JLG 1930ES Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

Keep this manual with the machine at all times.

ANSI

Models

1930ES/2030ES/2630ES/

2646ES/3246ES

P/N - 3121165

February 16, 2006

FOREWORD

3121165 – JLG Lift – a

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and

operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes

without prior notification. Contact JLG Industries, Inc. for updated information.

FOREWORD

b– JLG Lift – 3121165

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT

AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE

A YELLOW BACKGROUND.

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

This is the Safety Alert Symbol. It is used to alert you to the potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death

FOREWORD

3121165 – JLG Lift – c

IMPORTANT

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

IMPORTANT

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR

WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL

PROPERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

1 JLG Drive

McConnellsburg, PA 17233

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

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

Outside USA:

Phone: 717-485-5161

E-mail: ProductSafety@JLG.com

For:

• Accident Reporting

• Product Safety Publica-

tions

• Current Owner Updates

• Questions Regarding

Product Safety

• Standards and Regulations

Compliance Information

• Questions Regarding Spe-

cial Product Applications

• Questions Regarding Prod-

uct Modifications

FOREWORD

d– JLG Lift – 3121165

REVISION LOG

Original Issue - March 31, 2003

Revised - April 30, 2003

Revised - May 21, 2003

Revised - June 13, 2003

Revised - June 25, 2003

Revised - August 26, 2003

Revised - December 3, 2003

Revised - March 3, 2004

Revised - September 17, 2004

Revised - June 15, 2005

Revised - September 12, 2005

Revised - October 21, 2005

Revised - February 16, 2006

TABLE OF CONTENTS

3121165 – JLG Lift – i

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

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge. . . . . . . . . . . 1-1

Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards. . . . . . . . . . . . . 1-8

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE

PREPARATION AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

SECTION - 3 - USER RESPONSIBILITIES AND MACHINE

CONTROL

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . 3-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . 3-2

Operator Responsibility. . . . . . . . . . . . . . . . . . . . 3-2

3.3 OPERATING CHARACTERISTICS AND

LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.4 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-3

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-3

3.5 PLATFORM CONTROL STATION . . . . . . . . . . . . . . 3-6

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Platform/Ground Select Switch. . . . . . . . . . . . . . 4-1

Emergency Stop Switch . . . . . . . . . . . . . . . . . . . 4-1

4.3 RAISING AND LOWERING . . . . . . . . . . . . . . . . . . . 4-2

Raising. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

TABLE OF CONTENTS

ii – JLG Lift – 3121165

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

Arm Guards (If equipped) . . . . . . . . . . . . . . . . . 4-3

Platform Extension. . . . . . . . . . . . . . . . . . . . . . . 4-3

Fold-Down Rails. . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.5 DRIVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Driving Forward . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-7

4.7 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . 4-7

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Battery Charger Fault Codes (delta-q) . . . . . . . 4-9

4.8 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 SAFETY PROP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.10 TIE DOWN/LIFT LUGS. . . . . . . . . . . . . . . . . . . . . . 4-11

4.11 LIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Remote Electric Brake Release . . . . . . . . . . . . 4-13

Push Button Electric Brake Release . . . . . . . . 4-13

Mechanical Brake Release . . . . . . . . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Emergency Stop Switch . . . . . . . . . . . . . . . . . . 5-1

Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-2

Operator Unable to Control Machine . . . . . . . . . 5-2

Platform Caught Overhead. . . . . . . . . . . . . . . . . 5-3

Righting of Tipped Machine . . . . . . . . . . . . . . . . 5-3

Post-Incident Inspection. . . . . . . . . . . . . . . . . . . 5-3

5.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-3

SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR

MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-2

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . .6-9

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-12

Oil Check Procedure (1) . . . . . . . . . . . . . . . . . 6-13

6.5 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . .6-15

Tire Wear and Damage. . . . . . . . . . . . . . . . . . . 6-15

Wheel and Tire Replacement . . . . . . . . . . . . . . 6-15

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-15

TABLE OF CONTENTS

3121165 – JLG Lift – iii

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

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Daily Walk-Around Inspection - Sheet 1 of 3. . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 2 of 3. . . . . .2-8

2-3. Daily Walk-Around Inspection - Sheet 3 of 3. . . . . .2-9

2-4. Switch Location . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-4

3-2. Battery Charger Status. . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Platform Control Station. . . . . . . . . . . . . . . . . . . . . .3-5

3-4. Decal Location - Sheet 1 of 4. . . . . . . . . . . . . . . . . .3-9

3-5. Decal Location - Sheet 2 of 4. . . . . . . . . . . . . . . . .3-10

3-6. Decal Location - Sheet 3 of 4. . . . . . . . . . . . . . . . .3-11

3-7. Decal Location - Sheet 4 of 4. . . . . . . . . . . . . . . . .3-12

4-1. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-2. Lifting and Tie Down Diagram . . . . . . . . . . . . . . . .4-12

4-3. Manual Disengage . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-4. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . .4-15

6-1. Lubrication Diagram. . . . . . . . . . . . . . . . . . . . . . . .6-12

LIST OF TABLES

1-1 Minimum Safe Approach Distances (M.S.A.D.) . . . 1-6

2-1 Inspection and Maintenance Table. . . . . . . . . . . . . 2-3

2-2 Maximum High Drive Cutout Height . . . . . . . . . . . . 2-6

2-3 Tilt vs. Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

3-1 Decal Location Legend (1930ES). . . . . . . . . . . . . 3-13

3-2 Decal Location Legend (2030ES). . . . . . . . . . . . . 3-16

3-3 Decal Location Legend (2630ES). . . . . . . . . . . . . 3-19

3-4 Decal Location Legend (2646ES). . . . . . . . . . . . . 3-22

3-5 Decal Location Legend (3246ES). . . . . . . . . . . . . 3-25

4-1 Battery Charger Fault Codes (delta-q) . . . . . . . . . . 4-9

6-1 Operating Specifications. . . . . . . . . . . . . . . . . . . . . 6-2

6-2 Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-5 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-6 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-9

6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-9 Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-11

6-10 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . 6-11

6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-16

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

TABLE OF CONTENTS

iv – JLG Lift – 3121165

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

This page left blank intentionally.

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