Operation and Safety Manual

Keep this manual with the machine at all times.

LIFTLUX Model 245-12D

P/N - 3121312 September 13, 2006

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.

3121312 – JLG Lift – a 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 INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY WILL HAVE A RED BACKGROUND. ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.

b – JLG Lift – 3121312 FOREWORD

For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- • Accident Reporting • Standards and Regulations Compliance Information TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions • Questions Regarding Spe- RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS cial Product Applications PRODUCT. • Current Owner Updates • Questions Regarding Prod- • Questions Regarding uct Modifications IMPORTANT Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE Contact: OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE Product Safety and Reliability Department UPDATED AND ACCURATE. JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233 IMPORTANT JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL or Your Local JLG Office INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN (See addresses on inside of manual cover) ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL In USA: PROPERTY OR THE JLG PRODUCT. Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 717-485-5161 E-mail: [email protected]

3121312 – JLG Lift – c FOREWORD REVISION LOG

Original Issue - September 13, 2006

d – JLG Lift – 3121312 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS 2.2 PREPARATION, INSPECTION, AND 1.1 GENERAL ...... 1-1 MAINTENANCE...... 2-2 1.2 PRE-OPERATION ...... 1-1 2.3 PRE-START INSPECTION...... 2-4 Operator Training and Knowledge...... 1-1 2.4 FUNCTION CHECK...... 2-5 Workplace Inspection...... 1-2 2.5 WALK-AROUND INSPECTION ...... 2-10 Machine Inspection ...... 1-3 GENERAL ...... 2-12 1.3 OPERATION ...... 1-3 General ...... 1-3 SECTION - 3 - MACHINE CONTROLS AND INDICATORS Trip and Fall Hazards ...... 1-4 3.1 GENERAL ...... 3-1 Electrocution Hazards ...... 1-5 3.2 CONTROLS AND INDICATORS ...... 3-1 Tipping Hazards ...... 1-7 Engine Control...... 3-1 Crushing and Collision Hazards...... 1-8 Ground Control Console...... 3-2 1.4 TOWING, LIFTING, AND HAULING ...... 1-9 Platform Ground Control Station...... 3-3 1.5 MAINTENANCE ...... 1-10 Platform Control Station ...... 3-5 General ...... 1-10 Platform LED Panel ...... 3-8 Maintenance Hazards...... 1-10 Battery Hazards ...... 1-11 SECTION - 4 - MACHINE OPERATION 4.1 DESCRIPTION...... 4-1 SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA- Description Of The Work Platform ...... 4-1 RATION AND INSPECTION General Description of the Functions and 2.1 PERSONNEL TRAINING ...... 2-1 Components...... 4-1 Operator Training ...... 2-1 Load Sensing System (LSS) ...... 4-1 Training Supervision...... 2-1 4.2 OPERATION ...... 4-2 Operator Responsibility ...... 2-1 Lifting and Lowering ...... 4-3 Automatic Self Leveling...... 4-3

3121312 – JLG Lift – i TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Driving The Machine From The Platform...... 4-4 SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR Steering ...... 4-6 MAINTENANCE 4.3 MANUAL PLATFORM EXTENSION ...... 4-6 6.1 INTRODUCTION...... 6-1 Platform Extension Lock Removal...... 4-6 6.2 OPERATING SPECIFICATIONS ...... 6-1 Platform Extension ...... 4-7 6.3 CAPACITIES ...... 6-2 4.4 EMERGENCY LOWERING - MANUAL DESCENT . 4-9 Batteries ...... 6-2 4.5 PARKING AND STOWING ...... 4-12 Lubrication ...... 6-3 4.6 LIFT/TIE DOWN LUGS...... 4-13 6.4 OPERATOR MAINTENANCE ...... 6-6 Lifting ...... 4-13 6.5 TIRES AND WHEELS ...... 6-13 Tie Down ...... 4-14 Tire Wear and Damage...... 6-13 4.7 TRANSPORT AND STORAGE OF THE MACHINE 4-15 Wheel and Tire Replacement ...... 6-13 Wheel Installation ...... 6-13 SECTION - 5 - EMERGENCY PROCEDURES 6.6 LOAD SENSING SYSTEM VERIFICATION ...... 6-14 5.1 GENERAL ...... 5-1 Emergency Stop Switch ...... 5-1 SECTION - 7 - INSPECTION AND REPAIR LOG Platform Caught Overhead ...... 5-1 Righting of Tipped Machine...... 5-1 Post-Incident Inspection ...... 5-1 5.2 EMERGENCY OPERATION...... 5-2 Use of Ground Controls...... 5-2 Operator Unable to Control Machine ...... 5-2 Incident Notification ...... 5-2

ii – JLG Lift – 3121312 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

LIST OF FIGURES LIST OF TABLES 2-1. Limit Switch Locations - Sheet 1 of 2...... 2-8 1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . 1-6 2-2. Limit Switch Locations - Sheet 2 of 2...... 2-9 2-1 Inspection and Maintenance Table...... 2-3 2-3. Walk - Around Inspection Diagram (Sheet 1 of 4).2-10 2-2 Cutout Switch Limits ...... 2-7 2-4. Walk - Around Inspection Diagram (Sheet 2 of 4).2-11 4-1 Decal Listing ...... 4-19 2-5. Walk - Around Inspection Points (Sheet 3 of 4). . .2-12 6-1 Operating Specifications...... 6-1 2-6. Walk - Around Inspection Points (Sheet 4 of 4). . .2-13 6-2 Capacities ...... 6-2 3-1. Engine Control ...... 3-1 6-3 Battery Specifications ...... 6-2 3-2. Ground Control Console ...... 3-2 6-4 Hydraulic Oil ...... 6-3 3-3. Platform Ground Control ...... 3-4 6-5 Mobilfluid 424 Specs...... 6-3 3-4. Platform Control Station...... 3-7 6-6 Lubrication Specifications...... 6-7 3-5. Platform LED Panel ...... 3-8 6-7 Wheel Torque Chart ...... 6-14 4-1. Grade and Sideslope ...... 4-5 7-1 Inspection and Repair Log ...... 7-1 4-2. Lifting Lugs Location ...... 4-13 4-3. Tie Down Lugs Location ...... 4-14 4-4. Decal Location - Sheet 1 of 3...... 4-16 4-5. Decal Location - Sheet 2 of 3...... 4-17 4-6. Decal Location - Sheet 3 of 3...... 4-18 6-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2...... 6-4 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2...... 6-5 6-3. Operator Maintenance & Lubrication Diagram . . . .6-6

3121312 – JLG Lift – iii TABLE OF CONTENTS

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iv – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL

This section outlines the necessary precautions for proper FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN and safe machine usage and maintenance. In order to pro- THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY mote proper machine usage, it is mandatory that a daily rou- DAMAGE, PERSONAL INJURY OR DEATH. tine is established based on the content of this manual. A maintenance program, using the information provided in this 1.2 PRE-OPERATION manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to Operator Training and Knowledge ensure that the machine is safe to operate. • The Operators and Safety Manual must be read and The owner/user/operator/lessor/lessee of the machine understood in its entirety before operating the machine. should not accept operating responsibility until this manual For clarification, questions, or additional information has been read, training is accomplished, and operation of regarding any portions of this manual, contact JLG Indus- the machine has been completed under the supervision of tries, Inc. an experienced and qualified operator. These sections contain the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation.If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

3121312 – JLG Lift – 1-1 SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities Workplace Inspection until adequate training has been given by competent and authorized persons. • Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine. • Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they • Do not operate or raise the platform from a position on understand the safe and proper operation and mainte- trucks, trailers, railway cars, floating vessels, scaffolds or nance of the unit. other equipment unless the application is approved in writing by JLG. • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine • Before operation, check work area for overhead hazards and in this manual. such as electric lines, bridge cranes, and other potential overhead obstructions. • Ensure that the machine is to be used in a manner which is within the scope of its intended application as deter- • Check floor surfaces for holes, bumps, drop-offs, obstruc- mined by JLG. tions, debris, concealed holes, and other potential hazards. • All operating personnel must be familiar with the emergency controls and emergency operation of the machine • Check the work area for hazardous locations. Do not as specified in this manual. operate the machine in hazardous environments unless approved for that purpose by JLG. • Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to • Ensure that the ground conditions are adequate to sup- your utilization and application of the machine. port the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. • Do not operate the machine when wind conditions exceed values specified in Section 6.2 of this manual.

