Professional Documents
Culture Documents
Model
450A
450AJ
3120748
April 24, 2002
ANSI
JLG Lift
FOREWORD
FOREWORD
The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.
REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL.
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS.
THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these
areas. They are defined as follows:
JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
3120748
JLG Lift
FOREWORD
JLG Lift
3120748
FOREWORD
3120748
JLG Lift
FOREWORD
REVISON LOG
Original Issue
Revised
3-6
3-8
3-6
2-12 and 2-13
5-3
Prop 65 page added
4-1
3-6
3-11
May, 1998
June 1, 1999
Updated 9-21-99
Updated 9-21-99
Updated 10-14-99
Updated 11-8-99
Updated 2-2-00
Updated 4-20-00
Updated 4-20-00
Updated 9-19-00
Updated 4-24-02
JLG Lift
3120748
TABLE OF CONTENTS
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH
SECTION
PAGE NO.
- FOREWORD
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Delivery and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Lift Up and Platform Level Down Disable Switch Functional Check . . . . . . . . . . . . . . . . . . . . . . .4-5
Shut Down and Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Oscillating Axle Lockout Test (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
3120748
JLG Lift
PAGE NO.
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Emergency Controls and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Emergency Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
TITLE
PAGE NO.
LIST OF TABLES
TABLE NO.
1-1
2-1
7-1
ii
TITLE
PAGE NO.
JLG Lift
3120748
GENERAL
1.2
DRIVING/TOWING
3120748
JLG Lift
1-1
Table 1-1.Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts
Voltage Range
(Phase to Phase)
0 to 300V
AVOID CONTACT
Over 300V to 50 KV
10 (3)
15 (5)
20 (6)
25 (8)
35 (11)
45 (14)
DANGER: DO NOT maneuver machine or personnel inside PROHIBITED ZONE. ASSUME all electrical parts and wiring
are ENERGIZED unless known otherwise.
1.3
ELECTROCUTION HAZARD
1.4
PRE-OPERATIONAL
1-2
ALLOW ONLY AUTHORIZED AND QUALIFIED PERSONNEL TO OPERATE MACHINE WHO HAVE DEMONSTRATED THAT THEY UNDERSTAND SAFE AND
PROPER OPERATION AND MAINTENANCE OF THE
UNIT.
JLG Lift
3120748
DO NOT OPERATE MACHINE WHEN WIND CONDITIONS EXCEED 30 MPH (48 KMH).
NEVER OPERATE BOOM FUNCTIONS (TELE, SWING,
LIFT) WHEN MACHINE IS ON A TRUCK, OTHER VEHICLE, OR ABOVE GROUND STRUCTURE.
PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN
THE WORK AREA MUST BE TAKEN BY THE OPERATOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.
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JLG Lift
1-3
DO NOT USE DRIVE FUNCTION TO POSITION PLATFORM CLOSE TO OBSTACLES. USE BOOM FUNCTION INSTEAD.
ALWAYS USE THREE POINT CONTACT WHEN
ENTERING OR EXITING THE MACHINE. FACE THE
MACHINE WHEN YOU ENTER OR LEAVE. THREE
POINT CONTACT MEANS THAT TWO HANDS AND
ONE FOOT OR ONE HAND AND TWO FEET ARE IN
CONTACT WITH THE MACHINE AT ALL TIMES DURING MOUNT AND DISMOUNT.
1.5
DRIVING
1-4
JLG Lift
3120748
1.6
OPERATION
CHECK TRAVEL PATH FOR PERSONS, DEPRESSIONS, HOLES, BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS, AND COVERINGS WHICH MAY
CONCEAL HOLES AND OTHER HAZARDS.
TRAVEL IS PERMITTED ON GRADES NO GREATER
THAN THOSE INDICATED ON THE SERIAL NUMBER
PLATE.
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5.
OPERATION WITH BOOM RAISED IS RESTRICTED
TO FIRM, LEVEL AND UNIFORM SURFACE.
DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES,
AS TIPPING WILL OCCUR.
ENSURE THAT GROUND CONDITIONS ARE ADEQUATE TO SUPPORT THE MAXIMUM TIRE LOAD.
DO NOT DRIVE MACHINE NEAR PITS, LOADING
DOCKS OR OTHER DROP-OFFS.
