Operation and Safety Manual

Transcription

1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model 260MRT ANSI P/N June 5, 2012

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3 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 JLG Lift a

4 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY 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. INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- TECTION OF PROPERTY. b JLG Lift

5 FOREWORD THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. For: Accident Reporting Product Safety Publications Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applications Questions Regarding Product Modifications JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT. Contact: Product Safety and Reliability Department JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA or Your Local JLG Office (See addresses on inside of manual cover) In USA: Toll Free: 877-JLG-SAFE ( ) Outside USA: Phone: ProductSafety@JLG.com JLG Lift c

6 FOREWORD REVISION LOG Original Issue - June 27, 2005 Revised - July 17, 2006 Revised - March 29, 2007 Revised - October 22, 2008 Revised - April 15, 2010 Revised - May 14, 2010 Revised - June 5, 2012 d JLG Lift

7 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION SAFETY PRECAUTIONS 1.1 GENERAL PRE-OPERATION Operator Training and Knowledge Workplace Inspection Machine Inspection OPERATION General Trip and Fall Hazards Electrocution Hazards Tipping Hazards Crushing and Collision Hazards TOWING, LIFTING, AND HAULING MAINTENANCE General Maintenance Hazards Battery Hazards SECTION USER RESPONSIBILITIES, MACHINE PREPA- RATION AND INSPECTION 2.1 PERSONNEL TRAINING Operator Training Training Supervision Operator Responsibility PREPARATION, INSPECTION, AND MAINTENANCE PRE-START INSPECTION Preparing the Machine for Operation Function Check DUAL FUEL SYSTEM (IF EQUIPPED) GENERAL SECTION USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 GENERAL OPERATING CHARACTERISTICS AND LIMITATIONS General Placards Capacities CONTROLS AND INDICATORS Ground Control Station PLATFORM CONTROL STATION Platform Control Front Panel Indicator Panel LED s SECTION MACHINE OPERATION 4.1 DESCRIPTION ENGINE OPERATION Power Selector Switch JLG Lift i

8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Emergency Stop Switch Starting Procedure OPERATING CHARACTERISTICS Leveling Jacks Auto Leveling Manual Level Adjustment (Trim) PLATFORM Raising Lowering Platform Extension DRIVING Steering Driving Forward Driving in Reverse PARKING AND STOWING PLATFORM LOADING SAFETY PROP TIE DOWN Lifting TOWING SECTION EMERGENCY PROCEDURES 5.1 GENERAL Emergency Stop Switch Manual Descent EMERGENCY OPERATION Operator Unable to Control Machine Platform Caught Overhead Righting of Tipped Machine Post-Incident Inspection INCIDENT NOTIFICATION SECTION GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 INTRODUCTION OPERATING SPECIFICATIONS Dimensional Data Capacities Engine Lubrication OPERATOR MAINTENANCE TIRES AND WHEELS Tire Damage Tire Replacement Wheel Replacement Wheel Installation SUPPLEMENTAL INFORMATION SECTION INSPECTION AND REPAIR LOG ii JLG Lift

9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF FIGURES 2-1. Walk Around Inspection Diagram Walk Around Inspection Points - Sheet Walk Around Inspection Points - Sheet Ground Control Station Platform Control Station Indicator Panel Platform Control Front Panel Decal Location (ANSI) Decal Location (ANSI Export) Decal Location (CE/AUS) Grade and Sideslope Depiction Lifting Chart Engine Operating Temperature Specifications (Kubota)- Sheet 1 of Engine Operating Temperature Specifications (Kubota)- Sheet 2 of Lubrication Diagram LIST OF TABLES Beaufort Scale (For Reference Only) Minimum Approach Distances (M.A.D.) Inspection and Maintenance Table Tilt Sensor Preset Configuration Decal Legend (ANSI) Decal Legend (ANSI Export) Decal Legend - (CE/AUS) Operating Specifications Dimensional Data Capacities Tire Specifications Engine Specifications Engine Battery Specifications Hydraulic Oil Lubrication Specifications Inspection and Repair Log JLG Lift iii