1-2 – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS

• This machine can be operated in nominal ambient tem- • Avoid accumulation of debris on platform deck. Keep peratures of -15°C to 45°C (5°F to 113°F). Consult JLG to mud, oil, grease, and other slippery substances from foot- optimize operation outside of this temperature range. wear and platform deck. Machine Inspection • Do not operate this machine until the inspections and 1.3 OPERATION functional checks have been performed as specified in Section 2 of this manual. General • Do not operate this machine until it has been serviced and • Do not use the machine for any purpose other than posi- maintained according to the maintenance and inspection tioning personnel, their tools, and equipment. requirements as specified in the machine’s Service and • Before operation, the user must be familiar with the Maintenance Manual. machine capabilities and operating characteristics of all • Ensure all safety devices are operating properly. Modifica- functions. tion of these devices is a safety violation. • Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM • Do not remove, modify, or disable any safety devices. SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER • Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and • Do not operate any machine on which the safety or stop before moving the switch to the next function. Oper- instruction placards or decals are missing or illegible. ate controls with slow and even pressure. • Check the machine for modifications to original compo- • Do not allow personnel to tamper with or operate the nents. Ensure that any modifications have been approved machine from the ground with personnel in the platform, by JLG. except in an emergency.

3121312 – JLG Lift – 1-3 SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless Trip and Fall Hazards approved by JLG. • JLG Industries, Inc. recommends that all persons in the • When two or more persons are in the platform, the opera- platform wear a full body harness with a lanyard attached tor shall be responsible for all machine operations. to an authorized lanyard anchorage point while operating • Always ensure that power tools are properly stowed and this machine. For further information regarding fall protec- never left hanging by their cord from the platform work tion requirements on JLG products, contact JLG Indus- area. tries, Inc. • Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs. • Stow scissor arm assembly and shut off all power before leaving machine.

• Prior to operation, ensure all gates and rails are fastened and secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. Attach only one (1) lanyard per lanyard anchorage point

1-4 – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS

. Electrocution Hazards • This machine is not insulated and does not provide protection from contact with an electrically charged conduc- tor.

• 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. • Never use the scissor arm assembly to gain access to or leave the platform. • Use extreme caution when entering or leaving platform. Ensure that the scissor arm assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. • Keep oil, mud, and slippery substances cleaned from foot- wear and the platform floor.

3121312 – JLG Lift – 1-5 SECTION 1 - SAFETY PRECAUTIONS

Table 1-1.Minimum Safe Approach Distances (M.S.A.D.)

MINIMUM SAFE APPROACH Voltage Range DISTANCE (Phase to Phase) in Meters (Feet) 0 to 50KV 3 (10) Over 50V to 200 KV 5 (15) Over 200KV to 350 KV 6 (20) Over 350 KV to 500 KV 8 (25) Over 500 KV to 750 KV 11 (35) • Maintain safe clearance from electrical lines, apparatus, or Over 750 KV to 1000 KV 14 (45) any energized (exposed or insulated) parts in accordance with the Minimum Safe Approach Distance (MSAD) as NOTE: This requirement shall apply except where specified in Table 1-1. Allow for machine movement and employer, local or governmental regulations electrical line swaying. are more stringent.

• Maintain a clearance of at least 3m (10 ft) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. • The minimum safe 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

1-6 – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS

machine. The minimum safe approach distance shall be . reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MSAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. Tipping Hazards

• Ensure that the ground conditions are adequate to sup- • Do not elevate platform or drive with platform elevated port the maximum tire load indicated on the tire load while on or near a sloping, uneven, or soft surface. Ensure decals located on the chassis adjacent to each wheel. Do machine is positioned on a firm, uniform surface before not travel on unsupported surfaces. elevating platform or driving with the platform in the ele- • The user should be familiar with the driving surface before vated position. driving. Do not exceed the allowable sideslope and grade • Before driving on floors, bridges, trucks, and other sur- while driving faces, check allowable capacity of the surfaces. • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis of the machine a minimum of 0.6 m (2 ft) from holes, bumps, drop-offs, obstructions, debris, con-

3121312 – JLG Lift – 1-7 SECTION 1 - SAFETY PRECAUTIONS

cealed holes, and other potential hazards at the ground • Watch for obstructions around machine and overhead level. when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform. • Never attempt to use the machine as a crane. Do not tie- off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. • Do not operate the machine when wind conditions exceed the maximum allowable wind speed. • Do not cover the platform sides or carry large surface-area items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the machine. • Do not increase the platform size with unauthorized deck extensions or attachments. • If scissor arm assembly or platform is caught so that one • During operation, keep all body parts inside platform rail- or more wheels are off the ground, all persons must be ing. removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to • Always post a lookout when driving in areas where vision stabilize machine and remove personnel. is obstructed. Crushing and Collision Hazards • Keep non-operating personnel at least 1.8 m (6 ft) away from machine during all driving operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel. speed according to conditions of ground surface, conges- • Keep hands and limbs out of the scissor arm assembly tion, visibility, slope, location of personnel, and other fac- during operation. tors causing hazards of collision or injury to personnel.

1-8 – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS

• Be aware of stopping distances in all drive speeds. When 1.4 TOWING, LIFTING, AND HAULING driving in high speed, switch to low speed before stopping. Travel grades in low speed only. • Never allow personnel in platform while towing, lifting, or hauling. • Do not use high speed drive in restricted or close quarters or when driving in reverse. • This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unload- • Exercise extreme caution at all times to prevent obstacles ing. Refer to emergency towing procedures. from striking or interfering with operating controls and persons in the platform. • Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling. • Ensure that operators of other overhead and floor level machines are aware of the aerial work platform’s pres- • When lifting machine with a forklift, position forks only at ence. Disconnect power to overhead cranes. Barricade designated areas of the machine. Lift with a forklift of ade- floor area if necessary. quate capacity. • Avoid operating over ground personnel. Warn personnel • Refer to Section 4 for lifting information. not to work, stand, or walk under a raised platform. Posi- tion barricades on floor as necessary.