3120748
JLG Lift
1-5
1-6
THE OPERATOR IS RESPONSIBLE TO AVOID OPERATING MACHINE OVER GROUND PERSONNEL AND
TO WARN THEM NOT TO WORK, WALK OR STAND
UNDER A RAISED BOOM OR PLATFORM. POSITION
BARRICADES ON FLOOR IF NECESSARY.
JLG Lift
3120748
CHECK CLEARANCES ABOVE, ON SIDES AND BOTTOM OF PLATFORM WHEN RAISING, LOWERING,
SWINGING, AND TELESCOPING BOOM.
EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER-
3120748
JLG Lift
1-7
1.7
DO NOT TOW A MACHINE EXCEPT IN AN EMERGENCY. SEE SECTION 6 FOR EMERGENCY TOWING
PROCEDURES.
LOCK TURNTABLE BEFORE TRAVELING LONG DISTANCES OR BEFORE HAULING MACHINE ON A
TRUCK OR TRAILER.
DO NOT OPERATE ANY MACHINE ON WHICH DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE.
1-8
JLG Lift
3120748
GENERAL
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.
2.2
Chassis
1. Check front tires and wheel assemblies for loose or
worn spindles, components and hardware for security, tires for wear and damage.
All preparation necessary to place the machine in operation readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate properly) coupled with a series of visual inspections. The mandatory requirements are given in the Daily Walk Around
Inspection (see section 2-4).
It should be assured that the items appearing in the Delivery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.
2.3
NOTE: This machine requires periodic safety and maintenance inspections by an authorized JLG Dealer. A
decal located on the frame provides a place to
record (stamp) inspection dates. Check decal and
notify dealer if inspection is overdue.
3120748
JLG Lift
7. Check oscillating axle (if equipped) for loose, missing and worn parts, pivot pin and lockout cylinder
pins for security, lockout cylinders and hydraulic
hoses for damage and leaks.
2-1
Turntable
12. Check all pin and shaft retaining hardware for security and wear.
Boom
3. Check solenoid valves and hydraulic lines for damage, leakage, security and electrical connections for
tightness and evidence of corrosion.
2. Check all pin and shaft retaining hardware for security and wear.
3. Check hydraulic lines and electrical cable for damage, missing parts and security.
4. Check ground controls for damage, loose or missing parts, security, electrical connections for evidence of corrosion and tightness and wiring for
insulation damage. Assure that all switches function
properly.
4. Check limit switch connections and plunger for corrosion and security.
5. Check Lower Upright, cross pins and hydraulic lines
for damage, wear, lubrication, leakage and security.
2-2
JLG Lift
3120748
PLATFORM
CONSOLE
EXTEND-A-REACH
or JIB
PLATFORM
EXTEND-A-REACH
CYLINDER
FLY BOOM
LEVEL CYLINDER
POWER TRACK
BASE BOOM
MAIN BOOM ASSEMBLY
MID BOOM
LOWER UPRIGHT
TOWER or
LOWER BOOM
DRIVE WHEELS
STEER WHEELS
Figure 2-1. Machine Nomenclature
3120748
JLG Lift
2-3
5. Check platform rotator mechanism for proper operation, damage, security. Check hydraulic lines for
leakage, damage and security.
Platform
1. Check platform and control console for damage,
loose or missing parts, and security.
2. Check control switches and levers for damage,
loose or missing parts and security. Assure that
levers function properly.
3. Check control switches, levers and electrical connections for tightness and evidence of corrosion,
and wiring for defects and chafing damage. Assure
that switches function properly.
2-4
Torque Requirements
The Torque Chart (Figure 2-6.) consists of standard torque
values based on bolt diameter and grade, also specifying
dry and wet torque values in accordance with recommended shop practices. This chart is provided as an aid
to the operator in the event he/she notices a condition that
requires prompt attention during the walk-around inspection or during operation, until the proper service personnel
can be notified. The Service and Maintenance manual
provides specific torque values and periodic maintenance
procedures with a listing of individual components. Utilizing this Torque Chart in conjunction with the preventive
maintenance section in the Service and Maintenance
manual will enhance safety, reliability, and performance of
the machine.
JLG Lift
3120748
2.4
3120748
JLG Lift
8. Assure that all items requiring lubrication are serviced. Refer to Figure 2-5., Lubrication Diagram for
specific requirements.
