate the bearing teeth.

DO NOT OVRESULT IN B


6-1 3121210

ulic Return Filter

- Change after first 50 hrs. and every 6 months or thereafter.ts - Under certain conditions, it may be neces-

replace the hydraulic filter on a more frequent common symptom of a dirty filter is sluggishnessced in hydraulic functions.

0 – JLG Lift –

3. Hydraulic Tank

Lube Point(s) - Fill CapCapacity - 4 Gal. (15.1 L)Lube - HOInterval - Check Level daily; Change every 2 years or 1200hours of operation.Comments - On new machines, those recently over-hauled, or after changing hydraulic oil, operate all systemsa minimum of two complete cycles and recheck oil level inreservoir.

4. Hydra

Interval 300 hrs.Commensary to basis. Aexperien


6-11

heel Bearings

e Point(s) - Repackacity - A/Re - MPGrval - Every 2 years or 1200 hours of operation

indles/Bushing

acity - A/Re - Lithium Lubricantrval - Every 2 years or 1200 hours of operationments - At Spindle/Bushing Replacement; Coat I.D. of

hings prior to installing king pins.


3121210 – JLG Lift –

5. Wheel Drive Hub

Lube Point(s) - Level/Fill PlugCapacity - 17 oz. (1/2 Full)Lube - EPGLInterval - Check level every 3 months or 150 hrs of opera-tion; change every 2 years or 1200 hours of operation

6. W

LubCapLubInte

7. Sp

CapLubInteCombus


6-1 3121210

int(s) - Fill Cap - Refer to Engine ManualO 3 Months or 150 hours of operationnts - Check level daily/Change in accordance with

anual.

2 – JLG Lift –

8. Boom Pivot Pins/Bushing

Capacity - A/RLube - Lithium LubricantInterval - Every 2 years or 1200 hours of operationComments - At boom pivot pins/bushing replacement;Coat I.D. of bushings prior to installing pivot pins.

9. Engine

Lube PoCapacityLube - EInterval -Commeengine m


6-13

move battery cables from each battery post one at a e, negative first. Clean cables with acid neutralizing

lution (e.g. baking soda and water or ammonia) and ire brush. Replace cables and/or cable clamp bolts as quired.

lean battery post with wire brush then re-connect cable post. Coat non-contact surfaces with mineral grease petroleum jelly.

hen all cables and terminal posts have been cleaned, sure all cables are properly positioned and do not get

nched. Close battery compartment cover.

art hydraulic system and ensure that it functions prop-ly.


3121210 – JLG Lift –

6.4 BATTERY MAINTENANCE AND CHARGING

Battery Maintenance, Quarterly1. Open battery compartment cover to allow access to bat-

tery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTRO-LYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTRO-LYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries, non-metalliccontainers and/or funnels must be used.

To avoid electrolyte overflow, add distilled water to batter-ies after charging.

When adding water to the battery, fill only to level indi-cated.

2. Remove all vent caps and inspect electrolyte level of each cell. Electrolyte level should be to the ring approxi-mately one inch from top of battery. Fill batteries with distilled water only. Replace and secure all vent caps.

3. Retimsowre

4. Ctoor

5. Wenpi

6. Ster


6-1 3121210

Op

EXHLAT

WHEFORGENSTACHA

NOT

TO ASPAWEA

rging (On Board Charger)imum battery life:

oid completely discharging the batteries.

lly charge the batteries each day the machine ised.

harge the batteries at available times betweenarging.

sure the battery fluid covers the battery platesfore charging, but to avoid overflow, do not top

f the fluid level until charging.

rge the batteries, connect the charger to an riate volt source with a 15 amp minimum capac-

arger will shut off automatically when the batter- fully charged.

arge cycle is complete when the ammeter reads s. Any reading indicates the charge cycle is not ete.

ed batteries will take approximately 17 hours to .

4 – JLG Lift –

tional On Board Generator

AUST GAS HAZARD. RUN THE GENERATOR IN A WELL VENTI-ED AREA ONLY.

N THE GENERATOR ENABLE CONTROL LOCATED IN THE PLAT-M CONTROL BOX IS IN THE ON POSITION AND THE GROUND EMER-CY STOP SWITCH IN ON (PULLED OUT), THE GENERATOR WILLRT AUTOMATICALLY WHEN THE BATTERIES REACH A LOW-RGE STATE AUTOMATICALLY CHARGING THE BATTERIES.

E: The engine will automatically shut down under the follow-ing conditions:

High Engine Oil TemperatureLow Engine Oil PressureEngine OverspeedGenerator Overvoltage

VOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOWRKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYSR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.

Battery Cha1. For max

a. Av

b. Fuus

c. Cch

d. Bebeof

2. To chaappropity.

3. The Chies are

4. The ch0 ampcompl

5. Depletcharge


6-15

any damage to the bead area cords of the tire

damaged but is within the above noted criteria, the tireinspected on a daily basis to insure the damage hasgated beyond the allowable criteria.

lacement

mmends a replacement tire be the same size, ply andoriginally installed on the machine. Please refer to the Manual for the part number of the approved tires for a machine model. If not using a JLG approved replace- we recommend that replacement tires have the follow-cteristics:

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 tothe original

Approved for the application by the tire manufacturer(including inflation pressure and maximum tire load)

pecifically approved by JLG Industries Inc. do not foam filled or ballast filled tire assembly with a pneu-. When selecting and installing a replacement tire,at all tires are inflated to the pressure recommended


3121210 – JLG Lift –

6.5 TIRES & WHEELS

Tire InflationThe air pressure for pneumatic tires must be equal to the airpressure that is stenciled on the side of the JLG product orrim decal for safe and proper operational characteristics.

