Operation And Safety Manual - JLG Industries

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Operation and Safety ManualOriginal Instructions, Keep this manual with the machine at all /N - 3121165 May 1, 2013

FOREWORDFOREWORDThis 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 andoperating 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 changeswithout prior notification. Contact JLG Industries, Inc. for updated information.IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS.SHOULD PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONICCOMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT AMINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURATION.3121165– JLG Lift –a

FOREWORDSAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDSThis is the Safety Alert Symbol. It is used to alert you to the potential personalinjury hazards. Obey all safety messages that follow this symbol to avoid possibleinjury or deathINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALWILL HAVE A RED BACKGROUND.INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISDECAL WILL HAVE AN ORANGE BACKGROUND.bINDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOTAVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAYALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEA YELLOW BACKGROUND.NOTICEINDICATES INFORMATION OR A COMPANY POLICY THAT RELATESDIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.– JLG Lift –3121165

FOREWORDFor:THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT. Accident Reporting Product Safety Publications Current Owner Updates Questions RegardingProduct SafetyNOTICEJLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.NOTICEJLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL ORWHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONALPROPERTY OR THE JLG PRODUCT. Standards and RegulationsCompliance Information Questions Regarding Special Product Applications Questions Regarding Product ModificationsContact:Product Safety and Reliability DepartmentJLG Industries, Inc.13224 Fountainhead PlazaHagerstown, MD 21742or Your Local JLG Office(See addresses on manual rear cover)In USA:Toll Free:877-JLG-SAFE (877-554-7233)Outside USA:Phone:E-mail:3121165– JLG Lift –240-420-2661ProductSafety@JLG.comc

FOREWORDREVISION LOGOriginal Issue . . . . . . . . . . . March 31, 2003Revised. . . . . . . . . . . . . . . . April 30, 2003Revised. . . . . . . . . . . . . . . . May 21, 2003Revised. . . . . . . . . . . . . . . . June 13, 2003Revised. . . . . . . . . . . . . . . . June 25, 2003Revised. . . . . . . . . . . . . . . . August 26, 2003Revised. . . . . . . . . . . . . . . . December 3, 2003Revised. . . . . . . . . . . . . . . . March 3, 2004Revised. . . . . . . . . . . . . . . . September 17, 2004Revised. . . . . . . . . . . . . . . . June 15, 2005Revised. . . . . . . . . . . . . . . . September 12, 2005Revised. . . . . . . . . . . . . . . . October 21, 2005Revised. . . . . . . . . . . . . . . . February 16, 2006Revised. . . . . . . . . . . . . . . . April 11, 2007Revised. . . . . . . . . . . . . . . . February 19, 2010Revised. . . . . . . . . . . . . . . . January 18, 2011Revised. . . . . . . . . . . . . . . . July 13, 2011Revised. . . . . . . . . . . . . . . . September 28, 2012Revised. . . . . . . . . . . . . . . . May 1, 2013d– JLG Lift –3121165

TABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, SUBJECTSECTION - 1 - SAFETY PRECAUTIONS1.11.21.31.41.5GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1Operator Training and Knowledge . . . . . . . . . . . 1-1Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-3OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-4Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-5Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Crushing and Collision Hazards. . . . . . . . . . . . . 1-8TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-9MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-10Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-11MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . .Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . .Function Check . . . . . . . . . . . . . . . . . . . . . . . . . .General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2.231211652-22-42-52-8SECTION - 3 - USER RESPONSIBILITIES ANDMACHINE CONTROLSSECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION & INSPECTION2.1PAGEPERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1PREPARATION, INSPECTION, AND– JLG Lift –3.13.23.33.43.53.6GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . 3-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 3-1Training Supervision . . . . . . . . . . . . . . . . . . . . . . 3-2Operator Responsibility. . . . . . . . . . . . . . . . . . . . 3-2OPERATING CHARACTERISTICS ANDLIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-3Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-3PLATFORM CONTROL STATION . . . . . . . . . . . . . 3-5MDI (MULTIFUNCTION DIGITAL INDICATOR). . . . 3-9MDI Description . . . . . . . . . . . . . . . . . . . . . . . . . 3-10i

TABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, SUBJECTSECTION - 4 - MACHINE OPERATION4.14.2DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Platform/Ground Select Switch . . . . . . . . . . . . . 4-1Emergency Stop Switch . . . . . . . . . . . . . . . . . . 4-14.3 RAISING AND LOWERING . . . . . . . . . . . . . . . . . . . 4-2Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Arm Guards (If equipped) . . . . . . . . . . . . . . . . . 4-3Platform Extension . . . . . . . . . . . . . . . . . . . . . . . 4-3Fold-Down Rails . . . . . . . . . . . . . . . . . . . . . . . . . 4-34.4 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44.5 DRIVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Driving Forward . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . 4-54.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-74.7 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . 4-8Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Battery Charger Fault Codes . . . . . . . . . . . . . . . 4-94.8 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . 4-104.9 SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104.10 TIE DOWN/LIFT LUGS. . . . . . . . . . . . . . . . . . . . . . 4-114.11 LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Remote Electric Brake Release . . . . . . . . . . . . 4-13ii– JLG Lift –PAGEPush Button Electric Brake Release. . . . . . . . . 4-13Mechanical Brake Release . . . . . . . . . . . . . . . . 4-14Mechanical Brake Release . . . . . . . . . . . . . . . . 4-15Mechanical Brake Release . . . . . . . . . . . . . . . . 4-164.13 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . .4-18Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-184.14 DTC CHECK TABLES - CONTROL MODULE . . . .4-190-0 Help Comments . . . . . . . . . . . . . . . . . . . . . 4-192-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . 4-212-2 Platform Controls . . . . . . . . . . . . . . . . . . . . 4-212-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . 4-232-5 Function Prevented . . . . . . . . . . . . . . . . . . 4-233-1 Line Contactor Open Circuit. . . . . . . . . . . . 4-253-2 Line Contactor Short Circuit . . . . . . . . . . . . 4-263-3 Ground Output Driver . . . . . . . . . . . . . . . . . 4-264-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . 4-294-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . 4-296-6 Communication . . . . . . . . . . . . . . . . . . . . . 4-306-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . 4-317-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . 4-318-1 Tilt Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . 4-328-2 Platform Load Sense . . . . . . . . . . . . . . . . . 4-339-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . 4-333121165

TABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECTPAGESECTION - PARAGRAPH, SUBJECTSECTION - 5 - EMERGENCY PROCEDURES5.15.25.36.5GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1Emergency Stop Switch . . . . . . . . . . . . . . . . . . . 5-1Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-2Operator Unable to Control Machine . . . . . . . . . 5-2Platform Caught Overhead. . . . . . . . . . . . . . . . . 5-3Righting of Tipped Machine . . . . . . . . . . . . . . . . 5-3Post-Incident Inspection . . . . . . . . . . . . . . . . . . . 5-3INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-36.6PAGETIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . .Tire Wear and Damage . . . . . . . . . . . . . . . . . . .Wheel and Tire Replacement . . . . . . . . . . . . . .Wheel Installation . . . . . . . . . . . . . . . . . . . . . . .SUPPLEMENTAL INFORMATION. . . . . . . . . . . . .6-156-156-156-156-16SECTION - 7 - INSPECTION AND REPAIR LOGSECTION - 6 - GENERAL SPECIFICATIONS ANDOPERATOR MAINTENANCE6.16.26.36.43121165INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . .6-2Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-6Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . .6-9Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-11Oil Check Procedure (1) . . . . . . . . . . . . . . . . . 6-12Lower (2) & Upper Slide Pads (3) . . . . . . . . . . 6-13– JLG Lift –iii

TABLE OF CONTENTSSECTION - PARAGRAPH, SUBJECTPAGELIST OF -2.ivSECTION - PARAGRAPH, SUBJECT6-3.Daily Walk-Around Inspection - Sht. 1 of 3 . . . . . . . 2-7Daily Walk-Around Inspection - Sht. 2 of 3 . . . . . . . 2-8Daily Walk-Around Inspection - Sht. 3 of 3 . . . . . . . 2-9Switch Location - 1 of 2 . . . . . . . . . . . . . . . . . . . . . 2-10Switch Location - 2 of 2 . . . . . . . . . . . . . . . . . . . . . 2-11Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-4Battery Charger Status . . . . . . . . . . . . . . . . . . . . . . 3-4Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-5MDI Indicator - Location and Description . . . . . . . . 3-9Decal Location - 1930ES- Sht. 1 of 2 . . . . . . . . . . 3-11Decal Location - 1930ES - Sht. 2 of 2 . . . . . . . . . . 3-12Decal Location - 2030ES & 2630ES - Sht. 1 of 2 . 3-13Decal Location - 2030ES & 2630ES - Sht. 2 of 2 . 3-14Decal Location - 2646ES & 3246ES - Sht. 1 of 2 . 3-15Decal Location - 2646ES & 3246ES - Sht. 2 of 2 . 3-16Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-6Securing Control Station to Platform . . . . . . . . . . . 4-7Lifting and Tie Down Diagram. . . . . . . . . . . . . . . . 4-12Manual Disengage . . . . . . . . . . . . . . . . . . . . . . . . 4-14Manual Disengage . . . . . . . . . . . . . . . . . . . . . . . . 4-15Manual Disengage . . . . . . . . . . . . . . . . . . . . . . . . 4-16Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-17Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . 6-11Lower Slide Pad Channel . . . . . . . . . . . . . . . . . . . 6-13PAGEUpper Slide Pad Channel . . . . . . . . . . . . . . . . . . .6-14LIST OF 97-1– JLG Lift –Minimum Approach Distances (M.A.D.). . . . . . . . . 1-6Inspection and Maintenance Table . . . . . . . . . . . . 2-3Tilt vs. Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6High Drive Speed Cutout Height . . . . . . . . . . . . . . 2-6Decal Location Legend . . . . . . . . . . . . . . . . . . . . 3-17Battery Charger Flash Codes. . . . . . . . . . . . . . . . . 4-9Operating Specifications . . . . . . . . . . . . . . . . . . . . 6-2Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . 6-5Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Battery Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-7Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . 6-9Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . 6-10Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-16Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-13121165