2-5
2-6
JLG Lift
3120748
GENERAL
Begin the "Walk-Around Inspection" at Item 1, as noted on
the diagram. Continue to the right (counterclockwise
viewed from top) checking each item in sequence for the
conditions listed in the Walk-Around Inspection Checklist.
20. Engine Air Filter - No loose or missing parts; no visible damage; element clean.
21. Hood, Right Side - Properly secured; no loose or
missing parts.
22. Engine Oil Supply - Full mark on dipstick; filler cap
secure.
3120748
JLG Lift
2-7
2-8
JLG Lift
3120748
2.5
3120748
JLG Lift
2-9
2.6
BATTERY MAINTENANCE
1. The battery is maintenance free except for occasional battery terminal cleaning, as noted in the following.
2-10
JLG Lift
3120748
3120748
JLG Lift
2-11
Number/Type
Lube Points
Capacity
Lube
2 Grease Fitting
A/R
MPG
X
X
3
Months
150 hrs
Hours
6
Months
300 hrs
1 Year
600 hrs
2 Years
1200 hrs
Comments
Lubrication
1
2a
Spray On
A/R
OGL
2b
A/R
MPG
Repack
A/R
MPG
Level/Fill Plug
EPGL
N/A
N/A
N/A
N/A
N/A
N/A
Hydraulic Oil
Fill Cap
HO
N/A
N/A
Steer Cylinder
A/R
MPG
10
Oscillation Cylinders
A/R
MPG
Engines
11
Fill Cap/Spin-on
Element
5 Quarts (4.7 L)
EO
12
Fill Cap/Spin-on
Element
EO
13
Fill Cap/Spin-on
Element
EO
14
Replaceable
Element
N/A
N/A
15
Replaceable
Element
N/A
N/A
16
Replaceable
Element
N/A
N/A
17
Replaceable
Element
N/A
N/A
Updated 11-8-99
2-12
JLG Lift
3120748
Number/Type
Lube Points
Capacity
Lube
3
Months
150 hrs
Hours
6
Months
300 hrs
1 Year
600 hrs
2 Years
1200 hrs
Comments
18
Replaceable
Element
N/A
N/A
19
Replaceable
Element
N/A
N/A
NOTES:
KEY TO LUBRICANTS
Lubrication intervals are based on machine operation under normal conditions. For machines used in multi shift operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.
* If necessary install grease fittings into worm gear housing and grease bearings.
EO
EPGL
HO
MPG
OGL
Engine Oil
Extreme Pressure Gear Lube
Hydraulic Fluid (Mobil DTE-11M)
Multi-Purpose Grease
Open Gear Lubricant - Mobiltac 375 or
equivalent
Updated 11-8-99
3120748
JLG Lift
2-13
2-14
JLG Lift
3120748
GENERAL
3.2
4. Proper use of all required personnel safety equipment, in particular the wearing of a safety harness or
other approved fall protection devices with a lanyard
attached to the platform at all times.
5. Sufficient knowledge of the mechanical operation of
the machine to recognize a malfunction or potential
malfunction.
6. The safest means to operate the machine where
overhead obstructions, other moving equipment,
and obstacles, depressions, holes, drop-offs, etc. on
the supporting surface exist.
PERSONNEL TRAINING
The aerial platform is a personnel handling device; therefore it is essential that it be operated and maintained only
by authorized and qualified personnel who have demonstrated that they understand the proper use and maintenance of the machine. It is important that all personnel
who are assigned to and responsible for the operation
and maintenance of the machine undergo a thorough
training program and check out period in order to become
familiar with the characteristics prior to operating the
machine.
In addition, personnel operating the machine should be
familiar with ANSI standard A92.5-1992 Responsibilities
Section. This outlines the responsibilities of the owners,
users, operators, lessors and lessees concerning safety,
training, inspection, maintenance, application and operation.
Persons under the influence of drugs or alcohol or who
are subject to seizures, dizziness or loss of physical control must not be permitted to operate the machine.
Operator Training
Operator training must include instruction in the following
areas:
1. Use and limitations of the platform controls, ground
controls, emergency controls and safety systems.
