Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY.
FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
FOREWORD REVISION LOG Original Issue d - July 4, 2014 – JLG Lift – 3121678
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1 Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection. . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.7 4.8 4.9 4.10 4.11 4.12 4.13 PAGE Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-10 Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NUMBER - TITLE 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 2-8. 3-1. 3-1. 3-2. 3-3. 3-4. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 6-1. 6-2. 3121678 PAGE FIGURE NUMBER - TITLE Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . 2-6 Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . 2-7 Daily Walk-Around Inspection - Sheet 1 of 2 . . . . . . . . . . 2-8 Daily Walk-Around Inspection - Sheet 2 of 2 . . . . . . . . . .
LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally.
LIST OF TABLES TABLE NUMBER - TITLE 1-1 1-2 2-1 4-1 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 7-1 3121678 PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3 Decal Location Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22 Operating Specifications . .
LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally.
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage.
SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. • Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. • Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection 1.3 • Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed. General • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations. • Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. Trip and Fall Hazards • During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. Electrocution Hazards • This machine is not insulated and does not provide protection from contact or proximity to electrical current. • Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) • Allow for machine movement and electrical line swaying.
SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier.
SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only). • Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ S). Table 1-2. Beaufort Scale (For Reference Only) 3121678 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 Calm Calm. Smoke rises vertically 1 1-3 0.3-1.5 Light air Wind motion visible in smoke 2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle Description Land Conditions 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 4 13-18 5.5-7.
SECTION 1 - SAFETY PRECAUTIONS • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. Crushing and Collision Hazards • Approved head gear must be worn by all operating and ground personnel. • Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.
SECTION 1 - SAFETY PRECAUTIONS 1.4 TOWING, LIFTING, AND HAULING 1.5 • Never allow personnel in platform while towing, lifting, or hauling. This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual.
SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid. • Do not use machine as a ground for welding. • When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. • Do not refuel the machine with the engine running. • Use only approved non-flammable cleaning solvents.
SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical components or when performing welding on the machine. • Do not allow smoking, open flame, or sparks near battery during charging or servicing. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Do not contact tools or other metal objects across the battery terminals.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121678
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, dropoffs. 2.1 PERSONNEL TRAINING The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Type Primary Responsibility Frequency Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 5. “Walk-Around” Inspection – Refer to Figure 2-3. and Figure 2-4. Pre-Start Inspection The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 7. Fuel (Combustion Engine Powered Machines) – Add the proper fuel as necessary. 2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3. With the platform in the transport (stowed) position: Function Check Perform the Function Check as follows: a. Drive the machine on a grade, not to exceed the rated gradeability, and stop to ensure the brakes hold; 1. From the ground control console with no load in the platform: b. Check the tilt sensor alarm to ensure proper operation. a. Check that all guards protecting the switches or locks are in place; b.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 14 13 12 14 8 3 6 10 7 11 13 12 4 5 9 2 8 3 6 10 7 4 5 1 2 1 Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. Steer Wheels Drive Wheels Lift Cylinder Tower Level Link Upright Base Boom Section Mid Boom Section Fly Boom Section Boom Assembly Power Track Jib (If Equipped) Platform Platform Console Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11 5 6 2 6 10 5 7 9 8 4 9 3 9 9 5 3 11 6 12 7 12 2 9 14 1 13 6 5 Figure 2-3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 5. Wheel/Tire Assemblies - No loose or missing lug nuts, 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 following checklist. proper inflation (pneumatic). Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion. 6.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES Figure 2-5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Item Description Operation Characteristic 1 Boom Capacity Length Switch Activates platform capacity light to indicate the platform capacity at a designated boom length. 2 Boom Extension Switch Reduces drive speed when boom reaches a designated length. 3 Boom Capacity Angle Switch Activates platform capacity light to indicate the platform capacity at a designated boom height.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-7.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-8.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.4 3. Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block. OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 4. Carefully activate Swing control lever and position boom over right side of machine. NOTE: 5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel. 9. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block. 10. With boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp. 12.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-16 – JLG Lift – 3121678
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 NOTE: GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. This section provides the necessary information needed to understand control functions. 3.2 CONTROLS AND INDICATORS NOTE: 3121678 All machines are equipped with control consoles that use symbols to indicate control functions.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel. The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. Ground Control Console (See Figure 3-1., Ground Control Console).
