Boom Lift Models E300AJ E300AJP - Construction … · Operation and Safety Manual ANSI ® Original...

Operation and Safety Manual

ANSI ®

Original Instructions - Keep this manual with the machine at all times.

Boom Lift ModelsE300AJE300AJPS/N 0300138358 to Present

3121252August 9, 2012

FOREWORD

a

l times.

lessors, and lessees with the precautions anderation for its intended purpose.

erves the right to make specification changesformation.

3121252 – JLG Lift –

FOREWORD

This manual is a very important tool! Keep it with the machine at al

The purpose of this manual is to provide owners, users, operators,operating procedures essential for the safe and proper machine op

Due to continuous product improvements, JLG Industries, Inc. reswithout prior notification. Contact JLG Industries, Inc. for updated in

FOREWORD

b 3121252

SIGNAL WORDS

INDIAVOWIL

INDAVODEC

OTENTIALLY HAZARDOUS SITUATION. IF NOTRESULT IN MINOR OR MODERATE INJURY. IT MAYINST UNSAFE PRACTICES. THIS DECAL WILL HAVE AOUND.

RMATION OR A COMPANY POLICY THAT RELATESDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-PERTY.

the potential personalymbol to avoid possible

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALL HAVE A RED BACKGROUND.

ICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOTIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A PAVOIDED, MAY ALSO ALERT AGAYELLOW BACKGR

INDICATES INFODIRECTLY OR INTECTION OF PRO

This is the Safety Alert Symbol. It is used to alert you toinjury hazards. Obey all safety messages that follow this sinjury or death

FOREWORD

c

act:

uct Safety and Reliability Department Industries, Inc.4 Fountainhead Plaza

erstown, MD 21742

our Local JLG Office addresses on inside of manual cover)

A:

Free: 877-JLG-SAFE (877-554-7233)

ide USA:

ne: 240-420-2661 301-745-3713ail: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

tions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

3121252 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

JLG 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.

JLG 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 PERSONAL PROP-ERTY OR THE JLG PRODUCT.

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FOREWORD

d 3121252

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– JLG Lift –

REVISION LOG

riginal Issue - June 26, 2009

evised - September 29, 2009

evised - October 28, 2009

evised - November 19, 2009

evised - November 8, 2010

evised - February 6, 2012

evised - August 9, 2012

TABLE OF CONTENTS

3121 i

SEC - PARAGRAPH, SUBJECT PAGE

SEC

SECPRE

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

- 3 - MACHINE CONTROLS AND INDICATORS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-2Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Platform Control Indicator Panel . . . . . . . . . . . . 3-11

- 4 - MACHINE OPERATION

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1BOOM OPERATING CHARACTERISTICS AND LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-6Power/Emergency Stop Switch . . . . . . . . . . . . . 4-6Platform/Ground Select Switch. . . . . . . . . . . . . . 4-6Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-7Traveling Forward and Reverse . . . . . . . . . . . . . 4-9

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-9Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . 4-9

252 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

TION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge. . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-81.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

TION - 2 - USER RESPONSIBILITIES, MACHINE PARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION

3.13.2

SECTION

4.14.2

4.3

4.4

4.54.6

TABLE OF CONTENTS

ii 3121252

SECTIO RAGRAPH, SUBJECT PAGE

4.7

4.84.94.10

SECTION

5.15.25.3

5.45.55.6

SECTIONMAINTEN

6.16.2

imensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2apacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3ydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4ajor Component Weights. . . . . . . . . . . . . . . . . 6-7RATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-9TERY MAINTENANCE AND CHARGING. . . . .6-13attery Maintenance, Quarterly . . . . . . . . . . . . 6-13attery Charging, Daily. . . . . . . . . . . . . . . . . . . 6-14S & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-15

re Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-15heel and Tire Replacement . . . . . . . . . . . . . . 6-15heel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-15PLEMENTAL INFORMATION . . . . . . . . . . . . .6-16

INSPECTION AND REPAIR LOG

LIST OF FIGURES

ic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7y Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-8y Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-9y Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10und Control Station - E300AJ . . . . . . . . . . . . . .3-3und Control Station - E300AJP . . . . . . . . . . . . .3-4

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-11Raising and Lowering the Upper Boom . . . . . 4-11

FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . 4-11SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-11LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1Platform or Boom Caught Overhead. . . . . . . . . 5-2

EMERGENCY TOWING PROCEDURES . . . . . . . . . 5-2MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . . 5-2MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . 5-4

- 6 - GENERAL SPECIFICATIONS & OPERATOR ANCE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1OPERATING SPECIFICATIONS AND PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operating Specifications . . . . . . . . . . . . . . . . . . 6-1

DCTiHM

6.3 OPE6.4 BAT

BB

6.5 TIRETiWW

6.6 SUP

SECTION - 7 -

2-1. Bas2-2. Dail2-3. Dail2-4. Dail3-1. Gro3-2. Gro

TABLE OF CONTENTS

3121 iii

SEC - PARAGRAPH, SUBJECT PAGE

LIST OF TABLES

Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10Inspection and Maintenance Table. . . . . . . . . . . . . 2-3Operating specifications - E300AJ . . . . . . . . . . . . . 6-1Operating specifications - E300AJP . . . . . . . . . . . . 6-2Dimensional Data - E300AJ . . . . . . . . . . . . . . . . . . 6-2Dimensional Data - E300AJP . . . . . . . . . . . . . . . . . 6-3Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . 6-4Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . 6-5Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . 6-5Mobil EAL Envirosyn H Specs . . . . . . . . . . . . . . . . 6-6Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . 6-6Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-7Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-9Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-16Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

252 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

3-2. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-83-3. Platform Control Indicator Panel . . . . . . . . . . . . . .3-124-1. Position of Least Forward Stability . . . . . . . . . . . . .4-34-2. Position of Least Backward Stability - E300AJ . . . .4-44-3. Position of Least Backward Stability - E300AJP . . .4-54-4. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-84-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . .4-134-6. Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . .4-144-7. Decal Location Sheet 2 of 5. . . . . . . . . . . . . . . . . .4-154-8. Decal Location Sheet 3 of 5. . . . . . . . . . . . . . . . . .4-164-9. Decal Location Sheet 4 of 5. . . . . . . . . . . . . . . . . .4-174-10. Decal Location Sheet 5 of 5. . . . . . . . . . . . . . . . . .4-185-1. Manual Descent Location . . . . . . . . . . . . . . . . . . . .5-36-1. Operator Maintenance and Lubrication Diagram . .6-8

1-11-22-16-16-26-36-46-56-66-76-86-96-106-116-126-136-146-157-1

TABLE OF CONTENTS

iv 3121252

SECTIO RAGRAPH, SUBJECT PAGE

lly.

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

This page left blank intentiona

SECTION 1 - SAFETY PRECAUTIONS

1-1

CAUTIONS

E-OPERATION

Training and Knowledged and understand this manual before operating thehine.

not operate this machine until complete training is per-ed by authorized persons.

y authorized and qualified personnel can operate thehine.

3121252 – JLG Lift –

SECTION 1. SAFETY PRE

1.1 GENERALThis section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of this manual. A maintenanceprogram, using the information provided in this manual andthe Service and Maintenance Manual, must also be estab-lished by a qualified person and followed to ensure themachine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not operate the machine until this manual has beenread, training is accomplished, and operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.

If there are any questions with regard to safety, training,inspection, maintenance, application, and operation, pleasecontact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-AGE, PERSONAL INJURY OR DEATH.

1.2 PR

Operator• Rea

mac

• Do form

• Onlmac


1-2 3121252

Wo

pection achine operation, perform inspections and func-

hecks. Refer to Section 2 of this manual for instructions.

perate this machine until it has been serviced anded according to requirements specified in theand Maintenance Manual.

the footswitch and all other safety devices areg properly. Modification of these devices is aolation.

R ALTERATION OF AN AERIAL WORK PLATFORMONLY WITH WRITTEN PERMISSION FROM THE MANU-

perate any machine on which safety or instruction or decals are missing or illegible.

ny buildup of debris on the platform floor. Keep, grease, and other slippery substances from foot-d platform floor.

– JLG Lift –

• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

• Use the machine in a manner which is within the scope ofits intended application set by JLG.

• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain tooperation of the machine.

rkplace Inspection• The operator is to take safety measures to avoid all haz-

ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail-ers, railway cars, floating vessels, scaffolds or other equip-ment unless approved in writing by JLG.

• Do not operate the machine in hazardous environmentsunless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support themaximum load shown on the decals located on themachine.

