Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
FOREWORD 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 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS 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 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, MAY RESULT IN MINOR OR MODERATE INJURY.
FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates 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.
FOREWORD REVISION LOG d Original Issue - April 25, 2011 Revised - May 23, 2011 Revised - November 10, 2011 Revised - September 10, 2012 Revised - September 4, 2014 – JLG Lift – 3121261
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1 Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection. . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 PAGE SECTION - PARAGRAPH, SUBJECT Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-9 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-12 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 EXTENDING THE AXLES . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 5.5 PAGE SECTION - PARAGRAPH, SUBJECT Put Foot In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41 BCS Lamp On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42 Broken Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 Platform Overload . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally.
LIST OF FIGURES FIGURE NUMBER - TITLE 2-1. 2-2. 2-3. 2-4. 2-5. 2-6. 2-7. 3-1. 3-2. 3-3. 3-4. 3-5. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 5-1. 5-2. 5-3. 3121261 PAGE FIGURE NUMBER - TITLE Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-8 Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . 2-9 Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . 2-10 Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . . . . .
LIST OF FIGURES FIGURE NUMBER - TITLE 5-29. 5-30. 5-31. 5-32. 5-33. 5-34. 5-35. 5-36. 5-37. 5-38. 5-39. 5-40. 5-41. 5-42. 7-1. 7-2. 7-3. 7-4. vi PAGE FIGURE NUMBER - TITLE PAGE BCS Lamp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43 Broken Cable Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44 Level System DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45 Overload DTC Screen . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF TABLES TABLE NUMBER - TITLE 1-1 1-2 2-1 4-1 5-1 7-1 7-2 7-3 7-4 7-5 7-6 7-7 7-8 7-9 7-10 7-11 7-12 7-13 7-14 7-15 8-1 3121261 PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26 Operational Fault Codes.
LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally.
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage.
SECTION 1 - SAFETY PRECAUTIONS • 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 maintenance of the unit. • Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection 1.3 • Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed. General • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations. • Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area. Trip and Fall Hazards • During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. Electrocution Hazards • This machine is not insulated and does not provide protection from contact or proximity to electrical current. • Keep 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.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) • Allow for machine movement and electrical line swaying.
SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers 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.
SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only). • Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ S). Table 1-2. Beaufort Scale (For Reference Only) 3121261 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 Calm Calm. Smoke rises vertically 1 1-3 0.3-1.5 Light air Wind motion visible in smoke 2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle Description Land Conditions 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 4 13-18 5.5-7.
SECTION 1 - SAFETY PRECAUTIONS • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. Crushing and Collision Hazards • Approved head gear must be worn by all operating and ground personnel. • Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.
SECTION 1 - SAFETY PRECAUTIONS 1.4 TOWING, LIFTING, AND HAULING 1.5 • Never allow personnel in platform while towing, lifting, or hauling. This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual.
SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid. • Do not use machine as a ground for welding. • When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. • Do not refuel the machine with the engine running. • Use only approved non-flammable cleaning solvents.
SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical components or when performing welding on the machine. • Do not allow smoking, open flame, or sparks near battery during charging or servicing. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Do not contact tools or other metal objects across the battery terminals.
SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121261
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, or drop-offs exist. 2.1 PERSONNEL TRAINING The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Type Primary Responsibility Frequency Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operation and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 4. Operation and Safety Manuals – Make sure a copy of the Operation and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage container. Pre-Start Inspection The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific operating instructions. Function Check 12. Boom Control System Check - Perform a check of the boom control system as specified in this section. Perform the Function Check as follows: 1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3. From the platform 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. a. The machine is in transport position (booms retracted; main boom below elevation [5 degrees]; jib boom below 40 degrees; axles retracted). c. Operate all functions and ensure proper operation. b. The boom capacity select switch is in 500# mode. d.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Boom Control System Check Procedure Perform the following check with no load (personnel or material) in the platform from the ground control station. 1. Extend all axles fully. 2. With the boom fully retracted, raise the boom off the boom rest to horizontal. 3. Position the jib horizontal and fully retracted, jib straight and locked, and platform level. 4. Extend the boom until it stops. 3121261 – JLG Lift – 5.