3120748
Training Supervision
Training must be done under the supervision of a qualified
person in an open area free of obstructions until the
trainee has developed the ability to safely control a
machine in congested work locations.
Operator Responsibility
The operator must be instructed that he/she has the
responsibility and authority to shut down the machine in
case of a malfunction or other unsafe condition of either
the machine or the job site and to request further information from his/her supervisor or an authorized JLG Distributor before proceeding.
NOTE: Manufacturer or distributor will provide qualified persons for training assistance with first unit(s) delivered
and thereafter as requested by the user or his/her
personnel.
JLG Lift
3-1
3.3
General
A thorough knowledge of the operating characteristics
and limitations of the machine is always the first requirement for any user, regardless of the users experience with
similar types of equipment.
TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE.
Placards
Important points to remember during operation are provided at the control stations by DANGER, WARNING,
CAUTION, IMPORTANT and INSTRUCTION placards. This
information is placed at various locations for the express
purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations
of the machine. See FOREWORD for definitions of the
above placards.
If the lower boom does not fully lower, use the following
procedure.
Capacities
5. Pull and hold out the red re-level knob on the synchronizing valve located beside the main control
valve.
Stability
This machine as originally manufactured by JLG Industries Inc., when operated within its rated capacity on a
smooth, firm and level supporting surface, and in accordance with the instructions provided on the machine and
this manual, provides a stable machine for all platform
positions.
3-2
JLG Lift
3120748
UPPER BOOM
HORIZONTAL
TELESCOPE
FULLY EXTENDED
MID/LOWER BOOM
STOWED POSITION
3120748
JLG Lift
3-3
3-4
JLG Lift
3120748
3.4
Ground Controls
P E R F O R M P R E- O P E R AT I O N A L C H E C K S A N D
INSPECTIONS FROM THE GROUND CONTROL STATION. WHEN PERSONNEL ARE IN THE PLATFORM,
OPERATION OF THE BOOM WILL ONLY BE PERFORMED WITH THE PERMISSION OF THE PLATFORM
OCCUPANT(S).
c. Position PLATFORM/GROUND
GROUND.
3120748
STOP
to
switch
WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.
JLG Lift
3-5
4. Tower Lift.
The Tower Lift control switch provides raising and
lowering of the lower and mid booms when positioned up or down.
The Main Telescope control switch provides extension and retraction of the main boom, when positioned to in or out.
7. Swing Control.
When illuminated indicates that engine coolant temperature is abnormally high and service is required.
The Swing control switch provides 360 degrees noncontinuous turntable rotation when positioned to the
right or left.
8. Hourmeter.
Updated 9-19-00
3-6
JLG Lift
3120748
PLATFORM
ROTATE
INDICATOR
PANEL
PLATFORM
LEVELING
OVERRIDE
MAIN
TELESCOPE
MAIN
LIFT
ENGINE START/
AUX. POWER
POWER/
EMERGENCY
STOP
PLATFORM/GROUND
SELECT SWITCH
TOWER
LIFT
QUARTZ
1
10
HOURS
SWING
HOURMETER
1703690
A Models
PLATFORM
ROTATE
INDICATOR
PANEL
PLATFORM
LEVELING
OVERRIDE
MAIN
TELESCOPE
ARTICULATING
JIB BOOM
MAIN
LIFT
ENGINE START/
AUX. POWER
POWER/
EMERGENCY
STOP
PLATFORM/GROUND
SELECT SWITCH
TOWER
LIFT
QUARTZ
HOURS
1
10
SWING
HOURMETER
1703691
AJ Models
3120748
JLG Lift
3-7
Updated 9-21-99
3-8
JLG Lift
3120748
Platform Station
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
NOTE: Main Lift, Swing, and Drive control levers are springloaded and will automatically return to neutral (off)
position when released.
2. Power/Emergency Stop.
An on-off Power/Emergency Stop switch and a separate Engine Start/Auxiliary Power toggle switch on
the platform console supply electrical power to the
starter solenoid, when the ignition switch is placed in
the ON position and the ENGINE START switch is
push forward.
3. Enable Indicator. (Green)
This green illuminator indicates that the footswitch is
depressed and the platform controls are ready for
use. To enable the controls, depress the footswitch
and select any function within seven seconds. The
controls will then remain active as long as there is
not a delay of seven seconds between stopping one
function and starting the next one. If the seven second interval is exceeded, the enable light will go out
and the controls will not operate. To enable the controls again, remove your foot from the footswitch
and depress the footswitch.