Machine Ins• Before m

tional cdetailed

• Do not omaintainService

• Be sureoperatinsafety vi

MODIFICATION OSHALL BE MADE FACTURER

• Do not oplacards

• Avoid amud, oilwear an


1-3

plies or tools which extend outside the platform arehibited unless approved by JLG.

en driving, always position boom over rear axle in line the direction of travel. Remember, if boom is over thet axle, steer and drive functions will be reversed.

not assist a stuck or disabled machine by pushing,ing, or by using boom functions. Only pull the unit the tie-down lugs on the chassis.

not place boom or platform against any structure tody the platform or to support the structure.

w boom and shut off all power before leaving machine.

Fall Hazards operation, occupants in the platform must wear a fullarness with a lanyard attached to an authorized lan-

nchorage point. Attach only one (1) lanyard per lan-nchorage point.

3121252 – JLG Lift –

1.3 OPERATION

General • Do not use the machine for any purpose other than posi-

tioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If amalfunctions occurs, shut down the machine.

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

• Do not allow personnel to tamper with or operate themachine from the ground with personnel in the platform,except in an emergency.

• Do not carry materials directly on platform railing. ContactJLG for approved material handling accessories.

• When two or more persons are in the platform, the opera-tor shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Suppro

• Whwithfron

• Do pullfrom

• Do stea

• Sto

Trip and Duringbody hyard ayard a


1-4 3121252

reme caution when entering or leaving platform. that the boom is fully lowered. It may be neces-elescope out to position the platform closer to thefor entry/exit. Face the machine, maintain “threentact” with the machine, using two hands and one

o feet and one hand during entry and exit.

n Hazardschine is not insulated and does not provide pro-rom contact or proximity to electrical current.

– JLG Lift –

• Before operating the machine, make sure all gates areclosed and fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at alltimes. Never use ladders, boxes, steps, planks, or similaritems on platform to provide additional reach.

• Never use the boom assembly to enter or leave the plat-form.

• Use extBe suresary to tground point cofoot or tw

Electrocutio• This ma

tection f


1-5

in a clearance of at least 10 ft. (3m) between any part machine and its occupants, their tools, and their

ent from any electrical line or apparatus carrying up00 volts. One foot additional clearance is required for

additional 30,000 volts or less.

1-1. Minimum Approach Distances (M.A.D.)

oltage Rangease to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

r 50KV to 200 KV 15 (5)

200 KV to 350 KV 20 (6)

350 KV to 500 KV 25 (8)

500 KV to 750 KV 35 (11)

50 KV to 1000 KV 45 (14)

This requirement shall apply except whereemployer, local or governmental regulationsare more stringent.

3121252 – JLG Lift –

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintaof theequipmto 50,0every

Table

V(Ph

Ove

Over

Over

Over

Over 7

NOTE:


1-6 3121252

•

DO ZONENE

ardsr must be familiar with the surface before driving.exceed the allowable sideslope and grade while

– JLG Lift –

The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Theminimum approach distance shall be reduced to a distancewithin the designed working dimensions of the insulatingbarrier. This determination shall be made by a qualified per-son in accordance with the employer, local, or governmentalrequirements for work practices near energized equipment

NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARERGIZED UNLESS KNOWN OTHERWISE.

Tipping Haz• The use

Do not driving.


1-7

oom assembly or platform is in a position that one ore wheels are off the ground, all persons must beoved before attempting to stabilize the machine. Usees, forklift trucks, or other appropriate equipment toilize machine.

and Collision Hazardsroved head gear must be worn by all operating and

und personnel.

ck work area for clearances overhead, on sides, andom of platform when lifting or lowering platform, anding.

ing operation, keep all body parts inside platform rail-

3121252 – JLG Lift –

• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft surface.

• Before driving on floors, bridges, trucks, and other sur-faces, check allowable capacity of the surfaces.

• Never exceed the maximum platform capacity. Distributeloads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi-tion unless the machine is on firm, level and smooth sur-faces.

• Keep the chassis of the machine at least 2 ft. (0.6m) fromholes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards on the floor/surface.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (ForReference Only).

• Do not increase the surface area of the platform or theload. Increase of the area exposed to the wind willdecrease stability.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If bmorremcranstab

Crushing• App

gro

• Chebottdriv

• During.


1-8 3121252

G, LIFTING, AND HAULINGllow personnel in platform while towing, lifting, or

chine should not be towed, except in the event ofcy, malfunction, power failure, or loading/unload-

er to the Emergency Procedures section of thisfor emergency towing procedures.

boom is in the stowed position and the turntablerior to towing, lifting or hauling. The platform mustletely empty of tools.

ting machine, lift only at designated areas of the. Lift the unit with equipment of adequate capac-

the Machine Operation section of this manual forormation.

– JLG Lift –

• Use the boom functions, not the drive function, to positionthe platform close to obstacles.

• Always post a lookout when driving in areas where visionis obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) awayfrom machine during all driving and swing operations.

• Limit travel speed according to conditions of ground sur-face, congestion, visibility, slope, location of personnel,and other factors which may cause collision or injury topersonnel.

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quartersor when driving in reverse.

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Be sure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedboom or platform. Position barricades on floor if neces-sary.

1.4 TOWIN• Never a

hauling.

• This maemergening. Refmanual

• Ensure locked pbe comp

• When lifmachineity.

• Refer tolifting inf


1-9

not refuel the machine with the engine running.

tery fluid is highly corrosive. Avoid contact with skin clothing at all times.

rge batteries only in a well ventilated area.

3121252 – JLG Lift –

1.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations,precautions must be taken to protect the chassis fromdirect exposure to weld and metal cutting spatter.

• Do

• Batand

• Cha


1-1 3121252

DO NMPH

Only)

Land Conditions

ertically

n smoke

skin. Leaves rustle

wigs in constant motion

r raised. Small branches begin to move.

tion. Whistling heard in overhead wires. es difficult.

n. Effort needed to walk against the wind.

ees. Cars veer on road.

ge.

0 – JLG Lift –

OT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 (12.5 M/S).

Table 1-2. Beaufort Scale (For Reference

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises v

1 1-3 0.3-1.5 Light air Wind motion visible i

2 4-7 1.6-3.3 Light breeze Wind felt on exposed

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller t

4 13-18 5.5-7.9 Moderate breeze Dust and loose pape

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in moUmbrella use becom

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motio

8 39-46 17.2-20.7 Fresh Gale Twigs broken from tr

9 47-54 20.8-24.4 Strong Gale Light structure dama

CHINE PREPARATION, AND INSPECTION

2-1

PREPARATION, AND INSPECTION

e safest means to operate the machine where over-ad obstructions, other moving equipment, and obsta-

es, depressions, holes, drop-offs.

eans to avoid the hazards of unprotected electricalnductors.

ecific job requirements or machine application.

Supervisiong must be done under the supervision of a qualified in an open area free of obstructions until the traineeveloped the ability to safely control and operate the

ne.

Responsibilityerator must be instructed that he/she has the respon-

and authority to shut down the machine in case of action or other unsafe condition of either the machinejob site.

SECTION 2 - USER RESPONSIBILITIES, MA

3121252 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

Persons under the influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and atthe ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on themachine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of themachine to recognize a malfunction or potential mal-function.

6. Thhecl

7. Mco

8. Sp

Training Traininpersonhas demachi

OperatorThe opsibilitymalfunor the

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121252

2.2, INC. RECOGNIZES A FACTORY-TRAINED SERVICEA PERSON WHO HAS SUCCESSFULLY COMPLETED TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for further requirements for aerial work plat-forms. The frequency of inspections and maintenance mustbe increased as necessary when the machine is used in aharsh or hostile environment, if the machine is used withincreased frequency, or if the machine is used in a severemanner.

JLG INDUSTRIESTECHNICIAN AS THE JLG SERVICEMODEL.


2-3

ance Table

ryibility

Service Qualification

Reference

or User or Operator Operator and Safety Manual

or User Qualified JLG Mechanic

Service and Maintenance Manual and applicable JLG inspection form



or User Factory-TrainedService Technician(Recommended)



Service and Maintenance Manual

nce Manual to perform inspections.


3121252 – JLG Lift –

Table 2-1. Inspection and Mainten

Type Frequency PrimaRespons

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operat

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer,

Frequent Inspection(See Note)

In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer,

Annual Machine Inspec-tion(See Note)

Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer,

Preventative Maintenance At intervals as specified in the Service and Main-tenance Manual.

Owner, Dealer,

NOTE: Inspection forms are available from JLG. Use the Service and Maintena


2-4 3121252

Pre tion and Safety Manuals – Make sure a copy oferator and Safety Manual, AEM Safety Manual

markets only), and ANSI Manual of Responsibili-NSI markets only) is enclosed in the weathernt storage container.

-Around” Inspection – Refer to Figure 2-2.

y – Charge as required.

ulic Oil – Check the hydraulic oil level. Ensurelic oil is added as required.

sories/Attachments - Reference the Operatorafety Manual of each attachment or accessoryd upon the machine for specific inspection, oper-

and maintenance instructions.