3121312 – JLG Lift – 1-9 SECTION 1 - SAFETY PRECAUTIONS

1.5 MAINTENANCE • Always disconnect batteries when servicing electrical components or when performing welding on the machine. General • Shut down the engine (if equipped) while fuel tanks are being filled. This section contains general safety precautions which must be • Ensure replacement parts or components are identical or observed during maintenance of this machine. Additional pre- equivalent to original parts or components. cautions to be observed during machine maintenance are inserted at the appropriate points in this maunual and in the Ser- • Never attempt to move heavy parts without the aid of a vice and Maintenance Manual. It is of utmost importance that mechanical device. Do not allow heavy objects to rest in maintenance personnel pay strict attention to these precautions an unstable position. Ensure adequate support is pro- to avoid possible injury to personnel or damage to the machine vided when raising components of the machine. or property. A maintenance program must be established by a • Remove all rings, watches, and jewelry when performing qualified person and must be followed to ensure that the any maintenance. Do not wear loose fitting clothing or machine is safe. long hair unrestrained which may become caught or Maintenance Hazards entangled in equipment. • Use only clean approved non-flammable cleaing solvents. • Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to per- • Never alter, remove, or substitute any items such as coun- forming any adjustments or repairs. terweights, tires, batteries, platforms or other items that may reduce or affect the overall weight or stability of the • Never work under an elevated platform until it has been machine. fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with • Reference the Service and Maintenance Manual for the appropriate safety props, blocking, or overhead supports. weights of critical stability items. • Always relieve hydraulic pressure from all hydraulic cir- cuits before loosening or removing hydraulic components.

1-10 – JLG Lift – 3121312 SECTION 1 - SAFETY PRECAUTIONS

• Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER. 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. • Do not contact tools or other metal objects across the battery terminals. • Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.

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.

• Charge batteries only in a well ventilated area.

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1-12 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obsta- The aerial platform is a personnel handling device; so it is cles, depressions, holes, drop-offs. necessary that it be operated and maintained only by trained 7. Means to avoid the hazards of unprotected electrical personnel. conductors. Persons under the influence of drugs or alcohol or who are 8. Specific job requirements or machine application. subject to seizures, dizziness or loss of physical control must not operate this machine. Training Supervision Operator Training Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee Operator training must cover: has developed the ability to safely control and operate the 1. Use and limitations of the controls in the platform and at machine. the ground, emergency controls and safety systems. Operator Responsibility 2. Control labels, instructions, and warnings on the machine. The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a 3. Rules of the employer and government regulations. malfunction or other unsafe condition of either the machine 4. Use of approved fall protection equipment. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.

3121312 – JLG Lift – 2-1 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.2 PREPARATION, INSPECTION, AND IMPORTANT MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- and maintenance recommended by JLG Industries, Inc. UCT MODEL. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

2-2 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Primary Service Type Frequency Reference Responsibility Qualification Before using each day; or User or Operator User or Operator Operator and Safety Manual Pre-Start Inspection whenever there’s an Operator change. Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Pre-Delivery Inspection Manual and applicable JLG (See Note) inspection form In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance ever comes first; or Manual and applicable JLG Frequent Inspection Out of service for a period of more than 3 inspection form months; or Purchased used. Semi annually Owner, Dealer, or User Factory Certified Service Operator and Safety Manual Load Sensing System Technician Verification (Recommended) Annually, no later than 13 months from the Owner, Dealer, or User Factory Certified Service Service and Maintenance Annual Machine date of prior inspection. Technician Manual and applicable JLG Inspection (See Note) (Recommended) inspection form Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Maintenance Maintenance Manual. Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

3121312 – JLG Lift – 2-3 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.3 PRE-START INSPECTION 4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual is enclosed in the The Pre-Start Inspection should include each of the follow- weather resistant storage container. ing: 5. “Walk-Around” Inspection – Refer to Figure 2-3. to Fig- 1. Cleanliness – Check all surfaces for leakage (oil, fuel, ure 2-6. or battery fluid) or foreign objects. Report any leakage to 6. Battery – Charge as required. the proper maintenance personnel. 7. Fuel - (Combustion Engine Powered Machines) – Add 2. Structure - Inspect the machine structure for dents, the proper fuel as necessary. damage, weld or parent metal cracks or other discrep- encies. 8. Fluid Levels - Be sure to check the hydraulic oil level. 9. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions. 10. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in Parent Metal Crack Weld Crack an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions on the operation of each function. 3. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

2-4 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.4 FUNCTION CHECK d. Ensure that all LED’s in the control box are working properly. Perform the Function Check as follows: e. Check that the platform extension extends and 1. From the ground emergency control panel with no load retracts properly. in the platform: f. With the platform in the transport (stowed) position: a. Check that all guards protecting the function control •Drive the machine on a level surface and stop to switches and locks are in place. ensure the brakes hold. b. Check manual descent. •To ensure proper operation of the tilt sensor, drive c. Ensure that all machine functions are disabled the machine onto a slope greater than the preset when the Emergency Stop Button is activated. 1° and attempt to lift. The tilt LED should be out when the 1° is exceeded. NOTE: Be sure the platform extension is retracted before lower- •Check wheel alignment indicator by visually ing. aligning the wheels and verify indicator lights on the platform control box are lit. Also, check that d. Check for proper lifting and lowering of the plat- lift up is allowed beyond 4 m (13.1 m) when form. wheels are aligned with the chassis. Check that 2. From the platform control console: the lifing function is disabled above 4 m (13.1 ft) when wheels are not aligned with the chassis. a. Ensure that the control console is firmly secured in the proper location. b. Check that all guards protecting the switches are in place. c. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in.

3121312 – JLG Lift – 2-5 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

3. Limit Switches: a. Outriggers: NOTE: Check that all limit switches are functioning properly: •Outriggers Selected - Senses ground contact for all outriggers then enables lift up. If the available indoor height is not suitable to perform the •Outriggers Not Selected - Senses when all outrig- limit switch checks, they may be performed outdoors pro- gers are retracted and enables drive. vided the following precautions are observed. b. Steering - Senses when wheels are in line < 3° from straight. Enables lift up above 4 m (13.1 ft) platform •Machine is positioned on a firm level surface. height and enables drive above 4 m platform height •The platform is empty (no personnel or materials). with wheels straight. Also illuminates LEDs at con- •The platform control box is plugged in at the distribu- sole when in line. tion terminal at the chassis. c. Pot Hole Protection: •The operator maintains a safe distance from the •Pot Hole Protection Down - Senses when pothole machine. protection is down and permits drive above 4 m (13.1 ft) platform height. •The machine is not elevated in winds that exceed 9 m/sec (20 mph). •Pot Hole Protection Up - Senses when pothole protection is retracted. d. Platform Fully Lowered - Senses when platform is fully lowered. Enables jacks retract (select by reset- ting lift button when fully lowerd and continue to lift down) and re-enables drive function. Only when jacks are selected. e. Fast Drive Height - Senses at +/- 3.7 m (12.1 ft) platform height and interlock fast drive speed. Interlock cuts out drive and lift if tilted (tilt switch tripped). Also indicates lift available LED at console.

2-6 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

f. Max Steer Height - Senses 4 m platform and inter- . lock lift if wheels are not stratight. Above this Table 2-2. Cutout Switch Limits height, rear wheel steering is prevented. g. Max Drive Height - Senses max drive height at 18 m Limit and Cutout Switch Limit platform height and interlock drive function. Also High Drive Cutout 3.7 m (12.1 ft) indicates lift available LED at console. Maximum Drive Height 18 m (59.1 ft) h. Max Platform Height - Senses max platform height Tilt Sensor Setting 1° 24.5 m and stops lift up. Also indicates lift available LED at console Maximum Height 24.5 m (80.4 ft) Minimum Height 0 m Outrigger Interlock drive cut out when outriggers activated; lift cut out when not level Pot Hole Protection allows drive above 4 m (13.1 ft) when deployed LSS senses when platform is overloaded;cuts all movements

3121312 – JLG Lift – 2-7 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

5 1 1. Platform Fully Lowered Limit Switch 2. Fast Drive Limit Switch 2 4 3. Max Steer Height Limit Switch 3 6 4. Max Drive Height Limit Switch 5. Max Platform Height Limit Switch 6. Outriggers Limit Switch (all 4 outriggers) 7 7. Tilt Sensor

