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Operators and Safety Manual

1. L 120 MAX SPEED UA DRIVE AND STEER Pg Co 76 70 I S 60 ap EXTEND A REACH LEVEL w Ro ED E t TD 20 2 P 4 1 N D NS 10 20 30 4050 60 TELESCOPE ROTATE AWARNING 17 15 19 7 14 13 12 9 1 Footswitch 11 Drive Steer Controller 2 Power Emergency Stop 12 Platform Level 3 Start Button 13 Platform Rotate 4 Warning Horn 14 Extend A Reach 5 Chassis Out of Level Warning Light 15 Steer Lift 16 Axles Set Indicator 7 Telescope 17 Capacity Indicator 8 Swing 18 Auxiliary Power 9 Function Speed 19 Torque Switch 10 Creep 3120685 Figure 3 8 Platform Station May 1994 to Present J LG Lift 3 13 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 12 13 14 15 16 NOTE 17 3 14 Platform Level The PLATFORM LEVEL control switch allows the operator to compensate for any difference in the automatic self leveling system by positioning the switch up or down Platform Rotate The platform ROTATE control switch allows operator to rotate the basket to the left or right when posi tioned to the desired direction Extend A Reach The EXTEND A REACH LIFT control switch allows operator to raise or lower the
2. 3 12 Figure 3 7 Platform Station Prior to May 1994 J LG Lift DRIVE AND STEER DEG f r 3 ELS gt nid Qr EXTEND A REACH LEVEL 5 h 20 A pe ato Fr 0 V 20 TELESCOPE S 2 ROTATE OFROTATION 2 BLINKING LIGHT amp AUDIO ALARM EXCEEDING CAPACITY 17 15 19 7 14 13 12 9 1 Footswitch 11 Drive Steer Controller 2 Power Emergency Stop 12 Platform Level 3 Start Button 13 Platform Rotate 4 Warming Horn 14 Extend A Reach 5 Chassis Out of Level Warning Light 15 Steer 6 Lift 16 Axles Set Indicator 7 Telescope 17 Capacity Indicator 8 Swing 18 Auxiliary Power 9 Function Speed 19 Torque Switch 10 Creep 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 18 10 5 16 i74 EH e pe CHASSIS OUT M JN e BROKEN CHAI
3. JAG N 0 P ia N 4 8 z d fem Oe X 2 MARCH 1994 TO PRESENT Figure 3 6 Remote Control Box J LG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Platform Station NOTE For engine starting the footswitch must be in the released up position Footswitch must be actuated in order for controls to function l Footswitch This feature makes it necessary to depress the foot switch to allow operation of the controls A WARNING TO AVOID SERIOUS URY DO NOT REMOVE MODIFY OR DIS ABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS A IMPORTANT THE FOOTSWITCH MUST BE ADJ USTED SO FUNCTIONS WILL OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS CEN TER OF TRAVEL IF THE SWITCH OPERATES WITHIN LAST 6 35 OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJ USTED 2 Power Emergency Stop An on off POWER EMERGENCY STOP switch and a separate START push button on the platform con sole supply electrical power to the starter solenoid when the power switch is pulled out to the on posi tion and the START button is depressed 3 Start Button The START button is a momentary contact push button switch With the POWER EMERGENCY STOP switch pulled up and the START button depressed electrical power is supplied to the start s
4. GROUND 538 CONTROL CHASSIS OUT OF HIGH ENGINE LEVEL BREAKER EXTEND A REACH TELESCOPE Figure 3 11 Control Panel Symbols Sheet 1 of 2 J LG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL FUNCTION SYMBOL FUNCTION SYMBOL MAXIMUM SPEED MINIMUM TORQUE MINIMUM SPEED PLATFORM MAXIMUM TORQUE LEVEL PLATFORM ROTATE IGNITION EMERGENCY STOP BROKEN CHAIN Figure 3 12 Control Panel Symbols Sheet 2 of 2 3120685 JLG Lift 3 21 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL This page left blank intentionally 3 22 JLG Lift 3120685 3120685 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION This machine is a self propelled aerial work platform on the end of an elevating telescoping and rotating boom The LG Lift s intended purpose 15 to position personnel with their tools and supplies at positions above ground level The machine can be used to reach work areas located above and over machinery or equipment The LG Lift has a primary operator Control Station in the platform From this Control Station the operator can drive and steer the machine in both forward and reverse direc tions The operat
5. 4 9 4 5 Machine DOWN jr deis Sa Sed ade price 4 10 4 6 Machine TIE Down 5 4 bra 4 11 4 7 GNO Cal te 4 12 4 8 SWING AW 4 13 6 1 Discohnecung the DIVE 6 1 LIST TABLES TABLE NO TITLE PAGE NO 1 1 Minimum Safe Approach Distances M S A D to energized exposed or insulated power lines and 1 2 7 1 INSPECTOR 7 1 J LG Lift 3120685 TABLE OF CONTENTS continued SECTION 1 SAFETY PRECAUTIONS SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL This section prescribes the proper and safe practices for major areas of machine usage In order to promote proper usage of the machine it is mandatory that a daily routine be established based on instructions given in this section A maintenance program must be also be established by a qualified person and must be followed to ensure that the machine is safe to operate The owner user operator of the machine should not accept operating responsibility until this manual has been read and understood and operation of the machine under the supervision of an experienced and qualified per son has been completed Owner user operator must be familiar with Sections 6 7 8
6. 3 VA FLY BOOM FOOTSWITCH inu OUTER MID BOOM n INNER MID BOOM BASE BOOM TELESCOPE CYLINDER inside Q LIFT CYLINDER o GROUND lt SWING CONTROL BEARING BOX TURNTABLE DRIVE STEER WHEELS FRAME Figure 2 1 Machine Nomenclature DRIVE STEER WHEELS 3120685 JLG Lift 2 3 2 4 SECTION 2 PREPARATION AND INSPECTION 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 con nections for tightness and evidence of corrosion and wiring for defects and chafing damage Assure that switches function properly 4 Check capacity indicator for correct operation any damage and that decals are not defaced Ensure indicator dial is zeroed with boom at horizontal and indicator dial moves in accordance with boom angle 5 Check access gate hinges and latch for proper operation damage and security 6 Check platform rotator mechanism for proper opera tion damage security Check hydraulic lines for leakage damage and security NOTE Check all DANGER WARNING CAUTION INSTRUCTION placards for legibility and security o
7. gt 2 1 2 3 Delivery and 1 lt 2 1 2 4 Daily Walk Around 1 5 2 4 2 5 Dally FUNNENE eee bd 2 9 2 6 Requirements vvs GS TAE 2 12 2 7 Battery MalblenallGe s3 2 13 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 2 ETC 3 1 3 2 as o i bd 3 1 3 3 Operating Characteristics and Limitations 3 2 3 4 Controls and IridiCatoTS raini aiie SCC RUP LOCO or Ede reo o dei 3 5 3 5 Placards Decals Lin he a d RID eder dod oer queo cede rac 3 15 SECTION 4 MACHINE OPERATION 4 1 JO __ ere 4 1 4 2 M RETI ETE 4 1 4 3 ENE OPEN ae Be psi e 4 2 4 4 Traveling Drivihng Steerindg _____ 4 2 4 5 TTA N deh ame ea 4 3 4 6 e e 4 5 4 7 a em le Be eee GER 4 5 4 8 BOOM es Peces 4 6 4 9 STED and PER ean iua a ete aq iti
8. uonnquisip 191194 5141 1 34 uo sapuljAo Jo exei 61 9JON 2 1snfpe 15 195 suonipuoo Joalqns SI uo paseq 310N JO SPIS uo 5 eg 310N Figure 2 3 Lubrication Chart Sheet 1 of 2 3120685 J LG Lift 2 10 Index No A N 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 3120685 Component Wheel Drive Hubs Steer Cylinders Rod End Steer Cylinders Barrel End King Pins Tie Rods Rotary Platform Stand Rotary Worm Gear Platform Level cylinder Platform Pivot Pin Link Level Pin E A R Pivot Pin E A R Lift Cylinder Rod End E A R Lift Cylinder Barrel End Sheave Pin Fly Extend Sheave Pin Upper Aux Tele Cyl Sheave Pin Boom Chains Sheave Pin Fly Retract Sheave Pin Outer Mid Retract Lift Cylinder Barrel End Master Cylinder Barrel End Swing Bearing Swing Bearing Gear Master Cylinder Rod End Boom Pivot Bearings Lift Cylinder Rod End Load Moment Pivot Pins Hydraulic
9. 15 LON OG x 00 10 71 N d 2622071 ONIHSNYD ONINSVM gt Bee ASSNHOVM SN OH ONY WV mm RYNFNI 3snv9 DNIHSNED 3 8123780 3 18VAOWWI N3HlO SISSVHO BUNLONYLSYAENS N33ML38 9NI3S IOAW I NOLIVLS TOMLNO9 WON N3HM SISSYHO HO FTBVANENL WOOS INHOSLVTd WOOS 5123 80 NO S3NI3SW3HL NOlllSOd LON TIVHS TANNOSYId 7 DNIHSNYD V HEN ED EN voLLOZL 6691041 Nid 2822021 Nid 82002 340220 SNOIYIS SNOLLVLIWIT SNOILONYLSNI TVNOLLIQGV 404 W S MIYNLIVINNVIN 338 QS LV TANI JYV 59311 GO09 NI JYV 9311 IYNS ALMIGVLS 193434 OL AVM ASIGOW LON OG WYO4LVTd ANIONI 037115 SAYILLVE YO LHOIAM 1188 33210 30 SWALI OL SWILI 32V 1d334 LON OG ONINSHVM WV 021 Nid AL
10. AXLE JACK CONTROL SWITCH Figure 3 5 Axle Extension Axle J acks Control Axle Extension Axle J acks Control NOTE The boom must be fully retracted in the stowed posi tion when axles are being extended Also the SELECT SWITCH must be the GROUND with the engine running Axle J ack Control S witch The axle jack control switch allows the operator to raise the axle so it can be extended before operating the boom Place the switch in the down position to raise the axle or to the up position to lower the axle Axle Extension Switch The axle extension switch allows the operator to extend the axle after it has been raised by the axle jack Place the switch to the left to extend the axle or to the rightto retract the axle J LG Lift Remote Control Box NOTE To operate the remote control box set the SELECT SWITCH to GROUND and start the engine Power Emergency Stop Switch Position the Power Emergency Stop switch to the on position Steer Switch Front This switch allows the operator to steer the front wheels as desired The Speed Control switch does not affect the steer function Drive Switch Position the Drive switch to forward or reverse as desired Speed Control Rotate the speed control when driving to increase or decrease drive speed as desired Steer Switch Rear This switch al
11. STEER POSITION B SECTION 4 MACHINE OPERATION Repeat steps 1 thru 3 for the for the rear axle The machine is now ready for boom operations To Retract the Axles 1 a m TP bon y ES EXTEND RETRACT FOBITICN 5 J LG Lift Remove the pins from the front steer cylinder and tie rod Be sure the SELECT SWITCH is set to GROUND On machines after S N 47227 place the stop pin in the Axle Extend Retract position E Ae Fi ae Tal 72 CU L1 E From the controls at the front axle with the engine running push the axle jack control switch down to raise the axle Swing the steer cylinder clear of the axle tube before retracting the axle When the tires are off the ground push the axle extend switch to the right to retract the axle When the axle is fully retracted align the steer cylinder with the mounting bracket and return the pins to the front steer cylinder and tie rod On machines after S N 47227 return the spindle stop pin to the steering po STEER POSTIIN Repeat steps 1 thru 4 for the for the rear axle 4 3 SECTION 4 MACHINE OPERATION 1704421 Figure 4 1 Spindle Stop Pin Usage 4 4 J LG Lift 3120685 4 6 PARKING AND STOWING Park and stow machine as follows 1 Park machine in travel pos
12. Operators Safety Manual Model 120HX 3120685 April 20 2000 ANSI CALIFORNIA PROPOSITION 65 BATTERY WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm WASH HANDS AFTER HANDLING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 J LG 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 OPER ATING 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 J LG INDUSTRIES PER
13. 19 20 21 22 23 24 25 SECTION 2 PREPARATION AND INSPECTION Drive Hub Right Rear No visible damage no evi dence of leakage Wheel Tire Assembly Right Rear Properly secured no loose or missing lug nuts no visible damage Extendable Axle Lock pins in place properly secured Check both sides S wing Drive Motor and Brake No visible damage no evidence of leakage Fuel Supply Fuel filler cap secure Tank no visible damage no evidence of leaks Cowling and Latches All cowling and latches in working condition properly secured no loose or missing part Control Valve Compartment No loose or missing parts evidence of leakage unsupported wires or hoses damaged or broken wires Extendable Axle Lock pins in place properly secured Check both sides Hydraulic Oil Supply Recommended oil level in sight gauge Check level with cold oil systems shut down machine in stowed position Cap in place and secure Hydraulic Oil Filter Housing Housing secure no visible damage or signs of leakage Hydraulic Oil Breather Element in place not clogged no signs of overflow Wheel Tire Assembly Right Front Properly secured no loose or missing lug nuts no visible damage Turntable Springs Properly secured no loose or missing nuts or bolts Ground Controls Switches operable no visible damage decals secure and legible Engine Air Filter No loose or missing