10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page intentionally left blank. iv JLG Lift

11 SECTION 1. SAFETY PRECAUTIONS SECTION 1 - SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. In order to promote proper machine usage, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate. The owner/user/operator/lessor/lessee of the machine should not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of 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 ). FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN 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 portions of this manual, contact JLG Industries, Inc JLG Lift 1-1

12 SECTION 1 - SAFETY PRECAUTIONS An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual. Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG. All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual. Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utilization and application of the machine. Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before operation of the machine. Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is approved in writing by JLG. Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions. Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards. Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. This machine can be operated in nominal ambient temperatures of 0 o F to 104 o F (-20 o C to 40 o C). Consult JLG to optimize operation outside of this temperature range. 1-2 JLG Lift

13 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). Table 1-1. Beaufort Scale (For Reference Only) Beaufort Wind Speed Number mph m/s Description Land Conditions Calm Calm. Smoke rises vertically Light air Wind motion visible in smoke Light breeze Wind felt on exposed skin. Leaves rustle Gentle breeze Leaves and smaller twigs in constant motion Moderate breeze Dust and loose paper raised. Small branches begin to move Fresh breeze Smaller trees sway Strong breeze Large branches in motion. Whistling heard in overhead wires. Umbrella use becomes difficult Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind Fresh Gale Twigs broken from trees. Cars veer on road Strong Gale Light structure damage JLG Lift 1-3

14 SECTION 1 - SAFETY PRECAUTIONS Machine Inspection Do not operate this machine until the inspections and functional checks have been performed as specified in Section 2 of this manual. Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine s Service and Maintenance Manual. Ensure all safety devices are operating properly. Modification of these devices is a safety violation. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER Do not operate any machine on which the safety or instruction placards or decals are missing or illegible. Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG. Avoid accumulation of debris on platform deck. Keep mud, oil, grease, and other slippery substances from footwear and platform deck. 1.3 OPERATION General Do not use the machine for any purpose other than positioning personnel, their tools, and equipment. Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions. Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities. Do not remove, modify, or disable any safety devices. Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure. Hydraulic cylinders, other than the outrigger cylinders, should never be left at end of travel (fully extended or fully retracted) before shutdown or for long periods of time. Always bump control in opposite direction slightly when function reaches end of travel. This applies both to machines in operation or in the stowed position. 1-4 JLG Lift

15 SECTION 1 - SAFETY PRECAUTIONS Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. Do not carry materials directly on platform railing unless approved by JLG. When two or more persons are in the platform, the operator shall be responsible for all machine operations. Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. 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. Trip and Fall Hazards JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG products, contact JLG Industries, Inc. 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 JLG Lift 1-5

16 SECTION 1 - SAFETY PRECAUTIONS. Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current. Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose. 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 footwear and the platform floor. 1-6 JLG Lift

17 SECTION 1 - SAFETY PRECAUTIONS Maintain safe clearance from electrical lines, apparatus, or any energized (exposed or insulated) parts in accordance with the Minimum Approach Distance (MAD) as specified in Table 1-1. Allow for machine movement and electrical line swaying. Table 1-2.Minimum Approach Distances (M.A.D.) Voltage Range (Phase to Phase) MINIMUM APPROACH DISTANCE in Feet (Meters) 0 to 50KV 10 (3) Over 50 kv to 200 KV 15 (5) Over 200KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) NOTE: This requirement shall apply except where employer, local or governmental regulations are more stringent. Maintain a clearance of at least 10 ft. (3m) 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 approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. 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 (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE JLG Lift 1-7

18 SECTION 1 - SAFETY PRECAUTIONS. Tipping Hazards Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces. The user should be familiar with the driving surface before driving. Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm uniform surface before elevating platform or driving with the platform in the elevated position. Before driving on floors, bridges, trucks, and other surfaces, 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 0.6m (2 ft.) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level. Never attempt to use the machine as a crane. Do not tieoff machine to any adjacent structure. Never attach wire, cable, or any similar items to platform. 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. 1-8 JLG Lift