Figure 2-1. Limit Switch Locations - Sheet 1 of 2

2-8 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

8. Pot Hole Limit Switch 9. Steering Limit Switch

8 Figure 2-2. Limit Switch Locations - Sheet 2 of 2

3121312 – JLG Lift – 2-9 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2.5 WALK-AROUND INSPECTION

Figure 2-3. Walk - Around Inspection Diagram (Sheet 1 of 4)

2-10 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

2,3 2,3

4 4 5 13 12 14 5 Figure 2-4. Walk - Around Inspection Diagram (Sheet 2 of 4)

3121312 – JLG Lift – 2-11 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

GENERAL 1. Platform Control Console (Not Shown) - Placard secure and legible, joystick and trigger switch return Begin the “Walk-Around Inspection” at Item 1, as noted on to neutral, joystick detent and emergency stop switch the diagram. Continue to the right (counterclockwise function properly, operation and safety manual in stor- viewed from top) checking each item in sequence for the age box. conditions listed in the “Walk-Around Inspection Check- list”. 2. Tie Rod and Spindle - See Note 3. Steer Cylinder - See Note 4. Drive Motors - No unsupported hoses; No signs of TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” leakage. DURING “WALK-AROUND INSPECTION”. 5. Wheels and Tires - Properly secured, no missing lug nuts. See section 6, Tires and Wheels. Inspect wheels IMPORTANT for damage and corrosion. DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. 6. Ground Controls - Placard secure and legible, control CHECKING THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDI- switches return to neutral position, emergency stop TIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE. switch functions properly.

NOTE: On each item, make sure there are no loose or missing 7. Battery Compartment - See Note parts, that they are securely fastened, and that no visi- 8. Engine Control Box - Placard secure and legible, con- ble damage exists in addition to any other criteria men- trol buttons return to neutral position, hourmeter func- tioned. tions properly. 9. Valve Tray Area - No unsupported wires or hoses; no damaged or broken wires. No signs of leakage.

Figure 2-5. Walk - Around Inspection Points (Sheet 3 of 4)

2-12 – JLG Lift – 3121312 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

10. Scissor Arms and Sliding Wear Pads (Not Shown) - 13. Hydraulic Pump Motors - See Note See Note 14. Lift Cylinder - See Note 11. Platform/Handrail Installation (Not Shown) - See Note 12. Hydraulic Reservoir - Recommended hydraulic fluid level on level indicator on tank. Breather cap secure and working.

Figure 2-6. Walk - Around Inspection Points (Sheet 4 of 4)

3121312 – JLG Lift – 2-13 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION

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2-14 – JLG Lift – 3121312 SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL

ehbelectronics IMPORTANT THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE 1

RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. Vertragshandler

This section provides the necessary information needed to understand control functions. 3 2

3.2 CONTROLS AND INDICATORS Start Engine Control

1. Start Assist 3. Hourmeter DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON- NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. 2. Engine Start PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE. Figure 3-1. Engine Control

3121312 – JLG Lift – 3-1 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Start Assist - This push button is used to help assist starting the machine in cold temperatures. (overrides 6 second crank limit of Engine Start Button) 2. Engine Start - A push button switch that, when 4 depressed, will start the engine. (crank time limited to 6 seconds before power supply required recycling)

3. Hourmeter - A meter used to measure the amount of 1 time the machine is in use.

Ground Control Console 2

(Refer to Figure 3-2., Ground Control Console). 3 1. Outrigger Select Switch - A three position key operated switch allows the operator to select if outriggers are used or not. The center position will disable the machine.

1. Outrigger Select Switch 3. Battery Isolator 2. Emergency Stop Switch 4. Outdoor/Indoor Select Switch Figure 3-2. Ground Control Console

3-2 – JLG Lift – 3121312 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Emergency Stop Switch - A two-position, red, mush- 2. Tilt Left LED - When in Auto Level Mode, this LED will room-shaped emergency stop switch, when positioned illuminate any time the machine is tilted to the left. to ON with the power selector switch positioned to 3. Tilt Right LED - When in Auto Level Mode, this LED will ground, furnishes operating power to the ground control illuminate any time the machine is tilted to the right. station. In addition, the switch can be used to turn off power to the function controls in the event of an emer- 4. Tilt Front LED - When in Auto Level Mode, this LED will gency. Power is turned on by pulling the switch out (on), illuminate any time the machine is tilted toward the and is turned off by pushing the switch in (off). machine front. 3. Battery Isolator Switch - The battery isolator switch is 5. Tilt Rear LED - When in Auto Level Mode, this LED will located outside the battery compartment (chassis). illuminate any time the machine is tilted toward the Rotate handle counter clockwise to disconnect power machine rear. from the battery. 6. No Drive LED - This LED is illuminated when the outrig- 4. Outdoor/Indoor Select Switch - A 2-positioned key oper- gers are used and the lift function is operated. ated switch that allows the operator to pre-select the operating environment. Either INDOOR, where the 7. The Platform extension button is not used. The deck is operation is restricted to a zero wind environment, or manually extended and retracted. OUTDOOR, where the maximum operating platform 8. Lift Switch - This momentary switch is used to lift and height is restricted. lower the platform. The switch must be held for the dura- Platform Ground Control Station tion of either lifting or lowering.

(Refer to Figure 3-3., Platform Ground Control ).

1. Platform/Ground Select - This three way keyswitch is used to select between platform controls or ground controls. When in the center position, the machine is disabled

3121312 – JLG Lift – 3-3 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform/Ground Select 2. Tilt Left LED 3. Tilt Right LED 4. Tilt Front LED 5. Tilt Rear LED 6. No Drive LED 7. Not Used 8. Lift/Lower Switch

Figure 3-3. Platform Ground Control

3-4 – JLG Lift – 3121312 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Station 3. Drive/Lift/Platform Ext. Select - The platform drive/lift/ platform ext. select switch selects the functions of the (Refer to Figure 3-4., Platform Control Station). drive and lift.

1. Drive Speed Switch - This switch allows you to choose NOTE: The deck extension is extended and retracted manually, between three different speeds: not via the platform contol station. Refer to Section 4 for manual deck extension procedures. Differential lock 4X4 - The rotary switch must be held in the Differential lock position for the duration of function. 4. Steer Axle Select Switch - The steer axle select switch enables the selection of the active steer axle as indi- Low drive 4X4 (turtle symbol) cated by the symbols on the console. 5. Lift/Drive Controller/Joystick - The joystick operates in High drive 2X4 (rabbit symbol). conjunction with the Drive/Lift select switch. It also incorporates a trigger enable switch. When the trigger is After selecting the speed desired, move the controller operated, there is a 5 second window to operate the joy- forward or backward depending upon the direction you stick in the desired direction. After this 5 seconds, the want to travel. enable function will timeout and the trigger must be NOTE: Tight turns are not possible while differential lock is acti- recycled to re-enable the joystick operation. This trigger vated. must be held and the joystick operated in the desired direction for the full duration of the selected function. NOTE: Only slow drive is possible when the machine is in the 6. Glow Plug Wait Indicator - Indicates the glow plug is on. elevated position Start the engine only after the light goes out.

2. Lift/Lower Enable - This switch works in conjunction with 7. Start Switch - Start the Diesel engine by turning the start the lift/lower function. It must be depressed once after switch on the control panel to the right. selecting the lift/lower direction. 8. Horn - The machine is equipped with a horn. The horn is activated by a push-button located on the control panel.