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Indicator Panel Telescope Swing Lift Platform/Ground Select Switch Hourmeter Power/Emergency Stop Engine Start/Auxiliary Power/Function Enable Platform Leveling Override Platform Rotate Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Swing Control NOTE: Provides 360 degrees continuous turntable rotation. When the Platform/Ground Select Switch is in the center position, power is shut off to the controls at both operating consoles. Remove the key to prevent the controls from being actuated. The key is removable in the platform position on CE specification machines. The key must be available to ground personnel in the event of an emergency. 5.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Hourmeter 8. Engine Start/ Auxiliary Power Switch /Function Enable. To start the engine, the switch must be held "Up" until the engine starts. Registers the amount of time the machine has been in use, with engine running. By connecting into the oil pressure circuit of the engine, only engine run hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Platform Rotate ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. Provides rotation of the platform. 9. Platform Leveling Override A three position switch allows the operator to adjust the automatic self leveling system.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Engine Oil Temperature Indicator (Deutz, If Equipped) Ground Control Indicator Panel (See Figure 3-1., Ground Control Indicator Panel.) Indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required. 1. No Alternator Output Indicator Indicates a problem in the charging circuit, and service is required. 5. Malfunction Indicator 2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 3-8 No Alternator Output 4. Engine Oil Temp. 7. Platform Overload Engine Oil Pressure 5. Malfunction Indicator 8. Drive and Steer Disable Engine Water Temp. 6. Glow Plug/Wait to Start Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Platform Overload Indicator. (If Equipped) Platform Console Indicates the platform has been overloaded. (See Figure 3-2., Platform Console) 8. Drive and Steer Disable Indicator (If equipped) Indicates the Drive and Steer Disable function has been activated. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. 1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Steer Select (If Equipped) When equipped with four wheel steering, the action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is for normal driving at maximum speeds. The forward position is for “crab” steering. When in this mode both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 3121678 Drive Speed / Torque Select Steer Select Platform Level Override Horn 5. 6. 7. 8. Power/Emergency Stop 9. Drive/Steer Engine Start / Aux Power 10. Telescope Fuel Select 11. Lights Drive Orientation Override 12. Soft Touch Override Figure 3-2. Platform Console – JLG Lift – 13. 14. 15. 16.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Engine Start/Auxiliary Power 8. Drive Orientation Override When pushed forward, the switch energizes the starter motor to start the engine. The Auxiliary Power control switch energizes the electrically operated hydraulic pump. (Switch must be held on for duration of auxiliary pump use.) The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) position when released. 10. Main Boom Telescope Provides extension and retraction of the main boom. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 14. Platform Rotate Provides rotation of the platform when positioned to the right or left. NOTE: MAIN LIFT, SWING, and DRIVE control levers are spring-loaded and will automatically return to neutral (OFF) position when released. NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. 16.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Capacity Indicator Platform Control Indicator Panel Indicates the maximum platform capacity for the current position of the platform. Restricted capacities are permitted at restricted platform positions (shorter boom lengths and higher boom angles). (See Figure 3-3., Platform Control Indicator Panel) 1. Level System Fault Indicator Indicates a fault in the electronic leveling system. The fault indicator will flash and an alarm sound.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Tilt Alarm Warning Light and Alarm 7. Footswitch/Enable Indicator This illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 2 3 * 4 ! 12 5 6 7 10 9 8 !! ** 11 * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. 2. 3. 4. 3121678 Level System 5. Tilt Alarm Warning 9. Creep Speed AC Generator 6. Glow Plug 10. System Distress Overload 7. Enable 11. Cable Service Capacity 8. Fuel Level 12. Drive Orientation Figure 3-3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more detailed information concerning the Low Fuel Indicator. 9. Creep Speed Indicator When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. 8. Fuel Level Indicator Indicates the level of fuel in the fuel tank. 10.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (i.e. controls reversed situations).
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-20 – JLG Lift – 3121678
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom. The primary operator control console is in the platform. From this control console, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the boom to the left or right.
SECTION 4 - MACHINE OPERATION 1. Turn key of Platform/Ground Select switch to Ground. TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE. 4.3 NOTE: 2. Pull the Power/Emergency Stop switch to On. ENGINE OPERATION Initial starting should always be performed from the Ground Control console. 3. Push the Engine Start switch until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.
SECTION 4 - MACHINE OPERATION 3. Turn Platform/Ground Select switch to Off. 6. From Platform, pull Power/Emergency Stop switch out. Refer to Engine Manufacturer’s manual for detailed information. 7. Push the Engine Start switch until engine starts. Fuel Reserve / Shut-Off System NOTE: NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.
SECTION 4 - MACHINE OPERATION After the 2 minute run time is complete or if the engine is shut down by the operator prior to the completion of the 2 minute run time, it cannot be restarted until fuel is added to the tank. . • Engine Restart - When the engine shuts down, the operator will be permitted to cycle power and restart the engine for approximately 2 minutes of run time.
SECTION 4 - MACHINE OPERATION TELESCOPE FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-2.
