JLG 450A Operator's And Safety Manual
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JLG 450A Operator's And Safety Manual

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Operators and Safety Manual
Model
450A
450AJ
3120748
April 24, 2002
ANSI

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  • Page 1 Operators and Safety Manual Model 450A 450AJ 3120748 April 24, 2002 ANSI...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 – JLG Lift –...
  • Page 4 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.
  • Page 5 FOREWORD This page left blank intentionally. – JLG Lift – 3120748...
  • Page 6 29 CFR these requirements constitute an assumption of 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR responsibility of liability on the part of JLG Indus- 1926.28, and 29 CFR 1926.453. tries, Inc.
  • Page 7 Original Issue May, 1998 Revised June 1, 1999 Updated 9-21-99 Updated 9-21-99 Updated 10-14-99 2-12 and 2-13 Updated 11-8-99 Updated 2-2-00 Prop 65 page added - Updated 4-20-00 Updated 4-20-00 Updated 9-19-00 3-11 Updated 4-24-02 – JLG Lift – 3120748...

  • Page 8: Table Of Contents

    Rotating Beacon ............. . .5-2 3120748 – JLG Lift –...
  • Page 9 Inspection and Repair Log ............7-1 – JLG Lift –...

  • Page 10: Section 1 - Safety Precautions

    FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN operation. If there is a question on application and/or THIS SECTION AND ON THE MACHINE COULD RESULT IN operation, JLG Industries Inc., should be consulted. MACHINE DAMAGE, PERSONNEL INJURY OR DEATH, AND IS A SAFETY VIOLATION.

  • Page 11: Electrocution Hazard

    SONNEL TO OPERATE MACHINE WHO HAVE DEM- LINES AND APPARATUS. ALLOW FOR BOOM SWAY, ONSTRATED THAT THEY UNDERSTAND SAFE AND ROCK OR SAG AND ELECTRICAL LINE SWAYING. PROPER OPERATION AND MAINTENANCE OF THE THE MACHINE DOES NOT PROVIDE PROTECTION UNIT. – JLG Lift – 3120748...
  • Page 12 BEEN SERVICED AND MAINTAINED ACCORDING TO THE MANUFACTURERS SPECIFICATIONS AND SCHEDULE. • ENSURE DAILY INSPECTION AND FUNCTION CHECK IS PERFORMED PRIOR TO PLACING MACHINE INTO OPERATION. • APPROVED HEAD GEAR MUST BE WORN BY ALL OPERATING AND GROUND PERSONNEL. 3120748 – JLG Lift –...

  • Page 13: Driving

    WH E N D RI V IN G IN ARE A S WH E RE V I S I O N I S OBSTRUCTED. • KEEP NON-OPERATING PERSONNEL AT LEAST 6 FEET (2 M) AWAY FROM MACHINE DURING DRIVING OPERATIONS. • WATCH FOR OBSTRUCTIONS AROUND MACHINE AND OVERHEAD WHEN DRIVING. – JLG Lift – 3120748...

  • Page 14: Operation

    GROUND. ENTER OR EXIT THRU GATE ONLY. PLAT- FORM FLOOR MUST BE WITHIN 1 FOOT (30 CM) OF ADJACENT - SAFE AND SECURE - STRUCTURE. ALLOW FOR PLATFORM VERTICAL MOVEMENT AS WEIGHT IS TRANSFERRED TO OR FROM PLAT- FORM. 3120748 – JLG Lift –...
  • Page 15 TO WARN THEM NOT TO WORK, WALK OR STAND • KEEP ALL NON-OPERATING PERSONNEL AT LEAST UNDER A RAISED BOOM OR PLATFORM. POSITION 6 FEET (2 M) AWAY FROM THE MACHINE AT ALL BARRICADES ON FLOOR IF NECESSARY. TIMES. – JLG Lift – 3120748...
  • Page 16 THEN MOVE SWITCH TO THE DESIRED POSITION. OPERATE LEVERS WITH SLOW, EVEN PRESSURE. • DO NOT CARRY MATERIALS ON PLATFORM RAILING UNLESS APPROVED BY JLG INDUSTRIES INC. • NEVER PUSH OR PULL THE MACHINE OR OTHER OBJECTS BY TELESCOPING THE BOOM.