19 SECTION 1 - SAFETY PRECAUTIONS If scissor arm assembly or platform is caught so that one or more wheels are off the ground, all persons must be removed before attempting to free the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine and remove personnel. Crushing and Collision Hazards Approved head gear must be worn by all operating and ground personnel. Keep hands and limbs out of the scissor arm assembly during operation. Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform. During operation, keep all body parts inside platform railing. Always post a lookout when driving in areas where vision is obstructed. Keep non-operating personnel at least 1.8m. (6 ft.) away from machine during all driving operations. Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel. Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only. Do not use high speed drive in restricted or close quarters or when driving in reverse. Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform. Ensure that operators of other overhead and floor level machines are aware of the aerial work platform s presence. Disconnect power to overhead cranes. Barricade floor area if necessary. Avoid operating over ground personnel. Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor as necessary JLG Lift 1-9

20 SECTION 1 - SAFETY PRECAUTIONS 1.4 TOWING, LIFTING, AND HAULING Never allow personnel in platform while towing, lifting, or hauling. This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to emergency towing procedures. Ensure platform is fully retracted and completely empty of tools prior to towing, lifting or hauling. When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity. Refer to Section 4 for lifting information. 1.5 MAINTENANCE General This section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this maunual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe. Maintenance Hazards Shut off power to all controls and ensure that all operating systems are secured from inadvertent motion prior to performing any adjustments or repairs. Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports. Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. Always disconnect batteries when servicing electrical components or when performing welding on the machine. Shut down the engine (if equipped) while fuel tanks are being filled. Ensure replacement parts or components are identical or equivalent to original parts or components. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine JLG Lift

21 SECTION 1 - SAFETY PRECAUTIONS Remove all rings, watches, and jewelry when performing any maintenance. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment. Use only clean approved non-flammable cleaing solvents. Never alter, remove, or substitute any items such as counterweights, tires, batteries, platforms or other items that may reduce or affect the overall weight or stability of the machine. Reference the Service and Maintenance Manual for the weights of critical stability items. 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. 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 JLG Lift 1-11

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

24 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. 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. JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- UCT MODEL. 2-2 JLG Lift

25 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Type Pre-Start Inspection Pre-Delivery Inspection (See Note) Frequent Inspection Annual Machine Inspection (See Note) Preventative Maintenance Frequency Before using each day; or whenever there s an Operator change. Table 2-1.Inspection and Maintenance Table Primary Responsibility Service Qualification Reference User or Operator User or Operator Operator and Safety Manual Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of more than 3 months; or Purchased used. Annually, no later than 13 months from the date of prior inspection. At intervals as specified in the Service and Maintenance Manual. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form Owner, Dealer, or User Factory Trained Service Technician (Recommended) Service and Maintenance Manual and applicable JLG inspection form Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections JLG Lift 2-3

26 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.3 PRE-START INSPECTION The Pre-Start Inspection should include each of the following: 1. Cleanliness Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. Parent Metal Crack Weld Crack 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. 4. Operators and Safety Manuals Make sure a copy of the Operator and Safety Manual is enclosed in the weather resistant storage container. 5. Walk-Around Inspection Refer to Figure Battery Charge as required. 7. Fuel - (Combustion Engine Powered Machines) Add the proper fuel as necessary. 8. Engine Oil Supply - Ensure that the engine oil level is at the full mark on the dipstick and the filler cap is secure 9. Fluid Levels - Be sure to check the engine oil and the hydraulic oil levels. 10. Accessories/Attachments - Reference the Operator and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions. 11. Function Check Once the Walk-Around Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions on the operation of each function. 2-4 JLG Lift

