JLG E450AJ, Operation And Safety Manual

Page 1: ...ANSI Operation and Safety Manual Original Instructions Keep this manual with the machine at all times AS NZS Model E450AJ PVC 2001 31215012 September 28 2020 Rev B...

Page 2: ...ich are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service yo...

Page 3: ...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 prop...

Page 4: ...ORANGE BACK GROUND 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 BACKGROUN...

Page 5: ...S WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT Contact Product Safety and Reli...

Page 6: ...FOREWORD d 31215012 REVISION LOG Original Issue A October 3 2019 Revision B September 28 2020...

Page 7: ...NTENANCE 2 2 Pre Start Inspection 2 5 Daily Walk Around Inspection 2 6 Function Check 2 9 SkyGuard Function Test 2 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND INDICAT...

Page 8: ...CTION 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...

Page 9: ...4 BATTERY MAINTENANCE AND CHARGING 7 15 Battery Maintenance Quarterly 7 15 Optional On Board Generator 7 16 Battery Charging On Board Charger 7 16 7 5 TIRES WHEELS 7 17 Tire Inflation 7 17 Tire Damag...

Page 10: ...iv 31215012 TABLE OF CONTENTS...

Page 11: ...Side Slopes 4 7 4 4 Traveling on a Grade 4 8 4 5 Lifting Chart 4 18 4 6 Decal Installation Sheet 1 of 6 4 19 4 7 Decal Installation Sheet 2 of 6 4 20 4 8 Decal Installation Sheet 3 of 6 4 21 4 9 Decal...

Page 12: ...vi 31215012 LIST OF FIGURES...

Page 13: ...able Accessories 6 1 6 2 Options Accessories Relationship Table 6 2 7 1 Operating Specifications 7 1 7 2 Capacities 7 2 7 3 Tire Specifications 7 3 7 4 Dimensional Data 7 3 7 5 Torque Requirements 7 4...

Page 14: ...viii 31215012 LIST OF TABLES...

Page 15: ...ing is accomplished and operation of the machine has been completed under the supervision of an experienced and quali fied operator This section contains the responsibilities of the owner user oper at...

Page 16: ...ontrols Read understand and obey all applicable employer local and governmental regulations as they pertain to your utilization and application of the machine WorkplaceInspection Precautions to avoid...

Page 17: ...mud oil grease and other slippery substances from footwear and plat form floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any de...

Page 18: ...jewelry when operating machine Do not wear loose fitting clothing or long hair unre strained which may become caught or entangled in equip ment Persons under the influence of drugs or alcohol or who a...

Page 19: ...p both feet firmly positioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slipper...

Page 20: ...s occupants their tools and their equip ment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less Table...

Page 21: ...near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH ERWISE Tipping Hazards Ensure that the g...

Page 22: ...be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions exceed specificatio...

Page 23: ...ibleinsmoke 2 4 7 1 6 3 3 Lightbreeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallb...

Page 24: ...ditions the operator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors Be aware of stopping distances in all drive s...

Page 25: ...during machine maintenance are inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention t...

Page 26: ...such as batteries or solid tires with items of different weight or specification Do not modify the MEWP in any way to affect stability Refer to the Service and Maintenance Manual for the weights of cr...

Page 27: ...the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 7 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles...

Page 28: ...reading understanding and following the manufacturer s operator s man ual Prior to users authorization of an operator to use a specific model of MEWP the user shall ensure the operator is familiarized...

Page 29: ...dofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfrom...

Page 30: ...asic Nomenclature 1 PlatformControlConsole 2 Platform 3 UpperBoom 4 TelescopeCylinder inside 5 MasterCylinder 6 UpperUpright 7 UpperLiftCylinder 8 MidLiftCylinder 9 LowerBoom 10 Turntable 11 Frame 12...

Page 31: ...ulic oil level Ensure hydrau lic oil is added as required 8 Accessories Attachments Refer to the Accessories section in this manual or accessory installed upon the machine for specific inspection oper...

Page 32: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 6 31215012 Walk Around Inspection...

Page 33: ...disabled or blocked Gate latches and hinges in working condition 2 SkyGuard See Inspection Note 3 Platform Control Console Switches and levers return to neutral when activated and released decals plac...

Page 34: ...er See Inspection Note 17 Ground Control Console Switches and levers return to neutral when activated and released decals placards secure and legible control markings legible 18 Manual Descent See Ins...

Page 35: ...orm control console a Ensure that the control console is firmly secured in the proper location b Check that all guards protecting the switches or locks are in place c Ensure that all machine functions...

Page 36: ...racket c SkyGuard SkyEye Put arm or hand in path of sensor beam 3 Once the sensor has been activated verify the following conditions a Telescope out function stops and telescope in function operates f...