2-8 – JLG Lift – 8 6 10 9 5 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Platform Jib Fly Boom Section Outer Mid Boom Section Inner Mid Boom Section Base Boom Section Boom Assembly Lift Cylinder Turntable Chassis Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 12 11 15 16 18 13 11. 12. 13. 14. 15. 16. 17. 18. 17 14 Platform Platform Control Console Platform Level Cylinder Platform Rotator Jib Fly Boom Jib Base Boom Jib Lock Cylinder Jib Rotator Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 19. 20. 21. 22. 23. 24. 19 Turntable Drive Hub Rear Drive Wheels Frame Front Drive/Steer Wheels Ground Control Console 20 24 21 22 23 Figure 2-3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 6 6 5 5 11 11 9 12 7 9 4 9 10 9 3 2 9 8 7 11 11 6 6 5 5 Figure 2-4.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2 3 9 9 13 14 1 Figure 2-5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3. Boom Sections/Turntable - See Inspection Note. General Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist. 4. Swing Drive - No evidence of damage. 5. Wheel/Tire Assemblies - Properly secured, no missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion. 6.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 12. Hydraulic Pump - See Inspection Note. 13. Platform Rotator - See Inspection Note. 14. Jib Rotator and Jib Lock Cylinder - See Inspection Note. Figure 2-7.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) The front axles will oscillate when the boom is in the transport position (i.e. when the boom is less than 6° above horizontal and not extended beyond 12" [30.4 cm]) and drive is selected. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-16 – JLG Lift – 3121261
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 NOTE: GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. This section provides the necessary information needed to understand control functions. 3.2 CONTROLS AND INDICATORS NOTE: 3121261 All machines are equipped with control panels that use symbols to indicate control functions.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Jib Telescope Control TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. Provides extension and retraction of the jib. Ground Control Station (See Figure 3-1., Ground Control Station) NOTE: 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2 1 3 13 4 12 5 6 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Indicator Panel Jib Telescope Control Platform Rotate Platform Leveling Override Jib Lift Engine Start/Auxiliary Power Switch/Function Enable Power/Emergency Stop Hourmeter Platform/Ground Select Lift Swing Telescope Boom Control System Test 7 8 1001120323 B 11 10 9 Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. Auxiliary power only works if there is no engine oil pressure, and is disabled if engine is running. Functions will operate at a slower than normal rate because of the reduced hydraulic flow. 4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES. 7. Power/Emergency Stop Switch A two-position red mushroom shaped switch supplies power to PLATFORM/GROUND SELECT switch when pulled out (on). When pushed in (off ), power is shut off to the PLATFORM/GROUND SELECT switch.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Lift Control 12. Main Telescope Control Provides raising and lowering of the main boom. 11. Swing Control Provides extension and retraction of the main boom. 13. Boom Control System Test Button Provides 360 degrees continuous turntable rotation. 3-6 The push button is used to test the boom control system and confirm that it is working properly.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Glow Plug Indicator Ground Control Indicator Panel Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine. (See Figure 3-2., Ground Control Indicator Panel) 1. No Alternator Output Indicator Indicates a problem in the charging circuit, and service is required. 6. Axles Set Indicator Indicates that the axles are fully extended.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. 2. 3. 4. 3-8 No Alternator Output 5. Glow Plug Indicator 8. Platform Overload Low Engine Oil Pressure 6. Axles Set 9. Boom Control System Warning High Engine Coolant Temperature 7. Platform Capacity 10. Boom Control System Calibrated Engine Oil Temperature Figure 3-2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Platform Overload Indicator (If Equipped) 10. Boom Control System Calibrated Indicator Indicates the platform has been overloaded. When the Boom Control System Test Button is pushed, illuminates to indicate that the Boom Control System is calibrated properly. 9. Boom Control System Warning Indicator Indicates the platform is outside the operating area and operation of certain boom functions may be disabled (i.e. lift, telescope).