27 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION Preparing the Machine for Operation Emergency Ground Control Station 1. Turn key-switch to ground control select. 2. Pull emergency stop switch to the On position. 3. Check the function of the protective scissor cage. Platform Control Box 1. Ensure the control box is connected at the platform. 2. Complete pre-operational checks: Check all functions Machine should not be drivable with outriggers extended. Check all limit switches Check the emergency-stop button Check the automatic self levelling IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. Function Check NOTE: Perform the Function Check as follows: 1. From the ground emergency control panel with no load in the platform: a. Check for proper lifting and lowering of the platform. b. Check manual descent. c. Ensure that all machine functions are disabled when the Emergency Stop Button is activated. Be sure the platform extension is retracted before lowering. 2. From the platform control console: a. Ensure that the control console is firmly secured in the proper location. b. Check that all guards protecting the switches locks are in place. c. Check the high drive cut out switch by raising the platform beyond the preset high drive speed cutout height of in. ( m) and ensure the high drive speed cuts out. d. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in JLG Lift 2-5

28 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION e. Ensure that all LED s in the control box are working properly. f. Check that the platform extension extends and retracts properly. 3. With the platform in the stowed position: a. Drive the machine on a level grade and stop to to ensure the brakes hold. b. To ensure proper operation of the tilt sensor, drive the machine onto a grade (front/rear) greater than the allowed tilt sensor preset (see Table 2-2 below), and attempt to raise the platform. The tilt alarm should sound when the platform elevation sensor detects the platform rising. Table 2-2. Tilt Sensor Preset Configuration Australia Only Global (Special Option - Long Leveling Jack Machines) JLG Lift

29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 2.4 DUAL FUEL SYSTEM (IF EQUIPPED) IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. Changing from Gasoline to LP Gas. 1. Start the engine from the ground control station. 2. Open the hand valve on the LP Gas supply tank by turning counterclockwise. Changing from LP Gas to Gasoline. 1. With the engine operating on LP gas under a no load condition, position the LPG/GAS SELECT switch at the platform control station to the GAS SELECT position. 2. If the engine stumbles because of a lack of gasoline, place the switch to the LPG position until the engine regains smoothness, then return the switch to the GAS SELECT position. Repeat as necessary until the engine runs smoothly on gasoline. Close the hand valve on the LP gas supply tank by turning clockwise. BE SURE ALL GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP GAS. 3. While the engine is operating, place the LPG/GAS SELECT switch at the platform control station to the LP Gas position JLG Lift 2-7

30 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 20 4, ,13 21 NOT SHOWN , ,13 Figure 2-1. Walk Around Inspection Diagram 2-8 JLG Lift

31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION GENERAL Begin the Walk-Around Inspection at Item 1, as noted on the diagram.continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the Walk-Around Inspection Checklist. TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DURING WALK-AROUND INSPECTION. DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDI- TIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE. NOTE: On each item, make sure there are no loose or missing parts, that they are securely fastened, and that no visible damage exists in addition to any other criteria mentioned. 1. Platform Controls - Properly secured, no loose or missing parts, no visible damage. Placards secure and legible, control switches return to neutral. Control markings legible, manual in manual storage box. 2. Steer Linkage - See Note. 3. Wheels and Tires - Properly secured, no missing lug nuts. Refer to section 6, Tires and Wheels. Inspect wheels for damage and corrosion. 4. Drive Motor, Left Front (4 Wheel Drive) - See Note. No evidence of leakage. 5. Drive Brake, Left Front (4 Wheel Drive) - See Note. No evidence of leakage. 6. Lift Cylinder - See Note. 7. Scissor Arms and Sliding Wear Pads - Properly secured, no visible damage, evidence of proper lubrication. Inspect scissor arm guards for damage and proper installation. 8. Hydraulic Reservoir - No visible damage or missing parts, No evidence of leaks. recommended oil level in sight glass. Breather cap secure and working. Figure 2-2. Walk Around Inspection Points - Sheet JLG Lift 2-9