14. MOOSGNVH AL33VS TYNNYN OL 93338 OL NOLLOV ONINVY NOILONN 9NDIO3H2 N3HM NOILNV9 SNOILOMYLSEO 30 3304 NV 123138 SNOILONN TIY 6 2181991 39V 1d 445 OL SAYVOV Id 8 S3H21IMS 1931 1 S31XV ATAVONALXA SYIOOLNO 493H2 1004 781138 AL33VS WHOdLV Td LON OG 7 1404418 OL Q3N31sv4 11340236 SI 1 14 JANS 340553447 MOIHI 15 AL34VS SNINNVM 77 4466040 Nid 2622021 Nid 171938 TIM 10188 HVAC 3ONVISIO 33VS LOVLNOO 44310 dr EGLTOLL Nid TIONVG V 6091041 N d 5 01102 9NIHSIO 6123780 318 YSHLO SISSYH ANY N33M138 NOILWLS 1031405 QNnO39 N3HM SISSVHD 3T8VINSNL WOOS N33MLI38 Waodivid ANY WOOS 6123780 COZLOLL S3ATSSW3HL NOILISOd LON TIVHS 3NNOS33d GUVZYH DNIHSNYD Y
15. NOTE When boom is above horizontal the DRIVE function will be in CREEP mode NOTE When machine exceeds 5 degree slope DRIVE functions will be cut out and SWING and LIFT are in CREEP mode if boom is above horizontal 3 Position the STEER thumb rocker to the right for traveling right and left for traveling left 4 To obtain maximum travel speed make sure the boom 15 positioned below horizontal and position the DRIVE controller to fast 3120685 4 5 AXLES NOTE To extend or retract jacks or to extend or retract the axles the boom must be below horizontal and not extended more than 10 feet 3 meters The machine must also be on a flat level surface To Extend the Axles 1 3 3120685 Remove the pins from the front steer cylinder and rod Be sure the SELECT SWITCH is set to GROUND Machines after S N 47227 have spindle stop pins to keep the spindles centered while extending the axle Place the stop pin in the hole closest to the spindle as shown Tau ET AXLE EXTE From the controls at the front axle with the engine running push the axle jack control switch down to raise the axle When the tires are off the ground push the axle extend switch to the left to extend the axle When the axle is fully extended return the pins to the front steer cylinder and tie rod On machines after S N 47227 return the spindle stop pin to the steering
16. Keep all information and operating placards clean and unobstructed Cover when spray painting or shot blasting to protect legibility 3 Operator s and Safety Manual Ensure a copy of this manual and the ANSI A92 5 1992 Responsibilities are enclosed in the manual storage box 4 Machine Log Ensure a machine operating record or log is kept check to see that it is current and that no entries have been left uncleared leaving machine in an 3120685 5 Start each day with a full fuel tank A WARNING TO AVOID INJ URY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSIBLE INJ URY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Check boom horizontal limit switch for proper opera tion and security both visually and manually Switch must shut down high engine and high drive speed when boom is raised above horizontal 6 Check platform footswitch for proper operation Switch must be released to start engine and depressed to operate machine 7 Check that drive brakes hold when machine is driven up a grade and stopped NOTE On new machines those recently overhauled or after changing hyaraulic oil operate all systems a 3120685 SECTION 2 PREPARATION AND INSPECTION NOTE J LG Lift minimum of two complete cycles and recheck oil level in reservoir Hydraulic oils must have anti wear qualities a
17. ul 4000241 Nid TOYLNOD ANNOYD 4466040 SNORIIS H1V3G 35 2 01102 5 76123780 37T8VWAONNI YSHLO SISSVHO ANY 3404914153415 ONIWLOY N33M138 9NI38 5 1051409 ANNOYS SISSVHD WOOS NIIMLIG YO Waodivid WOOS 5123780 YSHLO S3AT3SW3Hl NOLLISOd LON TIVHS 3NNOS33d 2 DNIHSNYD ONINYVM V 3 17 J LG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL PROCEDURE FOR DAILY CHECK OF LOAD MANAGEMENT SYSTEM AT THE BEGINNING OF EACH DAY S USE PERFORM CHECK WITH NO LOAD PERSONS OR MATERIAL IN PLATFORM FROM GROUND CONTROL STATION EXTEND ALL AXLES FULLY AND INSERT LOCK PINS WITH BOOM FULLY RETRACTED RAISE BOOM TO HORIZONTAL POSITION TOGGLE SWITCH LOCATED ON THE RIGHT SIDE OF GROUND CONTROL STATION IN THE P POSITION AND HOLD EXTEND BOOM UNTIL IT STOPS BOOM MUST STOP ON WHITE TAPE ON MID BOOM RELEASE TOGGLE SWITCH RETRACT BOOM UNTIL TELE OUT WILL FUNCTION SYSTEM IS NOT RESET POSITION TOGGLE SWITCH IN THE M POSITION AND HOLD EXTEND BOOM UNTIL IT STOPS BOOM MUST STOP ON WHITE TAPE ON MID BOOM IF BOOM DOES NOT STOP AT WHITE TAPE SYSTEM MUST BE REPAIRED BY JLG AUTHORIZED SERVICE PERSONNEL BEFORE MACHINE CAN BE USED 1701296 P N 1701296 IMPORTANT firs
18. 3 6 JLG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL elf 16 ly Power Emergency Stop Switch lololor E Control Station Selector AN TOTAL HOURS am Start Button Capacity Indicator Lift Control Main Boom Lift Control Extend A Reach Telescope Control swing Control Auxiliary Power Control 10 Circuit Breaker 11 Hourrneter 12 Voltmeter 13 Oil Pressure Gauge 14 Axles Set Indicator 15 Rotate 16 Level 1 o go if Engine Oil ee ue PLATFORM SELECT SWITCH O GAS AXLES SET ENGINE DISTRESS 10 BREAKER L 9 50018 1 EMERGENCY STOP AUXILIARY POWER N START GLOW PLUG 3 ICHOKE Ri d E OPERATING 16 erie OR ROTATE LEVEL TELESCOPE IN 15 4 CO En TELESCOPE 10 20 30 40 50 60 A WARNING TIP OVER HAZARD DO NOT EXCEED OPERATING RADIUS OR CAPACITY AN BLINKING LIGHT amp AUDIO ALARM CAPACITY LIMIT EXCEEDED FAILURE TO FOLLOW INSTRUCTIONS COULD RESULT IN SERIOUS INJURY OR DEATH EXTEND A REACH Figure 3 4 Ground Control Station May 1994 to Present 3120685 J LG Lift 3 7 SEC
19. 4 MACHINE OPERATION Figure 4 5 Machine Tie Down Sheet 3 J LG Lift 3120685 SECTION 4 MACHINE OPERATION 399us UMO 9 4 SOS FEE PS 22 lt 2 4 11 J LG Lift 3120685 4 LIFT HERE Dimension A Gross Weight Standard Machine 82 7 in 210 cm 44 000 Ibs 19 960 kg H A F dy 3 NA x ROTATION 5 2 I 1 19 Figure 4 7 Lifting Chart This page left blank intentionally A IMPORTANT SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAV ELING LONG DISTANCES OR HAULING MACHINE ON TRUCK TRAILER 4 11 SWING AWAY J IB To Erect the J ib 1 Remove the lockpin from the jib plates 2 With the aid of an assistant swing the jib until Straight with the boom and the holes in the jib plates align 3 Install the lockpin through aligned holes the jib plates The machine can now be operated from the platform controls To Stow the J ib 1 Remove the lockpin from the jib plates 2 Wi
20. 9 and 10 of ANSI A92 5 1992 These sections contain the responsibilities of the owner users operators lessors and lessees concerning safety training inspection maintenance application and operation If there is a question on application and or operation J LG Industries Inc should be consulted A WARNING 1 2 DRIVING TOWING Before driving the machine the user must be familiar with the drive steer and stopping characteristics This is espe cially important when driving in close quarters The user should be familiar with the driving surface before driving The surface should be firm and level and grades should not exceed the allowable grade for the machine NOTE Hemember that the key to safe and proper usage is common sense and its careful application The machine is not equipped with provisions for towing Refer to Section 6 for emergency towing procedures SPECIAL NOTE A WARNING FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION AND ON THE MACHINE COULD RESULT IN MACHINE DAMAGE PERSONNEL INJ URY OR DEATH AND IS A SAFETY VIOLATION MODIFICATION OR ALTERATION OF AN AERIAL PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION OF THE MANUFACTURER 3120685 J LG Lift 1 1 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Safe Approach Distances M S A D to energized exposed or insulated power lines and parts Voltage Range MINIMUM SAFE APPROACH DISTANCE Phas
21. GENCY STOP Switch is pulled out and the SELECT SWITCH is in the Ground position Push and hold the button until the engine starts NOTE One of the capacity indicator lights should be illumi nated at all times during operation If no capacity lights are on a bulb is probably burned out Opera tion of the machine must be halted until the lights are working properly 4 Capacity Indicator The capacity indicator displays to the operator the maximum rated platform capacity and the maximum radius for that capacity using colored lights and a reach diagram The operator must not exceed the rated capacity or the rated radius for the load per sonnel tools and supplies shown on the indicator The blue light indicates operating within 500 Ib range A steady red light indicates you have exceeded the machines operating radius You must immediately stop and LIFT UP or TELE IN until the red light goes out A blinking red light and a buzzer sounding indicates you have exceeded the platform load capacity personnel tools and sup plies or operating radius You must immediately stop and LIFT UP or TELE IN until the red light goes out and the buzzer stops Check to make sure the load in the platform does not exceed the rated Capacity NOTE Lift Swing and Telescope control switches are spring loaded and will automatically return to neutral off when released A WARNING WHEN OPERATING THE BOOM ENSURE THERE ARE
22. NO PER SONNEL AROUND OR UNDER PLATFORM 5 Lift Control Main Boom The three position LIFT control switch provides rais ing and lowering of the main boom when positioned up or down EG Witt 3 5 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL Power Emergency Stop Switch 17 E Control Station Selector AN TOTAL HOURS Start Button Capacity Indicator Lift Control Main Boom Lift Control Extend A Reach Telescope Control Swing Control Auxiliary Power Control 1O Circuit Breaker 11 Hourrneter 12 Voltmeter 13 Oil Pressure Gauge 14 Axles Set Indicator 15 16 Level SS am PLATFORM SELECT SWITCH GROUND oll AXLES SET ENGINE DISTRESS 10 BREAKER EMER 7 STOP IIGNITION N START GLOW PLUG ICHOKE AUXILIARY POWER 3 15 9 1 TELESCOPE o RE lt gt 0 10 20 30 40 50 60 OF ROTATION BLUE LIGHT INDICATES OPERATING WITHIN 500 LB RANGE RED LIGHT INDICATES EXCEEDING OPERATING RADIUS BLINKING LIGHT amp AUDIO ALARM EXCEEDING CAPACITY LIMIT 8 S 2 58 GLT EXTEND A REACH LIFT Figure 3 3 Ground Control Station Prior to May 1994
23. OF THE BOOM WILL ONLY BE PERFORMED WITH THE PERMISSION OF THE PLATFORM OCCUPANT S A IMPORTANT WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY 1 Power Emergency Stop Switch The two position POWER EMGENCY STOP switch furnishes battery power to the platform or ground control switches when station power is selected from the ground control panel Push in to shut off the engine and remove power from the controls The ground control emergency stop switch must be pulled out to operate the machine from either the Ground Control or Platform Control 2 Control Station Selector A three position center off key activated SELECT SWITCH supplies power to the platform control con sole when positioned to PLATFORM With the switch in the GROUND position power is shut off to the platform station and only the controls on the ground control panel are operable NOTE With the Platform Ground Select Switch in the center position power is shut off to controls at both operat ing stations 3120685 A WARNING TO AVOID SERIOUS URY DO NOT OPERATE MACHINE IF CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED 3 Start Button The START button is a momentary contact push button type switch that supplies electrical power to the starter solenoid when the POWER EMER
24. Product Safety amp 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 Cs State Zip Telephone 03 Date Of Transfer Current Owner Address State Zip _________________ Telephone Who in your organization should we notify Name Title Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Phone 717 485 5161 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia Phone 61 2 65 811111 Fax 61 2 65 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil Phone 55 19 3295 0407 Fax 55 19 3295 1025 JLG Industries Europe Kilmartin Place Tannochside Park Uddingston G71 5PH Scotland Phone 44 1 698 811005 Fax 44 1 698 811055 JLG Industries UK Unit 12 Southside Bredbury Park Industrial Estate Bredbury Stockport SK6 2sP England Phone 44 870 200 7700 Fax 44 870 200 7711 JLG Europe B V Jupiterstraat 234 2132 HJ Foofddorp The Netherlands Phone 31 23 565 5665 Fax 31 23 557 2493 JLG Industries Pty Ltd Unit 1 24 Industrial Complex Herman Stre
25. hourmeter installed in the ground control box registers the amount of time the machine has been in use with the engine running The hourmeter reg isters up to 9 999 9 hours and cannot be reset Voltmeter An voltmeter installed in the ground control box indicates battery condition i e charging or dis charging Oil Pressure Gauge An oil pressure gauge installed in the ground con trol box provides an indication of the engine lubri cating oil pressure Normal operating pressure at 2000 rpm is 40 to 60 psi Axles Set Indicator The AXLES SET indicator provides a visual indica tion that the extendable axles are properly set It consists of a green indicator that lights up when the axles are extended and the retaining pins are prop erly installed A WARNING TO AVOID SERIOUS INJ URY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED 15 16 LG Lift Rotate If equipped The three position plattorm ROTATE control switch permits rotation of the platform when positioned to left or right Level The three position platform LEVEL control switch allows the operator to compensate for any differ ence in the automatic self leveling system by posi tioning the control switch to up or down 3120685 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL AXLE EXTENSION Ec c SWITCH