4. Travel Warning Horn.
3120748
JLG Lift
3-9
ENABLE
INDICATOR
TILT
INDICATOR
500 LB
1000 LB
CREEP
INDICATOR
PLATFORM
LEVELING
OVERRIDE
DRIVE
SPEED
ENGINE
DISTRESS
INDICATOR
POWER/
EMERGENCY
STOP
HORN
AUX.
POWER
FUEL
SELECT
LIGHTS
1703689
1703679
1703680
MAIN LIFT/
SWING
FUNCTION
SPEED
PLATFORM
ROTATE
TELESCOPE
TOWER or
LOWER
LIFT
DRIVE/
STEER
ARTICULATING
JIB BOOM
9. Drive/Steer.
Proportional single axis joystick is provided to control drive. Push forward to drive forward, pull back to
drive in reverse. Steering is accomplished via a
thumb-activated rocker switch on the end of the
3-10
JLG Lift
3120748
The Platform Level control switch allows the operator to adjust the level of the platform by positioning
the switch to UP or DOWN.
16. Articulating Jib Boom. (If Equipped)
Push level, toggle switch forward to lift up, pull back
to lift down.
17. Fuel Select (Dual Fuel Engine Only). (If Equipped)
Gasoline or liquid propane fuel may be selected by
moving the switch to the appropriate position. It is
unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is running.
18. Lights. (If Equipped)
This switch operates control console panel lights
and head lights if the machine is so equipped. The
ignition switch does not have to be on to operate the
lights, so care must be taken to avoid draining the
battery if left unattended. The master switch and / or
the ignition switch at the ground control will turn off
power to all lights.
3120748
JLG Lift
3-11
Updated 4-24-02
3-12
3.5
JLG Lift
3120748
DANGER
ELECTROCUTION HAZARD
WARNING
CRUSHING HAZARD
WARNING
CRUSHING HAZARD
1703804 A
1703804 A
WARNING
If this machine is not properly maintained, death or serious injury could occur.
DOM 1703798
1703798
WARNING
CRUSHING HAZARD
Do not stand under a raised platform or boom,
or between a rotating platform and the boom.
Keep all body parts away from any moving components.
DANGER
1703804 A
1703804 A
ELECTROCUTION HAZARD
This machine is not insulated.
Maintain a clearance of at least 10 ft. between any part of machine
or load and any electrical line or apparatus charged up to 50,000 volts.
One foot additional clearance is required for each additional 30,000
volts or less.
Allowances must be made for operator error, machine deflection and
electrical line swaying.
1703805 A
DANGER
ELECTROCUTION HAZARD
This machine is not insulated.
Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or apparatus charged up to 50,000 volts.
One foot additional clearance is required for each additional 30,000 volts or less.
Allowances must be made for operator error, machine deflection and electrical line swaying.
Death or serious injury will occur from contact or being too close to electrical lines.
WARNING
TIP-OVER HAZARD
Machine must be on a smooth, firm and level surface before swinging, elevating and/or
extending boom.
DO NOT exceed platform rated capacity.
Make sure the operating surface will support the machine.
DO NOT drive with platform raised, or raise platform, when on uneven, sloping or soft surfaces
including trucks, trailers, railway cars, floating vessels, scaffolds or similar areas.
DO NOT raise platform during high winds.
DO NOT drive near drop offs, holes or other hazards.
Make sure all tires are in good condition and air filled tires are properly inflated.
To drive on a slope, boom must be retracted, lowered below horizontal and centered between
the rear wheels.
When Chassis out of level indicator light is on, retract and lower boom and move machine
to a level surface.
Driving with boom above horizontal or extended is restricted to smooth, firm and level surfaces
free of obstructions.
DO NOT operate this machine unless you have been properly trained as
described in the JLG Operation and Safety Manual by a qualified person
and authorized to operate this machine. Your training includes reading
and understanding the safety, operating and maintenance instructions in
manufacturers manuals, knowing your employers work rules and
applicable governmental regulations.
FALLING HAZARD
Check the condition of the approved fall protection device, lanyard and the
designated attachment point to the platform.