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that whenany cut, rip, or tear is discovered that exposes sidewall or treadarea cords in the tire, measures must be taken to remove theJLG product from service immediately. Arrangements must bemade for replacement of the tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recom-mends that when any of the following are discovered, measuresmust be taken to remove the JLG product from service immedi-ately and arrangements must be made for replacement of thetire or tire assembly.

• a smooth, even cut through the cord plies whichexceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plieswhich exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

•

If a tire is must be not propa

Tire Rep

JLG recobrand as JLG Partsparticularment tire,ing chara

•

•

•

•

Unless sreplace amatic tireensure th


6-1 3121210

bo

Wh

Tfosupfare

llation important to apply and maintain proper wheelue.

ST BE INSTALLED AND MAINTAINED AT THE PROPERVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI- SEPARATION OF WHEEL FROM THE AXLE. BE SURE

HE NUTS MATCHED TO THE CONE ANGLE OF THE

nuts to the proper torque to prevent wheels from. Use a torque wrench to tighten the fasteners. Ifve a torque wrench, tighten the fasteners with aen immediately have a service garage or dealer

g nuts to the proper torque. Over-tightening willking the studs or permanently deforming the holes in the wheels. The proper procedure for

els is as follows:

nuts by hand to prevent cross threading. DO NOTricant on threads or nuts.

6 – JLG Lift –

y JLG. Due to size variations between tire brands, both tiresn the same axle should be the same.

eel Replacement

he rims installed on each product model have been designedr stability requirements which consist of track width, tire pres-re, and load capacity. Size changes such as rim width, center

iece location, larger or smaller diameter, etc., without writtenctory recommendations, may result in an unsafe conditiongarding stability.

Wheel InstaIt is extremelymounting torq

WHEEL NUTS MUTORQUE TO PREBLE DANGEROUSTO USE ONLY TWHEEL.

Tighten the lugcoming looseyou do not halug wrench, thtighten the luresult in breamounting studattaching whe

1. Start all use a lub


6-17

e tightening of the nuts should be done in stages. Fol-wing the recommended sequence, tighten nuts per heel torque chart.

el nuts should be torqued after first 50 hours of opera- and after each wheel removal. Check torque every 3ths or 150 hours of operation.

Table 6-10. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft. lbs.(55 Nm)

100 ft. lbs.(130 Nm)

170 ft. lbs.(255 Nm)


3121210 – JLG Lift –

2. Tighten nuts in the following sequence: 3. Thlow

4. Whetionmon


6-1 3121210

6.6

8 – JLG Lift –

SUPPLEMENTAL INFORMATIONThe following information is provided in accordance with therequirements 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 lessthan 70dB(A)

For combustion engine powered machines, guaranteedSound Power Level (LWA) per European Directive 2000/14/EC (Noise Emission in the Environment by Equipment forUse Outdoors) based on test methods in accordance withAnnex III, Part B, Method 1 and 0 of the directive, is 104 dB.

The vibration total value to which the hand-arm system issubjected does not exceed 2,5 m/s2. The highest root meansquare value of weighted acceleration to which the wholebody is subjected does not exceed 0,5 m/s2.

TION 7 - INSPECTION AND REPAIR LOG

7-1

D REPAIR LOG

ir Log

nts

SEC

3121210 – JLG Lift –

SECTION 7. INSPECTION ANMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121210

og

– JLG Lift –

Table 7-1. Inspection and Repair L

Date Comments

TRA

NS

FE

R O

F O

WN

ER

SH

IP

To P

rod

uct

Ow

ner

:If

yo

u n

ow o

wn

bu

t A

RE

NO

T t

he

ori

gin

al p

urc

has

er o

f th

e p

rod

uct

cov

ered

by

this

m

anu

al, w

e w

ou

ld li

ke t

o k

now

wh

o y

ou

are

. Fo

r th

e p

urp

ose

of

rece

ivin

g s

afet

y-re

late

d

bulle

tin

s, it

is v

ery

imp

ort

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Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG France SASZ.I. de Baulieu47400 FauilletFrance

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

Oshkosh-JLG Singapore Technology Equipment Pte Ltd29 Tuas Ave 4,Jurong Industrial EstateSingapore, 639379

+65-6591 9030

JLG PolskaUI. Krolewska00-060 WarsawaPoland

+48 (0)914 320 245

+48 (0)914 358 200

JLG Industries (Scotland)Wright Business Centre1 Lonmay RoadQueenslie, Glasgow G33 4ELScotland

+44 (0)141 781 6700

+44 (0)141 773 1907

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

3121210

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Operation and Safety Manual - BlueLine Rental · Operation and Safety Manual ... 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2 ... THIS MANUAL COULD RESULT IN MACHINE DAMAGE,