26. ply with the requirements Nor shall the listing of these requirements constitute an assumption of responsibility of liability on the part of J LG Indus tries Inc Only trained and authorized operators shall be permitted to operate the aerial lift 2 A malfunctioning lift shall be shut down until repaired 3 The controls shall be plainly marked as to their function 4 The controls shall be tested each day prior to use to determine that they are in safe operating condition FOREWORD 5 All personnel in the platform shall at all times wear approved fall protection devices and other safety gear as required 6 Load limits specified by the manufacturer shall not be exceeded 7 Instruction and warning placards must be legi ble 8 Aerial lifts may be field modified for uses other than those intended by the manufacturer only if certified in writing by the manufacturer to be in conformity to J LG requirements and to be at least as safe as it was prior to modification 9 Aerial lifts shall not be used near electric power lines unless the lines have been de energized or adequate clearance is maintained See OSHA 29 CFR 1910 67 and 1926 453 10 Employees using aerial lifts shall be instructed on how to recognize and avoid unsafe condi tions and hazards 11 Ground controls shall not be operated unless permission has been obtained from personnel in the platform except in case of an emer gency 12 Regular
27. position of the control lever Functions controlled by toggle switches are either on or off and higher or lower Speed is possible when the Function Speed control switch is uSed in conjunction with the function toggle switch A foot operated switch in the platform must be depressed before any controls will function and provides a means of emergency stop when the operator s foot is removed from the footswitch The JLG Lift is a four wheel drive four wheel steer machine with drive power being supplied by a hydraulic motor for each drive wheel Each drive wheel is supplied with a hydraulically released spring applied brake The swing drive is also equipped with such a brake These brakes are automatically applied any time the Drive or Swing Control lever are returned to the neutral position The maximum rated capacity of the J LG Lift is 500lbs 230 kg This means that with a platform load of 500lbs 230 kg or less the platform may be positioned anywhere in the Blue light Area of the reach diagram 4 2 GENERAL This section provides the necessary information needed to operate the machine Included in this section are the procedures for starting stopping traveling steering park ing platform loading and transporting It is important that the user read and understand the proper procedures before operating the machine Updated 4 20 00 J LG Lift 4 1 SECTION 4 MACHINE OPERATION 4 3 ENGINE OPERATION NOTE Initial start
28. reduction of internal engine temperature 2 Position POWER EMERGENCY STOP switch to OFF 4 2 J LG Lift 3 Turn the SELECT SWITCH to OFF position NOTE Refer to Engine Manufacturers manual for detailed information 4 4 TRAVELING DRIVING STEERING A WARNING DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDE SLOPES DO NOT DRIVE MACHINE ON GRADES OR SIDE SLOPES EXCEEDING THOSE SPECIFIED ON SERIAL NUM BER PLATE ASSURE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGIN NING ANY EXTENDED TRAVELING AVOID ANY TERRAIN FEA TURES WHICH COULD CAUSE THE MACHINE TO UPSET USE EXTREME CAUTION WHEN DRIVING IN REVERSE AT ALL TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND ESPE CIALLY WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET 2 METERS OF AN OBSTRUCTION DO NOT USE DRIVE TO MANEUVER PLATFORM CLOSE TO AN OBSTRUCTION USE ONE OF THE BOOM FUNCTIONS BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR AXLE IF BOOM IS OVER FRONT AXLE STEER WHEELS STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIREC TIONS TO MACHINE CONTROLS Traveling Forward or Reverse 1 With engine running depress footswitch and posi tion DRIVE STEER control forward and hold for the duration of forward travel desired 2 Depress footswitch and pull the DRIVE STEER con trol back to reverse and hold for duration of reverse travel desired
29. snoot as required Steer Controls operation of the front steer wheels When the steer switch is positioned right or left the machine will steer in the corresponding direction Axles Set Indicator If equipped The green AXLES SET indicator lights to inform the operator that the axles are set in position One of the capacity indicator lights should be illumi nated at all times during operation If no capacity lights are on a bulb is probably burned out Opera tion of the machine must be halted until the lights are working properly Capacity Indicator The capacity indicator displays to the operator the maximum rated platform capacity and the maximum radius for that capacity using colored lights and a reach diagram The operator must not exceed the rated capacity or the rated radius for the load per sonnel tools and supplies shown on the indicator The blue light indicates operating within 500 Ib range A steady red light indicates you have exceeded the machines operating radius You must immediately stop and LIFT UP or TELE IN until the red light goes out A blinking red light and a buzzer sounding indicates you have exceeded the platform load capacity personnel tools and sup plies You must immediately stop and LIFT UP or TELE IN until the red light goes out and the buzzer stops Check to make sure the load in the platform does not exceed the rated capacity 18 Auxiliary Power The AUXIL
30. 0917 00 1 00955 007 00105 00944 0009 00926 09206 00202 0408 0048 0079 06691 00 OG LHL OGZ CL 01811 00 0 0690 0446 08 8 006 05 000 0084 0244 0 04 079 0cZv 13 81 79200 0818 81200 000400 05 100 VLVLO O 00710 0 9000 606000 9900 0 a1 Ponar 88 0901 NI 8I NI 871 NI 8I 172 272 3111901 292 311201 ami 292 201 Aud 139 201 M349 137905 31935 0961 ONWHANN 53998 avol 12 NI 81 NI 81 NI aT NI 97 272 3111901 292 3111901 an 92 201 Aud Zinouo L avol dINV19 SLNN 8 3QV39 51108 8 AVS AINO S1108 31 14 INIZ 403 SINIYA SLNN c 8 51108 S AGVYS AVS 70900 0 Figure 2 4 Torque Chart 3120685 J LG Lift 2 14 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 1 GENERAL A IMPORTANT SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI B
31. ACHINE 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 DUR ING MOUNT AND DISMOUNT DRIVING 1 WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING LG Lift ALWAYS POSITION BOOM OVER REAR DRIVE AXLE IN LINE WITH DIRECTION OF TRAVEL REMEMBER IF BOOM IS OVER FRONT STEER AXLE DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPO SITE FROM NORMAL OPERATION DO NOT USE DRIVE FUNCTION TO POSITION PLAT FORM CLOSE TO OBSTACLES USE BOOM FUNC TION INSTEAD WHEN DRIVING IN HIGH SPEED SWITCH TO LOW SPEED BEFORE STOPPING TRAVEL GRADES IN LOW DRIVE HIGH ENGINE ONLY DO NOT USE HIGH SPEED DRIVE WHEN RESTRICTED OR CLOSE QUARTERS OR WHEN DRIVING IN REVERSE BE AWARE OF STOPPING DISTANCES WHEN TRAV ELING IN HIGH AND LOW SPEEDS ALWAYS POST A LOOKOUT AND SOUND HORN WHEN DRIVING IN AREAS WHERE VISION IS OBSTRUCTED KEEP NON OPERATING PERSONNEL AT LEAST 6 FEET 2 M AWAY FROM MACHINE DURING DRIVING OPERATIONS 3120685 3120685 V CHECK TRAVEL PATH FOR PERSONS HOLES BUMPS DROP OFFS OBSTRUCTIONS DEBRIS AND COVERINGS WHICH MAY CONCEAL HOLES AND OTHER HAZARDS TRAVEL IS PERMITTED ON GRADES AND SIDES LOPES NO GREATER THAN THOSE INDICATED IN WARNING PLACARD AT MACHINE PLATFORM OPERATION WITH BOOM RAISED 15 RESTRICTED TO FIRM LEVEL AND UNIFORM SURFACE DO NOT TRAVEL ON SOFT
32. Check hydraulic lines electrical cable and track assemblies for damage missing parts and security 3 Check lift cylinder and cross pins and hydraulic lines for damage wear leakage and security 4 Check boom pivot pins for damage wear and secu rity 5 Check hydraulic line and electrical cable track assembly for visible damage loose or missing parts and security 6 Check boom for damage missing parts and secu rity 7 Check boom wear pads for damage wear and secu rity 8 Check boom telescope cylinder and cross pins and hydraulic lines for damage wear leakage and secu rity 9 Check platform leveling cylinder and cross pins and hydraulic lines for damage wear leakage and secu rity 10 Check boom platform pivot pin for damage wear and security 11 Check horizontal and capacity limit switches mounted on turntable for security of mounting dam age to switch arms and rollers and for debris 12 Check boom tape for correct length and tearing or defacing at any point Extend A Reach 1 J LG Lift Check the slave cylinder weld link and cross pins and lines for visible damage wear lubrication evi dence of leakage and security Check extend a reach for visible damage loose or missing parts and security Check hydraulic lines and electrical cable for dam age missing parts and security 3120685 SECTION 2 PREPARATION AND INSPECTION PLATFORM CONTROL PLATFORM BOX
33. ERING SWINGING AND TELESCOPING BOOM EXERCISE EXTREME CAUTION AT ALL TIMES TO PREVENT OBSTACLES FROM STRIKING OR INTER 3120685 J LG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS 1 8 NEVER ATTEMPT TO FREE A MACHINE STUCK IN SOFT GROUND OR ASSIST A MACHINE UP A STEEP HILL OR RAMP BY USING BOOM LIFT TELE SCOPE OR SWING FUNCTIONS NEVER ATTACH WIRE CABLE OR ANY SIMILAR ITEMS TO PLATFORM DO NOT PLACE BOOM OR PLATFORM AGAINST ANY STRUCTURE TO STEADY PLATFORM OR SUPPORT STRUCTURES DO NOT USE THE LIFT SWING OR TELESCOPE FUNCTIONS FOR THE BOOM TO MOVE EITHER THE MACHINE OR OTHER OBJ ECTS HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT FULLY EXTENDED OR RETRACTED FOR ANY LENGTH OF TIME ALWAYS BUMP CONTROL IN OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION BEING USED REACHES END OF TRAVEL THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE DO NOT OPERATE ANY MACHINE ON WHICH DAN GER WARNING CAUTION OR INSTRUCTION PLAC ARDS OR DECALS ARE MISSING OR ILLEGIBLE LG Lift MACHINE MUST ALWAYS BE SHUT DOWN WHEN REFUELING NO SMOKING IS MANDATORY NEVER REFUEL DURING AN ELECTRICAL STORM ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES 17 TOWING AND HAULING DO NOT TOW A MACHINE EXCEPT IN AN EMER GENCY SEE SECTION 6 FOR EMERGENCY TOWING PROCEDURES LOCK TURNTABLE BEFORE TRAVELING LONG DIS TANCES OR BEFORE HAULING MACHINE ON A TRUCK OR TRAILER 3120685 SECTION 2
34. Filter Function Pump Hydraulic Filter Drive Pump Hydraulic Fluid Engine Crankcase Engine Oil Filter Platform Door Hinges Access Door Hinges Access Door Latches Axle Beams SECTION 2 PREPARATION AND INSPECTION Number Type Lube amp Interval Comments Lube Points Method Hours Fill Drain Plugs EPGL SAE 90 150 1200 Check Every 150 Hours Change Every 1200 Hours 2 Grease Fitting MPG Pressure Gun 150 2 Grease Fittings MPG Pressure Gun 150 4 Grease Fittings MPG Pressure Gun 150 4 Grease Fitting MPG Pressure Gun 150 2 Grease Fittings MPG Pressure Gun 150 N A MPG Brush 150 Remove Cover to Grease 3 Grease Fittings MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 2 Grease Fittings MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 Extend boom until grease fitting is accessible thru hole in fly sec N A Chain Lube Hot Oil Dip 1200 Extend and Retract Chains 2 Grease Fittings MPG Pressure Gun 150 Extend boom until fitting is accessible thru hole in tly 2 Grease Fittings MPG Pressure Gun 150 Extend boom until fitting is accessible thru hole in tly 1 Grease Fitting MPG Pressure Gun 150 Remote Access 1 Grease Fitting MPG Pressure Gun 150 Remote Access 1 Grease Fitting MPG Pressure Gun 150 Re
35. GE CRANES HIGHWAY RAILWAY AND CONSTRUCTION EQUIPMENT W PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN THE WORK AREA MUST BE TAKEN BY THE OPERA TOR AND HIS SUPERVISOR BEFORE STARTING THE WORK DO NOT OPERATE THIS MACHINE UNLESS IT HAS BEEN SERVICED AND MAINTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION SECTION 1 SAFETY PRECAUTIONS NEVER DISABLE OR MODIFY THE FOOTSWITCH OR ANY OTHER SAFETY DEVICE ANY UNAUTHORIZED MODIFICATION OF THE MACHINE IS A SAFETY VIO LATION AND IS A VIOLATION OF OSHA REGULA TIONS AND ANSI STANDARDS V DO NOT OPERATE MACHINE WHEN WIND CONDI TIONS EXCEED 30 MPH 48 KMH NEVER OPERATE BOOM FUNCTIONS TELE SWING LIFT WHEN MACHINE IS ON A TRUCK OTHER VEHI CLE OR ABOVE GROUND STRUCTURE THIS MACHINE CAN BE OPERATED IN NOMINAL AMBIENT TEMPERATURES OF 0 F TO 104 F 20 TO 40 CONSULT FACTORY TO OPTIMIZE OPER ATION OUTSIDE THIS RANGE 1 APPROVED HEAD GEAR MUST BE WORN BY ALL J LG Lift OPERATING AND GROUND PERSONNEL 1 3 SECTION 1 SAFETY PRECAUTIONS 1 5 READ AND OBEY ALL DANGERS WARNINGS CAU TIONS AND OPERATING INSTRUCTIONS ON MACHINE AND IN THIS MANUAL BE FAMILIAR WITH LOCATION AND OPERATION OF GROUND STATION CONTROLS ALWAYS USE THREE POINT CONTACT WHEN ENTERING OR EXITING THE MACHINE FACE THE M