– JLG Lift –

-Start InspectionThe Pre-Start Inspection should include each of the follow-ing:

1. Cleanliness – Check all surfaces for leakage (oil, fuel,or battery fluid) or foreign objects. Report any leakage tothe proper maintenance personnel.

2. Structure - Inspect the machine structure for dents,damage, weld or parent metal cracks or other discrep-ancies.

3. Decals and Placards – Check all for cleanliness andlegibility. Make sure none of the decals and placards aremissing. Make sure all illegible decals and placards arecleaned or replaced.

4. Operathe Op(ANSI ties (Aresista

5. “Walk

6. Batter

7. Hydrahydrau

8. Accesand Sinstalleation,

Parent Metal Crack Weld Crack


2-5

Check the Function Check as follows:

om the ground control console with no load in theatform:

. Check that all guards protecting the switches orlocks are in place;

. Operate all functions and ensure proper operation;

. Ensure that all machine functions are disabledwhen the Emergency Stop Button is pushed in.

. Ensure all boom functions stop when the functionenable switch is released.


3121252 – JLG Lift –

9. Function Check – Once the “Walk-Around” Inspectionis complete, perform a functional check of all systems inan area free of overhead and ground level obstructions.Refer to Section 4 for more specific operating instruc-tions.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THEMACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPERMAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL ITIS DECLARED SAFE FOR OPERATION.

FunctionPerform

1. Frpl

a

b

c

d


2-6 3121252

the boom over either of the rear tires and ensuree Drive Orientation indicator illuminates and thative Orientation Override switch must be used forve function to operate.

– JLG Lift –

2. From the platform control console:

a. Ensure that the control console is firmly secured inthe proper location;

b. Check that all guards protecting the switches orlocks are in place;

c. Operate all functions and ensure proper operation;

d. Ensure that all machine functions are disabledwhen the Emergency Stop Button is pushed in.

e. Ensure that all machine functions stop when thefootswitch is released.

3. With the platform in the stowed position:

a. Drive the machine on a grade, not to exceed therated gradeability, and stop to ensure the brakeshold;

b. Check that the tilt indicator is illuminated to ensureproper operation.

4. Swingthat ththe Drthe dri


2-7

1

ure

1. Platform2. Platform Console3. Jib Rotator (E300AJP Only)4. Boom Fly Section5. Main Boom6. Turntable7. Counterweight8. Non-Drive Hub9. Battery Box10. Drive Hub11. Ground Console12. Powertrack13. Jib14. Platform Rotator


3121252 – JLG Lift –

2

3

4

56

7

8

9

10

11

1213 14

Figure 2-1. Basic Nomenclat


2-8 3121252

1

21283

heet 1 of 3

– JLG Lift –

13

564

14

7118

105

8

5 1015

92

167

146 5

Figure 2-2. Daily Walk-Around Inspection - S


2-9

oom Sections/Uprights/Turntable - See Inspectionote.

wing Motor and Worm Gear - No evidence of dam-ge.

heel/Tire Assemblies - Properly secured, no miss-g lug nuts. Inspect for worn tread, cuts, tears or otheriscrepancies. Inspect wheels for damage and corro-ion.

rive Motor, Brake, and Hub - No evidence of leak-ge.

ood Assemblies - See Inspection Note.

ll Hydraulic Cylinders - No visible damage; pivotins and hydraulic hoses undamaged, not leaking.

urntable Bearing - Evidence of proper lubrication.o evidence of loose bolts or looseness betweenearing and machine.

ie Rod Ends and Steering Spindles - See Inspec-ion Note.

n - Sheet 2 of 3


3121252 – JLG Lift –

GeneralBegin the "Walk-Around Inspection" at Item 1, as noted onthe diagram. Continue checking each item in sequence forthe conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEENCORRECTED.

INSPECTION NOTE: On all components, make sure thereare no loose or missing parts, that they are securely fas-tened, and no visible damage, leaks or excessive wearexists in addition to any other criteria mentioned.

1. Platform Assembly and Gate - Footswitch worksproperly, not modified, disabled or blocked. Latch andhinges in working condition.

2. Platform & Ground Control Consoles - Switches andlevers return to neutral, decals/placards secure andlegible, control markings legible.

3. BN

4. Sa

5. Winds

6. Da

7. H

8. Ap

9. TNb

10. Tt

Figure 2-3. Daily Walk-Around Inspectio


2-1 3121252

ry Compartment - Batteries have proper elec- level; cables tight; see Inspection Note.

terweight - See Inspection Note.

al Descent - See Inspection Note.

heet 3 of 3

0 – JLG Lift –

11. Hydraulic Pump and Reservoir - See InspectionNote.

12. Platform Rotator - See Inspection Note.

13. Jib Rotator - See Inspection Note.

14. Battetrolyte

15. Coun

16. Manu

Figure 2-4. Daily Walk-Around Inspection - S

MACHINE CONTROLS AND INDICATORS

3-1

AND INDICATORS

e indicator panels use different shaped symbols to alert operator to different types of operational situationst could arise. The meaning of those symbols arelained below.

Indicates a potentially hazardous situation, whichif not corrected, could result in serious injury ordeath. This indicator will be red.

Indicates an abnormal operating condition,which if not corrected, may result in machineinterruption or damage. This indicator will be yel-low.

Indicates important information regarding theoperating condition, i.e. procedures essential forsafe operation. This indicator will be green withthe exception of the capacity indicator which willbe green or yellow depending upon platformposition.

SECTION 3 -

3121252 – JLG Lift –

SECTION 3. MACHINE CONTROLS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control panels that usesymbols to indicate control functions. On ANSI machinesrefer to decal located on the control box guard in front ofthe control box or by the ground controls for these sym-bols and the corresponding functions.

NOTE: Ththethaexp

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121252

TO ATROMOV

Gro

(S

NOT

NOT

NOT

Charge Status

LED lights indicate charge status of battery.; indicates 100% charged. Yellow; indicatesr on. Red; indicates abnormal battery condition.

on Enable

able switch must be held "DOWN" to enable allcontrols when the machine power is on.

oom Lift

es raising/lowering of the main boom when posi- up or down.

Boom Lift

es raising and lowering of the upright and lower.

es 350 degrees non-continuous turntable rotation.vate SWING, position switch to LEFT or RIGHT.

– JLG Lift –

VOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-L LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

und Control Station

ee Figure 3-1. and Figure 3-2. )

E: When machine is shut down the Platform/Ground Selectswitch and Emergency Stop must be positioned to OFF.

E: When Power/Emergency Stop Switch is in the on positionand motor is not running, an alarm will sound, indicatingpower is on.

E: The Function Enable switch must be helddown in order to operate Boom Telescope,Lower Lift, Swing, Main Lift, Jib Lift, PlatformLevel Override, and Platform Rotate functions.

1. Battery

Three Greencharge

2. Functi

The enboom

3. Main B

Providtioning

4. Lower

Providbooms

5. Swing

ProvidTo acti


3-3

- E300AJ

1. Battery Charge Status2. Function Enable3. Main Boom Lift4. Lower Boom Lift5. Swing6. Platform/Ground Select7. Power/Emergency Stop8. Telescope9. Jib Lift10. Not Used11. Platform Level12. Platform Rotate13. Platform Overload14. Battery Condition/Hourmeter

SECTION 3 -

3121252 – JLG Lift –

1001109630 B

1

2

3

4

5

6

7

8

9

11

12

13

14

Figure 3-1. Ground Control Station


3-4 3121252

1. Battery Charge Status2. Function Enable3. Main Lift4. Lower Lift5. Swing6. Platform/Ground Select 7. Power/Emergency Stop8. Telescope9. Jib Lift10. Jib Swing11. Platform Level12. Platform Rotate13. Platform Overload14. Battery Condition/Hourmeter

00AJP

– JLG Lift –

1001109655 B

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Figure 3-2. Ground Control Station - E3


3-5

ACHINE IS SHUT DOWN THE POWER/EMERGENCY STOPST BE POSITIONED TO THE OFF POSITION TO PREVENTE BATTERIES.

wer/Emergency Stop Switch

two-position red mushroom shaped switch supplieswer to PLATFORM/GROUND SELECT switch whenlled out (on). When pushed in (off), power is shut off

the PLATFORM/GROUND SELECT switch.

lescope Control

ovides extension and retraction of the boom.

SECTION 3 -

3121252 – JLG Lift –

NOTE: When the Platform/Ground Select Switch is in the centerposition, power is shut off to the controls at both operat-ing stations. Remove the key to prevent the controls frombeing actuated. The key is removable in the platform posi-tion on CE specification machines. The key must be avail-able to ground personnel in the event of an emergency.