SECTION 1 - SAFETY PRECAUTIONSSECTION 1. SAFETY PRECAUTIONS1.1GENERALThis section outlines the necessary precautions for properand safe machine usage and maintenance. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. Amaintenance program, using the information provided in thismanual and the Service and Maintenance Manual, must alsobe established by a qualified person and must be followed toensure that the machine is safe to operate.FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.1.2PRE-OPERATIONOperator Training and KnowledgeThe owner/user/operator/lessor/lessee of the machineshould not accept operating responsibility until this manualhas been read, training is accomplished, and operation ofthe machine has been completed under the supervision ofan experienced and qualified operator. The Operators and Safety Manual must be read in itsentirety before operating the machine. For clarification,questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.These sections contain the responsibilities of the owner,user, operator, lessor, and lessee concerning safety, training,inspection, maintenance, application, and operation.If thereare any questions with regard to safety, training, inspection,maintenance, application, and operation, please contact JLGIndustries, Inc. (“JLG”).3121165– JLG Lift –1-1

SECTION 1 - SAFETY PRECAUTIONS An operator must not accept operating responsibilitiesuntil adequate training has been given by competent andauthorized persons. Allow only those authorized and qualified personnel tooperate the machine who have demonstrated that theyunderstand the safe and proper operation and maintenance of the unit. Before operation, check work area for overhead hazardssuch as electric lines, bridge cranes, and other potentialoverhead obstructions. Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual. Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards. Ensure that the machine is to be used in a manner whichis within the scope of its intended application as determined by JLG. Check the work area for hazardous locations. Do notoperate the machine in hazardous environments unlessapproved for that purpose by JLG. All operating personnel must be familiar with the emergency controls and emergency operation of the machineas specified in this manual. Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire loaddecals located on the chassis adjacent to each wheel. Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain toyour utilization and application of the machine. Do not operate the machine when wind conditions exceed28 mph (12.5 m/s).Workplace Inspection Precautions to avoid all hazards in the work area must betaken by the user before operation of the machine.1-2 Do not operate or raise the platform from a position ontrucks, trailers, railway cars, floating vessels, scaffolds orother equipment unless the application is approved inwriting by JLG. This machine can be operated in nominal ambient temperatures of 0oF to 104oF (-20oC to 40oC). Consult JLG tooptimize operation outside of this temperature range.– JLG Lift –3121165

SECTION 1 - SAFETY PRECAUTIONSMachine Inspection1.3 Do not operate this machine until the inspections andfunctional checks have been performed as specified inSection 2 of this manual.OPERATIONGeneral Do not operate this machine until it has been serviced andmaintained according to the maintenance and inspectionrequirements as specified in the machine’s Service andMaintenance Manual. Ensure all safety devices are operating properly. Modification of these devices is a safety violation. Do not use the machine for any purpose other than positioning personnel, their tools, and equipment. Before operation, the user must be familiar with themachine capabilities and operating characteristics of allfunctions. Never operate a malfunctioning machine. If a malfunctionoccurs, shut down the machine. Remove the unit fromservice and notify the proper authorities. Do not remove, modify, or disable any safety devices.MODIFICATION OR ALTERATION OF AN

THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. 1.2 PRE-OPERATION Operator Training and Knowledge The Operators and Safety Manual must be read in its entirety before operating the machine. For clarification, questions, or additional information regarding any por-tions of this manual, contact JLG .

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