36. IARY POWER control switch energizes the electrically operated hydraulic pump when actu ated The switch must be held on for duration of aux pump use The auxiliary pump functions to provide sufficient oil flow to operate the basic machine system should the main pump or engine fail The auxiliary pump will operator boom lift telescope and swing It should be noted that the functions will operate at a slower than normal rate because of lower hydraulic flow A IMPORTANT WHEN OPERATING ON AUXILIARY POWER DO NOTOPERATE MORE THAN ONE FUNCTION AT THE SAME TIME SIMULTA NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR NOTE The main function of the auxiliary power is to lower the platform in the event of primary power failure Determine the reason for primary power failure and have the problem corrected by a qualified service technician NOTE Auxiliary power is primarily intended for platform low ering in the event of primary power failure However auxiliary power may be used for platform positioning when operating in close quarters in the following sequence a Position PLATFORM GROUND switch to PLAT FORM b Pull the POWER EMERGENCYSTOP switch out to the on position c Depress and hold footswitch d Operate appropriate control switch or lever for desired function and hold Position AUXILIARY POWER switch on and hold f Release AUXILIARY POWER switch selected control switch or lever and footswit
37. ILITY OF THE USER AND HIS HER OPERATING PERSONNEL This section provides the necessary information needed to understand control functions Included in this section are the operating characteristics and limitations and func tions and purposes of controls and indicators It is impor tant that the user and or operator read and understand the proper procedures before operating the machine These procedures will aid in obtaining optimum aerial platform service and safe operation 3 2 PERSONNEL TRAINING The aerial platform is a personnel handling device there fore it is essential that it be operated and maintained only by authorized and qualified personnel who have demon strated that they understand the proper use and mainte nance 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 opera tion Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical con trol must not be permitted to operat
38. LATFORM OR BOOM OR BETWEEN A ROTATING PLATFORM AND THE BOOM CRUSHING COULD CAUSE DEATH OR SERIOUS INJURY 1702284 1702284 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL A WARNING DAILY SAFETY CHECK LIST CHECK TIRES PRESSURE AND CONDITION MAKE SURE PLATFORM IS SECURELY FASTENED TO PLATFORM SUPPORT DO NOT EXCEED RATED PLATFORM CAPACITY CHECK SAFETY BELTS P N 1 702292 CHECK FOOT PEDAL FOR PROPER OPERATION CHECK OUTRIGGERS EXTENDABLE AXLES A CAUTION IF APPLICABLE NO HANDS OR SAFETY BELT DANGER ELECTROCUTION HAZARD AND MOVING MACHINERY KEEP CLEAR AVOID CONTACT KEEP A SAFE DISTANCE AWAY OR DEATH OR SERIOUS INJURY WILL RESULT TEST HIGH ENGINE AND HIGH DRIVE CUTOUT SWITCHES CHECK PLACARDS TO SEE IF IN PLACE AND LEGIBLE CHECK ALL FUNCTIONS SELECT AN AREA FREE OF OBSTRUCTIONS EXCERCISE CAUTION WHEN CHECKING DRIVE FUNCTION AND BRAKING ACTION 10 REFER TO OPERATION MANUAL AND SAFETY HANDBOOK FOR FURTHER DAILY PERIODIC CHECKS AND THE DAILY WALK AROUND INSPECTION P N 1702294 B OPERATING A MALFUNCTIONING MACHINE COULD CAUSE SEVERE INJURY OR DEATH 1702299 1702299 A PLACING HANDS HERE MAY RESULT IN MINOR OR MODERATE INJURY 3120685 J LG Lift 3 19 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL FUNCTION SYMBOL FUNCTION AUXILIARY POWER SYMBOL AXLE EXTEND AXLE JACK PLATFORM CONTROL
39. Lift 3 3 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL A MACHINE WILL UPSET IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE Boom fully retracted and elevated to approximately 76 with extend a reach elevated to 90 i 28 Figure 3 2 Position of Least Backward Stability 3 4 JLG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 4 CONTROLS AND INDICATORS Precision Control Governor This control allows the engine to remain at idle until any function is activated at which time the engine will acceler ate to perform that function Upon release of the function the engine will accelerate back to idle High engine can only be obtained if the drive handle is placed in the extreme drive position if the high engine switch is ON and the boom is horizontal or below Ground Controls Some machines are equipped with control panels that use symbols to indicate control functions Refer to Table 3 1 for these symbols and their corresponding functions A WARNING DO NOT OPERATE FROM THE GROUND STATION WITH PERSON NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY PERFORM PRE OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION WHEN PERSONNEL ARE IN THE PLATFORM OPERATION
40. OF A MALFUNC TIONING MACHINE IS A SAFETY VIOLATION TO AVOID POSSI BLE INJ URY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTE Do not overlook visual inspection of chassis under side Checking this area often results in discovery of conditions which could cause extensive machine damage 1 Platform Assembly No loose or missing parts no visible damage Lock bolts in place Footswitch in good working order not modified disabled or blocked Check area of fly boom nose section above and under platform slave level cylinder for accumulation of foreign material Remove any for eign material present 2 Platform Control Console Switches and levers return to neutral and are properly secured no loose or missing parts no visible damage decals plac ards secure and legible control marking legible 3 Slave Leveling Cylinder Extend A Reach Prop erly secured no visible damage no evidence of leakage 4 Extend A Reach Lift Cylinder Properly secured no visible damage or signs of leakage evidence of proper lubrication 5 Extend A Reach Pivot No loose damaged or missing parts evidence of proper lubrication 6 Hose and Cable Guards Clamps Properly secured no visible damage 7 Power Track No loose damaged or missing parts no visible damage 8 Drive Motor and Brake Right Rear No visible damage no evidence of leakage 10 11 12 15 14 15 16 17 18
41. OOR MACHINES ARE AWARE OF THE AERIAL PLATFORMS PRESENCE DISCONNECT POWER TO OVERHEAD CRANES POSITION BARRICADES ON FLOOR IF NECESSARY NEVER SLAM A CONTROL SWITCH OR LEVER THROUGH NEUTRAL TO THE OPPOSITE DIRECTION ALWAYS RETURN SWITCH TO NEUTRAL AND STOP THEN MOVE SWITCH TO THE DESIRED POSITION OPERATE LEVERS WITH SLOW EVEN PRESSURE DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC NEVER PUSH OR PULL THE MACHINE OR OTHER OBJ ECTS BY TELESCOPING THE BOOM NEVER USE BOOM FOR ANY PURPOSE OTHER THAN POSITIONING PERSONNEL THEIR TOOLS AND EQUIPMENT NEVER EXCEED MANUFACTURERS RATED PLAT FORM CAPACITY REFER TO CAPACITY DECAL ON MACHINE DISTRIBUTE LOADS EVENLY ON PLAT FORM FLOOR NEVER OPERATE A MALFUNCTIONING MACHINE IF A MALFUNCTION OCCURS SHUT DOWN THE MACHINE RED TAG IT AND NOTIFY PROPER AUTHORITIES DO NOT REMOVE MODIFY OR DISABLE FOOT SWITCH BY BLOCKING OR ANY OTHER MEANS DO NOT ASSIST A STUCK OR DISABLED MACHINE BY PUSHING OR PULLING EXCEPT BY PULLING AT CHASSIS TIE DOWN LUGS NEVER ATTEMPT USING BOOM AS A CRANE STRUCTURAL DAMAGE OR TIPPING MAY OCCUR STOW BOOM AND SHUT OFF ALL POWER BEFORE LEAVING MACHINE NO STUNT DRIVING OR HORSEPLAY IS PERMITTED V ENSURE MACHINE 15 POSITIONED ON A FIRM LEVEL AND UNIFORM SUPPORTING SURFACE BEFORE RAISING OR EXTENDING BOOM 1 CHECK CLEARANCES ABOVE ON SIDES AND BOT TOM OF PLATFORM WHEN RAISING LOW
42. OR UNEVEN SURFACES AS TIPPING WILL OCCUR ENSURE THAT GROUND CONDITIONS ARE ADE QUATE TO SUPPORT THE MAXIMUM TIRE LOAD DO NOT DRIVE MACHINE NEAR PITS LOADING DOCKS OR OTHER DROP OFFS J LG Lift SECTION 1 SAFETY PRECAUTIONS 1 6 OPERATION READ YOUR MANUAL UNDERSTAND WHAT YOU VE READ THEN BEGIN OPERATIONS PRIOR TO ENTERING AND EXITING PLATFORM AT GROUND LEVEL FULLY LOWER THE BOOM EXTEND BOOM UNTIL END OF FLY BOOM CON TACTS GROUND WITH BOOM LIFT IN THIS CONFIG URATION ENTER AND OR EXIT PLATFORM THROUGH GATE OPENING OSHA REQUIRES ALL PERSONS IN THE PLATFORM TO WEAR LANYARDS WITH AN APPROVED FALL PROTECTION DEVICE SECURE LANYARD TO DES IGNATED LANYARD ATTACH POINT ON PLATFORM KEEP GATE CLOSED AT ALL TIMES TO AVOID FALLING USE EXTREME CAUTION WHEN ENTERING OR LEAVING PLATFORM ABOVE GROUND ENTER OR EXIT THRU GATE ONLY PLAT FORM FLOOR MUST BE WITHIN 1 FOOT 30 CM OF ADJ ACENT SAFE AND SECURE STRUCTURE ALLOW FOR PLATFORM VERTICAL MOVEMENT AS WEIGHT IS TRANSFERRED TO OR FROM PLAT FORM 1 5 SECTION 1 SAFETY PRECAUTIONS 1 6 TRANSFERS BETWEEN A STRUCTURE AND THE AERIAL PLATFORM EXPOSE OPERATORS TO FALL HAZARDS THIS PRACTICE SHOULD BE DISCOUR AGED WHEREVER POSSIBLE WHERE TRANSFER MUST BE ACCOMPLISHED TO PERFORM THE TWO LANYARDS WITH AN APPROVED FALL PRO TECTION DEVICE WILL BE USED ONE LANYARD SHOULD BE ATTACHED TO THE AERIAL PLATFORM THE OTHER TO THE STRUCTURE THE LANYA
43. OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS S afety of personnel and proper use of the machine are of primary concern DANGER WARNING CAU TION IMPORTANT INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these areas They are defined as follows THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH MAY LEAD TO SERIOUS INJ URY OR DEATH IF IGNORED A DANGER DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED WILL RESULT IN SERIOUS URY OR DEATH A CAUTION CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJ URY IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE PRACTICES A WARNING WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION WHICH IF NOT AVOIDED COULD RESULT IN SERIOUS INJ URY OR DEATH A IMPORTANT IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES ESSENTIAL FOR SAFE OPERATION AND WHICH IF NOT FOL LOWED MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE MACHINE A IMPORTANT JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR J LG PRODUCT CONTACT J LG INDUSTRIES INC OR THE LOCAL AUTHORIZED J LG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR YOUR J LG PRODUCT ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST COM PLETED ON THE AFFECTED LG PRODUCT Due to continuous product improvements LG Industries Inc res
44. PREPARATION AND INSPECTION SECTION 2 PREPARATION AND INSPECTION 2 1 GENERAL This section provides the necessary information needed by those personnel that are responsible to place the machine in operation readiness and lists checks that are performed prior to use of the machine It is important that the information contained in this section be read and understood before any attempt is made to operate the machine Ensure that all the necessary inspections have been completed successfully before placing the machine into service These procedures will aid in obtaining maxi mum service life and safe operation A IMPORTANT SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON TROL OVER THE FIELD INSPECTION AND MAINTENANCE SAFETY IS THE RESPONSIBILITY OF THE OWNER OPERATOR 2 2 PREPARATION FOR USE Before a new machine 15 put into operation it must be carefully inspected for any evidence of damage resulting from shipment and inspected periodically thereafter as outlined in Delivery and Frequent Inspection see section 2 3 During initial start up and run the unit should be thoroughly checked for hydraulic leaks A check of all components should be made to ensure their security All preparation necessary to place the machine in opera tion readiness Status Is the responsibility of management personnel Preparation requires good common sense i e telescope works smoothly and brakes operate prop erly coupled with a series of visual in
45. RD THAT IS ATTACHED TO THE AERIAL PLATFORM SHOULD NOT BE DISCONNECTED UNTIL SUCH TIME AS THE TRANSFER TO THE STRUCTURE IS COMPLETE OTHERWISE DO NOT STEP OUTSIDE OF PLATFORM DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS TO THE PLATFORM ADDITION OF SUCH ITEMS INCREASES THE EXPOSED WIND AREA OF THE MACHINE NEVER POSITION LADDERS STEPS OR SIMILAR ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH FOR ANY PURPOSE WHEN RIDING IN OR WORKING FROM PLATFORM BOTH FEET MUST BE FIRMLY POSITIONED ON THE FLOOR KEEP OIL MUD AND SLIPPERY SUBSTANCES CLEANED FROM FOOTWEAR AND PLATFORM FLOOR NEVER WALK THE BOOM TO GAIN ACCESS TO OR LEAVE PLATFORM NEVER PLACE HANDS OR ARMS IN TOWER BOOM OR UPRIGHT MECHANISM KEEP ALL NON OPERATING PERSONNEL AT LEAST 6 FEET 2 M AWAY FROM THE MACHINE AT ALL TIMES LG Lift IF PLATFORM OR BOOM IS CAUGHT SO THAT ONE OR MORE WHEELS ARE OFF THE FLOOR ALL PER SONNEL MUST BE REMOVED FROM PLATFORM BEFORE ATTEMPTING TO FREE MACHINE USE CRANES FORKLIFT TRUCKS OR OTHER EQUIP MENT TO REMOVE PERSONNEL AND STABILIZE MACHINE MOTION IF NECESSARY e THE OPERATOR IS RESPONSIBLE TO AVOID OPER ATING 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 3120685 SECTION 1 SAFETY PRECAUTIONS FERING WITH OPERATING CONTROLS AND PER SONS IN PLATFORM ENSURE THAT OPERATORS OF OTHER OVERHEAD AND FL
