Professional Documents
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Operators and Safety Manual: Model
Operators and Safety Manual: Model
Model
3369electric
3969electric
3120880
March 8, 2000
AUSTRALIAN OFFICE EUROPEAN OFFICE CORPORATE OFFICE
JLG INDUSTRIES, INC. JLG INDUSTRIES (EUROPE) JLG INDUSTRIES, INC.
P.O. Box 5119 Kilmartin Place, 1 JLG Drive
11 Bolwarra Road Tannochside Park McConnellsburg, PA.
Port Macquarie, Australia Uddingston, Scotland, G71 5PH 17233-9533
Telephone: 065 811111 Telephone: 01698 811005 USA
Fax: 065 810122 Main Fax: 01698 811055 Telephone: (717) 485-5161
Parts Fax: 01698 811455 Fax: (717) 485-6417
FOREWORD
FOREWORD
The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.
REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER-
ATING PERSONNEL.
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS.
THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAU-
TION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these
areas. They are defined as follows:
DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
DEATH.] OR DEATH.
JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM-
PLETED ON THE AFFECTED JLG PRODUCT
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notifica-
tion. Contact JLG Industries, Inc. for updated information.
All procedures herein are based on the use of the 5. All personnel in the platform shall, at all times,
machine under proper operating conditions, with no wear approved fall protection devices and
deviations from original design intent... as per OSHA other safety gear as required.
regulations and applicable ANSI standards. 6. Load limits specified by the manufacturer shall
not be exceeded.
7. Instruction and warning placards must be legi-
ble.
READ & HEED! 8. Aerial lifts may be field modified for uses other
than those intended by the manufacturer only if
certified in writing by the manufacturer to be in
conformity to JLG requirements and to be at
The ownership, use, service, and/or maintenance of least as safe as it was prior to modification.
this machine is subject to various governmental and
local laws and regulations. It is the responsibility of 9. Aerial lifts shall not be used near electric power
the owner/user to be knowledgeable of these laws lines unless the lines have been de energized
and regulations and to comply with them. The most or adequate clearance is maintained.
prevalent regulations of this type in the United States 10. Employees using aerial lifts shall be instructed
are the Federal OSHA Safety Regulations*. Listed on how to recognize and avoid unsafe condi-
below, in abbreviated form are some of the require- tions and hazards.
ments of Federal OSHA regulations in effect as of the
date of publication of this handbook. 11. Ground controls shall not be operated unless
permission has been obtained from personnel
in the platform, except in case of an emer-
The listing of these requirements shall not relieve gency.
the owner/user of the responsibility and obligation
to determine all applicable laws and regulations and 12. Regular inspection of the job site and aerial lift
their exact wording and requirements, and to com- shall be performed by competent persons.
ply with the requirements. Nor shall the listing of 13. Personnel shall always stand on the floor of the
these requirements constitute an assumption of platform, not on boxes, planks, railing or other
responsibility of liability on the part of JLG Indus- devices, for a work position.
tries, Inc.
*Applicable Federal OSHA regulations for the
United States, as of the date of publication of this
1. Only trained and authorized operators shall be
manual, include, but are not limited to, 29 CFR
permitted to operate the aerial lift.
1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR
2. A malfunctioning lift shall be shut down until 1926.28, and 29 CFR 1926.453.
repaired.
3. The controls shall be plainly marked as to their
function.
4. The controls shall be tested each day prior to
use to determine that they are in safe operating
condition.
REVISON LOG
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Driving/Towing/Carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
1.8 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SECTION 2 - PREPARATION AND INSPECTION
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Preparation for Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Delivery and Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.7 Battery Maintenance and Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
SECTION 4 - MACHINE OPERATION
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Motor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.4 Raising and Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 Platform Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.6 Platform Handrails Fold Down Procedure (in sequence) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.7 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.8 Traveling (driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.9 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.10 Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.11 Safety Prop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.12 Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4.13 Machine Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
SECTION 5 - OPTIONAL EQUIPMENT
5.1 Battery Discharge Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Travel Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.4 Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.5 Descent Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.6 Tilt Alarm Warning Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.7 Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.8 220 Volt Receptacle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.9 Platform Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.10 Non-marking Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.11 Rotating Beacon Platform/Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Daily Walk-Around Inspection (Sheet 1 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2-1. Daily Walk-Around Inspection (Sheet 2 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2-1. Daily Walk-Around Inspection (Sheet 3 of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-2. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
2-3. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3. Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-4. Decal Location (Right Side & Rear) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-5. Decal Location (Left Side & Front) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-2. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
1-1 Minimum Safe Approach Distances (M.S.A.D.) to energized. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
(exposed or insulated) power lines and parts
2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1
Table 1-1.
Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts
1.4 PRE-OPERATIONAL
WITH THE MACHINE AT ALL TIMES DURING MOUNT • BE AWARE OF STOPPING DISTANCES WHEN TRAV-
AND DISMOUNT. ELING IN HIGH AND LOW SPEEDS.
• ALWAYS POST A LOOKOUT WHEN DRIVING IN
AREAS WHERE VISION IS OBSTRUCTED.
1.5 DRIVING
• KEEP NON-OPERATING PERSONNEL AT LEAST 2.0
M (6 FT) AWAY FROM MACHINE DURING DRIVING
OPERATIONS.
1.6 OPERATION
• WHEN RIDING IN OR WORKING FROM PLATFORM • NEVER EXCEED MANUFACTURERS RATED PLAT-
BOTH FEET MUST BE FIRMLY POSITIONED ON FORM CAPACITY - REFER TO CAPACITY DECAL ON
DECK. MACHINE. DISTRIBUTE LOAD EVENLY ON PLAT-
FORM FLOOR.
• DO NOT EXTEND REACH LIMITS OF THIS MACHINE
• ENSURE MACHINE IS POSITIONED ON A FIRM,
WITH ADDITIONAL EQUIPMENT SUCH AS PLANKS,
LEVEL AND UNIFORM SUPPORTING SURFACE
BOXES, ETC. BEFORE RAISING PLATFORM.
• DO NOT OPERATE WITHOUT HANDRAILS IN PLACE • DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS
AND SECURED. IT IS A SAFETY VIOLATION. T O P L AT F O R M . A D D I T I O N O F S U C H I T E M S
INCREASES EXPOSED WIND AREA OF MACHINE.
• DO NOT STEP OUTSIDE OF HANDRAILS.
• DO NOT ATTACH OVERHANGING LOADS TO THE
• AVOID ACCUMULATION OF DEBRIS ON PLATFORM PLATFORM OR INCREASE THE PLATFORM SIZE
WORK AREA. KEEP MUD, OIL, GREASE AND OTHER WITH UNAUTHORIZED DECK EXTENSIONS OR
SLIPPERY SUBSTANCES FROM FOOTWEAR AND ATTACHMENTS.
PLATFORM DECK. • DO NOT ELEVATE PLATFORM UNLESS MACHINE IS
LEVEL.
• DO NOT TIE OFF MACHINE TO ANY ADJACENT
STRUCTURE. NEVER ATTACH WIRE, CABLE OR ANY
SIMILAR ITEMS TO PLATFORM.
• NEVER OPERATE A MALFUNCTIONING MACHINE. IF that apply when servicing hydraulic and larger machine
A MALFUNCTION OCCURS, SHUT DOWN THE component parts.
MACHINE , RED TAG IT, AND NOTIFY PROPER
Your safety, and that of others, is the first consideration
AUTHORITIES.
when engaging in the maintenance of equipment. Always
• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED. be conscious of weight.
• DO NOT ALLOW PERSONNEL TO TAMPER WITH, Never attempt to move heavy parts without the aid of a
SERVICE, OR OPERATE THIS MACHINE FROM THE mechanical device. Do not allow heavy objects to rest in
GROUND WITH PERSONNEL IN PLATFORM EXCEPT an unstable position. When raising a portion of the equip-
IN AN EMERGENCY. ment, ensure that adequate support is provided.