3121312 – JLG Lift – 3-5 SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. LED Panel - See Platform LED Panel. 10. Emergency Stop Switch - Situated on the control panel is an Emergency Stop Switch, which is activated when being pressed and cuts out all functions, except emergency lowering. 11. Steering-in-Line LEDs - Green LEDs when illuminated, indicate wheels are in-line with the chassis. When all wheels are aligned, lifting above 4 m (13 ft) is permitted. 12. Steer Button - The steer button is a thumb operated button located on the top of the joystick. Choose the direction of steering by activating the button according to the direction symbol. The switch must be held for the duration of the steering function. 13. Fast Drive LED - Red LED that remains illuminated when the fast drive function is available.

3-6 – JLG Lift – 3121312 SECTION 3 - MACHINE CONTROLS AND INDICATORS

9 8 6 5

Max 0 m/s

1. Drive Speed 2. Lift/Lower Enable 10 3. Mode STOP 4. Steer Select Switch 5. Joystick 6. Glow Plug Indicator 12 7. Ignition 8. Horn 9. LED Panel NOT-STOP 10. Emergency Stop 11. Steering In-Line LEDs 12. Steer Button 13. Fast Drive LED

11113 2 7 3 11 4 Figure 3-4. Platform Control Station

3121312 – JLG Lift – 3-7 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform LED Panel (Refer to Figure 3-5., Platform LED Panel). 12 3 4 5 1. Tilt (slope) LED - This LED light will remain on until the machine is driven on a slope greater than 1° at which time the light will go out. Max 0 m/s 2. Indoor Operation Only LED - This LED remains illuminated when the indoor operation environment is selected with the OUTDOOR/INDOOR select keyswitch. 3. Lift Cutout LED - This LED light remains illuminated until the maximum height is reached. 4. Drive Cutout LED - This LED light remains illuminated 1. Tilt when the machine is in a drivable configuration. 2. Indoor Operation Only 5. Overload LED - This LED will illuminate when the plat- 3. Lift Cutout form becomes overloaded. 4. Drive Cutout 5. Overload NOTE: All LEDs are red.

Figure 3-5. Platform LED Panel

3-8 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION The allowable operation of the machine is within the following certain tolerance limits, which are monitored and con- Description Of The Work Platform trolled via limit switches: Load Sensing System (LSS) The work platform consists of a mobile chassis, an extendable scissors mechanism and an extendable platform. The The Load Sensing System (LSS) senses pressure in the main lift machine is controlled from a console on the platform. cylinder. If this pressure exceeds a pre-set level the following will General Description of the Functions and occur: Components 1. The overload warning indicator on the platform control box will flash. The normal location to operate the machine is on the plat- 2. The audible warning will sound form. However, the control box can be disconnected from the platform location and plugged in (for emergency use, 3. All normal movement will be prevented from both the functional testing, and loading onto a transport vehicle) at platform control box and the ground control box the distribution terminal on the chassis. 4. Engaging the manual descent system, located in the Situated on the control panel is an emergency STOP-button, valve compartment, will allow further movement. which is activated when pressed and cuts out all functions, except emergency lowering. IMPORTANT The machine is equipped with a horn. The horn is activated IF ALL NORMAL MOVEMENT IS PREVENTED WITH NO AUDIBLE, OR by a push-button located on the control panel. The machine VISUAL SIGNAL, THERE IS A FAULT IN THE SYSTEM. is also equipped with an audible alarm, which is automatically activated, when the machine driven. If this situation occurs, proceed as follows:

3121312 – JLG Lift – 4-1 SECTION 4 - MACHINE OPERATION

1. Return the platform to the retracted and lowered posi- 4.2 OPERATION tion by means of the manual descent system located in the valve compartment. NOTE: The platform control box can be plugged in at ground level inside the valve compartment. 2. Disable the machine 3. Have the fault assessed by a qualified JLG equipment •There is an emergency stop switch positioned on the plat- service technician before returning to normal operation. form control box (red button) and ground control console. When activated, the signals of the control board will be cut IMPORTANT off instantly and all functions will be stopped, except the emergency descent and emergency lifting functions (at THE LOAD SENSING SYSTEM MUST BE CALIBRATED WHEN ONE OR ground level). These will still work if the emergency button MORE OF THE FOLLOWING CONDITIONS OCCUR: at the control box is pressed. a. LSS component replacement •The Master Switch at the chassis acts as an isolator switch b. LSS Sensor removal or replacement for the batteries and cuts off the power supply. c. Platform is removed or replaced •The auto leveling outriggers can be turned on or off (Out- rigger-Switch ON/OFF). This is a keyswitch which is IMPORTANT located outside the hydraulic tank compartment. The acti- vation of the outriggers is controlled by the lift select func- THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFI- tion. The lift up select allows the outriggers to extend. The CATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. lift down select allows the outriggers to retract. REFER TO TESTING AND EVALUATION IN SECTION 6. •The machine is equipped with a horn, which can be activated from the control box. While driving, a constant acoustic signal is activated as an additional motion alarm.

4-2 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

Lifting and Lowering 3. When operating the lifting and lowering functions above a platform height of 18 m (59 ft), the motion alarm at the ground position will sound. If the lift/drive-switch is in the lift position, lifting/lowering will be activated by the joystick controller. After the joystick passes the neutral position with the trigger held, the maximum lift speed is achieved. To enable lifting above 4m, both DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLAT- the front and rear wheels must be aligned with the chassis. FORM EXTENSION. This is indicated by both the green LEDs above the steer select switch being illuminated. NOTE: The machine is equipped with gravity lift down.The engine does not need to be running to lower the platform. NOTE: If the lift/drive-switch is in the drive position, the functions lift/lower are deactivated. The emergency lift/lower switch, located in the bottom chassis however still Automatic Self Leveling remains active. This switch can only be activated when the keyswitch is in the ground control position. The machine is equipped with an auto leveling feature that allows the operator to automatically level the machine. This NOTE: With outriggers selected, the outriggers are part of the lift function can be turned on or off at the ground control station. function, and the machine will not lift until the outriggers With the auto leveling function selected, the outriggers are are deployed and the machine is level. deployed by using the lift controller. Lift up will extend the outriggers and Lift down will retract the outriggers. 1. With the Outdoor Mode selected, the maximum platform height is automatically restricted to 18 m (59 ft). All outriggers must be extended and in contact with the support surface before the platform is lifted from the stowed 2. With the Indoor Mode selected, the lift function automat- position. If one or more outriggers, despite being fully ically stops at a platform height of 18 m (59 ft). To con- extended, is not in contact with the support surface the out- tinue above this height, the Lift/Lower Enable button riggers must be retracted and the machine moved to a more must be depressed and held (refer to item 2 in Figure 3- appropriate position. The platform must be completely low- 4., Platform Control Station). ered to retract the outriggers.

3121312 – JLG Lift – 4-3 SECTION 4 - MACHINE OPERATION

Driving The Machine From The Platform

IF THE MACHINE BECOMES UNLEVEL, CAREFULLY LOWER THE PLAT- To activate the drive of the machine, the controller (joystick) FORM AND REPOSITION THE MACHINE. has to be moved forward for forward-drive and back for reverse-drive. The controller has a neutral zone of about ± NOTE: The outriggers can not be used from the ground control 7% of the total possible moving distance. After reaching the station. end of the neutral zone, the valves "drive, brake and motion alarm" will be activated. The machine starts to move. When the automatic leveling system is activated, the drive function is cutout, the control lamps on the Nivolux-box show the results of the measurement and the outriggers start to extend. At this stage the system solely controls the setting of DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM the outriggers to level the chassis. AND LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES.