  • Page 17: Towing And Hauling

    BEING USED REACHES END OF TRAVEL. THIS APPLIES TO MACHINES IN OPERATION OR IN STOWED MODE. • DO NOT OPERATE ANY MACHINE ON WHICH DAN- GER, WARNING, CAUTION OR INSTRUCTION PLAC- ARDS OR DECALS ARE MISSING OR ILLEGIBLE. – JLG Lift – 3120748...

  • Page 18: Section 2 - Preparation And Inspection

    (Contact Service NOTE: This machine requires periodic safety and mainte- Personnel for assistance if needed). nance inspections by an authorized JLG Dealer. A decal located on the frame provides a place to NOTE: Torque hubs should be one-half full of lubricant.
  • Page 19 14. Check Upper Boom Lift Cylinder and cross pins and hydraulic lines for damage, wear, lubrication, leak- NOTE: JLG recommends replacing the hydraulic filter ele- age and security. ment after the first 50 hours of operation and then every 300 hours thereafter, unless system indicator require earlier replacement.

  • Page 20: Machine Nomenclature

    POWER TRACK BASE BOOM MAIN BOOM ASSEMBLY UPPER LIFT CYLINDER MID BOOM MID LIFT CYLINDER LOWER UPRIGHT TOWER or LOWER BOOM TOWER or LOWER LIFT CYLINDER TURNTABLE DRIVE WHEELS STEER WHEELS Figure 2-1. Machine Nomenclature 3120748 – JLG Lift –...

  • Page 21: Torque Requirements

    3. Check control switches, levers and electrical con- manual will enhance safety, reliability, and performance of nections for tightness and evidence of corrosion, the machine. and wiring for defects and chafing damage. Assure that switches function properly. – JLG Lift – 3120748...

  • Page 22: Daily Walk-Around Inspection

    Ensure a machine operating record or log is kept, 8. Assure that all items requiring lubrication are ser- check to see that it is current and that no entries viced. Refer to Figure 2-5., Lubrication Diagram for specific requirements. 3120748 – JLG Lift –...

  • Page 23: Daily Walk-Around Inspection - Sheet 1 Of 3

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3 – JLG Lift – 3120748...

  • Page 24: Daily Walk-Around Inspection - Sheet 2 Of 3

    22. Engine Oil Supply - Full mark on dipstick; filler cap evidence of leakage. secure. 7. Wheel/Tire Assembly, Right Rear - Properly secured, no loose or missing lug nuts, no visible damage. Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 3 3120748 – JLG Lift –...

  • Page 25: Daily Walk-Around Inspection - Sheet 3 Of 3

    26. Auxiliary Power Pump - No loose or missing parts, no parts. evidence of leakage, no damaged wires. Figure 2-4. Daily Walk-Around Inspection - Sheet 3 of 3 – JLG Lift – 3120748...

  • Page 26: Daily Functional Check

    If it does not, shut down machine tion. If the upright is tilted or the boom will not fully and contact a certified JLG service technician. lower, refer to the Boom Synchronizing Procedure in c. With engine power shut down, depress the foot- Section 3.

  • Page 27: Battery Maintenance

    ALWAYS WEAR EYE PROTECTION WHEN SERVICING BATTER- and are not pinched. Close battery compartment IES. cover. 1. The battery is maintenance free except for occa- sional battery terminal cleaning, as noted in the fol- lowing. 2-10 – JLG Lift – 3120748...

  • Page 28: Lubrication Diagram

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-5. Lubrication Diagram 3120748 – JLG Lift – 2-11...
  • Page 29 Adjust final oil level by mark on dipstick. Fuel Filter - Ford Replaceable Element Fuel Filter - Deutz Replaceable Element Fuel Filter - Isuzu Replaceable Element Air Filter - Ford Replaceable Or as indicated by condition indicator Element Updated 11-8-99 2-12 – JLG Lift – 3120748...
  • Page 30 [10.5 L], capacity of both crankcase and cooler combined). Start engine, allow the engine to run until the thermostat opens (approximately 221 degrees F) cooler will fill up within minutes; shut down and wait for approximately two minutes. Check oil level, fill oil to max marking on dipstick. Updated 11-8-99 3120748 – JLG Lift – 2-13...
  • Page 31 SECTION 2 - PREPARATION AND INSPECTION 2-14 – JLG Lift – 3120748...

  • Page 32: Section 3 - User Responsibilities And Machine Control

    JLG Distribu- trol must not be permitted to operate the machine. tor before proceeding.

  • Page 33: Operating Characteristics And Limitations

    4. Proper tire pressure exists in the tires. 8. Activate the lift control switch and fully lower the boom and continue to hold down the switch for an 5. Machine is as originally equipped from JLG. additional 5 seconds. Stability 9.