• WHEN TWO OR MORE PERSONS ARE IN PLATFORM, • ALWAYS DISCONNECT BATTERIES WHEN REPLAC-
THE OPERATOR SHALL BE RESPONSIBLE FOR ALL ING ELECTRICAL COMPONENTS.
MACHINE OPERATIONS. • REMOVE RINGS, WATCHES AND JEWELRY WHEN
• ALWAYS ENSURE THAT POWER TOOLS ARE PROP- PERFORMING ANY MAINTENANCE.
ERLY STOWED AND NEVER LEFT HANGING BY • DO NOT WEAR LOOSE FITTING CLOTHING OR LONG
THEIR CORD FROM THE PLATFORM WORK AREA. HAIR UNRESTRAINED, WHICH IS APT TO BECOME
CAUGHT ON, OR ENTANGLED IN EQUIPMENT.
• USE ONLY CLEAN APPROVED NONFLAMMABLE
1.7 TOWING AND HAULING
CLEANING SOLVENTS.
• TOW OR PULL MACHINE IN THE EVENT OF AN
• SHUT OFF ALL POWER CONTROLS BEFORE MAK-
EMERGENCY ONLY. TO MOVE MACHINE, CARRY
ING ADJUSTMENTS, LUBRICATING OR PERFORM-
MACHINE WITH FORKLIFT OF SUITABLE CAPACITY.
ING ANY OTHER MAINTENANCE.
• HAVE PLATFORM COMPLETELY EMPTY OF TOOLS
AND DEBRIS BEFORE CARRYING.
• WHEN LIFTING MACHINE, POSITION FORKS ONLY
AT DESIGNATED AREAS AT FRONT OR REAR OF
MACHINE.
• HAVE PLATFORM FULLY RETRACTED WHILE
MACHINE IS BEING CARRIED.
• NEVER ALLOW PERSONNEL IN PLATFORM WHILE
CARRYING.
• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL IT HAS BEEN RESTRAINED FROM MOVEMENT
WITH SAFETY PROPS, BLOCKING OR OVERHEAD
1.8 MAINTENANCE SLING.
This section contains the general safety precautions
which must be observed during maintenance of the aerial
work platform. It is of utmost importance that maintenance
personnel pay strict attention to these warnings and pre-
cautions to avoid possible injury to themselves or others
or damage to the equipment. A maintenance program
must be established by a qualified person and must be
followed to ensure that the machine is safe to operate.
2.4 DAILY WALK-AROUND INSPECTION NOTE: On new machines, those recently overhauled, or
after changing hydraulic oil, operate all systems a
It is the users responsibility to inspect the machine before minimum of two complete cycles and recheck oil
the start of each workday. It is recommended that each level in reservoir.
user inspect the machine before operation, even if the
machine has already been put into service under another 1. Check Enable Switch for proper operation. Switch
user. This Daily Walk-Around Inspection is the preferred must be pressed before activating any functions.
method of inspection.
Overall Cleanliness 2. Raise and lower platform several times. Check for
smooth elevation and lowering. Check that High
Check all standing surfaces for hydraulic oil spillage and Drive cut-out as platform begins to raise.
foreign objects. Ensure overall cleanliness.
NOTE: Perform checks from ground controls first, then from
Placards platform controls.
Keep all information and operating placards clean and 3. Drive forward and reverse, check for proper opera-
unobstructed. Cover when spray painting or shot blasting tion.
to protect legibility. Uncover prior to machine operation
4. Check that drive brakes hold when machine is
driven up a hill, not to exceed rated gradeability, and
Operators and Safety and Service and stopped.
Maintenance Manual
5. Steer left and right. Check for proper operation.
Ensure that a copy of this manual is enclosed in the man- 6. Check hydraulic oil reservoir level marks. Refer to
ual storage holder. Lubrication Chart.
to the operator in the event he/she notices a condition that 6. Start hydraulic system and ensure that it functions
requires prompt attention during the walk-around inspec- properly.
tion or during operation until the proper service personnel
can be notified. The Service and Maintenance section pro- Battery Charging, Daily
vides specific torque values and periodic maintenance
procedures with a listing of individual components. Utiliz- NOTE: To avoid excessive battery charging time, do not
ing this torque chart in conjunction with preventive mainte- allow batteries to become completely discharged.
nance section will enhance safety, reliability and To avoid electrolyte overflow, add distilled water to
performance of the machine. batteries after charging.