6. Platform/Ground Select Switch

The three position, key operated switch supplies powerto the platform control console when positioned toPLATFORM. With the switch key turned to the GROUNDposition, power is shut off to platform and only groundcontrols are operable.

WHEN THE MSWITCH MUDRAINING TH

7. Po

A poputo

8. Te

Pr


3-6 3121252

ONLSLIGTHERES

m Rotate

es rotation of the platform.

m Overload (If equipped)

tes the platform has been overloaded.

Indicator and Hourmeter

ttery indicator displays the present charge of thees. The hourmeter counts the amount of machineing time, up to 9,999.9 hours, and cannot be

– JLG Lift –

9. Jib Lift

Provides raising and lowering of the jib.

10. Jib Swing

Allows swinging of the jib.

Y USE THE PLATFORM LEVELING OVERRIDE FUNCTION FORHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE

LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULDULT IN DEATH OR SERIOUS INJURY.

11. Platform Leveling Override

A three position switch allows the operator to adjust theautomatic self leveling system. This switch is used toadjust platform level in situations such as ascending/descending a grade.

12. Platfor

Provid

13. Platfor

Indica

14. Battery

The babatterioperatreset.


3-7

THE PLATFORM LEVELING OVERRIDE FUNCTION FORLING OF THE PLATFORM. INCORRECT USE COULD CAUSE

CCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULDEATH OR SERIOUS INJURY.

atform Leveling Override

three position switch allows the operator to adjust thetomatic self leveling system. This switch is used tojust platform level in situations such as ascending/scending a grade.

orn

push-type HORN switch supplies electrical power to audible warning device when pressed.


two-position red mushroom shaped switch furnisheswer to PLATFORM Controls when pulled out (on).hen pushed in (off), power is shut off to the platformnctions.

SECTION 3 -

3121252 – JLG Lift –

Platform Station

(See Figure 3-2., Platform Control Console)

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMMOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITIONWHEN RELEASED.

1. Posi-Track

When one wheel is slipping and the machine is notdescending a grade, automatic traction control will pro-vide added torque to both drive wheels. While this func-tion is automatic, it may also be manually engaged bymoving the toggle switch to the forward position. Posi-trac will be engaged for approximately 20 seconds.

ONLY USE SLIGHT LEVETHE LOAD/ORESULT IN D

2. Pl

A auadde

3. H

A an

4. Po

A poWfu


3-8 3121252

1702565 B

1001107677 A

A

5

67

. Lower Boom Lift

. Platform Rotate

. Function Speed

. Main Lift/Swing

– JLG Lift –

1702566 B

1704422

1 2 3 4

89101113 12

1. Posi-Track2. Platform Leveling Override3. Horn4. Power/Emergency Stop5. Drive Orientation Override

6. Drive/Steer7. Telescope8. Jib9. Jib Swing

10111213

Figure 3-2. Platform Control Console


3-9

lescope

ovides extension and retraction of the main boom.

b

ovides for raising or lowering of the jib by positioning/down.

b Swing (If equipped)

ovides jib swing right or left.

wer Boom Lift

ovides for raising and lowering of Upright when posi-ned to UP or DOWN.

atform Rotate

ovides rotation of the platform when positioned to theht or left.

SECTION 3 -

3121252 – JLG Lift –

5. Drive Orientation Override

When the boom is swung over the rear tires or further ineither direction, the Drive Orientation indicator will illumi-nate when the drive function is selected. Push andrelease the switch, and within 3 seconds move theDrive/Steer control to activate drive or steer. Before driv-ing, locate the black/white orientation arrows on boththe chassis and the platform controls. Move the drivecontrols in a direction matching the directional arrows.

NOTE: To operate the Drive joystick, pull up on the locking ringbelow the handle.

NOTE: The Drive joystick is spring loaded and will automaticallyreturn to neutral (off) position when released.

6. Drive/Steer

Push forward to drive forward, pull back to drive inreverse. Steering is accomplished via a thumb-activatedrocker switch on the end of the steer handle.

NOTE: When boom is positioned above horizontal and Posi-Trackengaged or Function speed are positioned to high, highfunction speeds are automatically cut out and themachine continues to operate at a lower speed.

7. Te

Pr

8. Ji

Prup

9. Ji

Pr

10. Lo

Prtio

11. Pl

Prrig


3-1 3121252

rate the Main Boom Lift/Swing joystick, pull up oning ring below the handle.

in Boom Lift/Swing joystick is spring loaded andtomatically return to neutral (off) position whend.

ift/Swing Controller

es main lift and swing. Push forward to lift up, pullard to boom down. Move right to swing right,left to swing left. Moving the joystick activateses to provide the functions selected. Proportionall of these functions can be attained by using theon Speed knob.

0 – JLG Lift –

12. Function Speed Control

Adjusts speed of Boom and Swing Functions. Rotatecounterclockwise for slower speed and clockwise forfaster speed. To adjust Drive, Swing, and Main Boom Liftto creep, turn knob fully counterclockwise until it clicks.

NOTE: To opethe lock

NOTE: The Mawill aurelease

13. Main L

Providbackwmove switchcontroFuncti


3-11

lt Alarm Warning Light and Alarm

is red illuminator indicates that the chassis is on aope. An alarm will also sound when the chassis is on aope and the boom is above horizontal. If lit when boom raised or extended, retract and lower to below hori-ntal then reposition machine so that it is level beforentinuing operation. If the boom is above horizontald the machine is on a slope, the tilt alarm warninght will illuminate and an alarm will sound and CREEP

automatically activated.

NING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED ORRETRACT AND LOWER TO BELOW HORIZONTAL THEN MACHINE SO THAT IT IS LEVEL BEFORE EXTENDINGISING BOOM ABOVE HORIZONTAL.

Tilt Angle Market

3° CE & Australia

5° ANSI & Japan

SECTION 3 -

3121252 – JLG Lift –

Platform Control Indicator Panel

(See Figure 3-3., Platform Control Indicator Panel)

NOTE: The platform control indicator panel uses different shapedsymbols to alert the operator to different types of opera-tional situations that could arise. The meaning of thosesymbols are explained below.

1. Ti

Thslsliszocoanligis

IF TILT WAREXTENDED, REPOSITIONBOOM OR RA

Indicates a potentially hazardous situation, whichif not corrected, could result in serious injury ordeath. This indicator will be red.

Indicates an abnormal operating condition,which if not corrected, may result in machineinterruption or damage. This indicator will be yel-low.

Indicates important information regarding theoperating condition, i.e. procedures essential forsafe operation. This indicator will be green withthe exception of the capacity indicator which willbe green or yellow depending upon platformposition.


3-1 3121252

ur likely causes of a system fault are:

e seven second enable time has been allowed topse or a function was selected before depressinge footswitch. The system reads this condition as ault, just as it would if the footswitch were jammed the depressed position or a function switch wereuck in the on position. Re-depress the footswitch power the controls and extinguish the light.

e maximum power limit has been reached ande machine is not moving. This could happenhen the machine is stuck or when attempting tovel over rough terrain or on steep grades whichceed the rated gradeability of the machine. Thisndition is comparable to stalling the engine byking i t to provide more power than it wassigned to do.

e batteries are nearly depleted, and should bearged very soon to prevent having the machine

op at an inconvenient place.

ere is some other fault in one of the circuits.etermine the cause by counting the flash code, amber of flashes followed by a pause followed byother number of flashes, and refer to the serviceanual.

2 – JLG Lift –

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. System Distress Indicator

The system distress indicator lights to signify an electri-cal system fault.

The fo

a. Thlathfainstto

b. Ththwtraexcoasde

c. Thchst

d. ThDnuanm

1001110226 A

+-

8 7

1 65432

1. Tilt2. Platform Overload3. System Distress4. Drive Orientation

5. Posi-Track6. Enable7. Low Battery8. Creep

Figure 3-3. Platform Control Indicator Panel


3-13

ERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLEITCH BY BLOCKING OR ANY OTHER MEANS.

MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHENY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT-

w Battery Indicator

dicates the batteries are low and need to be charged.

reep Speed Indicator

hen the Function Speed Control is turned to the creepsition, the indicator acts as a reminder that all func-ns are set to the slowest speed.

SECTION 3 -

3121252 – JLG Lift –

4. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires orfurther in either direction, the Drive Orientation indicatorwill illuminate when the drive function is selected. This isa signal for the operator to verify that the drive control isbeing operated in the proper direction (i.e. controlsreversed situations).

5. Posi-Track Indicator

This indicator lights to show that posi-track is operating.

6. Enable Indicator/Footswitch

To operate any function, the footswitch must bedepressed and the function selected within seven sec-onds. The enable indicator shows that the controls areenabled. If a function is not selected within seven sec-onds, or if a seven second lapse between ending onefunction and beginning the next function, the enablelight will go out and the footswitch must be released anddepressed again to enable the controls.