  • Page 34: Position Of Least Forward Stability

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL UPPER BOOM TELESCOPE HORIZONTAL FULLY EXTENDED MID/LOWER BOOM STOWED POSITION MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 3-1. Position of Least Forward Stability 3120748 – JLG Lift –...

  • Page 35: Position Of Least Backward Stability

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL Figure 3-2. Position of Least Backward Stability – JLG Lift – 3120748...

  • Page 36: Controls And Indicators

    PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION a. The auxiliary pump functions to provide suffi- WHEN RELEASED. cient oil flow to operate the basic machine func- tions should the main pump or engine fail. The 3120748 – JLG Lift –...

  • Page 37: Ground Control Indicator Panel

    11. Articulating Jib Boom. (If Equipped) The Articulating Jib Boom control switch provides Figure 3-3. Ground Control Indicator Panel raising and lowering of the jib when positioned up or down. Updated 9-19-00 – JLG Lift – 3120748...
  • Page 38 PANEL PLATFORM LEVELING MAIN OVERRIDE TELESCOPE ARTICULATING MAIN JIB BOOM LIFT ENGINE START/ AUX. POWER POWER/ TOWER EMERGENCY LIFT STOP QUARTZ PLATFORM/GROUND SELECT SWITCH HOURS SWING HOURMETER 1703691 AJ Models Figure 3-4. Ground Control Station 3120748 – JLG Lift –...

  • Page 39: Malfunction Indicator Light And Test Button

    Diagnostic Trouble Codes will be displayed on the Malfunction Indicator Light. Refer to the Service Manual for instructions concerning the trouble codes and trou- ble code retrieval. Updated 9-21-99 – JLG Lift – 3120748...
  • Page 40 NOTE: Main lift and swing functions may be selected in and depress the footswitch. combination. The handle features a round gate so that maximum speed is reduced when multiple func- 4. Travel Warning Horn. tions are selected. 3120748 – JLG Lift –...

  • Page 41: Platform Station - Proportional Controls

    Function Speed, are positioned to High, high func- drive in reverse. Steering is accomplished via a tion speeds are automatically cut out and the thumb-activated rocker switch on the end of the machine continues to operate at a lower speed. 3-10 – JLG Lift – 3120748...
  • Page 42 13. Creep Speed Indicator. Illuminated (Green) when the Function Speed Con- trol is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. 3120748 – JLG Lift – 3-11 Updated 4-24-02...

  • Page 43: Placards And Decals

    All controls are cut out until the the problem corrected by a certified JLG service override button is pushed, at which time controls are technician. Operate as follows: active in the Creep mode.

  • Page 44: Danger And Warning Decal Location

    INSPECTED AND OPERATING PROPERLY. DO NOT operate this machine unless you have been properly trained as described in the JLG Operation and Safety Manual by a qualified person and authorized to operate this machine. Your training includes reading and understanding the safety, operating and maintenance instructions in manufacturer’s manuals, knowing your employers work rules and...
  • Page 45 DO NOT operate this machine unless you have been properly trained as DO NOT raise platform during high winds. described in the JLG Operation and Safety Manual by a qualified person DO NOT drive near drop offs, holes or other hazards.
  • Page 46 INSPECTED AND OPERATING PROPERLY. DO NOT operate this machine unless you have been properly trained as described in the JLG Operation and Safety Manual by a qualified person and authorized to operate this machine. Your training includes reading and understanding the safety, operating and maintenance instructions in manufacturer’s manuals, knowing your employers work rules and...

  • Page 47: Control Panel Symbols - Sheet 1 Of 2

    CREEP LIFT 500 LB PLATFORM TOWER CAPACITY TELESCOPE 1000 LB INDICATOR ARTICULATING ENGINE FLY BOOM DISTRESS MAIN LOW FUEL TELESCOPE LEVEL FUEL GENERATOR SELECT Figure 3-8. Control Panel Symbols - Sheet 1 of 2 3-16 – JLG Lift – 3120748...