IMPORTANT TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDE- SLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES ALWAYS BE SURE THAT THE OPERATING SURFACE THE MACHINE IS EXCEEDING THOSE SPECIFIED. REFERENCE Figure 4-1., Grade and Side- TO BE USED ON IS FIRM AND FREE OF ANY VOIDS OR OBSTRUCTIONS slope. THAT MAY CAUSE THE OUTRIGGERS TO NOT PERFORM PROPERLY.

To retract the outriggers activate the lowereing function with the joystick. As soon as all outriggers are completely retracted the maximum hydraulic pressure will be reached at which time the machine will be okay to drive.

4-4 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

DE GRA S IDESLOPE HORIZONTAL

Figure 4-1. Grade and Sideslope

3121312 – JLG Lift – 4-5 SECTION 4 - MACHINE OPERATION

Steering 4.3 MANUAL PLATFORM EXTENSION

The steer function is operated by a button switch on top of Platform Extension Lock Removal the joystick in the direction indicated by the symbols on the console. Before extending the platform extension the transport exten- A separate steer axle select switch, positioned below the joy- sion locking pin must be removed. stick, enables the selection of the active steer axle as indi- 1. Remove the retaining pin from the transport locking pin. cated by the symbols on the console. NOTE: Only one axle can be steered at one time and steering of the rear axle above a platform height of 4 m (13 ft) is not permitted. Green indicator LED’s will be lit when wheels are aligned, making lifting above 4 m possible.

2. Remove the transport locking washer from the pin coming through the hole in the platform extension.

4-6 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

3. Place the retaining washer over the pin in the platform Platform Extension and install the retaining pin into the platform pin. 1. Locate the two retaining pins at the rear of the platform extension and pull from the locking pin.

IMPORTANT DURING TRANSPORT THE PLATFORM EXTENSION MUST ALWAYS BE LOCKED INTO THE STOWED POSITION.

3121312 – JLG Lift – 4-7 SECTION 4 - MACHINE OPERATION

2. Firmly grasp the handles and pull upward to remove the 4. Once the platform extension has been fully extended locking pin from the stowed position. push downward on the handles and ensure that the locking pins are properly placed in the locking pin holes in the handrails. Replace the retaining pin.

3. After lifting the handles extend the platform extension evenly until fully extended.

4-8 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

4.4 EMERGENCY LOWERING - MANUAL 1. Locate the main valve block inside the hydraulic cover DESCENT on the right side of the machine.

All control switches have to be set to the neutral position. After that, the emergency lowering valve, which is located on the lift cylinder, can be opened hydraulically by a hand pump located inside the hydraulic compartment. Once the lowering is completed all levers of the emergency lowering function have to be placed into the neutral position. NOTE: The manual descent system is provided as an emergency means to lower personnel from the platform.

1. Hand Pump 2. Main Valve Block

3121312 – JLG Lift – 4-9 SECTION 4 - MACHINE OPERATION

3. Turn the valve knob (1) on the hand-pump clockwise 4. Locate the lever at the end of the valve bank near the until tight. back. Lift lever to engage valve.

4-10 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

5. Locate handle and place it on the third valve from the left (1). Press handle downward while activating the manual pump (2).

1. 2.

3121312 – JLG Lift – 4-11 SECTION 4 - MACHINE OPERATION

4.5 PARKING AND STOWING

PLATFORM WILL CONTINUE TO DESCEND ONCE MOVEMENT IS Once the work carried out is completed the machine has to STARTED. TO STOP PLATFORM DESCENT, TURN VALVE KNOB COUN- be fully lowered and the battery isolator switch should be TERCLOCKWISE. turned off.

6. After manual lowering is complete, release valve on the valve bank and remove handle from valve. Turn the valve THE MACHINE HAS TO BE LOCKED USING THE KEYSWITCH ON THE on the hand pump counterclockwise to open and push GROUND CONTROL PANEL SWITCH TO AVOID THE USE BY ANY pump handle forward. Push the lever at the end of the UNAUTHORIZED PERSONNEL. valve bank back to the original position. In case the machine is not used for a longer period of time, the batteries should be charged once every two weeks due to the self discharge and power consumption of the machine at rest.

4-12 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

4.6 LIFT/TIE DOWN LUGS Lifting

If it becomes necessary to lift the machine, it is possible to do so from the lifting lugs located at the four corners of the machine (Refer to Figure 4-2., Lifting Lugs Location). These lugs enable the machine to be lifted using cranes or suitable lifting devices

NOTE: If lifting becomes necessary from the lifting lugs, JLG Industries Inc. recommends the use of a proper spreader bar and straps/chains to avoid damage to the machine. Cranes or other lifting devices must be capable of handling the weights listed in the Operating Specifications table in section 6 of this manual.

Lifting Lugs Both Sides

Figure 4-2. Lifting Lugs Location

3121312 – JLG Lift – 4-13 SECTION 4 - MACHINE OPERATION

Tie Down

When transporting the machine, the platform extension must be fully retracted and the platform fully lowered in the stowed position with the machine securely tied down to the truck or trailer deck (Refer toFigure 4-3., Tie Down Lugs Location).

Tie Down Lugs Both Ends Figure 4-3. Tie Down Lugs Location

4-14 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

4.7 TRANSPORT AND STORAGE OF THE The platform control box must be unplugged during the transport of the machine. The socket at the platform must be closed, MACHINE whenever the control box is not plugged in. This is the best way to prevent any damages due to moisture and transport to the IMPORTANT electrical components of the machine. DURING TRANSPORT THE BATTERY ISOLATOR SWITCH SHOULD BE •Ensure the platform control box is stored in a safe and dry DISCONNECTED. location and the main joystick controller is not affected by any harsh forces.

1. Battery Isolator Switch

3121312 – JLG Lift – 4-15 SECTION 4 - MACHINE OPERATION

Both 16 25, 26, 27, 28, 18 Sides

Top of Tube Both Sides 6 19 Both Sides Top of Tubes 19 Both Sides

Both Sides 1 1 Both Sides Both Sides 11 Both Sides 23 11 Both Sides 2 Both Sides 23 Both Sides

Both Sides 2 12 Both Sides 5 Both Sides Both Sides 12 One on Tank, 17 29 Both Sides One on Cover Near to Filler Figure 4-4. Decal Location - Sheet 1 of 3

4-16 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

7 5 20 5

End of Tube Both Ends 6 5 30 29 1 Both Ends 20 Both Sides 4 4 Both Sides 4 Both Sides 4 1 Both Ends

15 5 8

3 Both Ends

23 Each Corner Figure 4-5. Decal Location - Sheet 2 of 3

3121312 – JLG Lift – 4-17 SECTION 4 - MACHINE OPERATION

24 21

31 5 22 9

Front

Figure 4-6. Decal Location - Sheet 3 of 3

4-18 – JLG Lift – 3121312 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Listing Table 4-1. Decal Listing

Item # 0275451-D Item # 0275451-D 1 1701785 20 1703819 2 1703811 21 1704412 3 1703814 22 3252801 4 1704277 23 4420051 5 1705671 24 1703812 6 1705673 25 0860520 7 1706900 26 1060279 8 1706472 27 2080040 9 1706954 28 S900129 10 1706482 29 1705864 11 1706901 30 1704885 12 1706902 31 1707027 13 1706485 14 1707050 15 1705515 16 1706903 17 1701505 18 1701509 19 1703687

3121312 – JLG Lift – 4-19 SECTION 4 - MACHINE OPERATION

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4-20 – JLG Lift – 3121312 SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL Platform Caught Overhead This section provides information on the procedures to be If the platform becomes jammed or snagged in overhead followed and on the systems and controls to be used in the structures or equipment, do not continue operation of the event an emergency situation is encountered during machine from either the platform or the ground until the machine operation. Prior to operation of the machine and operator and all personnel are safely moved to a secure periodically thereafter, the entire operating manual, including location. Only then should an attempt be made to free the this section, should be reviewed by all personnel whose platform using any necessary equipment and personnel. Do responsibilities include any work or contact with the not operate controls to cause one or more wheels to leave machine. the ground. Emergency Stop Switch Righting of Tipped Machine These large red buttons, one located outside the valve com- A forktruck of suitable capacity or equivalent equipment partment and one at the Platform Control Station, will imme- should be placed under the elevated side of the chassis, with diately stop the machine when depressed. a crane or other suitable lifting equipment used to lift the platform while the chassis is lowered by the forklift or other IMPORTANT equipment. CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP BUTTON Post-Incident Inspection IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE. 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 meters) until all damage has been repaired and all controls are operating correctly.