46. TION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 6 9 10 3 8 Lift Control Extend A Reach A three positon EXTEND A REACH lift control switch provides raising lowering of the Extend A Reach when positioned up or down Telescope Control The three position TELESCOPE control switch pro vides extension and retraction of the boom when positioned to in or out Swing Control The three position SWING control switch provides 360 degrees continuous turntable rotation when positioned to right or left A CAUTION WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THEN ONE FUNCTION AT THE SAME TIME SIMULTA NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP MOTOR Auxiliary Power Control A toggle type AUXILIARY POWER control switch energizes the electrically operated auxiliary hydrau lic pump when actuated The switch must be held in the ON position for the duration of auxiliary pump use The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main hydraulic pumps or engine fail The auxil iary pump enables the telescope lift and swing functions to be operated It should be noted that the functions will operate at a slower than normal rate due to the lower amount of hydraulic flow provided Circuit Breaker The 3 amp circuit breaker return control power to the High Engine circuit when depressed 11 12 13 14 Hourmeter An
47. VYACGOW NI JINSIY AVIA 33H ONIOW 1d 1188 144 5 HO SGNVH ON NOLLNVO Y 9681071 9651041 5 3210338 TINNOSYId 3435 GIZYOHLNV OT LSNN W31SAS 1Y 4018 LON 304 WOO WOOS NO 3dY1 NO 4015 15 WOOS SdOLS TINN QN31X3 Nu IHL NI HOLIMS 319901 14538 LON SI NILSAS NOILONN 3131 LNN WOOS 19VeL3H 7 HOLIMS 319901 4008 4015 LSNW WOOS SdOLS QN31X3 NOLLISOd JHL NOLLWLS 103 1NO2 30 341 LH9IY 3197201 HILIMS 319901 NOILISOd 1 1 2 OL WOO8 5 1 1 ATINA WOOS SNId 4207 1835 531 ANILXI 9222021 Nid 1139 AL33VS HOVLIV 1138 AL33VS NOLIVLS ANNONS NYOALVTd NI TVIX AVOT ON NYOIYId ASN 5 JO 9NINNIO38 LV W31SAS LN3A39VNVMW QAYOT 40 MO3H2 4000 3015 1 J LG Lift 3 16 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 19945 UOREJOT je eg uonne 0091041 66v 10ZL 0022021 0022021 Nid LOSLOZL Nid LO
48. ZLOZL Nid 00ZLOZL Nid 2021021 Nid EE 2622021 Nid 270533 3101433 YO SONVISIG 34 5 4333 LOVLNOO d33 ONIAOW ONY NOLL120319313 WV 246805 Nid SNOMAS 4 35 2 5 78123780 318 H3HlO SISSVHO ANY SYNLONSLSYAdNS ONILVLOY NIIMLIG NOILVLS DNILYYIdO SISSVHO YO JTSVLNANL Wsodivid WOOS 5123780 NO SaWl3SW3Hl NOILISOd LON TIVHS TANNOSUSd QuVZVH DNIHSNYD V 5912041 dl SI NOLLO3dSNI WISN NOLLVIOT SJDNVYHI 40 YITVIG AJILON 91 OL AdO9 VHSO 301 NIVLAY NOLL23dSNI 3I314V MONAY OL LX3N IAVQ HLNOW 91 TYYNLIONYLS LOVLNOS SLUVd STVNNVW ISN I3NNOS33d GANIVYL 6622021 A8 NOILO3dSNI H1V3Q 5 3SnV9 ATNOD 1N3n03243 33In033 ISNV ANY VHSO DNINOLLONNSTVIN V DNILYYIdO XTYM ATIVA 201434 I 1 4
49. afety training inspection maintenance application and operation It is absolutely necessary that the J LG Lift be regularly maintained in accordance with this manual and the machine Service and Maintenance manual and that any evidence of lack of maintenance malfunction excessive wear damage or modification to the machine be reported immediately to the machine owner or the jobsite supervisor or safety manager and that the machine be taken out of service until all discrepancies are corrected The J LG Lift is not intended to be used to lift material other than supplies which personnel in the platform require to do their job Supplies or tools which extend outside the platform are prohibited It must not be used as a forklift Crane Support for overhead structure or to push or pull another object The machine is equipped with an auxiliary battery oper ated power unit which will provide hydraulic power in the event of a primary engine power loss Auxiliary power can be controlled from either the Platform Control Station or the Ground Control Station Follow the instructions placed at the control stations The J LG Lift is hydraulically powered using hydraulic motors and cylinders for various machine motions The hydraulic components are controlled by electrically acti vated hydraulic valves using switches and control levers The speeds of functions controlled by control levers are variable from zero to maximum speed depending upon the
50. and hold control Remove foot from footswitch motion should stop If it does not shut down machine and contact a certified LG service technician c With engine power shut down depress the foot switch Attempt to start engine Engine should not attempt to start when footswitch is depressed If starter engages or engine turns over shut down machine and contact a certified J LG service technician 14 Auxiliary Power Operate each function control switch e g TELE LIFT and SWING to assure that they function in both directions using auxiliary power instead of engine power 15 Ground Controls Place GROUND PLATFORM SELECT switch to GROUND Start engine Platform controls should not operate 2 6 TORQUE REQUIREMENTS The Torque Chart Figure 2 4 consists of standard torque values based on bolt diameter and grade also specifying dry and wet torque values in accordance with recom mended shop practices This chart is provided as an aid to the operator in the event a condition is noticed that requires prompt attention during the walk around inspec tion 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 Utiliz ing this Torque Chart in conjunction with the preventive maintenance section in the Service and Maintenance manual will enhance safety reliability and pe
51. ating the use of extension cords hanging freely from the platform 3120685 J LG Lift 5 1 SECTION 5 OPTIONAL EQUIPMENT This page left blank intentionally 5 2 J LG Lift 3120685 SECTION 6 EMERGENCY PROCEDURES SECTION 6 EMERGENCY PROCEDURES 6 1 GENERAL This section provides information on the procedures to be followed and on the systems and controls to be used in the event an emergency situation is encountered during machine operation Prior to operation of the machine and periodically thereafter the entire operating manual includ ing this section should be reviewed by all personnel whose responsibilities include any work or contact with the machine DISCONNECT B CAP Drive Hub Engaged 6 2 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine in case of a malfunction or power failure have been incorpo rated The following procedures are to be used ONLY for emergency movement to a suitable maintenance area 1 Chock wheels securely 2 Disengage drive hubs by reversing disconnect caps REVERSED 3 Connect suitable equipment remove chocks and move machine After moving machine complete the following proce 5 dures Drive Hub Disconnected l Position machine on a firm and level surface 2 Chock wheels securely 3i m drive hubs by reversing discon
52. by mov ing axle switch to the left d Reinstall the pins in the steer cylinder and tie rod and lower the rear axle by raising the jack cylin der completely e Remove the pins from the steer cylinder and tie rod of the front axle f Using the controls on the frame lower the jack cylinder to raise the front axle When the wheels are off the ground extend the axle completely by moving the axle switch to the left The green AXLES SET indicator light will illuminate when the axles are fully extended 3120685 SECTION 2 PREPARATION AND INSPECTION g Reinstall the pins in the steer cylinder and tie rod and lower the front axle by raising the jack cylinder completely h Shut down the hydraulic system as required 2 Load Management System Functional Check a Activate the hydraulic system from the ground controls The blue light should illuminate when the SELECT SWITCH 15 in the ground position the EMERGENCY STOP switch is pulled out and the boom is retracted b With the boom fully retracted raise the boom to horizontal c Position the toggle switch located on the right Side of the ground control box to the P position and hold d Extend the boom until the red marking band on the inner mid section is exposed from the base section The red light should illuminate at this point e Continue extending the boom until the white marking band on the inner mid section 15 exposed from the base section The red light S
53. ch g Push the POWER EMERGENCY STOP switch to the off position 19 Torque Switch With the Torque Switch in the upper position the operator will have maximum drive motor speed and minimum torque With the switch in the lower posi tion you have minimum drive motor speed and maximum torque Use maximum torque for driving on slopes or rough terrain J LG Lift 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL gn Decals are made of Lexan Pressure Sensitive Adhesive 3 5 PLACARDS AND DECALS with a protective film on the front Remove the damaged Read and understand all placards and decals Do not decal and thoroughly clean the surface before installing a operate any machine on which DANGER WARNING new decal Simply peel off press on to the surface CAUTION or INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE Replace placards and decals if damaged missing or illegible NOTE Placards and Decals can be ordered by using the part numbers located by each placard or decal See Figure 3 8 Placards Decals and Part Numbers Location 3120685 J LG Lift 3 15 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 29945 uone2o1 je eq 6 2 4 02102 Nid 2202 0610 1 97855011 SNOIYIS YO 3snv5 91105 3120685 LOZLOZL Nid NO YOAN E
54. cted position with or without any load in plat form is based on the following criteria 1 Machine is positioned on a smooth firm and level surface 2 Load is within manufacturer s rated design capacity 3 All machine systems are functioning properly 4 Propertire pressure exists in the tires 5 Machine is as originally equipped from LG Stability This machine as originally manufactured by J LG Indus tries Inc when operated within its rated capacity on a smooth firm and level supporting surface and in accor dance with the instructions provided on the machine and this manual provides a stable machine for all platform positions Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY The machines position of least forward stability is shown in Figure 3 1 and its position of least backward stability is shown in Figure 3 2 3120685 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL s lt gt MACHINE WILL UPSET IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE Approx 50 fft 15 4 m Figure 3 1 Position of Least Forward Stability 3120685 JLG
55. curity and hardware for proper installation 3 Check rear tire and wheel assemblies for security tires for wear and damage 4 Check drive hubs hydraulic motors brakes and hydraulic lines for damage and leaks 5 Check oil level in drive hub by removing pipe plug on side and feeling for oil level Contact Service Personnel for assistance if needed NOTE Torque hubs should be one half full of lubricant 6 Check counterbalance flow divider valves hydraulic swivel assembly and lines for visible damage evi dence of leakage and security and electrical con nections for corrosion and tightness 7 Check extending axle assemblies for evidence of leakage and security pressure lines for abnormal chafing drive hubs hydraulic motors brakes and hydraulic lines for damage and leaks 8 Check extending axles for visible damage and loose or missing parts 3120685 J LG Lift 2 1 SECTION 2 PREPARATION AND INSPECTION Turntable 10 NOTE 11 2 2 l Check turntable and turntable lock for damage loose or missing parts and security Check swing drive hub hydraulic motor and brake for damage loose or missing parts hydraulic lines and compo nent housings for evidence of leakage pinion for proper mesh with swing gear Check swing bearing for damage wear lubrication and loose or missing bearing bolts Check solenoid valves and hydraulic lines for dam age leakage security and electrical connectio
56. d ec uc ar op EGRE Sp qt d 2 10 2 4 TFS 2 14 3 1 Position of Least Forward Stability 3 3 3 2 Position of Least Backward 5 3 4 3 3 Ground Control Station Prior to 1994 3 6 3 4 Ground Control Station May 1994 to 3 7 3 5 Axle Extension Axle acks 3 9 3 6 Remote Conmol BOX Sa Ge Er 3 10 3 7 Platform Station Prior to May 1994 3 12 3 8 Platform Station 1994 to Present 3 13 3 9 Caution Decal Location Sheet 1 3 16 3 10 Caution 5 2 3 17 3 11 Control Panel Symbols 5 1072 3 20 3 12 Control Panel Symbols Sheet 2072 3 21 4 1 SPINNE SQUE be ete eae Oe 4 4 4 2 Grade and Side Slope usc UR ew o e oc ob e m ele e dut cad 4 6 4 3 Machine Tie Down Sheet 1 4 8 4 4 Machine Tie DON 2