Page 37: ...ped symbols to alert the operator to different types of operational situations that could arise The meaning of those symbols are explained below Indicates a potentially hazardous situation which if no...

Page 38: ...tor 2 PlatformOverloadIndicator 3 IndicatorGauge 4 ChargerStatus 5 Telescope 6 MachineSafetySystemOverride MSSO IfEquipped 7 Swing 8 AuxiliaryPower 9 Power EmergencyStop 10 Platform GroundSelect 11 Lo...

Page 39: ...cates the platform has been overloaded 3 Indicator Gauge Registers the amount of time the machine has been in use with functions operating In the event of a fault the hourmeter also dis plays the thre...

Page 40: ...m shaped switch furnishes power to Platform Ground Select switch when pulled out on When pushed in off power is shut off to the Platform Ground Select switch 10 Platform Ground Select Switch A three p...

Page 41: ...CORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 14 Platform Leveling Override A three position switch allows the operator to adjust...

Page 42: ...Power EmergencyStop 5 DriveOrientationOverride 6 Drive Steer 7 Telescope 8 Lights 9 Jib 10 SoftTouch SkySense SkyGuardOverride 11 LowerBoomLift 12 PlatformRotate 13 FunctionSpeed 14 MainLift Swing Fig...

Page 43: ...on switch allows the operator to adjust the automatic self leveling system This switch is used to adjust platform level in situa tions such as ascending descending a grade 3 Horn A push type Horn swit...

Page 44: ...ded and will auto matically return to neutral off position when released 6 Drive Steer The Drive controller provides for driving either forward or back ward when positioned to For ward or Reverse The...

Page 45: ...quipped with both SkyGuard and Soft Touch The switch operates like the SkyGuard override switch as described above The switch also enables the functions cut out by the Soft Touch system to operate aga...

Page 46: ...e puts the functions listed above as well as the Drove Steer and Main Lift Swing functions into the slowest speed setting NOTE To operate the Main Boom Lift Swing joystick pull up on the locking ring...

Page 47: ...UpperLift DriveandSteer Swing No Telescope Telescope DriveandSteer Swing LowerLift UpperLift Jib DriveandSteer Swing LowerLift UpperLift Telescope PlatformRotate DriveandSteer No No No No Note Boomfu...

Page 48: ...S 3 12 31215012 100 75 50 25 0 1 2 3 4 5 6 7 8 OAC02310 1 BatteryCharge 2 SystemDistress 3 DriveOrientation 4 CapacityZoneIndicator 5 TiltAlarmWarning 6 CreepSpeed 7 Footswitch 8 PlatformOverload Figu...

Page 49: ...either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to verify that the drive control is being operated in the proper...

Page 50: ...or if a seven second lapse between ending one function and beginning the next function the enable light will go out and the footswitch must be released and depressed again to enable the controls Relea...

Page 51: ...machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate all functions except drive and steer Except for performing inspections and the Function C...

Page 52: ...ight in the platform to not exceed the rated workload indi cated on the capacity decal then the controls will work again Stability Machine stability is based on two 2 positions which are called Forwar...

Page 53: ...1215012 4 3 Figure 4 1 Position of Least Forward Stability MACHINEWILLTIPOVERINTHISDIRECTIONIFOVER LOADEDOROPERATEDBEYONDTHELIMITSOFTHE MAXIMUMOPERATINGSLOPE FLYBOOM FULLYEXTENDED UPPERBOOM HORIZONTAL...

Page 54: ...of Least Backward Stability LOWER BOOM FULLY ELEVATED MID BOOM FULLY ELEVATED UPPER BOOM FULLY ELEVATED AND RETRACTED PLATFORM ROTATED 90 DEGREES MACHINE WILLTIP OVER IN THIS DIRECTION IF OVERLOADED...

Page 55: ...The Platform Ground Select switch directs battery power to the desired control station when the Power Emergency Stop switch is pulled out on With the switch held in the Ground position battery power...

Page 56: ...SECTION 4 MACHINE OPERATION 4 6 31215012 Figure 4 3 Grade and Sideslope...

Page 57: ...E FOOT FROM FOOT SWITCH AND DEPRESS FOOTSWITCH TO RESET DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM SUR FACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE TO AVOID LOSS OF TRAVE...

Page 58: ...console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer in the opposite direction from the movement of the controls If the indicator is illuminated operate...

Page 59: ...on Drive Steer controller to Right for steering right or to Left for steering left 4 6 PLATFORM Loading FromGround Level 1 Position chassis on a smooth firm and level surface 2 If total load personnel...

Page 60: ...WARNING LIGHT AS A LEVEL INDICATOR FOR THE CHASSIS TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE 3 DEGREES OR GREATER CHASSIS MUST BE POSITIONED WITHIN THE ALLOWABLE OPERATING SLOPE BEFORE SW...