Releasing the footswitch removes power from all con-trols and applies the drive brakes.

TO AVOID STHE FOOTSW

FOOTSWITCHSWITCH ONLTOM.

7. Lo

In

8. C

Wpotio


3-1 3121252
4 – JLG Lift –
NOTES:

SECTION 4 - MACHINE OPERATION

4-1

PERATIONimary operator control station is in the platform. Fromntrol station, the operator can drive and steer the

ne in both forward and reverse directions. The opera- raise or lower the boom or swing the boom to the leftt. Standard boom swing is 350 degree non-continu-he machine has a Ground Control Station which wille the Platform Control Station. Ground Controls oper-om Lift and Swing, and are to be used in an emer- to lower the platform to the ground should theor in the platform be unable to do so.

3121252 – JLG Lift –

SECTION 4. MACHINE O

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic personnel liftequipped with a work platform on the end of an elevatingand rotating boom.

The prthis comachitor canor righous. Toverridate Bogencyoperat


4-2 3121252

4.2

Ca

tability is based on two (2) conditions which areWARD and BACKWARD stability. The machine’s

least FORWARD stability is shown in Figure 4-1.,ition of least BACKWARD stability is shown in Fig-d Figure 4-3.

ARD OR BACKWARD TIPPING, DO NOT OVERLOADRATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

– JLG Lift –

BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

pacities

Raising boom above horizontal with or without any load inplatform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level sur-face.

2. Load is within manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Machine is as originally equipped from JLG.

StabilityMachine scalled FORposition ofand its posure 4-2. an

TO AVOID FORWMACHINE OR OPE


4-3

d Stability

LOWER BOOMFULLY ELEVATED

MAIN BOOMHORIZONTAL

3121252 – JLG Lift –

Figure 4-1. Position of Least Forwar

MAIN BOOMFULLY EXTENDED

MACHINE WILL "TIP OVER" IN THISDIRECTION IF OVERLOADED OR

OPERATED ON ANOUT-OF-LEVEL SURFACE


4-4 3121252

.

ility - E300AJ




– JLG Lift –

Figure 4-2. Position of Least Backward Stab

MAIN BOOM FULLY ELEVATEDAND FULLY RETRACTED


4-5

Stability - E300AJP




3121252 – JLG Lift –

Figure 4-3. Position of Least Backward

PLATFORM ROTATED90 DEGREES

MAIN BOOM FULLY ELEVATEDAND FULLY RETRACTED


4-6 3121252

4.3

Po

Pla

tion

ST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC-E FUNCTION WILL NOT OPERATE.

becomes activated and operates the desireden the Emergency Stop switch is pulled out (on),/Ground select switch is in the appropriate posi-

e Footswitch is depressed.

LFUNCTION NECESSITATES UNSCHEDULED SHUT-NE AND CORRECT THE CAUSE BEFORE RESUMING

N EMERGENCY STOP SWITCH TO THE ‘OFF’ POSI-) WHEN MACHINE IS NOT IN USE.

– JLG Lift –

MOTOR OPERATION


This red, mushroom-shaped switch provides battery powerto the Platform/Ground Select switch, when pulled out (on),for all machine functions. The switch should be pushed in(off) when recharging the batteries or parking the machineovernight.

tform/Ground Select Switch

The Platform/Ground Select switch functions to direct batterypower to the desired control station when the POWER/EMERGENCY STOP switch is pulled out (on). With theswitch in the GROUND position, battery power is supplied tothe ground control station. When the switch is in the PLAT-FORM position, battery power is supplied to the platformcontrol station.

The key is removable in the platform position on CEmachines. The key must be available to ground personnel inthe event of an emergency.

Motor Activa

FOOTSWITCH MUTION, OTHERWIS

The motorfunction whthe Platformtion and th

IF A MOTOR MADOWN, DETERMIANY OPERATION.

ALWAYS POSITIOTION (PUSHED IN


4-7

ng is limited by two factors:

radeability, which is the percent of grade of the incline e machine can climb.

deslope, which is the angle of the slope the machine n be driven across.

3121252 – JLG Lift –

4.4 TRAVELING (DRIVING)

See Figure 4-4., Grade and Side Slopes

NOTE: Refer to the Operating Specifications table for Gradeabil-ity and Sideslope ratings.

All ratings for Gradeability and Sideslope are based uponthe machine’s boom being in the stowed position, fullylowered, and retracted.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVEMACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIALNUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALLTIMES WHEN THE PLATFORM IS ELEVATED.

MATCH THE BLACK AND WHITE DIRECTION ARROWS ON BOTH PLAT-FORM CONTROL PANEL AND THE CHASSIS TO DETERMINE THE DIREC-TION THE MACHINE WILL TRAVEL.

Traveli

1. Gth

2. Sica


4-8 3121252

SIDE SLOPE

– JLG Lift –

GRADE

LEVEL

Figure 4-4. Grade and Side Slopes


4-9

ERINGn thumb switch on Drive/Steer controller to RIGHT forg right, or to LEFT for steering left.

ATFORM

THE PLATFORM LEVELING OVERRIDE FUNCTION FORLING OF THE PLATFORM. INCORRECT USE COULD CAUSE

CCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULDEATH OR SERIOUS INJURY.

Level Adjustmentnually Level Up or Down - Position the Platform/Levell switch Up or Down and hold until the desired plat-osition is obtained.

Rotationate the platform to the left or right, use the Platform control switch to select the direction and hold until

d position is reached.

3121252 – JLG Lift –

Traveling Forward and Reverse1. At Platform Controls, pull out Emergency Stop switch

and activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as desired.

This machine is equipped with a Drive Orientation Indicator.The yellow light on the platform control console indicatesthat the boom is swung beyond the rear drive tires and themachine may Drive/Steer in the opposite direction from themovement of the controls. If the indicator is illuminated,operate the Drive function in the following manner:

1. Match the black and white direction arrows on both plat-form control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

4.5 STEPositiosteerin

4.6 PL

ONLY USE SLIGHT LEVETHE LOAD/ORESULT IN D

PlatformTo macontroform p

PlatformTo rotRotatedesire


4-1 3121252

4.7

A REWHINOT

DO CHASLOSWITHE

TO AIS RLEVBEF

TRAGRAFRA

US INJURY, DO NOT OPERATE MACHINERY IF ANY OR TOGGLE SWITCH CONTROLLING PLATFORM NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION

.

LISION AND INJURY IF PLATFORM DOES NOT STOPL SWITCH OR LEVER IS RELEASED, REMOVE FOOT

CH OR USE EMERGENCY STOP SWITCH TO STOP THE

0 – JLG Lift –

BOOM

D TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLECH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THESSIS. TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVEPE (5 DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORENGING, OR RAISING BOOM ABOVE HORIZONTAL OR DRIVING WITH BOOM ELEVATED.

VOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOMAISED ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND

EL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVELORE RAISING BOOM.

VELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ONDES AND SIDE SLOPES SPECIFIED ON SERIAL NAMEPLATE ON THEME.

TO AVOID SERIOCONTROL LEVERMOVEMENT DOESWHEN RELEASED

TO AVOID A COLWHEN A CONTROFROM FOOTSWITMACHINE.


4-11

NCTION SPEED CONTROLontrol affects the speed of boom functions and plat-otate Lift, Telescope, and Swing. When in the fullyrclockwise position, Drive is placed in creep speed.

UT DOWN AND PARKen parking battery powered units overnight, batteriesuld be charged in accordance with instructions in

ction 6 to ensure readiness for following workday.

ctric machines are equipped with a static strap due totic electricity build-ups. Strap is located under rear ofchine chassis.

ocedures to shut down and park the machine are as:

rive machine to a reasonably well protected area.

sure boom is lowered over rear drive axle.

3121252 – JLG Lift –

Swinging the Boom

To swing boom, use Swing control to select Right or Leftdirection.

Raising and Lowering the Upper BoomTo raise or lower the Upper Boom, position Upper Boom Liftswitch to Up or Down until desired height is reached.

4.8 FUThis cform rcounte

4.9 SHNOTE: Wh

shoSe

NOTE: Elestama

The prfollows

1. D

2. En


4-1 3121252

4.1

Lif

RTING THE MACHINE, THE BOOM MUST BE FULLYHE BOOM REST.

the boom in the stowed position.

e all loose items from the machine.

the chassis and the platform using straps or of adequate strength.

2 – JLG Lift –

3. Shut down Emergency Stop at Platform Controls.

4. Shut down Emergency Stop at Ground Controls. Posi-tion Platform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instruc-tion placards, warning decals, and operating controlsfrom hostile environment.

0 LIFTING AND TIE DOWN(See Figure 4-5.)

ting1. Refer to the Serial Number Plate, refer to the Specifica-

tions section of this manual, or weigh the individual unitto find out the Gross Vehicle Weight.