3121312 – JLG Lift – 5-1 SECTION 5 - EMERGENCY PROCEDURES

5.2 EMERGENCY OPERATION and stabilize motion of the machine in case machine controls are inadequate or malfunction when used. Use of Ground Controls Incident Notification IMPORTANT It is imperative that JLG Industries, Inc. be notified immediately of any incident involving a JLG product. Even if no KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SIT- injury or property damage is evident, JLG should be con- UATION. tacted by telephone and provided with all necessary details at: Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control USA - 877-JLG-SAFE (877-554-7233) functions. Training should include operation of the machine, Europe - 717-485-5161 review and understanding of this section and hands-on operation of the controls in simulated emergencies. It should be noted that failure to notify the Manufacturer of an incident involving a JLG Industries product within 48 hours of Operator Unable to Control Machine such an occurrence may void any warranty consideration on that particular machine. 1. Operate the machine from ground controls ONLY with the assistance of other personnel and equipment (cranes, overhead hoists, etc.) as may be required to safely remove the danger or emergency condition. 2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY. 3. Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants

5-2 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 OPERATING SPECIFICATIONS

This section of the manual provides additional necessary Table 6-1. Operating Specifications information to the operator for proper operation and maintenance of this machine. Maximum Working Height 26.50 m The maintenance portion of this section is intended as infor- (87 ft) mation to assist the machine operator to perform daily main- Maximum Platform Height 24.50 m tenance tasks only, and does not replace the more thorough (80.3 ft) Preventive Maintenance and Inspection Schedule included Maximum Drive Height 18 m (59 ft) in the Service and Maintenance Manual. Transportation Height ( w/railing) 4.20 m Other Publications Available Specific to this Machine: (13.7 ft) Service and Maintenance Manual ...... 3121313 Turning Radius: Illustrated Parts Manual ...... 3121314 Inside 0.65 m (2.13 ft) Outside 4.3 m (14.1 ft) Wheelbase 3.93 m (12.89 ft) Load-carrying capacity: Main Platform 600 kg (1323 lbs) Platform Extension 600 kg (1323 lbs) Maximum Number of Persons 2 Maximum Operating Wind Speed: With "Outdoor Mode" selected 12.5 m/s (28 mph) With "Indoor Mode" selected 0 m/s (0 mph)

3121312 – JLG Lift – 6-1 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Table 6-1. Operating Specifications 6.3 Capacities Gross Machine Weight (Approximate) 15,500 kg (34,171.7 lbs) Table 6-2. Capacities Drive Speed: 245-12 (creep) 0.14 m/sec (0.3 mph) Fuel Tank 60 L (15.9 gal) (slow) 0.4 m/sec (0.9 mph) (fast) 0.67 m/sec (1.5 mph) Hydraulic Tank 135 L (35.7 gal) Lift Speed (without load) 125 sec Engine Crankcase 6.5 L (6.8 qts.) Lower Speed (without load) 80 sec Max Operating Hydraulic Pressure 185 bar (2683.2 psi) Batteries Gradeability (machine stowed) 15% Table 6-3. Battery Specifications Sideslope (machine stowed) 5° Tilt Sensor Setting 1° Volts (each)(2) 12 Platform Dimensions Amp Hour 88 Retracted: 5.20 x 1.20 m (17 x 3.9 ft) Extended 7.62 x 1.20 m (25 x 3.9 ft) Transport - dimensions 5.59 x 1.24 x 3.10 m (18.3 x 4.0 x 10.1 ft) Tire Size 28 x 10 x 22 Ground Bearing Pressure 11 kg/cm² (156.5 psi) Operating Temperature Range -15°C to + 45°C (5° to 113° F) Electrical System Supply Voltage 24 V

6-2 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Lubrication Table 6-5. Mobilfluid 424 Specs Table 6-4. Hydraulic Oil SAE Grade 10W30 HYDRAULIC SYSTEM OPERATING SAE VISCOSITY GRADE Gravity, API 29.0 TEMPERATURE RANGE Density, Lb/Gal 60°F 7.35 -18° to -5° C 10W Pour Point, Max -43°C (-46°F) (0° to +23° F) Flash Point, Min. 228°C (442°F) -18° to +100° C 10W-20, 10W-30 Viscosity (0° to +210° F) cP at -18°C 2700 +10° to +100° C 20W-20 cST at 40° C 55 cSt (+50° to +210° F) cST at 100° C 9.3 cSt Viscosity Index 152 NOTE: Hydraulic oils must have anti-wear qualities at least to API Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries NOTE: Aside from JLG recommendations, it is not advisable to recommends Mobilfluid 424 hydraulic oil, which has an mix oils of different brands or types, as they may not con- SAE viscosity index of 152. tain the same required additives or be of comparable vis- cosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

3121312 – JLG Lift – 6-3 SECTION 6 - GENERAL SPECIFICATIONS AND 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) 80°F (27°C) SUMMER ENGINE GRADE 70°F (21°C) FUEL SPECIFICATIONS 60°F (16°C) SAE 5W-30

SAE OW-30 SAE 50°F (10°C) SAE 5W-40 SAE SAE OW-40 SAE SAE 10W-40 SAE SAE 10W-30 SAE 10W-30 SAE 15W-40 SAE SAE 20W-50 40°F (4°C) 30°F (-1°C) WINTER 20°F (-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F (-12°C) FULLY CHARGED BATTERY 0°F (-18°C) WINTER ENGINE WILL START AND OPERATE AT THIS TEMPERATURE GRADE -10°F (-23°C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER WITH -20°F (-29°C) PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR GLOW KEROSENE PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) ADDED -30°F (-34°C) -40°F (-40°C) NO OPERATION BELOW THIS AMBIENT TEMPERATURE

4150548 C

Figure 6-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2

6-4 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180°F (82°C) OR ABOVE 180°F (82°C) (HYD. OIL TANK TEMP. IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE)

NOTE: 120°F (49°C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110°F (43°C) PROLONGED OPERATION IN 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES AMBIENT AIR TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 100°F (38°C) OF 100°F (38°C) OR ABOVE 90°F (32°C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 80°F (27°C) 70°F (21°C) 60°F (16°C) HYDRAULIC

50°F (10°C) 10W-30 424 MOBIL SPECIFICATIONS 40°F (4°C) 30°F (-1°C) °F °C EXXON UNIVIS HVI 26 HVI UNIVIS EXXON +32 0 20°F (-7°C) SUMMER - GRADE FUEL 10°F (-12°C) +23 -5 MOBIL 0°F (-18°C) DO NOT START UP HYDRAULIC SYSTEM DTE 13 WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10 -10°F (-23°C) HYDRAULIC OIL BELOW THIS TEMPERATURE +5 -15 -20°F (-29°C) DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER -30°F (-34°C) -4 -20 WINTER - GRADE HYDRAULIC OIL BELOW THIS TEMPERATURE FUEL -40°F (-40°C) NO OPERATION BELOW THIS -13 -25 AMBIENT TEMPERATURE TEMPERATURE AMBIENT -22 -30 0 10 20 30 40 50 60

% OF ADDED KEROSENE

Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2

3121312 – JLG Lift – 6-5 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.4 OPERATOR MAINTENANCE

1. Scissor Arm Pins 2. Slide Blocks 1 3. Hydraulic Oil Tank (Other Side) 4. Hydraulic Filter (Other Side) 5. Lift Cylinder Pin (Not Shown) 6. Tie Rod Ends 7. Spindles 8. Engine Oil 7 9. Fuel Filter 7 10. Steer Cylinder 11. Pothole Protection System 6

10 6 8, 9 11 Figure 6-3. Operator Maintenance & Lubrication Diagram

6-6 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

NOTE: The following numbers correspond with those in Figure 6- 1. Arm Pins 3., Operator Maintenance & Lubrication Diagram.