32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 9. Fuel Tank (Gasoline or Diesel Engine) - Filler cap secure, sight gauge visible, no damage or leaks. 10. Ground Controls - Switches operable, no visible damage, placards secure and legible. 11. Control Valve - See Note. 12. Drive Motor, Left Rear - See Note. 13. Drive Brake, Left Rear - No loose or missing parts, no visible damage, no evidence of leakage. 14. Manual Descent Cable and Pull Handle - See Note. 15. Ladder - No damage, securely attached. 16. Speed Cutout Switch - No visible damage, properly secured. 17. Battery Installation (Gasoline or Diesel Engine) - Proper electrolyte level, cables secure, no damage or corrosion. Hold-downs secure. 18. Hydraulic Pump - Pump properly secured, no visible damage, no evidence of leakage. Hoses and fittings properly secured, no visible damage, no evidence of leaks. 19. Engine Installation - Engine oil to full mark on dipstick, oil filler cap secure. Muffler/exhaust system properly secured, no leakage. Air filter assembly secure, no loose or missing parts, element clean. Radiator cap secure, coolant to correct level. 20. Steer Cylinder and Tie Rod Ends - No loose or missing parts, no visible damage. No steer cylinder leaks or damage. 21. Platform Assembly - See Note. Platform deck extension operates properly Figure 2-3. Walk Around Inspection Points - Sheet JLG Lift

33 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL 3.1 GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSIBILITY OF THE USER AND HIS OPERATING PERSONNEL. This section provides the necessary information needed to understand control functions. Included in this section are the operating characteristics and limitations, and functions and purposes of controls and indicators. It is important that the user read and understand the proper procedures before operating the machine. These procedures will aid in obtaining optimum service life and safe operation. 3.2 OPERATING CHARACTERISTICS AND LIMITATIONS General A thorough knowledge of the operating characteristics and limitations of the machine is always the first requirement for any user, regardless of user s experience with similar types of equipment. Placards Important points to remember during operation are provided at the control stations by DANGER, WARNING, CAUTION, IMPORTANT and INSTRUCTION placards. This information is placed at various locations for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and load limitations of the machine. See foreword for definitions of the above placards. Capacities Raising platform above horizontal with or without any load in platform, is based on the following criteria: 1. Machine is positioned on a smooth, firm and level surface. 2. Load is within manufacturer s rated capacity. 3. All machine systems are functioning properly JLG Lift 3-1

34 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3.3 CONTROLS AND INDICATORS (Refer to Figure 3-1.) The machine is equipped with control panels that use symbols instead of words to indicate control functions. Ground Control Station DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON- NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY. PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM THE GROUND CONTROL STATION AS POSSIBLE. NOTE: NOTE: power selector switch in the center off position, power is shut off to both platform and ground controls and the key can be removed to disable the machine. With the Power Selector switch in the off position, the key can be removed in order to incapacitate the machine on the jobsite to avoid unauthorized use of the machine. With the POWER SELECTOR switch positioned to GROUND, ground functions will operate at low speed at all times. Low speed is the default speed for all functions. When the platform is elevated, all functions operate in creep speed only. NOTE: When the machine is shut down for overnight parking or battery charging, the EMERGENCY STOP and POWER SELECTOR switches must be positioned to OFF to prevent draining the batteries. 1. Power Selector Switch - A three position, key-operated power selector switch supplies operating power to the platform or ground controls, as selected. When positioned to platform, the switch provides power to the emergency stop switch at the platform controls. When positioned to ground, the switch provides power to the emergency stop switch at the ground controls. With the 2. Latch - Allows box to be opened and closed. 3. Circuit Breaker - This 10 Amp circuit breaker, located on the left side of the platform control box, restores interrupted power to the platform controls. 4. Alternator LED - Illuminates when the alternator drops below a pre-set level. 5. Oil Pressure LED - Illuminates when the engine oil pressure drops below 7 psi (0.48 bar). 3-2 JLG Lift

