JLG E450AJ Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

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

Boom Lift Models

E450A

E450AJ

M450A

M450AJ

3121210

January 7, 2013

FOREWORD

3121210 – 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 – 3121210

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 POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

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

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A

YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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

3121210 – JLG Lift – c

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.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL

OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL

PROPERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

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: 240-420-2661

Fax: 301-745-3713

E-mail: Pr[email protected]m

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 – 3121210

REVISION LOG

Original Issue - June 21, 2005

Revised - July 21, 2006

Revised - December 7, 2009

Revised - August 26, 2010

Revised - October 6, 2011

Revised - August 14, 2012

Revised - January 7, 2013

TABLE OF CONTENTS

3121210 – 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 . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-

RATION, 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Platform Control Indicator Panel . . . . . . . . . . . . 3-12

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

4.3 MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Power/Emergency Stop . . . . . . . . . . . . . . . . . . . 4-2

Platform/Ground Select Switch. . . . . . . . . . . . . . 4-5

Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Loading From Ground Level . . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . . 4-8

TABLE OF CONTENTS

ii – JLG Lift – 3121210

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

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

Raising and Lowering the Lower and Mid Boom 4-9

Raising and Lowering the Upper Boom . . . . . . 4-9

4.8 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Automatic Operating Mode . . . . . . . . . . . . . . . 4-10

Battery Only Operating Mode . . . . . . . . . . . . . 4-10

Manual (Charge) Operating Mode. . . . . . . . . . 4-10

4.9 INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 MACHINE FUNCTION SPEEDS . . . . . . . . . . . . . . 4-11

4.11 BOOM SYNCHRONIZING PROCEDURE . . . . . . . 4-11

4.12 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-12

4.13 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

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

SECTION - 5 - EMERGENCY PROCEDURES

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

5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1

5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1

Platform or Boom Caught Overhead. . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2

5.5 MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . .5-2

5.6 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . .5-3

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Torque Specifications. . . . . . . . . . . . . . . . . . . . . 6-5

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Lubrication Specifications . . . . . . . . . . . . . . . . . 6-6

Critical Stability Weights . . . . . . . . . . . . . . . . . . . 6-6

Serial Number Locations . . . . . . . . . . . . . . . . . . 6-7

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-9

6.4 BATTERY MAINTENANCE AND CHARGING. . . . .6-14

Battery Maintenance, Quarterly . . . . . . . . . . . . 6-14

Optional On Board Generator . . . . . . . . . . . . . 6-15

Battery Charging (On Board Charger) . . . . . . . 6-15

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-16

TABLE OF CONTENTS

3121210 – JLG Lift – iii

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

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-17

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-19

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-8

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

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10

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

3-2. Ground Control Station w/ Function Enable . . . . . .3-4

3-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-7

3-4. Platform Control Console - w/Drive Orientation . . .3-8

3-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-13

3-6. Platform Control Indicator Panel w/Drive

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

4-1. Position of Least Forward Stability . . . . . . . . . . . . .4-3

4-2. Position of Least Backward Stability . . . . . . . . . . . .4-4

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-5. Chassis & Platform Tie Down - Sheet 1 of 2 . . . . .4-14

4-6. Chassis & Platform Tie Down - Sheet 2 of 2 . . . . .4-15

4-7. Decal Installation - Sheet 1 of 3 . . . . . . . . . . . . . . .4-16

4-8. Decal Installation - Sheet 2 of 3 . . . . . . . . . . . . . . .4-17

4-9. Decal Installation - Sheet 3 of 3 . . . . . . . . . . . . . . 4-18

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . 6-7

6-2. Operator Maintenance & Lubrication Diagram . . . 6-8

TABLE OF CONTENTS

iv – JLG Lift – 3121210

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

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

3-1 Simultaneous Functions . . . . . . . . . . . . . . . . . . . . 3-11

4-1 E450A/E450AJP Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-2 E450A/E450AJP Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-3 M450A/M450AJ Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-4 M450A/M450AJ Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

6-1 Operating Specifications - Prior to

S/N 0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Operating Specifications - S/N 0300141435

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

6-10 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-9

6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-18

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

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