SECTION 4 - MACHINE OPERATION 4.4 TRAVELING (DRIVING) NOTE: When the upper boom is raised approximately 11 degrees above horizontal, the high drive function will automatically be in low drive. NOTE: Refer to the Operating Specifications table for Gradeability and Sideslope ratings. DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.
SECTION 4 - MACHINE OPERATION 1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel. Traveling Forward and Reverse 1. At Platform Controls, pull out Emergency Stop switch and activate footswitch. 2. Position Drive controller to FORWARD or REVERSE as desired. This machine is equipped with a Drive Orientation Indicator.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION 4.6 PLATFORM 4.7 BOOM Platform Level Adjustment DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.
SECTION 4 - MACHINE OPERATION Swinging the Boom Telescoping the Main Boom To swing boom, use Swing control switch to select Right or Left direction. To extend or retract the boom, use the Telescope Control Switch to select In or Out movement. WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT. NOTE: 4.8 This control affects the speed of all boom functions and Platform Rotate.
SECTION 4 - MACHINE OPERATION 4.10 EMERGENCY TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) MAXIMUM TOWING GRADE 25%. DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED. 1. Retract, lower and position boom in travel position; lock turntable. 2.
SECTION 4 - MACHINE OPERATION 4.11 TOW BAR (IF EQUIPPED) . RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) MAXIMUM TOWING GRADE 25%. Prior to towing the machine, complete the following: DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED. 1.
SECTION 4 - MACHINE OPERATION After towing the machine, complete the following: 1. Actuate steer/tow selector valve for steering; push valve knob IN to the actuated position. 2. Reconnect drive hubs by inverting disconnect cap. 3. Disconnect towbar from towing vehicle and place it in the stowed position as shown below. The machine is now in the driving mode.
SECTION 4 - MACHINE OPERATION 4.12 SHUT DOWN AND PARK 4.13 LIFTING AND TIE DOWN To shut down and park the machine, the procedures are as follows: Lifting 2. Ensure boom is lowered over rear drive axle. 1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find out the Gross Vehicle Weight. 3. Push in the Emergency Stop at Platform Controls. 2. Place the boom in the stowed position. 4. Push in the Emergency Stop at Ground Controls.
SECTION 4 - MACHINE OPERATION Tie Down DRIVE AND STEER CONTROLLERS WILL BE REVERSED WHEN THE BOOM IS POSITIONED OVER THE FRONT WHEELS. WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. 1. Remove all loose items from the machine. 2. When transporting an 800S/860SJ a step-deck or singledrop trailer is required. To avoid damage to the platform and to obtain proper weight distribution, load the machine onto the trailer as follows; c.
SECTION 4 - MACHINE OPERATION Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION Figure 4-7.
SECTION 4 - MACHINE OPERATION Figure 4-8.
SECTION 4 - MACHINE OPERATION Figure 4-9.
SECTION 4 - MACHINE OPERATION Figure 4-10.
SECTION 4 - MACHINE OPERATION Table 4-1. Decal Location Legend Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1. Decal Location Legend 3121678 Table 4-1.
SECTION 4 - MACHINE OPERATION NOTES: 4-24 – JLG Lift – 3121678
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 5.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead 5.4 If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine. EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-1. Operating Specifications Gross Machine Weight (Platform Empty) Specifications and Performance Data 32675 lbs. (14,821 kg) Table 6-2. Specifications and Performance Data * With boom in stowed position Swing Tail Swing Platform Overall Width 4’8" (1.42 m) 48" x 160" (1.22 m x 4.06m) 8’ 2" (2.5 m) Stowed Height 9’ 10" (2.97 m) Stowed Length 38’ 5" (11.72 m) Wheel base 10’ 1" (3.1 m) Ground Clearance 12.4" (0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Data Table 6-3. Capacities Fuel Tank Fuel Tank (Optional) Hydraulic Tank Engine Oil Capacity Deutz D2011L04 Cooling System Crankcase Total Capacity Deutz TD 2.9L GM Table 6-4. Deutz D2011L04 Specifications Approx. 31 gallons (117 liters) Type Liquid Cooled (Oil) Approx. 52.8 gallons (200 liters) Fuel Diesel Approx. 21 gallons (79.5 liters) 5 Quarts (4.5 L) 11 Quarts (10.5 L) w/Filter 16 Quarts (15 L) 2.4 Gallon (8.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-5. Deutz TD 2.9 Specifications Fuel Table 6-6. GM 3.0L Ultra Low Sulfur Diesel (15 ppm) Output 67 hp (50 kW) Torque 173 ft.lbs. (234 Nm) @ 1800rpm Oil Capacity (Crankcase) Cooling System 2.4 Gallon (8.9 L) w/Filter 3.3 Gallon (12.5 L) Low RPM 1200 ±50 rpm High RPM 2600±50 rpm Alternator 95 Amp Fuel Consumption 0.65 GPH (2.48 lph) Fuel No. of Cylinders BHP Gasoline LP 4 83 hp @ 3000 rpm 75 hp @ 3000 rpm Bore 4.0 in. (101.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Battery Tires Table 6-7. Battery Specifications Table 6-8.