Oshkosh JLG 830P Use and care manual

Operation and Safety Manual
ANSI
Original Instructions - Keep this manual with the machine at all times.
®
Model
830P
3121742
July 20, 2018 - Rev B
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which 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 your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
3121742 a
FOREWARD
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.
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FOREWORD
b3121742
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
DANGER
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.
CAUTION
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.
NOTICE
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 possi-
ble injury or death
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FOREWORD
3121742 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.
NOTICE
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.
NOTICE
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCI-
DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-
ERTY 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 manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
E-mail: [e-mail]
For :
• Accident Reporting
•ProductSafetyPubli-
cations
•CurrentOwner
Updates
• Questions Regarding
Product Safety
• Standards and Regula-
tions Compliance Infor-
mation
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding
Product Modifications
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FOREWORD
d3121742
REVISION LOG
Original Issue of Manual - A .. . . . . . . . . . . . . . . . . . . . July 6, 2016
Revision - B... . . .. . . . .. . . . .. . . . .. . . . .. . . . .. . . . July 20, 2018
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TABLE OF CONTENTS
3121742 i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Operator Training and Knowledge . . . . . . . . . . . 1-4
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . 1-4
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
1.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Trip and Fall Hazard . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Crushing and Collision Hazards . . . . . . . . . . . . . 1-11
1.5 MOVING, LIFTING AND REPOSITIONING . . . . . . . .1-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Additional Safety Information. . . . . . . . . . . . . . . 1-12
1.6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . 1-12
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION - 2 - 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
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 DAILY WALK-AROUND INSPECTION. . . . . . . . . . . . . 2-4
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION - 3 - MACHINE OPERATION
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 MACHINE DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 MACHINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Machine Component Locations . . . . . . . . . . . . . . 3-3
Battery Charger Operation . . . . . . . . . . . . . . . . . . . 3-4
Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Positioning and Leveling Machine. . . . . . . . . . . . 3-6
Entering/Exiting The Platform . . . . . . . . . . . . . . . . 3-7
Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3.4 TRANSPORTING, LIFTING AND TIE-DOWN PROCE-
DURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Loading or Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Vehicle Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
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TABLE OF CONTENTS
ii 3121742
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.5 STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8
3.6 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-10
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . .4-1
Operator Unable to Control Machine . . . . . . . . . 4-1
Platform Caught Overhead . . . . . . . . . . . . . . . . . . 4-1
Righting of Tipped Machine. . . . . . . . . . . . . . . . . . 4-1
4.3 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 EMERGENCY LOWERING OPERATION . . . . . . . . . . . .4-2
SECTION - 5 - GENERAL SPECIFICATIONS
5.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . .5-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . . . 5-2
Power Source: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Battery Charger Specification:. . . . . . . . . . . . . . . . 5-3
Lubrication Specification . . . . . . . . . . . . . . . . . . . . 5-3
5.3 OPERATOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . .5-4
Accessing Hydraulic/Electrical Components In
Base Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Hydraulic System Maintenance . . . . . . . . . . . . . . 5-5
SECTION - 6 - INSPECTION AND REPAIR LOG
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TABLE OF CONTENTS
3121742 iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . 2-6
3-1. Machine Component Locations . . . . . . . . . . . . . . . . . 3-3
3-2. Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Charger AC Input Cable. . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-4. Battery Charge Indicator. . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-5. Charger LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
3-6. Machine Bubble Level Indicator. . . . . . . . . . . . . . . . . 3-6
3-7. Transport - ForkLift Truck - Tie-Down - Towing . . 3-9
3-8. Decal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
4-1. Emergency Lowering . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
5-1. Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . 5-3
5-2. Platform Maintenance Position . . . . . . . . . . . . . . . . . 5-4
5-3. Hydraulic Reservoir. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . 1-8
2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3
3-1 Decal Installation Chart . . . . . . . . . . . . . . . . . . . . . 3-11
5-1. Machine Specifications. . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-2. Machine Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-3 Battery Charger Specification. . . . . . . . . . . . . . . . . . 5-3
6-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . 6-1
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TABLE OF CONTENTS
iv 3121742
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This page left blank intentionally
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SECTION 1 - SAFETY PRECAUTIONS
3121742 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper and
safe machine usage and maintenance. In order to promote
proper machine usage, it is mandatory that a daily routine is
established based on the content of this manual. A mainte-
nance program, using the information provided in the Service
and Maintenance section, must also be established by a quali-
fied person and must be followed to ensure that the machine is
safe to operate.
The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has
been completed under the supervision of an experienced and
qualified operator.
These sections contain the responsibilities of the owner, user,
operator, lessor, and lessee concerning safety, training, inspec-
tion, maintenance, application, and operation. If there are any
questions with regard to safety, training, inspection, mainte-
nance, application, and operation, please contact JLG Industries,
Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MAN-
UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
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SECTION 1 - SAFETY PRECAUTIONS
1-2 3121742
1.2 TRANSPORTING
Tipping Hazards
FAILURE TO COMPLY WITH THE FOLLOWING TIPPING HAZARD INSTRUCTIONS
COULD CAUSE THE UNIT TO TIP OVER OR BE HARD TO CONTROL WHEN BEING
MOVED, WHICH COULD RESULT IN SERIOUS INJURY OR DEATH.
•On a level surface, always push machine from the platform
end with the mast end leading the way.
•Watch for obstructions around machine and overhead.
•Check travel path for persons, holes, bumps, drop-offs,
obstructions, debris, and coverings which may conceal
other hazards.
•Before placing machine on floors, trucks and other surfaces,
check allowable capacity of surfaces.