When adding water to the battery, fill only to level
indicated.
2.7 BATTERY MAINTENANCE AND
CHARGING 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
TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR
procedure:
ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC-
ING. a. Position the Platform/Ground Select Switch to
the off position.
Battery Maintenance, Quarterly b. Open battery compartment, and battery charger
compartment covers.
1. Open battery compartment cover to allow access to
battery terminals and vent caps.
WHEN BATTERY CHARGER IS TO BE USED, CHARGING HAR-
NESS MUST BE PLUGGED INTO A GROUNDED 110 VOLT RECEP-
TA C L E . I F R E C E P TA C L E I S N O T G R O U N D E D A N D A
WHEN ADDING WATER TO BATTERIES, ADD WATER UNTIL ELEC-
MALFUNCTION SHOULD OCCUR, THE MACHINE COULD CAUSE
TROLYTE COVERS PLATES. DO NOT CHARGE BATTERIES
SERIOUS ELECTRICAL SHOCK.
UNLESS ELECTROLYTE COVERS PLATES.
c. Remove charging harness cable and connect to
NOTE: When adding distilled water to batteries, non-metallic a 220 volt receptacle.
containers and/or funnels must be used.
d. Allow batteries to charge until ammeter on
To avoid electrolyte overflow, add distilled water to
charger, if equipped, is reading zero (0). Normal
batteries after charging.
charging time is 8-10 hours.
When adding water to the battery, fill only to level
indicated. NOTE: When batteries are completely charged, disconnect
charging harness cable from receptacle. Store
2. Remove all vent caps and inspect electrolyte level of charging harness cable.
each cell. Electrolyte level should be to the ring
approximately one inch from top of battery. Fill bat- e. Ensure battery cables are positioned and are not
teries with distilled water only. Replace and secure pinched. Close and secure all compartment
all vent caps. doors.
3. (Remove battery cables from each battery post one 3. The battery packs on each side of the frame are
at a time, negative first. Clean cables with acid neu- designed to be easily removed so that a machine
tralizing solution (e.g. baking soda and water or can have two sets of them in order to keep the
ammonia) and wire brush. Replace cables and/or machine functioning longer. Disconnect the cable
cable clamp bolts as required. quick connects, and remove the two clevis pins on
top of the frame. Now, using the forklift pockets
4. Clean battery post with wire brush then re-connect under the packs, have a forklift move them to a
cable to post. Coat non-contact surfaces with no-ox- place where they can be recharged. The new battery
id “A” compound, mineral grease or petroleum jelly. packs can be installed by reversing the above pro-
cedure.
5. When all cables and terminal posts have been
cleaned, ensure all cables are properly positioned NOTE: Battery packs are interchangeable.
and do not get pinched. Close battery compartment
cover.
30. Wheel and Tire Assembly (left front)- Properly damage, placard secure and legible, control lever
secured, no visible damage, no loose or missing and switches return to neutral, control lever lock
parts functions properly, emergency stop switch func-
tions properly, control markings legible.
31. Handrails Installation - All railings securely
attached, no missing parts, no visible damage, 33. Platform Assembly - No loose or missing parts, no
chains in proper working order. visible damage, platform extension operates prop-
erly.