35 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 6. Glow Plug Switch - A momentary contact, push button type switch that supplies electrical power to the engine s glow plugs, when depressed, to assist cold starting. 7. Water Temperature LED - Illuminates when engine water temperature becomes overheated. 8. Charge Pressure - Illuminates when the charge pressure drops below 70 psi (4.8 bar), indicating the charge filter is clogged and needs to be replaced. The indicator is also connected to a temperature sensor to prevent false signals from being generated when the hydraulic oil is below normal operating temperature. 9. Lift Switch - A three position, momentary contact Lift control switch provides raising and lowering of the platform when positioned to up or down. 10. Hourmeter -The machine may be equipped with an hourmeter to indicate the number of hours the machine has been operated. 11. Ignition/Emergency Stop Switch - A two-position, red, mushroom-shaped ignition/emergency stop switch, when positioned to ON with the power selector switch positioned to ground, furnishes operating power to the ground control station. In addition, the switch can be used to turn off power to the function controls in the event of an emergency. Power is turned on by pulling NOTE: the switch out (on), and is turned off by pushing the switch in (off). 12. Start Switch - A momentary contact, push button type switch that supplies electrical power to the starter solenoid when the emergency stop switch is in the ON position and the start button is depressed. 13. Platform Overload LED (If Equipped) - Indicates the platform has been overloaded. An audible alarm will also signal when the platform is overloaded. If the Overload Indicator is illuminated, all functions will be prevented from the platform controls. Using the ground controls or manual descent, fully lower the machine and reduce the weight in the platform so as to not exceed the rated workload indicated on the capacity decal JLG Lift 3-3

36 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL B Platform/Ground Select Switch 2. Latch 3. Circuit Breaker 4. Alternator LED 5. Oil Pressure LED 6. Glow Plug Switch 7. Water Temperature LED 8. Hydraulic Charge Pressure LED 9. Lift Switch 10. Hourmeter 11. Emergency Stop Switch 12. Start Switch 13. Platform Overload LED (does not apply to all machines) Figure 3-1. Ground - Control Station 3-4 JLG Lift

37 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 3.4 PLATFORM CONTROL STATION (Refer to Figure 3-2.) 1. Start Switch - A momentary contact, push button type switch that supplies electrical power to the starter solenoid when the emergency stop switch is in the on position and the start button is depressed. 2. Controller (Joystick) - The Joystick controls three functions: drive, lift, and drive/lift speed. The drive or the lift function switch must be selected prior to moving the machine with the Joystick. The speed is controlled by the travel distance of the Joystick. 3. Steer Switch - The thumb-operated steer switch on top of the Joystick handle activates the steer wheels in the direction it is moved (right or left). 4. Speed/Generator Switch - The three position speed/ generator switch permits the operator to select either high range, low range or the generator (if equipped). DO NOT USE HIGH ENGINE SPEED WHEN DRIVING IN CLOSE QUAR- TERS OR WHEN DRIVING IN REVERSE. NOTE: If machine is being operated in high range speed and the platform is raised above in. ( m), the engine speed switch will cut-out returning drive speed to low until the platform is again lowered below the cut-out level. 5. Emergency Stop Switch - A two-position, red, mushroom-shaped emergency stop switch functions to provide power to the platform control station and also to turn off power to the platform function controls in the event of an emergency. With the Power selector switch positioned to platform, power is turned on by pulling the switch out (on), and is turned off by pushing the switch in (off). NOTE: The machine cannot be lifted up from platform controls or driven when the generator is selected. 4 wheel drive is operational in low drive only. DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM EXTENSION. 6. Lift Select Switch - The lift switch provides for raising and lowering the platform. Lift is activated by pressing the enable switch and positioning the joystick forward or backward JLG Lift 3-5