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SECTION 1 - SAFETY PRECAUTIONS
3121742 1-3
•Two persons are required on slopes up to 5°. A forklift must
be used when moving units on slopes greater than 5°.
•Always travel up or down a slope with the platform end of
the machine positioned towards the low side of the slope.
The operator and assistant must walk side by side to guide
the machine.
•Never position the unit sideways on a slope.
•Do not elevate the platform or move the machine on a soft
surface.
•Use caution and check clearances when moving machine in
restricted or close quarters.
•Always use an assistant when moving machine in areas
where vision is obstructed.
•Keep non-operating personnel at least 6 ft. (1.8m) away
from machine during moving operations.
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SECTION 1 - SAFETY PRECAUTIONS
1-4 3121742
1.3 PRE-OPERATION
Operator Training and Knowledge
•This manual must be read and understood in its entirety
before operating the machine. For clarification, questions,
or additional information regarding any portions of this
manual, contact JLG Industries, Inc.
•An operator must not accept operating responsibilities
until adequate training has been given by competent and
authorized persons.
•Allow only those authorized and qualified personnel to
operate the machine who have demonstrated that they
understand the safe and proper operation and mainte-
nance of the unit.
•Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, and operating instructions on the machine and in
this manual.
•Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined
by JLG.
•All operating personnel must be familiar with the emer-
gency controls and emergency operation of the machine as
specified in this manual.
•Read, understand, and obey all applicable employer, local,
and governmental regulations as they pertain to your utili-
zation and application of the machine.
Workplace Inspection
•Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the
machine.
•Do not operate or raise the platform from a position on
trucks, trailers, railway cars, floating vessels, scaffolds or
other equipment unless the application is approved in writ-
ing by JLG.
•Before operation, check work area for overhead hazards
such as electric lines, bridge cranes, and other potential
overhead obstructions.
•Check floor surfaces for holes, bumps, drop-offs, obstruc-
tions, debris, concealed holes, and other potential hazards.
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SECTION 1 - SAFETY PRECAUTIONS
3121742 1-5
•Check the work area for hazardous locations. Do not oper-
ate the machine in hazardous environments unless
approved for that purpose by JLG.
•Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel.
Machine Inspection
•Do not operate this machine until the inspections and func-
tional checks have been performed as specified in Section 2
of this manual.
•Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the Service and Maintenance
section of this manual.
•Ensure all safety devices are operating properly. Modifica-
tion of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
•Do not operate any machine on which the safety or instruc-
tion placards or decals are missing or illegible.
•Check the machine for modifications to original compo-
nents. Ensure that any modifications have been approved
by JLG.
•Avoid accumulation of debris on platform deck. Keep mud,
oil, grease, and other slippery substances from footwear
and platform deck.
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SECTION 1 - SAFETY PRECAUTIONS
1-6 3121742
1.4 OPERATION
General
•Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell
phones, two-way radios, etc. that will distract your attention
from safely operating the machine.
•Do not use the machine for any purpose other than posi-
tioning personnel, their tools, and equipment.
•Before operation, the user must be familiar with the
machine capabilities and operating characteristics of all
functions.
•Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from ser-
vice and notify the proper authorities.
•Do not remove, modify, or disable any safety devices.
•Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
•Do not carry materials directly on platform railing unless
approved by JLG.
•Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
•Fully lower platform before leaving machine.
•Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair
unrestrained which may become caught or entangled in
equipment.
•Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
Trip and Fall Hazard
•Prior to operation, ensure all gates and rails are fastened
and secured in their proper position.
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SECTION 1 - SAFETY PRECAUTIONS
3121742 1-7
•JLG recommends that the operator utilizes a fall/travel
restraint system in the platform with a lanyard attached to
an authorized lanyard anchorage point. For further infor-
mation regarding fall protection requirements on JLG prod-
ucts, contact JLG.
•Identify the designated lanyard anchorage point at the plat-
form and securely attach the lanyard. Attach only one (1)
lanyard per lanyard anchorage point.
•Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the machine when entering
or leaving the platform. Always maintain “three point con-
tact” with the machine, using two hands and one foot or
two feet and one hand at all times during entry and exit.
•Keep both feet firmly positioned on the platform floor at all
times. Never position ladders, boxes, steps, planks, or simi-
lar items on unit to provide additional reach for any pur-
pose.
•Never use the mast assembly to gain access to or leave the
platform.
•Keep oil, mud, and slippery substances cleaned from foot-
wear and the platform floor.
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SECTION 1 - SAFETY PRECAUTIONS
1-8 3121742
Electrocution Hazard
•This machine is not insulated and does not provide protec-
tion from contact or proximity to electrical current.
•Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-1.
•Allow for machine movement and electrical line swaying.
•Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment 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 1-1. Minimum Approach Distances (M.A.D.)
VOLTAGE RANGE
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0to50KV 10(3)
Over50KV to200KV 15(5)
Over200KVto350KV 20(6)
Over350KVto500KV 25(8)
Over500 KV to750KV 35(11)
Over750 KVto1000KV 45(14)
NOTE: This requirement shall apply except where employer, local or govern-
mental regulations are more stringent.
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SECTION 1 - SAFETY PRECAUTIONS
3121742 1-9
•The minimum approach distance may be reduced if insulat-
ing barriers are installed to prevent contact, and the barri-
ers are rated for the voltage of the line being guarded.
These barriers shall not be part of (or attached to) the
machine. The minimum approach distance shall be reduced
to a distance within the designed working dimensions of
the insulating barrier. This determination shall be made by
a qualified person in accordance with the employer, local,
or governmental requirements for work practices near
energized equipment.
DANGER
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 ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not oper-
ate machine on unsupported surfaces.
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