Page 61: ...N until desired height is reached 4 8 INVERTER The inverter converts 48 VDC to 110 VAC to allow operation of power tools from the machine s batteries The inverter is operational when the emergency sto...

Page 62: ...ped for operating procedures 4 12 SKYGUARD OPERATION SkyGuard provides enhanced control panel protection When the SkyGuard sensor is activated functions in use at the time of actu ation will reverse o...

Page 63: ...m of force is applied to yellow bar SkyGuard SkyLine Cable is pressed breaking the magnetic connection between the cable and right bracket Reattach magnetic end of cable to bracket if it becomes disco...

Page 64: ...Lift Down Boom Lift Up Boom Lift Down Boom TeleOut Boom Tele In Jib Lift Jib Swing Basket Level Basket Rotate R C R C R R C R C R C C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated...

Page 65: ...batteries should be charged in accordance with instructions in Section 2 to ensure readiness for following workday NOTE Electric machines are equipped with a static strap due to static electricity bu...

Page 66: ...4 MACHINE OPERATION 4 16 31215012 LIFT HERE C L ROTATION A MODEL A Dimension Steer Axle To Center of Gravity Gross Weight Standard Machine E450AJ 46 Inches 1168 mm 14 300 lb 6486 kg Figure 4 5 Liftin...

Page 67: ...only to the designated lifting points 5 Properly adjust the rigging to prevent damage to the machine and so the machine remains level Tie Down WHEN TRANSPORTING THE MACHINE THE BOOM MUST BE FULLY LOWE...

Page 68: ...SECTION 4 MACHINE OPERATION 4 18 31215012 79 27 13 39 48 1 2 41 54 13 86 84 53 64 23 82 85 62 70 78 3 41 58 39 4 70 88 47 O AC 02330 Figure 4 6 Decal Installation Sheet 1 of 6...

Page 69: ...SECTION 4 MACHINE OPERATION 31215012 4 19 71 37 50 73 73 FourFootPlatform FiveFootPlatform O AC 02340 Figure 4 7 Decal Installation Sheet 2 of 6...

Page 70: ...SECTION 4 MACHINE OPERATION 4 20 31215012 78 54 39 19 21 58 6 52 2 20 88 O AC 02350 G BO NLY Figure 4 8 Decal Installation Sheet 3 of 6...

Page 71: ...SECTION 4 MACHINE OPERATION 31215012 4 21 11 65 70 70 83 37 50 D UALLANG UAG E O AC 02360 Figure 4 9 Decal Installation Sheet 4 of 6...

Page 72: ...SECTION 4 MACHINE OPERATION 4 22 31215012 Figure 4 10 Decal Installation Sheet 5 of 6 10 22 17 22 13 9 77 22 9 77 39 27 22 10 OAC02371...

Page 73: ...SECTION 4 MACHINE OPERATION 31215012 4 23 87 38 80 36 35 31 41 41 24 15 40 63 62 79 48 24 74 5 81 16 74 O AC 02380 Figure 4 11 Decal Installation Sheet 6 of 6...

Page 74: ...001253997 1001253997 1001253997 1001253997 1001253997 1001253997 1001253993 9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 10 1701642 1701642 1701642 1701642 1701642 1701642...

Page 75: ...04341 1705670 40 3252347 41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 1701518 47 1702265 1705977 1702271 1702265 1702265 1702265 1703988 1703991 1705977 48 0259550 0259550 025955...

Page 76: ...704885 81 1705351 1705426 1705427 1705910 1705429 1705430 1001113680 82 1001189882 1001189882 84 1001223055 1001224053 1001224048 1001224049 1001223971 1001224050 1001224052 85 1001222801 1001222801 1...

Page 77: ...h an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE...

Page 78: ...ine for damage If the machine is damaged or does not operate properly turn off the machine immedi ately Report the problem to the proper maintenance per sonnel Do not operate the machine until it is d...

Page 79: ...e To operate the manual swing override proceed as follows 1 Using a 7 8 inch socket and ratchet wrench locate nut on swing worm gear on left side of machine 2 Install wrench on nut and ratchet in the...

Page 80: ...SECTION 5 EMERGENCY PROCEDURES 5 4 31215012...

Page 81: ...ESSORIES 31215012 6 1 SECTION 6 ACCESSORIES Table 6 1 Available Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China SoftTouch FallArrestPlatform 36x60 FallArrestPlatform 36x72 PipeR...

Page 82: ...ent structure A button on the platform console allows override of the system Table 6 2 Options Accessories Relationship Table ACCESSORY REQUIREDITEM COMPATIBLE WITH Note1 INCOMPATIBLEWITH INTERCHANGAB...