32. Control Console - Switches and control lever prop-
erly secured, no loose or missing parts, no visible
1 Hydraulic Oil Fill Cap/Drain Plug HO - Kendall Hyken 8/800 Check oil every 8 hours of operation
052 Change oil every 800 hours of operation
2 Torque Hub Fill Plug/Half full EPGL - SAE 90 2000 Check oil level at side plug on hub
5 Hydraulic Filter Element N/A Replaceable Element 40/250 Replace filter element after first 40 hours of operation
(not shown) then every 250 hour thereafter
KEY TO LUBRICANTS:
HO - Hydraulic Oil - Kendall Hyken 052
EPGL - Extreme Pressure Gear Lube
Updated 3-8-00
3-2 – JLG Sizzor– 3120880
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-1. Ground Control Station on Machines Before Serial Number 020071522
Figure 3-2. Platform Control Station on Machines Before Serial Number 020071522
Updated 3-8-00
3120880 – JLG Sizzor – 3-3
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Figure 3-3. Ground Control Station on Machines After and Including Serial Number 020071522
Figure 3-4. Platform Control Station on Machines After and Including Serial Number 020071522
Updated 3-8-00
3-4 – JLG Sizzor– 3120880
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
Updated 3-8-00
3120880 – JLG Sizzor – 3-5
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
1. If machine is shut down, turn Emergency Stop 6. Lift up right handrail, fold handrail down onto plat-
Switch to ON position. form deck.
NOTE: When parking battery powered units overnight, bat- 3. Maximum capacity for each model is as follows:
teries should be charged in accordance with instruc- 3369 electric - 455 kg (1000 lb)
tions in Section 2 to ensure readiness for following
workday. 3969 electric - 340 kg (750 lb)
Towing this machine is prohibited. However, provisions for 1. Turn knob (clockwise) on lowering valve until fully
moving the machine have been incorporated. The follow- closed.
ing procedures are to be used ONLY for emergency 2. Install handle, and pump until holding valve opens
movement to a suitable maintenance area. and desired descent speed is attained.
1. Chock wheels securely. 3. When platform is fully lowered, turn knob on lower-
ing valve (counterclockwise) to reopen valve.
2. Engage the mechanical release on both drive
brakes by loosening, completely reversing, and 4. Return handle to stowed position.
tightening the three nuts on each brake.
After moving machine, complete the following procedure: Use of Ground Controls
1. Position machine on a firm level surface. Know how to use Ground Controls in an emergency situa-
tion. Ground personnel must be thoroughly familiar with
2. Chock wheels securely. the machine operating characteristics and the ground
control functions. Training should include operation of the
3. Disengage the mechanical release on both drive machine, review and understanding of this section and
brakes by loosening, completely reversing, and hands-on operation of the controls in simulated emergen-
tightening the three nuts on each brake. cies.
Emergency Stop Switch 1. Operate the machine from ground controls only with
the assistance of other personnel and equipment
There is red mushroom shaped switche located at the (cranes, overhead hoists, etc.) as may be required
Platform Controls Station. When depressed it will immedi- to safely remove the danger or emergency condi-
ately stop all functions at that station and shut down the tion.
machine.
2. Other qualified personnel on the platform may use
the platform controls. DO NOT CONTINUE OPERA-
TION IF CONTROLS DO NOT FUNCTION PROP-
CHECK DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS ERLY.
FUNCTIONING AND THAT CONTROL INSTRUCTIONS ARE IN
PLACE AND LEGIBLE.
Post-Incident Inspection
Following any accident, thoroughly inspect the machine
and test all functions first from the ground controls, then
from the platform controls. Do not lift above 3 m (10 ft)
until you are sure that all damage has been repaired, if
required, and that all controls are operating correctly.
Date Comments
Date Comments
TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and Sky Trak product owner:
If you now own, but ARE NOT the original purchaser of the product covered by this manual, we would like
to know who you are. For the purpose of receiving safety-related bulletins, it is very important to keep JLG
Industries, Inc. updated with the current ownership of all JLG products. JLG maintains owner information for each
JLG product and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current ownership of JLG
Products. Please return completed form to the JLG Product Safety & Reliability Department via facsimile (717) 485-
6573 or mail to address as specified on the back of this form.
Thank you,
Product Safety & Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533
Telephone: (717) 485-5161
Fax: (717) 485-6573
Mfg. Model:
Serial Number:
Previous Owner:
Address:
Please cut on the dotted line and fax to 717-485-6573
City: State:
Zip: Telephone: ( )
Date Of Transfer:
Current Owner:
Address:
City: State:
Zip: Telephone: ( )
Name:
Title:
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Customer Support Toll Free: (877) 554-5438
Fax: (717) 485-6417
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762