2. Place the boom in the stowed position.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to themachine and so the machine remains level.

Tie Down

WHEN TRANSPOLOWERED INTO T

1. Place

2. Remov

3. Securechains


4-13

A 41.4”/1.04mB 44.0”/1.11m

E300AJ/AJP

1001112461B

Chart

3121252 – JLG Lift –

A B

Figure 4-5. Lifting and Tie Down


4-1 3121252

BOTHSIDES

BOTHSIDES

BOTHSIDES

7

24

25

26

30

149

6

of 5

4 – JLG Lift –

HYD TANK VIEWINSIDE HOOD

19

28

Figure 4-6. Decal Location Sheet 1


4-15

46

23

1645

29

31

24

15

536

2 of 5

3121252 – JLG Lift –

336

14

23

24

Figure 4-7. Decal Location Sheet


4-1 3121252

34

12

t 3 of 5

6 – JLG Lift –

11

2232

25

25

26

9

42

40

41

Figure 4-8. Decal Location Shee


4-17

44

46

TAIL A3

4

8

20

29

12

18

394345

235

37

137

4 of 5

3121252 – JLG Lift –

SEE DE

DETAIL A

21

20

17

23

23

33

27

Figure 4-9. Decal Location Sheet


4-1 3121252

LOCATE ON SIDEOF CONTROL BOX.

9

38

of 5

8 – JLG Lift –

BOTHSIDES

13

13

30

10

Figure 4-10. Decal Location Sheet 5


4-19

ish828-B

French1001110829-C

Chinese1001110830-B

Portuguese1001110831-B

- - - - - -

- - - - - -

- - - - - -

- - - - - -

584 1700584 1700584 1700584

500 1701500 1701500 1701500

504 1701504 1701504 1701504

509 1701509 1701509 1701509

529 1701529 1701529 1701529

642 1701642 1701642 1701642

644 1701644 1701644 1701644

056 1707055 1707060 1707134

155 1702155 1702155 1702155

300 1702300 1702300 1702300

3171 1001113169 1001113168 1001113170

631 1702631 1702631 1702631

- - - - - -

- - - - - -

- - - - - -

3121252 – JLG Lift –

Item # ANSI1001109493-B

CE/Australia1001110824-C

Japan1001110825-B

Korea1001110827-B

Span1001110

1 - - - - - - - - - -

2 - - - - - - - - - -

3 - - - - - - - - - -

4 - - - - - - - - - -

5 1700584 1700584 1700584 1700584 1700

6 1701500 1701500 1701500 1701500 1701

7 1701504 1701504 1701504 1701504 1701

8 1701509 1701509 1701509 1701509 1701

9 1701529 1701529 1701529 1701529 1701

10 1701642 1701642 1701642 1701642 1701

11 1701644 1701644 1701644 1701644 1701

12 1701645 1705978 1707059 1707058 1707

13 1702155 1702155 1702155 1702155 1702

14 1702300 1702300 1702300 1702300 1702

15 1702391 1701517 1001113166 1001113509 100111

16 1702631 1702631 1702631 1702631 1702

17 - - - - - - - - - -

18 - - - - - - - - - -

19 - - - - - - - - - -


4-2 3121252

1704000 1705968 1704002

1703924 1703925 1703928

1703930 1703931 1703934

1703948 1703949 1703952

1703936 1703937 1703940

1704340 1704344 1704341

- - - - - -

1704277 1704277 1704277

1704412 1704412 1704412

- - - - - -

1706126 1706126 1706126

- - - - - -

1707047 1707044 1707133

3251243 3251243 - -

3251813 3251813 3251813

- - - - - -

- - - - - -

- - - - - -

1001110196 1001110196 1001110196

1001110276 1001110276 1001110276

French1001110829-C

Chinese1001110830-B


0 – JLG Lift –

20 1702868 - - - - 1705969 1704001

21 1703797 1705921 1703926 1703927 1703923

22 1703798 1705822 1703932 1703933 1703929

23 1703804 1701518 1703950 1703951 1703947

24 1703805 1705961 1703938 1703939 1703935

25 1703813 1705670 1704342 1704343 1704339

26 - - - - - - - - - -

27 1704277 1704277 1704277 1704277 1704277

28 1704412 1704412 1704412 1704412 1704412

29 - - - - - - - - - -

30 1706126 1706126 1706126 1706126 1706126

31 - - - - - - - - - -

32 1707013 - - 1707054 1707042 1707049

33 3251243 - - - - - - - -

34 3251813 - - 3251813 - - 3251813

35 - - - - - - - - - -

36 - - - - - - - - - -

37 - - - - - - - - - -

38 1001110196 1001110196 1001110196 1001110196 1001110196

39 1001110276 - - 1001110276 1001110276 1001110276

Item # ANSI1001109493-B


Japan1001110825-B

Korea1001110827-B

Spanish1001110828-B


4-21

0389 1001110389 1001110389 1001110389

2461 1001112461 1001112461 1001112461

2777 1001112777 1001112777 1001112777

910 1705429 1705430 1001113680

983 1703984 1703982 1703985

1705514 - - - -

- - - - - -

ish828-B

French1001110829-C

Chinese1001110830-B


3121252 – JLG Lift –

40 1001110389 - - 1001110389 1001110389 100111

41 1001112461 1001112461 1001112461 1001112461 100111

42 1001112777 1001112777 1001112777 1001112777 100111

43 1705351 - - 1705426 1705427 1705

44 - - 1705828 1703980 1703981 1703

45 - - - - - - - - - -

46 - - - - - - - - - -

Item # ANSI1001109493-B


Japan1001110825-B

Korea1001110827-B

Span1001110


4-2 3121252
2 – JLG Lift –
NOTES:

SECTION 5 - EMERGENCY PROCEDURES

5-1

ROCEDURES

ANY INCIDENT, THOROUGHLY INSPECT THE MACHINELL FUNCTIONS FIRST FROM THE GROUND CONTROLS,THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10OU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IFND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

ERGENCY OPERATION

Unable to Control Machine PLATFORM OPERATOR IS PINNED, TRAPPED OR

LE TO OPERATE OR CONTROL MACHINE:

ther personnel should operate the machine from ound controls only as required.

ther qualified personnel on the platform may use the atform controls. DO NOT CONTINUE OPERATION IF ONTROLS DO NOT FUNCTION PROPERLY.

ranes, forklift trucks or other equipment can be used to abilize motion of the machine.

3121252 – JLG Lift –

SECTION 5. EMERGENCY P

5.1 GENERALThis section explains the steps to be taken in case of anemergency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any inci-dent involving a JLG product. Even if no injury or propertydamage is evident, the factory should be contacted by tele-phone and provided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving aJLG Industries product within 48 hours of such an occur-rence may void any warranty consideration on that particularmachine.

FOLLOWINGAND TEST ATHEN FROM FT.) UNTIL YREQUIRED, A

5.3 EM

OperatorIF THEUNAB

1. Ogr

2. OplC

3. Cst


5-2 3121252

Pla

5.4

THEALL

age the mechanical release on both drive hubssening, completely reversing, and tightening thelts on each hub.

e chocks from wheels as desired.

AL DESCENT SYSTEM 5-1., Manual Descent Location)

escent system is used, in the event of total powerse the key is not accessible to the ground person-he upper and lower booms using gravity. The jibust be pumped down. To operate the manual

m, proceed as follows:

the manual descent knob on the boom functionPush the knob in to lower the tower and pull theout to lower the main boom. The knob must ben place to perform the lowering function; it is loaded to return to center when released. Install into manual descent pump and lower thed cylinders by pumping the handle until the

is completely lowered.

pped with a jib, locate the split ring on the boomn valve. Push the split ring in to lower the jib or

e split ring out to raise the jib by pumping the han-til it is completely lowered or raised. Stow the han-bracket provided.

– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged inoverhead structures or equipment, rescue platform occu-pants prior to freeing the machine.

EMERGENCY TOWING PROCEDURESTowing this machine is prohibited. However, provisions formoving the machine have been incorporated. The followingprocedures are to be used ONLY for emergency movementto a suitable maintenance area.

ALLOWABLE TOWING SPEED IS 1.9 MPH (3 KPH). THE MAXIMUMOWABLE TOWING DISTANCE IS 0.6 MILES (1 KM).

1. Chock wheels securely.

2. Engage the mechanical release on both drive hubs byloosening, completely reversing, and tightening the twobolts on each hub.