Page 83: ...SECTION 6 ACCESSORIES 31215012 6 3 Figure 6 1 Soft Touch NOTE Platform shown in phantom for clarity...

Page 84: ...se fall protection at all times A full body harness is required with lanyard not to exceed 6 ft 1 8 M in length that limits the maximum arrest force to 900 lb 408 kg for the trans fastener type and 13...

Page 85: ...n when not in use Use this option only on approved models PreparationandInspection Ensure racks are secured to the platform rails Replace torn or frayed tie down straps Operation 1 To prepare racks fo...

Page 86: ...RESPONSIBILITY TO BE AWARE OF THEIR SURROUNDINGS AT ALL TIMES DE RATE THE PLATFORM BY 10 LB 4 5 KG PER BAR WHEN INSTALLED ON THE PLAT FORM 20 LB 9 KG OR 30 LB 14 KG TOTAL NOTE SkySense is not active w...

Page 87: ...ense slows a machine s function to creep speed when it is a certain distance away from an object known as the warning zone If the machine continues to approach the object and moves into the stop zone...

Page 88: ...achine is in SkySense warning zone and will reduce function speed to creep Flash fre quency correlates to proximity of object LED Red Machine is in SkySense stop zone and all machine functions will ce...

Page 89: ...anel alarm will sound when the machine enters the SkySense stop zone even when muted Override Button The yellow override button allows operators to bypass normal SkySense operation in order to move cl...

Page 90: ...SECTION 6 ACCESSORIES 6 10 31215012 SkySenseCoverage Areas NOTE Sensor Cones shown are approximations for reference only Level1 2 Bar Level2 3 Bar...

Page 91: ...ed in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 31215013 Illustrated Parts Manual 31215014 7 2 OPERATING SPECIFICATIONS Table 7 1 Operating Specifi...

Page 92: ...GrossMachineWeight PlatformEmpty 15 100lb 6804kg Table 7 2 Capacities HydraulicOilTank 5Gallons 19L w 10 airspace HydraulicSystem IncludingTank 9Gallons 34 1L TorqueHub Drive 25 5ounces 0 75L Torquehu...

Page 93: ...ies If use of hydraulic oil other than standard UTTO is desired contact JLG Industries for proper recommendations Table 7 4 Dimensional Data MachineLength stowed 21ft 2in 6 45m UpandOverPlatformHeight...

Page 94: ...n toxic Fire Resistant ShellTellusS2VX15 Recommended 15 135 X X MobilDTE10Excel15 Optional 16 169 X X ShellNaturelleHF E32 Recommended 31 192 X X MobilEALEnvirosynH32 Optional 34 146 X X Readilybiodeg...

Page 95: ...e left rear of frame in front of left rear wheel If the serial number plate is damaged or missing the machine serial number is stamped on the top left side of the frame and the top left side of the tu...

Page 96: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 6 31215012 Figure 7 2 E450 Maintenance Lubrication Diagram...

Page 97: ...omments Remote Access Optional Table 7 7 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350degreesF Excellentwaterresistanceandadhesivequalities andbe...

Page 98: ...A R Comments If necessary install grease fittings into worm gear housing and grease bearings NOTE OG will allow better cycle times than Mobiltac375NC however Mobiltac375NC must be used in dusty envir...

Page 99: ...int s Fill Cap Capacity 4 Gal 15 1 L Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation Comments On new machines those recently overhauled or after changing hydraulic o...

Page 100: ...rn Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments Under certain conditions it may be necessary to replace the hydraulic filter on a more frequent basis A c...

Page 101: ...ths or 150 hrs of operation change every 2 years or 1200 hours of operation 6 Wheel Bearings Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 7 Spindles Bush...

Page 102: ...CATIONS OPERATOR MAINTENANCE 7 12 31215012 8 Engine Lube Point s Fill Cap Capacity Refer to Engine Manual Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accor...

Page 103: ...ve first Clean cables with acid neutralizing solution e g baking soda and water or ammonia and wire brush Replace cables and or cable clamp bolts as required 4 Clean battery post with wire brush then...

Page 104: ...lowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts Manual for the part number of th...

Page 105: ...EROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque w...

Page 106: ...ided in accordance with the requirements of the European Machinery Directive 2006 42 EC The A Weighted emission sound pressure level at the work plat form is less than 70dB A The vibration total value...

Page 107: ...C Machinery Directive 2014 30 EU EMC Directive 2014 53 EU RED Directive If fitted with optional equipment 2000 14 EC Outdoor Noise Directive NOTE This declaration conforms with the requirements of ann...

Page 108: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 18 31215012...

Page 109: ......

Page 110: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 Visit our website for JLG Worldwide Locations www jlg com...