  • Page 48: Control Panel Symbols - Sheet 2 Of 2

    SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL SYMBOL FUNCTION SYMBOL FUNCTION SOFT GLOW PLUG TOUCH INDICATOR OVERRIDE ENABLE SOFT TOUCH INDICATOR INDICATOR POWER DRIVE EMERGENCY STOP START AUXILIARY STEER POWER Figure 3-9. Control Panel Symbols - Sheet 2 of 2 3120748 – JLG Lift – 3-17...
  • Page 49 SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL This page left blank intentionally. 3-18 – JLG Lift – 3120748...
  • Page 50 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 51: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION The JLG Lift is not intended to be used to lift material other 4.1 DESCRIPTION than supplies which personnel in the platform require to do their job. Supplies or tools which extend outside the This machine is a self-propelled aerial work platform on platform are prohibited.

  • Page 52: Engine Operation

    Shutdown Procedure desired. 3. Depress footswitch and position STEER control to RIGHT for traveling right and LEFT for traveling left. IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION. – JLG Lift – 3120748...

  • Page 53: Steering

    1. Position chassis on a smooth, firm and level surface. 2. If total load (personnel, tools and supplies) is less then rated capacity, distribute load uniformly on plat- form floor and proceed to work position. 3120748 – JLG Lift –...

  • Page 54: Boom

    ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PAR- TITIONS AND EQUIPMENT. Raising and Lowering the Lower and Mid Boom. To raise or lower the Lower and Mid Boom, with footswitch activated, position Lower Boom Lift switch to UP or DOWN as desired. – JLG Lift – 3120748...

  • Page 55: Lift Up And Platform Level Down Disable Switch Functional Check

    NOTE: Crane and lifting devices, chains, slings, etc., must be capable of handling at least: PROXIMITY SWITCH 450A - 2WD (pneumatic tires) - 14,700 lbs. (6668 kg.) CONTACT PLATE COIN 450AJ - 2WD (pneumatic tires) - 15,500 lbs. (7030 kg.) Figure 4-2.

  • Page 56: Machine Tie Down - A Models

    This prevents the boom from bouncing up and down and preventing possible damage while transporting. Figure 4-3. Machine Tie Down - A Models – JLG Lift – 3120748...

  • Page 57: Machine Tie Down - Aj Models

    This prevents the boom from bouncing up and down and preventing possible damage while transporting. Figure 4-4. Machine Tie Down - AJ Models 3120748 – JLG Lift –...
  • Page 58 SECTION 4 - MACHINE OPERATION – JLG Lift – 3120748...

  • Page 59: Oscillating Axle Lockout Test (If Equipped)

    14. If lockout cylinders do not function properly, have block and ramp. qualified personnel correct the malfunction prior to 6. Have an assistant check to see that left front wheel any further operation. remains locked in position off of ground. 3120748 – JLG Lift –...

  • Page 60: Towing

    1. Retract, lower and position boom over rear drive wheels in line with direction of travel. 2. Disconnect drive hubs by inverting disconnect cap. (See Figure 4-6.) After towing the machine, com- plete the following: Figure 4-6. Drive Disconnect Hub 4-10 – JLG Lift – 3120748...

  • Page 61: Section 5 - Optional Equipment

    The lockout cylin- ders permit axle oscillation when the boom is centered over the rear, and lock and hold the axle when the boom is moved off center. 3120748 – JLG Lift –...

  • Page 62: Travel Alarm

    These components can be plugged in together or singly to preheat their associated components for easier cold weather starting. – JLG Lift – 3120748...

  • Page 63: Hostile Environment Package

    PLATFORM/ GROUND SELECT switch, the POWER/EMERGENCY STOP switch is ON, and the footswitch is depressed. The alarm warns personnel in the jobsite area to avoid the operating machine. Updated 2-2-2000 3120748 – JLG Lift –...
  • Page 64 SECTION 5 - OPTIONAL EQUIPMENT This page left blank intentionally. – JLG Lift – 3120748...

  • Page 65: Section 6 - Emergency Procedures

    CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP 5. Release AUXILIARY POWER switch, and appropriate SWITCH GUARD IS IN PLACE AND THAT GROUND CONTROL control switch or controller. INSTRUCTIONS ARE IN PLACE AND LEGIBLE. 6. Position POWER/EMERGENCY STOP switch to OFF. 3120748 – JLG Lift –...

  • Page 66: Emergency Operation

    It is imperative that JLG Industries, Inc. be notified imme- ment (cranes, overhead hoists, etc.) as may be be diately of any incident involving a JLG product. Even if no required to safely remove the danger or emergency injury or property damage is evident, the factory should condition.

  • Page 67: Section 7. Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments 3120748 – JLG Lift –...
  • Page 68 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.Inspection and Repair Log Date Comments – JLG Lift – 3120748...
  • Page 70 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

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