3. Connect suitable equipment, remove chocks, and movemachine.

After moving machine, complete the following procedure:

1. Position machine on a firm level surface.

2. Chock wheels securely.

3. Disengby lootwo bo

4. Remov

5.5 MANU(See Figure

The manual dfailure or in canel, to lower tlift cylinder mdescent syste

1. Locatevalve. knob held ispringhandleselecteboom

2. If equifunctiopull thdle undle in


5-3

Location

3121252 – JLG Lift –

Figure 5-1. Manual Descent

SPLIT RING

MANUAL DESCENT KNOB


5-4 3121252

5.6

Tanthat

– JLG Lift –

MANUAL SWING OVERRIDE

he manual swing override is used to manually swing the boomd turntable assembly in the event of a total power failure whene platform is positioned over a structure or obstacle. To oper-e the manual swing override, proceed as follows:

1. Using a 7/8 inch socket and ratchet wrench, locate nuton swing worm gear on left side of machine.

2. Install wrench on nut and ratchet in the directiondesired.

FICATIONS & OPERATOR MAINTENANCE

6-1

OPERATOR MAINTENANCE

ERATING SPECIFICATIONS AND RFORMANCE DATA

g Specifications

ble 6-1. Operating specifications - E300AJ

restricted: ANSI 500 lbs. (227 kg)

restricted: CE & Australia 500 lbs. (230 kg)

avel Grade, stowedadeability) see Figure 4-3.

25%

avel Grade, stowede Slope) see Figure 4-3.

5°

(High Drive) - 200 ft. (60.9 M) 45-50 sec

Above Horz.) - 50 ft. (15.24 M) 55-68 sec (0.6 mph[0.9 kph])

ne Weight - Approximate 15060 lbs. (6831 kg)

ing Pressure - Maximum 170 psi (11.95 kg/cm2)

stem Voltage 48V DC

SECTION 6 - GENERAL SPECI

3121252 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS &

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machine.

The maintenance portion of this section is intended as infor-mation to assist the machine operator to perform daily main-tenance tasks only, and does not replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual ............................ 3121253

Illustrated Parts Manual ............................................ 3121254

6.2 OPPE

Operatin

Ta

Capacity: Un

Capacity: Un

Maximum Tr Position (Gr

Maximum Tr Position (Sid

Drive Speed

Drive Speed(

Gross Machi

Ground Bear

Maximum Sy

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121252

DataMa

Ca

Ca

Ma Po

Ma Po

Dr

Dr

Gr

Gr

Ma

Ma

le 6-3. Dimensional Data - E300AJ

s (Inside) 5 ft. (1.52 m)

s (Outside) 10ft. 2in. (3.1 m)

ht (stowed) 6ft. 7in. (2.01 m)

th (stowed) 18ft. 2in. (5.54 m)

latform Height 13ft. 2in. (4.01 m)

ch Up and Over 20ft. 3in. (6.17 m)

h 4ft. (1.22 m)

5ft. 5in. (1.65 m)

ht 30ft. 2in. (9.19m)

nce 4in. (10 cm)

– JLG Lift –

Dimensionalximum Main Relief Hyd. Pressure 3000 psi (207 bar)

Table 6-2. Operating specifications - E300AJP

pacity: Unrestricted: ANSI 500 lbs. (227 kg)

pacity: Unrestricted: CE & Australia 500 lbs. (230 kg)

ximum Travel Grade, stowedsition (Gradeability) see Figure 4-3.

25%

ximum Travel Grade, stowedsition (Side Slope) see Figure 4-3.

5°

ive Speed (High Drive) - 200ft. (60.9 m) 45-50 sec (3 mph [4.8 kph])

ive Speed( Above Horz.) - 50 ft. (15.24 M) 55-68 sec (0.6 mph[0.9 kph])

oss Machine Weight- Approximate 15400 lbs. (6985 kg)

ound Bearing Pressure - Maximum 170 psi (11.95 kg/cm2)

ximum System Voltage 48V DC

ximum Main Relief Hyd. Pressure 3000 psi (207 bar)

Table 6-1. Operating specifications - E300AJ

Tab

Turning Radiu

Turning Radiu

Machine Heig

Machine Leng

Up and Over P

Horizontal Rea

Machine Widt

Wheel Base

Platform Heig

Ground Cleara


6-3

esTable 6-5. Capacities

Oil Tank 2.9 Gal. (11 L)2.1 Gal. ( 8 L) to Full Mark

25.5 oz. (0.75 L)(1/2 Full)

bs should be one half full of lubricant.

Table 6-6. Tires

25x7x12

Tire Load 8200 lbs. (3719 kg)

Solid Non-Marking


3121252 – JLG Lift –

Capaciti

Tires

Table 6-4. Dimensional Data - E300AJP

Turning Radius (Inside) 5 ft. (1.52 m)

Turning Radius (Outside) 10ft. 2in. (3.1 m)

Machine Height (stowed) 6ft. 7in. (2.01 m)

Machine Length (stowed) 18ft. 10in. (5.74 m)

Up and Over Platform Height 13ft. 2in. (4.01 m)

Horizontal Reach Up and Over 20ft. 1in. (6.12 m)

Machine Width 4ft. (1.22 m)

Wheel Base 5ft. 5in. (1.65 m)

Platform Height 29ft. 5in. (8.97 m)

Ground Clearance 4in. (10 cm)

Hydraulic

Drive Hub*

*Drive hu

Size

Maximum

Type


6-4 3121252

Hy

NOT

NOT

rom JLG recommendations, it is not advisable to of different brands or types, as they may not con- same required additives or be of comparable vis-. If use of hydraulic oil other than Mobil DTE 11Med, contact JLG Industries for proper recommen-.

Table 6-8. Mobil DTE 11M Specs

osity Grade #15

vity API 31.9

Point, Max -40°F (-40°C)

Point, Min. 330°F (166°C)

Viscosity

40° C 15 cSt

100° C 4.1 cSt

100° F 80 SUS

210° F 43 SUS

t -30° F 3.200

sity Index 140

– JLG Lift –

draulic Oil

E: Hydraulic oils require anti-wear qualities at least API Ser-vice Classification GL-3, and sufficient chemical stabilityfor mobile hydraulic system service.

E: Machines may be equipped with Mobil EAL224H biode-gradable and non-toxic hydraulic oil. This is vegetable oilbased and possesses the same antiwear and rust protec-tion characteristics as mineral oils, but will not adverselyaffect the ground water or the environment when spilledor leaked in small amounts. Mobil EAL224H has a viscos-ity of 34 cSt at 40° C. and viscosity index of 213. The oper-ating temperature range of this oil is -18° C. to +83° C.

NOTE: Aside fmix oilstain thecositiesis desirdations

Table 6-7. Hydraulic Oil

Hydraulic SystemOperating

Temperature Range

S.A.E. ViscosityGrade

+0° to + 180° F(-18° to +83° C)

10W

+0° to + 210° F(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F(+10° to +99° C

20W-20

ISO Visc

Gra

Pour

Flash

at

at

at

at

cp a

Visco


6-5

Table 6-10. Mobil EAL 224H Specs

Type Biodegradable Vegetable Oil

Viscosity Grade 32/46

pecific Gravity .922

our Point, Max -25°F (-32°C)

lash Point, Min. 428°F (220°C)

perating Temp. 0 to 180°F (-17 to 162°C)

Weight 7.64 lb. per gal.(0.9 kg per liter)

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

: Must be stored above 32°F (0°C)


3121252 – JLG Lift –

Table 6-9. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

ISO

S

P

F

O

NOTE


6-6 3121252

ble 6-12. Quintolubric 888-46

nsity 0.91 @ 15°C (59°F)

r Point <-20°C (<-4°F)

h Point 275°C (527°F)

Point 325°C (617°F)

Temperature 450°C (842°F)

Viscosity

(32°F) 360 cSt

C (68°F) 102 cSt

(104°F) 46 cSt

C (212°F) 10 cSt

ity Index 220

– JLG Lift –

Table 6-11. Mobil EAL Envirosyn H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32

Specific Gravity .950

Pour Point, Max -59°F (-51°C)

Flash Point, Min. 514°F (268°C)

Viscosity

at 40° C 33.1 cSt

at 100° C 6.36 cSt

Viscosity Index 147

Ta

De

Pou

Flas

Fire

Autoignition

at 0° C

at 20°

at 40° C

at 100°

Viscos


6-7


3121252 – JLG Lift –

Major Component Weights

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF-FERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES,FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TOAFFECT STABILITY.

Table 6-13. Critical Stability Weights

Components LBS. KG.

Counterweight (AJ) 6188 2807

Counterweight (AJP) 6348 2880

Tire and Wheel 120 54.4

Platform (including console) 169 78

Battery (minimum each) - 305AH 87 39.5

Battery (minimum each) - 375AH & UL 110 50


6-8 3121252

5

5

tion Diagram

– JLG Lift –

1

6 3,4

26

Figure 6-1. Operator Maintenance and Lubrica


6-9

ing Bearing

e Point(s) - Remote Fittingacity - A/Re - BGrval - Every 3 months or 150 hrs of operationments - Apply grease and rotate in 90 degree

rvals until bearing is completely lubricated


3121252 – JLG Lift –

6.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-1., Operator Maintenance and Lubrication Diagram.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATIONUNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFTOPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON-DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD-INGLY.