57. d lifting eyes 6 Cover the Platform Control Console to protect i that the turntable lock pin is engaged See Figure 4 3 ifting Chart instruction placards warning decals and operating controls from hostile environment 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 4 10 TIE DOWN AND LIFTING machine remains level when elevated When transporting machine boom and extend a reach must be in the stowed mode with turntable lock pin 3120685 J LG Lift 4 7 SECTION 4 MACHINE OPERATION 39945 uwog aunbig mean pp T LZ Ed Lr 2 See ATU KKK TOM yy TF VR AA 4 AN ERIE DON n ee ejqissod umop pue dn sjuaA aJd si ped si UO 1 94 si eseq pue pexoouo aq oj soouejsip 10 5 3120685 J LG Lift 4 8 SECTION 4 MACHINE OPERATION Figure 4 4 Machine Tie Down Sheet 2 3120685 JLG Lift 4 9 SECTION
58. e Platform Pivot and Slave Cylinder Attach Pins Properly secured evidence of proper lubrication where applicable Figure 2 2 Daily Walk Around Inspection Sheet 3 of 3 LG Lift 3120685 2 5 DAILY FUNCTIONAL CHECK A WARNING THE LOAD MANAGEMENT SYSTEM AND THE AXLES PROPER EXTENSION AND RETRACTION MUST BE CHECKED PRIOR TO ANY OTHER SYSTEMS AND OR FUNCTIONS A functional check of all systems should be performed once the walk around inspection is complete in an area free of overhead and ground level obstructions First using the ground controls check all functions controlled by the ground controls Next using the platform controls check all functions controlled by the platform controls A WARNING TO AVOID SERIOUS URY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THE OFF OR NEU TRAL POSITION WHEN RELEASED TO AVOID COLLISION AND INJ URY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE NOTE Perform checks from ground controls first then from platform controls 1 Axle Extension System a Remove pins from steer cylinder and tie rod of rear axle b Activate hydraulic system from ground controls c Using the controls on the frame lower the jack cylinder to raise the rear axle When wheels are off the ground extend axle completely
59. e machine operating characteristics and the ground control functions Training should include operation of the machine review and understanding of this section and hands on operation of the controls in simulated emergen cies Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS UNABLE TO OPER ATE OR CONTROL THE MACHINE FOR ANY REASON A WARNING DO NOT OPERATE WITH PRIMARY POWER SOURCE ENGINE IF PERSONS ARE PINNED OR TRAPPED USE AUXILIARY POWER INSTEAD l Operate the machine from ground controls ONLY with the assistance of other personnel and equip ment cranes overhead hoists etc as may be be required to safely remove the danger or emergency condition 2 Other qualified personnel on the platform may use the platform controls with regular or auxiliary power DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY 3 Cranes forklift trucks or other equipment which be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunc tion when used Platform or Boom Caught Overhead If the platform or boom becomes jammed or snagged in overhead structures or equipment do not continue opera tion of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location Only then should an attempt be made to free the platform using any necessary equipment and p
60. e 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 informa tion from his her supervisor or an authorized LG Distribu tor before proceeding NOTE Manufacturer or distributor will provide qualified per sons for training assistance with first unit s delivered and thereafter as requested by the user or his her personnel 3120685 J LG Lift 3 1 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 3 3 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first require ment for any user regardless of the user s experience with similar types of equipment Placards Important points to remember during operation are pro vided 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 consti tuted by the operating characteristics and load limitations of the machine See FOREWORD for definitions of the above placards 3 2 LG Lift Capacities Raising boom above horizontal and or extension of boom beyond retra
61. e 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 2 Knowledge and understanding of this manual and of the control markings instructions and warnings on the machine itself 3 Knowledge and understanding of all safety work rules of the employer and of Country Federal State and local statutes including training in the recogni tion and avoidance of potential hazards in the work place with particular attention to the work to be per formed 4 Proper use of all required personnel safety equip ment in particular the wearing of a safety harness or other approved fall protection devices with a lanyard attached to the designated lanyard attach point on 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 7 Means to avoid the hazards of unprotected electrical conductors 8 Any other requirements of a specific job or machine application Training Supervision Training must be done under the supervision of a qualified person an open area free of obstructions until the trainee has developed th
62. e to Phase in Feet Meters 0 to 300V AVOID CONTACT Over 300V to 50 KV 10 3 Over 50KV to 200 KV 15 5 Over 200 to 350 KV 20 6 Over 350 KV to 500 KV 25 8 Over500 KV to 750 KV 35 11 Over 750 KV to 1000 KV 45 14 DANGER DO NOT maneuver machine or personnel inside PROHIBITED ZONE ASSUME allelectrical parts and wiring are ENERGIZED unless known otherwise FROM CONTACT WITH OR PROXIMITY TO AN ELEC 13 ELECTROCUTION HAZARD TRICALLY CHARGED CONDUCTOR 7 A CLEARANCE OF AT LEAST 10 FEET 3 M BETWEEN ANY PART OF THE MACHINE OR ITS LOAD AND ANY ELECTRICAL LINE OR APPARATUS CARRYING UP TO 50 000 VOLTS ONE FOOT ADDI MAINTAIN SAFE CLEARANCE FROM ELECTRICAL LINES AND APPARATUS ALLOW FOR BOOM SWAY ROCK OR SAG AND ELECTRICAL LINE SWAYING TIONAL CLEARANCE IS REQUIRED FOR EVERY ADDITIONAL 30 000 VOLTS OR LESS THE MACHINE DOES NOT PROVIDE PROTECTION 1 4 PRE OPERATIONAL READ YOUR MANUAL UNDERSTAND WHAT YOU VE READ THEN BEGIN OPERATIONS ALLOW ONLY AUTHORIZED AND QUALIFIED PER SONNEL TO OPERATE MACHINE WHO HAVE DEM ONSTRATED THAT THEY UNDERSTAND SAFE AND PROPER OPERATION AND MAINTENANCE OF THE UNIT 1 2 J LG Lift 3120685 OPERATOR MUST ACCEPT OPERATING 3120685 RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS BEEN GIVEN BY COMPETENT AND AUTHORIZED PERSONS BEFORE OPERATION CHECK WORK AREA FOR OVERHEAD ELECTRIC LINES MACHINE TRAFFIC SUCH AS BRID
63. er sonnel Do not operate controls to cause one or more wheels to leave the ground 3120685 3120685 Righting Tipped Machine No attempt should be made to right the machine using platform or ground controls a fork truck of suitable capac ity or equivalent equipment may be placed under the ele vated side of the chassis A crane or other lifting equipment may also be used to lift the platform while the chassis is lowered by a fork truck jacks or other means Remove all personnel and equipment from the area before starting operation Post Incident Inspection and Repair Following any incident thoroughly inspect the machine and test all functions first from the ground controls then from the platform controls Do not lift above 10 feet 3 m until you are sure that all damage has been repaired if required and that all controls are operating correctly SECTION 6 EMERGENCY PROCEDURES 6 5 INCIDENT NOTIFICATION It is imperative that LG Industries Inc be notified imme diately of any incident involving a J LG product Even if no injury or property damage is evident the factory should be contacted by telephone and provided with all neces sary details Phone 877 LG SAFE 554 7233 8am till 4 45pm EST It should be noted that failure to notify the manufacturer of an incident involving a J LG Industries product within 48 hours of such an occurrence may void any warranty con sideration on that particular machi
64. erves the right to make specification changes without prior notifica tion Contact J LG Industries Inc for updated information 3120685 J LG Lift a FOREWORD This page left blank intentionally J LG Lift 3120685 3120685 All procedures herein are based on the use of the machine under proper operating conditions with no deviations from original design intent as per OSHA regulations and applicable ANSI standards READ amp HEED The ownership use service and or maintenance of this machine is subjectto various governmental and local laws and regulations It is the responsibility of the owner user to be knowledgeable of these laws and regulations and to comply with them Owner user operator lessor and lessee must be familiar with Sections 6 7 8 9 and 10 of ANSI A92 5 1992 These sections contain the responsibilities of the owner users operators lessors and lessees con cerning safety training inspection maintenance application and operation The most prevalent regu lations of this type in the United States are the Fed eral OSHA Safety Regulations Listed below in abbreviated form are some of the requirements of Federal OSHA regulations in effect as of the date of publication of this handbook The listing of these requirements shall not relieve the owner user of the responsibility and obligation to determine all applicable laws and regulations and their exact wording and requirements and to com
65. et Meadowdale Germiston South Africa Phone 27 11 453 1334 Fax 27 11 453 1342 JLG Deutschland GmbH Max Planck Strasse 21 D 27721 Ritterhude Ihlpohl Bei Bremen Germany Phone 49 421 693 500 Fax 49 421 693 5035 JLG Industries Norge AS Sofeimyrveien 12 N 1412 Sofienyr Norway Phone 47 6682 2000 Fax 47 6682 2001 Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755Castellbisbal Spain Phone 34 93 77 24700 Fax 34 93 77 11762 Industries Italia Via Po 22 20010 Pregnana Milanese MI Italy Phone 39 02 9359 5210 Fax 39 02 9359 5845 JLG Polska Ul Krolewska 00 060 Warsawa Poland Phone 48 91 4320 245 Fax 48 91 4358 200 JLG Industries Sweden Enkopingsvagen 150 Box 704 SE 175 27 Jarfalla Sweden Phone 46 8 506 59500 Fax 46 8 506 59534
66. for direction desired NOTE When boom functions are being operated there is an interlock that prevents the use of DRIVE and STEER functions Raising and Lowering the Main Boom To raise and lower Boom position LIFT control switch or controller to UP OR DOWN and hold until desired height is reached Telescoping the Main Boom To extend or retract Boom position TELESCOPE control switch to IN or OUT and hold until platform reaches desired position 4 9 SHUT DOWN AND PARK l Drive machine to a protected area 2 Position FUNCTION SPEED control on Platform Control Console to low 3 Assure main boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured DO NOT DRIVE MACHINE ON GRADES AND SIDESLOPES EXCEEDING THOSE SPECIFIED ON SERIAL NUMBER PLATE Figure 4 2 Grade and Side Slope 4 6 J LG Lift 3120685 SECTION 4 MACHINE OPERATION 4 Remove all load and allow engine to operate 3 5 engaged and machine securely tied down to truck or minutes at LOW setting to permit reduction of trailer deck Four tie down eyes are provided in the frame engine internal temperatures slab one at each corner of the machine 5 At Ground Controls turn MASTER SWITCH to cen If it becomes necessary to lift the machine using an over ter OFF Position the IGNITION switch down to head or mobile crane it is very important that the lifting OFF devices are attached only to the designate
67. he machine s horn signaling the operator A second switch mounted on the machine senses when the machine is out of level 5 degrees and will cut out two speed drive when activated 5 4 ROTATING BEACON An amber or red rotating beacon may be installed on the hood or platform and can be controlled by a two position toggle switch mounted on the platform control console When the switch is placed in the ON position the light is activated and provides a visual warning to the machine s operation 5 5 HOSTILE ENVIRONMENT PACKAGE The hostile environment package provides additional pro tection against the entry of dust dirt sand and other abra sive 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 5 6 110 VOLT GENERATOR A 110 volt generator mounted beside the engine is belt driven from the output shaft of the engine This application provides for a 110 volt receptacle at the ground control and also atthe platform The lead from the ground control and also atthe platform The lead from the ground control to the platform is routed along the boom power track thus elimin
68. hould blink and an audible alarm sound Also the telescope out and lift down will not function in this mode Release the toggle switch f Extend the boom The boom must stop on the white band on the mid boom section Release the toggle switch g Retract the boom until tele out will function The system IS now reset h Position the toggle switch to the M position and hold i Repeat step e A WARNING TIPOVER HAZARD IF THE RED LIGHT DOES NOT BLINK THE ALARM DOES NOT SOUND THE BOOM CONTINUES TO TELESCOPE BEYOND SEC OND MARKING BAND IF THE BOOM CAN BE LOWERED RETRACT THE BOOM IMMEDIATELY SHUT DOWN MACHINE AND CONTACT A QUALIFIED SERVICE PERSON 3 Drive forward and reverse check for proper opera tion 4 Steer left and right check for proper operation 5 Check rear steer left and right for proper operation J LG Lift 2 9 SECTION 2 PREPARATION AND INSPECTION SJeo oocL Jeo sinoy 009 Su1uoui 9 SJNOY 00 Su1uoui 5 061 y yeya SIU UI SJEAJ9JUI 94 L L JO 9 YJOQ uo CE SUIIY opis uo 67 pue 310N Buiysnq