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Major Component Weights Hydraulic Oil Table 6-9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations. Table 6-11. Mobilfluid 424 Specs SAE Grade 10W30 Gravity, API 29.0 Density, Lb/Gal. 60°F 7.35 Pour Point, Max -46°F (-43°C) Flash Point, Min.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-14. Mobil EAL 224H Specs Table 6-13. Mobil DTE 13M Specs ISO Viscosity Grade #32 Specific Gravity 0.877 Pour Point, Max -40°F (-40°C) Flash Point, Min. 330°F (166°C) Viscosity at 40° C 33cSt at 100° C 6.6 cSt at 100° F 169 SUS Synthetic Biodegradable 32/46 Specific Gravity .922 Pour Point, Max -25°F (-32°C) Flash Point, Min. 428°F (220°C) Operating Temp. 0 to 180°F (-17 to 162°C) Weight 7.64 lb. per gal. (0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 Table 6-15. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame. 217°F (103°C) Viscosity NOTE: at 40° C 25.8 cSt at 100° C 9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120°F(49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F(43°C) 100°F(38°C) 90°F(32°C) ENGINE SPECIFICATIONS SUMMER GRADE FUEL 80°F(27°C) 70°F(21°C) 60°F(16°C) 50°F(10°C) 40°F(4°C) 30°F(-1°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82°C) OR ABOVE. 180° F (82° C) (HYD. OIL TANK TEMP.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 110 F(43 C) 100 F(38 C) 90 F(32 C) 80 F(27 C) ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180°F (82° C) OR ABOVE. 180° F(82° C) (HYD. OIL TANK TEMP.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 1. Swing Bearing - Internal Ball Bearing MAINTENANCE AND LUBRICATION NOTE: The following numbers correspond to those in Figure 6-6., Maintenance and Lubrication Diagram. Table 6-16. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Bearings 3. Wheel Drive Hub Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation 6-16 Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.5 L) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 5. Hydraulic Charge Filter 4. Hydraulic Return Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 3121678 – JLG Lift – Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator (if equipped).
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank 7. Platform Filter Lube Point(s) - Fill Cap Capacity - 116 liters Tank 124 liters System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Deutz B. Oil Change w/Filter - Deutz TD2.9 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts(10.5 L) Crankcase; Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual. 3121678 – JLG Lift – Lube Point(s) - Fill Cap/Spin-on Element Capacity - 9.6 Quarts (9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL LEVEL MINIMUM LEVEL OIL HOT MAXIMUM LEVEL OIL HOT MINIMUM LEVEL OIL COLD MAXIMUM LEVEL OIL COLD MAXIMUM OIL LEVEL NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 6-7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Fuel Filter - Deutz D2011 9. Oil Change w/Filter - GM Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Fuel Filter - Deutz TD2.9 (On Hydraulic Tank) C. Fuel Filter - Deutz TD2.9 (On Engine) Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual 11.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Air Filter B. Air Filter (Deutz TD 2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 13. Fuel Filter (Propane) - GM Engine 6.5 TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.6, Propane Fuel Filter Replacement 6-24 For pneumatic tires, JLG Industries, Inc.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly. Tire Replacement • a smooth, even cut through the cord plies which exceeds 3 inches (7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability. It is extremely important to apply and maintain proper wheel mounting torque.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. Table 6-17. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 70 ft. lbs. (95 Nm) 170 ft. lbs. (225 Nm) 300 ft. lbs. (405 Nm) 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.6 PROPANE FUEL FILTER REPLACEMENT Installation Removal 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 2. Disconnect the negative battery cable. 1. Install the mounting plate to lock off O-ring seal. 3. Slowly loosen the Filter housing and remove it. 2. If equipped, install the retaining bolt seal. 4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS. To relieve propane fuel system pressure: 1. Close the manual shut-off valve on the propane fuel tank. 2. Start and run the vehicle until the engine stalls. 3.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.8 SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines.
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
TRANSFER OF OWNERSHIP Title:____________________________________________________________________ Name: ___________________________________________________________________________ Who in your organization should we notify? Country: _____________________________ Telephone: (_______) ________________________ _________________________________________________________________________________ Address: _________________________________________________________________________ Current Owner: __________________
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng.