1. Sw

LubCapLubInteCominte

Table 6-14. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qual-ities; and being of extreme pressure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Clas-sification GL-5 or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

*MPG may be substituted for these lubricants, if necessary, but service intervals will be reduced.


6-1 3121252

int(s) - Grease Fitting - A/Robile SHC 007 A/R

EASE BEARINGS. OVERGREASING BEARINGS WILLGE TO OUTER SEAL IN HOUSING.

0 – JLG Lift –

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - Grease FittingCapacity - A/RLube - BGInterval - A/R

Lube PoCapacityLube - MInterval -

DO NOT OVERGRRESULT IN DAMA


6-11

ydraulic Return Filter

rval - Change after first 50 hrs. and every 6 months or hrs. thereafter.ments - Under certain conditions, it may be neces- to replace the hydraulic filter on a more frequentis.


3121252 – JLG Lift –

3. Hydraulic Tank

Lube Point(s) - Fill CapCapacity - 2.9 Gal. (11 L), 2.1 Gal. ( 8 L) to Full Mark Lube - HOInterval - Check Level daily; Change every 2 years or 1200hours of operation.Comments - On new machines, those recently over-hauled, or after changing hydraulic oil, operate all systemsa minimum of two complete cycles and recheck oil level inreservoir.

4. H

Inte300Comsarybas


6-1 3121252

Bearings

int(s) - Repack - A/RPG Every 2 years or 1200 hours of operation

2 – JLG Lift –

5. Wheel Drive Hub

Lube Point(s) - Level/Fill PlugCapacity - 25.5 oz. (0.75 L)(1/2 Full)Lube - EPGLInterval - Check level every 3 months or 150 hrs of opera-tion; change every 2 years or 1200 hours of operation

6. Wheel

Lube PoCapacityLube - MInterval -

OIL LEVEL CHECKAND FILL


6-13

move all vent caps and inspect electrolyte level of ch cell. Electrolyte level should be to the ring approxi-ately one inch from top of battery. Fill batteries with stilled water only. Replace and secure all vent caps.

move battery cables from each battery post one at a e, negative first. Clean cables with acid neutralizing

lution (e.g. baking soda and water or ammonia) and ire brush. Replace cables and/or cable clamp bolts as quired.

lean battery post with wire brush then re-connect cable post. Coat non-contact surfaces with mineral grease petroleum jelly.

hen all cables and terminal posts have been cleaned, sure all cables are properly positioned and do not get

nched. Close battery compartment cover.

art hydraulic system and ensure that it functions prop-ly.


3121252 – JLG Lift –

6.4 BATTERY MAINTENANCE AND CHARGING

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR ALLOWSPARKS OR A FLAME NEAR BATTERY DURING SERVICING. ALWAYSWEAR EYE AND HAND PROTECTION WHEN SERVICING BATTERIES.

Battery Maintenance, Quarterly1. Open battery compartment cover to allow access to bat-

tery terminals and vent caps.

WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELECTRO-LYTE COVERS PLATES. DO NOT CHARGE BATTERIES UNLESS ELECTRO-LYTE COVERS THE PLATES.

NOTE: When adding distilled water to batteries, non-metalliccontainers and/or funnels must be used.

To avoid electrolyte overflow, add distilled water to batter-ies after charging.

When adding water to the battery, fill only to level indi-cated or 3/8" (9.5 mm) above separators.

2. Reeamdi

3. Retimsowre

4. Ctoor

5. Wenpi

6. Ster


6-1 3121252

Ba

NOT

WHEBE PGROCOU

move charging harness cable and connect to aceptacle or the correct voltage.

low batteries to charge until 100% LED is illumi-ted.

batteries are completely charged, disconnectg harness cable from receptacle. Store charging cable.

sure battery cables are properly positioned ande not pinched. Close and secure all compartmentors.

4 – JLG Lift –

ttery Charging, Daily

E: To avoid excessive battery charging time, do not allowbatteries to become completely discharged.

To avoid electrolyte overflow, add distilled water to batter-ies after charging.

When adding water to the battery, fill only to level indi-cated or 3/8" above separators.

1. Charge batteries at the end of each work day, or when machine performance is significantly reduced due to batteries becoming discharged.

2. Charge batteries in accordance with the following proce-dure:

a. Open battery compartment, and battery chargercompartment covers.

N BATTERY CHARGER IS TO BE USED, CHARGING HARNESS MUSTLUGGED INTO A GROUNDED RECEPTACLE. IF RECEPTACLE IS NOTUNDED AND A MALFUNCTION SHOULD OCCUR, THE MACHINELD CAUSE SERIOUS ELECTRICAL SHOCK.

b. Rere

c. Alna

NOTE: When charginharness

d. Enardo


6-15

d Tire Replacement

installed on each product model have been designedty requirements which consist of track width, tire pres- load capacity. Size changes such as rim width, centeration, larger or smaller diameter, etc., without writtencommendations, may result in an unsafe condition stability.

stallationmely important to apply and maintain proper wheel torque.

MUST BE INSTALLED AND MAINTAINED AT THE PROPERPREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI-OUS SEPARATION OF WHEEL FROM THE AXLE. BE SUREY THE NUTS MATCHED TO THE CONE ANGLE OF THE

e lug nuts to the proper torque to prevent wheels fromose. Use a torque wrench to tighten the fasteners. If

ot have a torque wrench, tighten the fasteners with ah, then immediately have a service garage or dealere lug nuts to the proper torque. Over-tightening willbreaking the studs or permanently deforming the


3121252 – JLG Lift –

6.5 TIRES & WHEELS

Tire Replacement

JLG recommends a replacement tire be the same size, ply andbrand as originally installed on the machine. Please refer to theJLG Parts Manual for the part number of the approved tires for aparticular machine model. If not using a JLG approved replace-ment tire, we recommend that replacement tires have the follow-ing characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal tothe original

• Approved for the application by the tire manufacturer(including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do notreplace a foam filled or ballast filled tire assembly with a pneu-matic tire. When selecting and installing a replacement tire,ensure that all tires are inflated to the pressure recommendedby JLG. Due to size variations between tire brands, both tireson the same axle should be the same.

Wheel an

The rims for stabilisure, andpiece locfactory reregarding

Wheel InIt is extremounting

WHEEL NUTSTORQUE TO BLE DANGERTO USE ONLWHEEL.

Tighten thcoming loyou do nlug wrenctighten thresult in


6-1 3121252

mat

EMENTAL INFORMATIONng information is provided in accordance with thets of the European Machinery Directive 2006/42/nly applicable to CE machines.

powered machines, the equivalent continuous A-ound pressure level at the work platform is lessA)

ustion engine powered machines, guaranteeder Level (LWA) per European Directive 2000/14/

Emission in the Environment by Equipment forors) based on test methods in accordance withart B, Method 1 and 0 of the directive, is 104 dB.

ion total value to which the hand-arm system isdoes not exceed 2,5 m/s2. The highest root meanue of weighted acceleration to which the wholejected does not exceed 0,5 m/s2.

Table 6-15. Wheel Torque Chart

TORQUE SEQUENCE

2nd Stage 3rd Stage

) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

6 – JLG Lift –

ounting stud holes in the wheels. The proper procedure fortaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DONOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence.

3. The tightening of the nuts should be done in stages. Fol-lowing the recommended sequence, tighten nuts per wheel torque.

4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check the torque after the first 10 miles, 25 miles, and again at 50 miles. Check periodically thereafter.

6.6 SUPPLThe followirequiremenEC and is o

For electricWeighted sthan 70dB(

For combSound PowEC (NoiseUse OutdoAnnex III, P

The vibratsubjected square valbody is sub

1st Stage

40 ft lbs (55 Nm

TION 7 - INSPECTION AND REPAIR LOG

7-1

D REPAIR LOG

ir Log

nts

SEC

3121252 – JLG Lift –

SECTION 7. INSPECTION ANMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121252

og

– JLG Lift –

Table 7-1. Inspection and Repair L

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Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65813058

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG France SASZ.I. de Baulieu47400 FauilletFrance

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

Oshkosh-JLG Singapore Technology Equipment Pte Ltd29 Tuas Ave 4,Jurong Industrial EstateSingapore, 639379

+65-6591 9030

+65-6591 9031

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

3121252

Boom Lift Models E300AJ E300AJP - Construction … · Operation and Safety Manual ANSI ® Original...

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Transcript of Boom Lift Models E300AJ E300AJP - Construction … · Operation and Safety Manual ANSI ® Original...