69. ing should always be performed from the Ground Control station Starting Procedure 1 Check engine oil If necessary add oil in accor dance with the Engine Manufacturer s manual 2 Check fuel level Add fuel if necessary 3 Check that air cleaner components are in place and securely fastened A CAUTION IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED PERIOD SHOULD ENGINE FAIL TO START ONCE AGAIN ALLOW STARTER TO COOL OFF FOR 2 3 MINUTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL 4 Position the SELECT SWITCH to ground Position the POWER EMERGENCY STOP switch to ON then push the START switch until engine starts A CAUTION ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 5 After engine has had sufficient time to warm up shut engine off 6 Position SELECT SWITCH to PLATFORM 7 From Platform position IGNITION switch to ON then push the START switch to the forward position until engine starts NOTE The footswitch must be in released up position before starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE THE MACHINE Shutdown Procedure A CAUTION IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION 1 Remove all load and allow engine to operate at low Speed setting for 3 5 minutes this allows for further
70. inspection of the job site and aerial lift shall be performed by competent persons 13 Personnel shall always stand on the floor of the platform not on boxes planks railing or other devices for a work position Applicable Federal OSHA regulations for the United States as of the date of publication of this manual include but are not limited to 29 CFR 1910 67 29 CFR 1926 20 29 CFR 1926 21 29 CFR 1926 28 and 29 CFR 1926 453 J LG Lift FOREWORD une 1992 September 1997 November 1997 March 1 1999 April 11 2000 Prop65 page added 4 1 REVISON LOG Original Issue Revised Revised Revised Revised Updated 4 20 00 Updated 4 20 00 J LG Lift 3120685 TABLE OF 5 TABLE OF CONTENTS SUBJ ECT SECTION PARAGRAPH PAGE NO SECTION FOREWORD SECTION 1 SAFETY PRECAUTIONS 1 1 GENERAL nd de 1 1 1 2 Baer 1c Magen cat tian dec pt DE a a gap 1 1 1 3 Electroc tion ur bates Ne 1 2 1 4 Ler ea s qa 1 2 1 5 DV ever nere Yd bacio ice dog NT 1 4 1 6 Nae dcr itl ato a 1 5 1 7 Towing and Hauling 3 5 1 8 SECTION 2 PREPARATION AND INSPECTION 2 1 ORO 2 1 2 2 Fer
71. ition boom lowered over rear all access panels and doors closed and secured ignition off turntable locked Check that brakes hold machine in position Chock wheels front and rear Turn off SELECT SWITCH and remove key 4 7 PLATFORM Loading From Ground Level 1 2 Loading From Positions Above Ground Level Position chassis on a smooth firm and level surface If total load personnel tools and supplies is less then rated capacity distribute load uniformly on plat form floor and proceed to work position Before loading weight to platform above ground level 3120685 SECTION 4 MACHINE OPERATION Determine what the total rated capacity weight will be after additional weight is loaded personnel tools and supplies If total weight in platform will be less then rated capacity proceed with adding weight Platform Level Adjustment 1 Leveling UP Depress footswitch to raise platform position PLATFORM LEVEL control switch UP and hold until platform is level Leveling DOWN Depress footswitch to lower plat form position PLATFORM LEVEL control switch to DOWN and hold until platform is level Platform Rotation 1 J LG Lift Depress footswitch to rotate platform to the left PLATFORM ROTATE control is positioned to the LEFT and held until desired position is reached Depress footswitch to rotate platform to the right PLATFORM ROTATE control is positioned to the RIGHT and held until desired pos
72. ition is reached 4 5 4 4 8 A WARNING A RED TILT ALARM WARNING LIGHT LOCATED ON THE CON TROL CONSOLE LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE 5 DEGREES OR GREATER DO NOT SWING EXTEND OR RAISE BOOM ABOVE HORIZONTAL WHEN LIT DO NOT DEPEND ON ALARM AS A LEVEL INDICATOR FOR THE CHASSIS TILT ALARM INDICATES CHASSIS IS ONA SEVERE SLOPE 5 DEGREES OR GREATER CHASSIS MUST BE LEVEL BEFORE SWINGING EXTENDING OR RAISING BOOM ABOVE HORIZONTAL TO AVOID UPSET IF RED TILT ALARM WARNING LIGHT LIGHTS WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZON TAL RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTENDING OR RAISING BOOM TRAVELING WITH BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES SPECIFIED ON SERIAL NUMBER PLATE TO AVOID SERIOUS URY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEU TRAL POSITION WHEN RELEASED TO AVOID A COLLISION AND INJ URY IF PLATFORM DOES STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE Swinging the Boom A IMPORTANT ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTING ANY SWING OPERATION Depress footswitch to swing boom position SWING con trol switch or controller to RIGHT or LEFT
73. lows the operator to steer the rear wheels as desired The Speed Control switch does not affect the steer function 3 9 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL CAUTION DRIVING PLATFORM SHALL NOT BE OCCUPIED WHILE USING THIS CONTROL KEEP CLEAR OF MACHINE WHILE FWD DRIVE STEER LEFT STEER RIGHT o mmsovz E P USH DOWN PRIOR TO JULY 1992 OCTOBER 1992 TO MARCH 1994 Drive Switch Speed Control Wigs F N MG E 0220 im 4 Ie 3 P 2 A OT JULY 1992 TO OCTOBER 1992 Emergency Stop Switch Steer Switch Front Steer Switch Rear b
74. mote Access Lube rotate 180 lube again N A MPG Brush 150 1 Grease Fitting MPG Pressure Gun 150 2 Grease Fittings MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 1 Grease Fitting MPG Pressure Gun 150 Position boom over side for access under turntable N A N A 50 300 Replace after first 50 hrs of operation then every 300 hrs thereafter N A N A 50 300 Replace after first 50 hrs of operation then every 300 hrs thereafter Fill Cap HO 10 1200 Check oil daily Change oil every 1200 hrs Fill Cap Drain Plug EO 10 300 Check oil daily Change oil every 300 hrs N A Replaceable Cartridge 300 2 Grease Fittings MPG Pressure Gun 150 N A SAE10 Oil Can 150 As Needed N A SAE10 Oil Can 150 As Needed N A MPG Brush 600 As Needed Key to Lubricants MPG Multipurpose Grease EPGL Extreme Pressure Gear Lubricant HO Hydraulic Fluid EO Engine Oil Figure 2 3 Lubrication Chart Sheet 2 of 2 J LG Lift 2 11 SECTION 2 PREPARATION AND INSPECTION 6 Check platform rotator for smooth operation and assure platform will rotate 90 degrees in both direc tions from centerline of boom Raise lower and swing boom to LEFT and RIGHT a minimum of 45 degrees Cycle function several times Check for smooth elevation and swing motion 7 Raise and lower Extend A Reach Cycle functions several times Check for smooth elevation and swing motion 8 Telescope boom in and out several cycles at vario
75. n the entire machine Torque Requirements The Torque Chart Figure 2 4 consists of standard torque values based on bolt diameter and grade also specifying dry and wet torque values in accordance with recom mended 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 inspec tion or during operation until the proper service personnel can be notified The Service and Maintenance manual provides specific torque values and periodic maintenance LG Lift procedures with a listing of individual components Utiliz ing 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 2 4 DAILY WALK AROUND INSPECTION It is the operator s responsibility to inspect the machine before the start of each workday It is recommended that each operator inspect the machine before operation even if the machine has already been put into service under another operator This Daily Walk Around Inspection is the preferred method of inspection See Figure 2 2 In addition to the Daily Walk Around Inspection be sure to include the following as part of the daily inspection 1 Overall cleanliness Check all standing surfaces for oil fuel and hydrau lic oil spillage and foreign objects Ensure overall cleanliness 2 Placards
76. ne SEG Tits 6 3 SECTION 6 EMERGENCY PROCEDURES This page left blank intentionally 6 4 J LG Lift 3120685 SECTION 7 INSPECTION AND REPAIR LOG SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3120685 J LG Lift 7 1 SECTION 7 INSPECTION AND LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 J LG Lift 3120685 Please cut on the dotted line and fax to 717 485 6573 4 e JLG Industries Inc TRANSFER OF OWNERSHIP To 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 amp Reliability Department via facsimile 717 485 6573 or mail to address as specified on the back of this form Thank you
77. nect caps on fee the Dave 4 Remove chocks from wheels as needed 6 3 EMERGENCY CONTROLS AND THEIR LOCATIONS Emergency Stop Switches There is an emergency stop switch at both the Ground Controls and Platform Controls When positioned to OFF it will immediately stop the machine WARNING CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP SWITCH GUARD IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE 3120685 JLG Lift 6 1 SECTION 6 EMERGENCY PROCEDURES Ground Control Station The Ground Control Station is located on the right front side of the turntable The controls on this panel provide the means for overriding the platform controls and for controlling the platform level boom and swing functions from the ground Place the SELECT switch to GROUND position and operate the proper switch to lift swing or telescope the boom or level the platform 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 l Position the platform ground SELECT SWITCH to PLATFORM 2 Position the EMERGENCY STOP switch to ON 3 Depress and hold foots
78. ns for tightness and evidence of corrosion Check ground controls for damage loose or miss ing parts security electrical connections for evi dence of corrosion and tightness and wiring for insulation damage Assure that all switches function properly Check battery for damage loose or missing vent caps electrical connections for tightness and evi dence of corrosion holddown brackets for tight ness and electrolyte for proper water level Add only clean distilled water to battery Check engine and accessories for damage loose or missing parts leakage and security Check throttle solenoid and linkage for damage electrical connec tions for tightness and evidence of corrosion and wiring for insulation damage Check fuel lines for damage leakage and security Check all access doors for damage proper opera tion of latches props and security Check fuel tank for damage leakage and filler cap for security Check hydraulic reservoir and hydraulic lines for damage leakage and security JLG recommends replacing the hydraulic filter ele ment after the first 50 hours of operation and then every 300 hours thereafter unless system indicator require earlier replacement Check all cylinder pin and shaft retaining hardware for security and wear 12 Check all electrical cables for defects damage loose or corroded connections Boom 1 Check all cylinder pin and shaft retaining hardware for security and wear 2
79. olenoid 4 Warning Horn A push type HORN switch when pressed supplies electrical power to activate the horn 5 Chassis Out of Level Warning Light This red indicator lights to indicate that the chassis is on a slope over 3 degrees If illuminated when boom is raised or extended retract and lower to below horizontal then reposition the machine so that it is level before extending the boom or raising the boom above horizontal A WARNING IF THE CHASSIS OUT OF LEVEL WARNING LIGHT IS ILLUMI NATED WHEN THE BOOM IS RAISED OR EXTENDED RETRACT AND LOWER THE PLATFORM TO BELOW HORIZONTAL THEN REPOSITION THE MACHINE SO IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING THE BOOM ABOVE HORIZONTAL 3120685 NOTE LIFT SWING and DRIVE control levers or switches are spring loaded and will automatically return to the neutral OFF position when released A WARNING TO AVOID SERIOUS INJ URY DO NOT OPERATE THE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING THE PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED 6 Lift The LIFT control lever provides raising and lowering of the boom when positioned to up or down and automatically returns to off when released 7 Telescope The TELESCOPE switch provides extension and retraction or the boom when positioned to in or out and automatically returns to off when released 8 Swing The SWING control lever provides continuous swing when