Wear approved fall protection items and attach to marked locations.
Keep both feet on platform floor.
Ensure entrance area is properly closed.
DO NOT use planks, ladders or similar items in platform to get added reach.
CRUSHING HAZARD
Test high engine and high drive cut out switches for proper operation.
1703797
WARNING
CRUSHING HAZARD
Do not stand under a raised platform or boom,
or between a rotating platform and the boom.
Keep all body parts away from any moving components.
1703804 A
1703804 A
3120748
JLG Lift
3-13
DANGER
ELECTROCUTION HAZARD
This machine is not insulated.
Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or apparatus charged up to 50,000 volts.
One foot additional clearance is required for each additional 30,000 volts or less.
Allowances must be made for operator error, machine deflection and electrical line swaying.
Death or serious injury will occur from contact or being too close to electrical lines.
WARNING
TIP-OVER HAZARD
Machine must be on a smooth, firm and level surface before swinging, elevating and/or
extending boom.
DO NOT exceed platform rated capacity.
Make sure the operating surface will support the machine.
DO NOT drive with platform raised, or raise platform, when on uneven, sloping or soft surfaces
including trucks, trailers, railway cars, floating vessels, scaffolds or similar areas.
DO NOT raise platform during high winds.
DO NOT drive near drop offs, holes or other hazards.
Make sure all tires are in good condition and air filled tires are properly inflated.
To drive on a slope, boom must be retracted, lowered below horizontal and centered between
the rear wheels.
When Chassis out of level indicator light is on, retract and lower boom and move machine
to a level surface.
Driving with boom above horizontal or extended is restricted to smooth, firm and level surfaces
free of obstructions.
DO NOT operate this machine unless you have been properly trained as
described in the JLG Operation and Safety Manual by a qualified person
and authorized to operate this machine. Your training includes reading
and understanding the safety, operating and maintenance instructions in
manufacturers manuals, knowing your employers work rules and
applicable governmental regulations.
FALLING HAZARD
Check the condition of the approved fall protection device, lanyard and the
designated attachment point to the platform.
Wear approved fall protection items and attach to marked locations.
Keep both feet on platform floor.
Ensure entrance area is properly closed.
DO NOT use planks, ladders or similar items in platform to get added reach.
CRUSHING HAZARD
Test high engine and high drive cut out switches for proper operation.
DOM 1703797
1703797 A
WARNING
CRUSHING HAZARD
Do not stand under a raised platform or boom,
or between a rotating platform and the boom.
Keep all body parts away from any moving components.
1703804 A
1703804 A
3-14
JLG Lift
3120748
DANGER
ELECTROCUTION HAZARD
This machine is not insulated.
Maintain a clearance of at least 10 ft. between any part of machine
or load and any electrical line or apparatus charged up to 50,000 volts.
One foot additional clearance is required for each additional 30,000
volts or less.
Allowances must be made for operator error, machine deflection and
electrical line swaying.
WARNING
CRUSHING HAZARD
Personnel shall not position themselves or other objects UNDER boom
and platform or BETWEEN boom and turntable or chassis.
When operating from ground control station avoid being BETWEEN
rotating superstructure and chassis or other immovable objects.
WARNING
If this machine is not properly maintained, death or serious injury could occur.
DOM 1703798
1703798 B
DANGER
ELECTROCUTION HAZARD
This machine is not insulated.
Maintain a clearance of at least 10 ft. between any part of machine
or load and any electrical line or apparatus charged up to 50,000 volts.
One foot additional clearance is required for each additional 30,000
volts or less.
Allowances must be made for operator error, machine deflection and
electrical line swaying.