Table 6-6. Lubrication Specifications

KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 177°C (350° F). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.) EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-Spec MIL-L-2105. EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

HO Hydraulic Oil. API service classification GL-3, e.g. Mobil 424. • Lube Points - Grease Fittings

NOTE: Be sure to grease all like items on the opposite side of • Capacity - As Required machine. •Lube - MPG • Interval - As Required

3121312 – JLG Lift – 6-7 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

2. Slide Blocks 3. Hydraulic Oil Tank

• Lube Points - Fill Cap & Sight Gage • Lube Points - 2 Grease Points • Capacity - 135 ltr (35.7 gal) • Capacity - As Required •Lube - HO •Lube - MPG • Interval - Check oil daily, change every 1200 hours of operation. • Interval - As Required

6-8 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

4. Hydraulic Filter 5. Lift Cylinder Pin

• Lube Points - 2 Grease Fittings/Pin • Capacity - As Required •Lube - MPG • Interval - As Required • Lube Points - Replaceable Element • Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator

3121312 – JLG Lift – 6-9 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6. Tie Rod Ends 7. Spindles

• Lube Points - 2 Grease Fittings • Capacity - As Required •Lube - MPG • Lube Points - 2 Grease Fittings • Interval - As Required • Capacity - As Required •Lube - MPG • Interval - As Required

6-10 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

8. Oil Change w/Filter 9. Fuel Filter - Deutz

• Lube Point(s) - Fill Cap/Spin-on Element • Lube Point(s) - Replaceable Element JLG P/N 7000347 JLG P/N 7000365 • Capacity - 6.5 L (6.8 qts.) w/Filter • Interval - Every year or 600 hours of operation •Lube - EO • Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on dipstick.

3121312 – JLG Lift – 6-11 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

10. Steer Cylinder 11. Pothole Protection

• Lube Points - 2 Grease Fittings • Capacity - As Required • Lube Points - 4 Grease Fittings •Lube - MPG • Capacity - As Required • Interval - As Required •Lube - MPG • Interval - As Required

6-12 – JLG Lift – 3121312 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.5 TIRES AND WHEELS Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. If Tire Wear and Damage you do not have a torque wrench, tighten the fasteners with a lug wrench, then immediately have a service garage or dealer Inspect tires periodically for wear or damage. Tires with worn tighten the lug nuts to the proper torque. Over-tightening will edges or distorted profiles require replacement. Tires with sig- result in breaking the studs or permanently deforming the nificant damage in the tread area or side wall, require immediate mounting stud holes in the wheels. The proper procedure for evaluation before placing the machine into service. attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO Wheel and Tire Replacement NOT use a lubricant on threads or nuts.

Replacement wheels must have the same diameter and profile 2. Tighten nuts in the following sequence:. as the original. Replacement tires must be the same size and rating as the tire being replaced. Wheel Installation

1 It is extremely important to apply and maintain proper wheel 6 mounting torque. 3 4 6 LUG PATTERN

5 2 WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI- BLE SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.

3121312 – JLG Lift – 6-13 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3. The tightening of the nuts should be done in stages. Fol- 6.6 LOAD SENSING SYSTEM VERIFICATION lowing the recommended sequence, tighten nuts per wheel torque. IMPORTANT Table 6-7. Wheel Torque Chart THE LOAD SENSING SYSTEM REQUIRES PERIODIC FUNCTION VERIFI- CATION NOT TO EXCEED 6 MONTHS FROM PREVIOUS VERIFICATION. TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage Confirm Load Sensing System Performance with Calibrated 210 - 270 Nm 320-380 Nm 440 - 480 Nm Weights: (150-190 ft lbs) (230 - 270 ft lbs) (305 - 343 ft lbs) 1. Operate the vehicle from Ground Control and place the platform in the fully stowed position for safety. Place 4. Wheel nuts should be torqued after the first 50 hours of 120% of the machines rated load in the center of the operation and after each wheel removal. Check torque platform and ensure that the overload visual and audible every 3 months or 150 hours of operation. warnings are active. Reduce the platform load to 100% rated load and ensure that the warnings are not active. For vehicles with multiple capacities, evaluate each operating mode with the proper rated load. If any of the modes are not working, calibrate per the Service & Maintenance Manual.

6-14 – JLG Lift – 3121312 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

3121312 – JLG Lift – 7-1 SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3121312

Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA Phone: (717) 485-5161 Fax: (717) 485-6417

JLG Worldwide Locations

JLG Industries (UK) JLG Industries (Europe) JLG Industries (Australia) JLG Industries (Pty) Ltd. Unit 12, Southside Kilmartin Place, P.O. Box 5119 Unit 1, 24 Industrial Complex Bredbury Park Industrial Estate Tannochside Park 11 Bolwarra Road Herman Street Bredbury Uddingston G71 5PH Port Macquarie Meadowdale Stockport Scotland N.S.W. 2444 Germiston SK6 2sP Phone: (44) 1 698 811005 Australia South Africa England Fax: (44) 1 698 811055 Phone: (61) 2 65 811111 Phone: (27) 11 453 1334 Phone: (44) 870 200 7700 Fax: (61) 2 65 810122 Fax: (27) 11 453 1342 Fax: (44) 870 200 7711

JLG Europe B.V. JLG Latino Americana Ltda. JLG Polska JLG Industries (Sweden) Jupiterstraat 234 Rua Eng. Carlos Stevenson, UI. Krolewska Enkopingsvagen 150 2132 HJ Foofddorp 80-Suite 71 00-060 Warsawa Box 704 The Netherlands 13092-310 Campinas-SP Poland SE - 175 27 Jarfalla Phone: (31) 23 565 5665 Brazil Phone: (48) 91 4320 245 Sweden Fax: (31) 23 557 2493 Phone: (55) 19 3295 0407 Fax: (48) 91 4358 200 Phone: (46) 8 506 59500 Fax: (55) 19 3295 1025 Fax: (46) 8 506 59534

JLG Deutschland GmbH JLG Industries (Italia) Plataformas Elevadoras Max Planck Strasse 21 Via Po. 22 JLG Iberica, S.L. D-27721 Ritterhude/lhlpohl 20010 Pregnana Milanese - MI Trapadella, 2 Bei Bremen Italy P.I. Castellbisbal Sur Germany Phone: (39) 02 9359 5210 08755Castellbisbal Phone: (49) 421 693 500 Fax: (39) 02 9359 5845 Spain Fax: (49) 421 693 5035 Phone: (34) 93 77 24700 Fax: (34) 93 77 11762 www.jlg.com