38 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 7. Drive Select Switch - The drive switch provides for driving the lift. Drive is activated by selecting the drive switch and positioning the joystick forward or backward. 8. Horn - (If Equipped) - This push-button switch, when activated, permits the operator to warn jobsite personnel when the machine is operating in the area. 9. Enable Trigger - Trigger on the front of the joystick must be held in to perform joystick controlled movements. 10. Glow Plug Switch - Glow Plug Switch - A momentary contact, push button type switch that supplies electrical power to the engine s glow plugs, when depressed, to assist cold starting. 11. Platform Overload LED (does not apply to all machines) - Illuminates when platform becomes overloaded. When LED illuminates, immediately remove excess weight from platform to continue safe operation. 3-6 JLG Lift

39 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 1. Start Switch 2. Joystick 3. Steer Switch A Speed/Generator Switch 5. Emergency Stop Switch 6. Lift Switch 7. Drive Switch 8. Horn Enable Trigger 10. Glow Plug Switch 11. Platform Overload LED B Figure 3-2. Platform - Control Station JLG Lift 3-7

40 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Platform Control Front Panel (Refer to Figure 3-3.) 1. Fuel/Glow Plug Selector Switch - Selects which fuel source will be used. LPG vs. Gasoline or Diesel for diesel machines. 2. Auto Leveling Jacks - The leveling jacks switch is located on the front of the platform control box. When depressed, the outrigger light will illuminate on the indicator pad. Moving the control handle forward will lower the leveling jacks. Moving the control handle backward will raise the leveling jacks. Once the machine is level, the jacks will discontinue extending and the jack set light will illuminate. a. Select the leveling jack selection switch and squeeze the red trigger switch on the controller. b. To adjust the leveling jacks to the left, activate the switch on top of the controller to the left. To adjust to the right, activate the switch on top of the controller to the right. The leveling jack indicator light for the side selected will be lit. NOTE: NOTE: After initial ground contact is made, the auto level function will pause 2-5 seconds and then begin to properly level the machine to the specified market specification. Once level, the tilt light on the platform control box will stop blinking. There is an override feature on the Auto Leveling system that allows the operator to adjust (trim) the level of the machine to the left or right when the platform is completely lowered. Use the following instructions to adjust the level of the machine. 3-8 JLG Lift

41 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL 1. Dual Fuel Selector Switch 2. Diesel Fuel Selector Switch 3. Outrigger Switch Figure 3-3. Platform - Control Front Panel JLG Lift 3-9

42 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Indicator Panel LED s (Refer to Figure 3-4.) 1. Drive - This LED will illuminate when the drive select button is activated. 2. Lift - This LED will illuminate when the lift select button is activated. 3. Fuel Gauge - This series of LED s give the operator a visual of the amount of fuel remaining. 4. Tilt Alarm Warning Light - This red warning light on the control panel will illuminate when the chassis is on a severe slope. 5. Engine/Filter Distress Light - This warning light, when illuminated, warns the operator of an engine or hydraulic system fault condition. A bank of warning lights, located at the ground control station, indicates the specific fault condition to the operator. The indicator lights are: Alternator, Charge Pressure, Engine Temperature, Oil Pressure, and Return Filter. 6. Leveling Jacks (retracted) - This set of lights will illuminate once all the leveling jacks are retracted. 7. Leveling Jacks (extended) - This set of lights will illuminate once all the leveling jacks are extended. FOR MACHINES EQUIPPED WITH THE YANMAR DIESEL ENGINE, THE TIMER RELAY MUST SEAT THE FUEL SOLENOID WITH ITS INITIAL PULSE, OR THE ENGINE WILL NOT START. PROLONGED NO-START IS AN INDICATION THAT THE FUEL SOLENOID HAS NOT SEATED OR THAT THERE IS NO FUEL. IF THE ENGINE FAILS TO START, THE START SWITCH MUST BE RE-CYCLED TO PULSE THE FUEL SOLENOID INTO THE SEATED POSITION. IF TILT ALARM IS ON WHEN PLATFORM IS RAISED, LOWER PLATFORM COMPLETELY, THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE RAISING PLATFORM. DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLATFORM IS RAISED ABOVE THE STOWED POSITION JLG Lift