1703805 B
3120748
JLG Lift
3-15
FUNCTION
SYMBOL
FUNCTION
DRIVE
SELECT
MAIN
LIFT
STEER
SELECT
SWING
PLATFORM
LEVEL
FUNCTION
SPEED
CONTROL
CHASSIS
OUT OF
LEVEL
PLATFORM
ROTATE
CREEP
TOWER
LIFT
SYMBOL
Main
Lift
500 LB
PLATFORM
CAPACITY
INDICATOR
1000 LB
TOWER
TELESCOPE
ENGINE
DISTRESS
ARTICULATING
FLY BOOM
LOW FUEL
LEVEL
MAIN
TELESCOPE
AC
GENERATOR
ON
FUEL
SELECT
3-16
JLG Lift
3120748
FUNCTION
SYMBOL
FUNCTION
SYMBOL
SOFT
TOUCH
OVERRIDE
GLOW PLUG
INDICATOR
ENABLE
INDICATOR
SOFT TOUCH
INDICATOR
POWER
EMERGENCY
STOP
DRIVE
START
AUXILIARY
POWER
STEER
3120748
JLG Lift
3-17
3-18
JLG Lift
3120748
DESCRIPTION
4.2
GENERAL
Updated 4-20-00
3120748
JLG Lift
4-1
4.3
ENGINE OPERATION
Starting Procedure
1. Check engine oil. If necessary, add oil in accordance with the Engine Manufacturers manual.
2. Check fuel level. Add fuel if necessary.
3. Check that air cleaner components are in place and
securely fastened.
4.4
TRAVELING (DRIVING)
1. With engine running, depress footswitch and position DRIVE control to FORWARD and hold for the
duration of forward travel desired.
NOTE: When DRIVE or STEER functions are being operated there is an interlock which prevents operation of
boom functions.
Shutdown Procedure
4-2
JLG Lift
3120748
LEVEL
DO NOT DRIVE MACHINE ON GRADES AND
SIDESLOPES EXCEEDING THOSE SPECIFIED ON
THE SERIAL NUMBER PLACARD.
Figure 4-1. Grade and Sideslope
BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSITIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE
(STEER WHEELS), STEER AND DRIVE CONTROLS WILL MOVE IN
OPPOSITE DIRECTION THAN INDICATED ON MACHINE PLACARDS.
4.6
4.7
4.5
PLATFORM
STEERING
3120748
JLG Lift
4-3
4.8
BOOM
Platform Rotation
AN ORANGE TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A 5
DEGREE OR GREATER SLOPE. DO NOT SWING OR RAISE BOOM
ABOVE HORIZONTAL WHEN LIGHT IS LIT.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR
THE CHASSIS. THE TILT ALARM INDICATES THE CHASSIS IS ON
A SEVERE SLOPE (5 DEGREE OR GREATER). CHASSIS MUST BE
LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL.
TO AVOID MACHINE UPSET IF THE ORANGE TILT WARNING
LIGHT ILLUMINATED WHEN THE BOOM IS RAISED ABOVE HORIZONTAL, LOWER THE PLATFORM TO GROUND LEVEL, THEN
REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE
RAISING BOOM.
4-4
JLG Lift
3120748
NOTE: Lift up will not function when the boom is near full
elevation and the platform is out of level.
4.9
PROXIMITY SWITCH
CONTACT PLATE
COIN
3120748
NOTE: Lifting eyes are provided at the front and rear in the
frame slab. Each of the four chains or slings used for
lifting machine must be adjusted individually so
machine remains level when elevated.
JLG Lift
4-5
Note
When transporting machine over rough terrain or long distance, the boom needs to be chocked and
strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing
up and down and preventing possible damage while transporting.
4-6
JLG Lift
3120748
Note
When transporting machine over rough terrain or long distance, the boom needs to be chocked and
strapped whenever the base boom is unable to rest on its pad. This prevents the boom from bouncing
up and down and preventing possible damage while transporting.
Figure 4-4. Machine Tie Down - AJ Models
3120748
JLG Lift
4-7
4-8
JLG Lift
3120748
8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel.
NOTE: Ensure boom is fully retracted, lowered, and centered between drive wheels prior to beginning lockout cylinder test.
9. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right
front wheel is on top of block.
1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.
3120748
JLG Lift
4-9
4.13 TOWING
RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL
MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.
MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) FOR NO LONGER
THAN 30-45 MINUTES.
MAXIMUM TOWING GRADE 25%.
4-10
JLG Lift
3120748
5.3
Description
The dual fuel system enables the standard gasoline
engine to run on either gasoline or LP gas. The system
includes pressurized cylinders mounted on the frame, and
the valves and switches needed to switch the fuel supply
from gasoline to LP gas or from LP gas to gasoline.