80. or can raise lower extend or retract the boom swing the boom to the left or right and when equipped with a platform rotator can rotate the platform around the boom end Standard boom swing is 360 con tinuous left and right of the stowed position The machine has a Ground Control Station which will override the Plat form Control Station Ground Controls operate boom lift telescope and swing and are to be used only in an emer gency to lower the platform to the ground should the operator in the platform be unable to do so Instruction and hazard warnings are posted adjacent to both operator control stations and at other places on the machine It is extremely important that operators know what instructions and warnings are placed on the machine and review these periodically so that they are fresh in their minds Vibrations emitted by these machines are not hazardous to an operator in the work platform The J LG Lift is designed to provide efficient and safe oper ation when maintained and operated in accordance with warnings on the machine in the Operators and Safety Manual and all jobsite and government rules and regula tions As with any type of machinery the operator is very important to efficient and safe operation Owner user operator lessors lessees must be familiar with Sections 6 7 8 9 and 10 of ANSI A92 5 1992 These sections con tain the responsibilities of the owner users operators les sors and lessees concerning s
81. parts no vis ible damage element clean Tie Rod and Steering Linkage No loose or miss ing parts no visible damage Tie rod end studs locked Wheel Tire Assembly Left Front Properly secured no loose or missing lug nuts no visible damage Figure 2 2 Daily Walk Around Inspection Sheet 2 of 3 3120685 J LG Lift 2 7 SECTION 2 PREPARATION AND INSPECTION 2 8 Engine Oil Supply Full mark on dipstick filler cap secure Muffler and Exhaust System Properly secured no evidence of leakage Cowling and Latches Right Side All cowling and latches in working condition properly secured no loose or missing part Turntable Bearing and Pinion No loose or missing hardware no visible damage evidence of proper lubrication No evidence of loose bolts or looseness between bearing and structure Battery Proper electrolyte levels cables tight no visible damage or corrosion Frame No visible damage no loose or missing hardware top and underside Drive Hub Left Rear No visible damage no evi dence of leakage Wheel Tire Assembly Left Rear Properly secured no loose or missing lug nuts no visible damage Drive Motor and Brake Left Rear No visible dam age no evidence of leakage Boom Sections No visible damage wear pads secure cylinders rod end shafts and barrel end shafts properly secured Rotator and Motor Properly secured no visible damage no evidence of leakag
82. positioned to left or right 9 Function Speed The FUNCTION SPEED switch controls the speed of Extend A Reach Telescope Basket Rotate and Basket Level functions Turning the knob to the left slows the speed and turning the knob to the right increases the speed rols is dependent upon the position of the STEER AXLES selector valve 10 Creep The CREEP switch allows the operator to select a lower speed for DRIVE LIFT or SWING NOTE When the boom is above horizontal the DRIVE func tion automatically goes into speed 11 Drive Steer Controller The Drive Steer controller allows the operator to select either forward or reverse when positioning the controller to the desired position The controller is electrically ramped to allow infinitely variable driving speed between fast and slow Also a thumb oper ated switch on top of the lever controls steer for the rear wheels J LG Lift 3 11 SECTION 3 USER RESPONSIBILITIES AND MACHINE CONTROL 18 16 9 ES SET A DISTRESS A
83. rformance of the machine 2 12 J LG Lift 3120685 2 7 BATTERY MAINTENANCE A WARNING TO AVOID IN URY FROM AN EXPLOSION DO NOT SMOKE OR ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC ING ALWAYS WEAR EYE PROTECTION WHEN SERVICING BATTER IES Battery Maintenance 3120685 1 The battery is maintenance free except for occa sional battery terminal cleaning as noted in the fol lowing J LG Lift SECTION 2 PREPARATION AND INSPECTION Remove battery cables from each battery post one time negative first Clean cables with acid neu tralizing solution e g baking soda and water or ammonia and wire brush Replace cables and or cable clamp bolts as required Clean battery post with wire brush then re connect cable to post Coat non contact surfaces with min eral grease or petroleum jelly Vaseline When all cables and terminal posts have been cleaned ensure all cables are properly positioned and are not pinched Close battery compartment cover 2 13 SECTION 2 PREPARATION AND INSPECTION 8 AVS 00089 AVS S19u9jseJ unipeo jou op anbJo 9594 9 ON 009071 00596 0015811 0099 00 0 1 00220 00996 00696 00728 00998 00022 00292 00289 00599 00269 00909 00919 00609 00847 00697 0
84. s 4 6 4 10 TE su 4 7 4 11 SVIN TD eot indice de oe dd 4 12 SECTION 5 OPTIONAL EQUIPMENT 5 1 Cold Start KIE DIESCLENGING s indo x e NP ar RC CR ON e CIO 5 1 5 2 FAE MINN ethic pd 5 1 5 3 HA I 5 1 5 4 BEACON an david AO a dc 5 1 5 5 Hostile Environment 5 1 5 6 TO oe rito a aa eee ut sd ed od e ceat Mee pet 5 1 SECTION 6 EMERGENCY PROCEDURES 6 1 GEN 6 1 6 2 Emergency Towing Procedures 6 1 3120685 JLG Lift TABLE CONTENTS Continued SUBJ ECT SECTION PARAGRAPH PAGE NO 6 3 Emergency Controls and TheirLocations 6 1 6 4 Emergency ar sad TD Feen at 6 2 6 5 NETTET NOMEN dn erd cur a 6 3 SECTION 7 INSPECTION AND REPAIR LOG LIST OF FIGURES FIGURE NO TITLE PAGE NO 2 1 Machine Nomenclature 4 235359 400470 _ 2 3 2 2 Daily Walk Around 2 6 2 3 NAE 235 do Pea pe Ph Pe
85. spections The man datory requirements are given in the Daily Walk Around Inspection See section 2 4 It should be assured that the items appearing in the Deliv ery and Frequent Inspection and Functional Check are complied with prior to putting the machine into service 2 3 DELIVERY AND FREQUENT INSPECTION NOTE This machine requires periodic safety and mainte nance inspections by an authorized JLG Dealer A decal located on the turntable provides a place to record stamp inspection dates Check decal and notify dealer if inspection is overdue An annual inspection shall be performed on the aerial plat form no later than thirteen 13 months from the date of the prior annual inspection the inspection shall be per formed by person s qualified as a mechanic on the spe cific make and model of the aerial platform The following checklist provides a systematic inspection to assist in detecting defective damaged or improperly installed parts The checklist denotes the items to be inspected and conditions to examine Frequent inspection shall be performed every 3 months or 150 hours whichever comes first or more often when required by environment severity and frequency of usage Chassis 1 Check front tire and wheel assemblies for loose or worn spindles components and hardware for secu rity tires for wear and damage 2 Check steering assembly for loose or bent tie rod cylinder and hydraulic lines for leaks and se
86. t delivery 1 year 4 2 4 OSHA and ANSI require frequent and annual inspection by properly trained personnel Use JLG approved manuals parts and procedures Contact JLG regarding structural repairs Stamp frame with MONTH DAY YEAR next to arrow after each inspection Retain records for OSHA Copy JLG Notify JLG of changes of owner user or location or if inspection is overdue Replace if defaced 1702153 C 5 years 6 years 7 years 8 years 9 years 10 years 3 18 P N 1702153 C LG Lift 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 CRUSHING COULD CAUSE DEATH OR SERIOUS INJURY 1702277 P N 1702277 WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES ENGINE PLATFORM DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY MAKE SURE ALL TIRES ARE IN GOOD CONDITION AND AIR FILLED TIRES ARE PROPERLY INFLATED SEE MANUFACTURER S MANUAL FOR ADDITIONAL INSTRUCTIONS AND LIMITATIONS DEATH OR SERIOUS INJURY COULD OCCUR FROM TIP OVER 1702282 P N 1702282 WARNING CRUSHING HAZARD DO NOT STAND UNDER RAISED P
87. t least to API Service Classification GL 3 and sufficient chemical stability for mobile hydraulic system ser vice JLG Industries recommends Mobilfluid 424 hydraulic which has an SAE viscosity index of 152 or Kendall Hyken 052 hydraulic oil which has an SAE viscosity of 10W 20 and viscosity index of 152 When temperatures remain consistently below 7 degrees C JLG Industries recommends the use of Mobil DTE 11 Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives of be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG industries for proper recommendations Assure that all items requiring lubrication are ser viced Refer to Lubrication Chart Figure 2 3 for specific requirements 2 5 SECTION 2 PREPARATION AND INSPECTION uo WU EI EY iL at Figure 2 2 Daily Walk Around Inspection 2 6 JLG Lift Sheet 1 of 3 3120685 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 Check list A WARNING TO AVOID INJ URY DO NOT OPERATE A MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED USE
88. th the aid of an assistant swing the jib closed until its alongside the boom and the holes in the jib plates align 3 Install lockpin through the aligned holes in the jib plates The machine must now be operated from the ground controls or the remote control box 4 12 J LG Lift 3120685 SECTION 4 MACHINE OPERATION Remove the left side attach pin to swing the jib Q 5 Ss D 0 zo o T 2 Figure 4 8 Swing Away J ib 4 13 J LG Lift 3120685 SECTION 4 MACHINE OPERATION 4 14 J LG Lift 3120685 SECTION 5 OPTIONAL EQUIPMENT SECTION 5 OPTIONAL EQUIPMENT 5 1 COLD START KIT DIESEL ENGINE A cold weather start system for the diesel engine functions automatically to provide starting fluid as necessary to the engine during starting A sensor switch mounted on the engine will permit ether injection into the air intake when the engine is cold A temperature sensor will not permit ether injection into a cold engine 5 2 TRAVEL MOTION ALARM A 12 volt alarm horn mounted on the turntable provides an audible warning when the machine is in the travel DRIVE mode It will function in FORWARD or REVERSE to warn jobsite personnel the machine is traveling 5 3 TILT ALARM Senses when the machine is out of level in any direction approximately 5 degrees and illuminates a warning light at the platform control station and sounds t
89. us degrees of elevation lengths Check for smooth tele scope operation 9 Check that platform automatic self leveling system functions properly during raising and lowering of the boom 10 Check platform level adjustment system for proper operation NOTE Turntable lock is on turntable facing platform To dis engage lock pull snap pin from lock pin lift lock pin up to unlock turntable Return snap pin to lock pin to hold lock pin in the disengaged position Reverse procedure to engage turntable lock 11 Swing turntable to LEFT and RIGHT a minimum of 45 degrees Check for smooth motion 12 With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform con trol console manually activate the indicator light by compressing any one of the three tilt indicator mounting springs If the light does not illuminate shut down machine and contact a qualified service technician before continuing operation 13 Footswitch A IMPORTANT FOOTSWITCH MUST BE ADJ USTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL IF SWITCH OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJ USTED a Activate hydraulic system by depressing foot switch Operate TELESCOPE and hold control Remove foot from footswitch motion should stop If it does not shut down machine and con tact a certified LG service technician b With footswitch depressed operate LIFT
90. witch 4 Operate appropriate control switch lever or control ler for desired function and hold 5 Position the AUXILIARY POWER switch to ON and hold 6 Release the AUXILIARY POWER switch selected control switch lever or controller and footswitch 7 Position the EMERGENCY STOP switch to OFF To activate auxiliary power from the ground control sta tion l Position the platform ground SELECT SWITCH to GROUND 2 Position EMERGENCY STOP switch to ON 3 Operate appropriate control switch or controller for desired function and hold 4 Position the AUXILIARY POWER switch to ON and hold 5 Release the AUXILIARY POWER switch and appro priate control switch or controller 6 Position the EMERGENCY STOP switch to OFF Remote Control Box The remote control box is located behind the left rear access door on the turntable To use these controls the engine must be running and the SELECT SWITCH must be in the ground position 1 Pullthe POWER EMERGENCY STOP out LG Lift 2 To steer push the steer switch to the left or to the right 3 To drive push the drive switch to forward or reverse 4 The speed control switch controls the speed of the drive function Rotate the switch to increase or decrease the drive speed 6 4 EMERGENCY OPERATION Use of Ground Remote Controls KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION Ground personnel must be thoroughly familiar with th

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