A two position, FUEL SELECT toggle switch at the platform control station supplies electrical power to open the
gasoline shut-off solenoid and close the LP gas shut off
solenoid when positioned to the GASOLINE position. This
switch supplies electrical power to open the LP gas shutoff solenoid and close the gasoline shut-off solenoid when
positioned to the LP position.
5.4
5.5
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE
OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME
CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS
MUST BE FOLLOWED.
5.2
OSCILLATING AXLE
3120748
JLG Lift
5-1
5.6
The ether start system in the diesel engine functions automatically to provide starting fluid, as necessary, to the
engine. A sensor switch mounted on the engine will permit ether injection when the engine is cold. The sensor will
not permit ether injection to a warm engine.
TRAVEL ALARM
5.7
ELECTRIC GENERATOR
5.8
5.9
In addition to the ether start system, the cold weather
package also includes an electric immersion heater for the
hydraulic oil tank, and an electric blanket type heater for
the battery. These components can be plugged in
together or singly to preheat their associated components
for easier cold weather starting.
ROTATING BEACON
Isuzu Engine
The cold weather package for the Isuzu engine consists of
the engine block heater (an electrical heater installed in
the left front core plug hole), an electric immersion heater
for the hydraulic oil tank, and an electric blanket type
heater for the battery. These components can be plugged
in together or singly to preheat their associated components for easier cold weather starting.
Ford Engine
Two different options are available for cold weather with
the Ford engine; an engine block heater and a cold
weather package which also includes the engine block
heater.
The engine block heater is an electrical heater installed in
the left (intake side) core plug hole. When plugged in, it
heats the engine coolant to warm the engine prior to starting.
5-2
JLG Lift
3120748
5.14 SEMI-TRACK
The hostile environment package provides additional protection against the entry of dust, dirt, sand and other abrasive materials into the hydraulic system, control handles
and switches, cylinders, boom wire ropes and wear pads,
and the air inlet of the engine. The package is intended for
machines that will be exposed to painting, sandblasting or
other similar hostile conditions. The hostile environment
package includes boom wipers, cylinder bellows, heavy
duty reservoir breather, an engine air cleaner and control
console cover, as required.
Updated 2-2-2000
3120748
JLG Lift
5-3
5-4
JLG Lift
3120748
6.2
GENERAL
Auxiliary Power
A toggle type auxiliary power control switch is located on
the platform control station and another is located on the
ground control station. Operation of either switch turns on
the electrically driven auxiliary hydraulic pump. This
should be used in case of failure of the main power plant.
The auxiliary pump will operate boom lift, telescope and
swing. To activate auxiliary power:
1. Position PLATFORM/GROUND
SWITCH to PLATFORM.
SELECT
KEY
4. Operate appropriate control switch, lever or controller for desired function and hold.
6.3
1. Position PLATFORM/GROUND
SWITCH to GROUND.
SELECT
KEY
3120748
JLG Lift
6-1
6.4
EMERGENCY OPERATION
6-2
6.5
INCIDENT NOTIFICATION
It is imperative that JLG Industries, Inc. be notified immediately of any incident involving a JLG product. Even if no
injury or property damage is evident, the factory should
be contacted by telephone and provided with all necessary details.
JLG Phone:877-JLG-SAFE (554-7233)
(8am till 4:45pm EST)
It should be noted that failure to notify the manufacturer of
an incident involving a JLG Industries product within 48
hours of such an occurrence may void any warranty consideration on that particular machine.
JLG Lift
3120748
3120748
Comments
JLG Lift
7-1
7-2
Comments
JLG Lift
3120748
TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and Sky Trak product owner:
If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like
to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG
Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each
JLG product and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current ownership of JLG
Products. Please return completed form to the JLG Product Safety & Reliability Department via facsimile (717) 4856573 or mail to address as specified on the back of this form.
Thank you,
Product Safety & Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533
Telephone: (717) 485-5161
Fax: (717) 485-6573
NOTE: Leased or rented units should not be included on this form.
Mfg. Model:
Serial Number:
Previous Owner:
Address:
City:
Zip:
State:
Telephone: (
Date Of Transfer:
Current Owner:
Address:
City:
Zip:
State:
Telephone: (
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Polska
UI. Krolewska
00-060 Warsawa
Poland
Phone: (48) 91 4320 245
Fax: (48) 91 4358 200
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: (34) 93 77 24700
Fax: (34) 93 77 11762