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Steer Select Platform Station (See Figure 3-3., Platform Control Console) TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. 1. Drive Speed/Torque Select The forward position gives maximum drive speed. The back position gives maximum torque for rough terrain and climbing grades.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2 5 4 3 6 8 7 9 10 11 1706741A 1 1705744 A 1702566 B 1702565 B 1001125195 B 1001125194 A 23 1. 2. 3. 4. 5. 6. 3121261 Drive Speed/Torque Select Steer Select Platform Leveling Override Axle Extend/Retract Horn Indicator Panel 22 7. 8. 9. 10. 11. 12. 21 20 19 18 1702938 1705170 A 17 16 15 Boom Control Select 13. Main Telescope Power/Emergency Stop 14. Lights Start/Auxiliary Power 15. Jib Lift Capacity Select 16.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Indicator Panel The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Manual Mode: 8. Power/Emergency Stop When the boom control is positioned to Manual, lift and telescope movements are controlled separately by the operator and the automatic platform leveling feature is active only during lift functions. A two-position red mushroom shaped switch supplies power to Platform Controls when pulled out (on). When pushed in (off ), power is shut off to the platform controls. 9.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Capacity Select NOTE: To operate the Drive Joystick, pull up on the locking ring below the handle. NOTE: The DRIVE control levers are spring-loaded and will automatically return to neutral (OFF) position when released. This switch allows the operator to select between an operating envelope with a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia markets) capacity restriction or a 1000 lb.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 14. Lights (If Equipped) UPON ACTIVATING THE JIB STOW CONTROL SWITCH, A SLIGHT DELAY WILL BE EXPERIENCED BEFORE THE JIB WILL BEGIN TO MOVE. Operates accessory light packages if the machine is so equipped. 15. Jib Lift 17. Jib Stow Provides raising and lowering of the jib. 16. Soft Touch equipped) Override Switch Allows the jib to be returned to the stowed position for transport and also taken out of the transport position for machine usage.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 19. Soft Touch Indicator (If Equipped) 22. Function Speed Control Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode. This control affects the speed of main boom telescope, jib telescope, and jib lift. Turning the knob all the way counterclockwise until it clicks puts drive, main lift, platform rotate, and swing into creep mode. 20.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Platform Overload Indicator (If Equipped) Platform Control Indicator Panel Indicates the platform has been overloaded. (See Figure 3-4., Platform Control Indicator Panel) 1. Level System Fault Indicator Indicates a fault in the electronic leveling system. The fault indicator will flash and an alarm sound. All functions will default to creep if the boom is out of transport mode. 4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 2 14 13 1. 2. 3. 4. 5. 3-18 3 12 4 5 6 7 11 10 9 8 Level System 6. Glow Plug 11. Cable Service 12. Drive Orientation AC Generator 7. Enable 13. Axles Set Platform Overload 8. Fuel Level Platform Capacity 9. Creep Speed 14. Boom Control System Warning Tilt Alarm Warning 10. System Distress Figure 3-4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Tilt Alarm Warning Light 7. Footswitch/Enable Indicator IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM FROM THE TRANSPORT POSITION. Indicates that the chassis is on a slope. If the boom is out of transport position and the machine is on a slope, an alarm will sound and CREEP is automatically activated.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more detailed information concerning the Low Fuel Indicator. 9. Creep Speed Indicator When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. The light flashes if the control system puts the machine into creep speed and will be on continuously if the operator selects creep speed. 8.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. System Distress Indicator tion (i.e. controls reversed situations). The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval. 13.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 – JLG Lift – 3121261
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom. BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions.
SECTION 4 - MACHINE OPERATION will function automatically, or when lifting up, telescope out will function automatically. Controlled Arc When the Boom Control Switch is in the manual mode, lift and telescope functions are independent functions controlled by the operator.
SECTION 4 - MACHINE OPERATION NOTE: Envelope Tracking ENVELOPE Boom Control System in Manual Mode: The boom will stop when the end of the envelope is reached and the operator must activate lift and/or telescope in the proper direction to bring the boom back into the envelope. BUFFER LINE SLOWDOWN LINE BUFFER ZONE Controlled Angle The control system automatically maintains a constant elevated boom angle when swinging the turntable.
SECTION 4 - MACHINE OPERATION Stability 4.3 Machine stability is based on two (2) conditions which are called FORWARD and BACKWARD stability. The machine’s position of least FORWARD stability is shown in Figure 4-1., and its position of least BACKWARD stability is shown in Figure 4-2. TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE. The Boom Control System allows the operator to select operation in a 500 lb.
SECTION 4 - MACHINE OPERATION JIB HORIZONTAL & FULLY EXTENDED MAIN BOOM FULLY EXTENDED MAIN BOOM ELEVATED 20 DEGREES MACHINE WILL "TIP OVER" IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE Figure 4-1.
4-6 JIB FULLY EXTENDED – JLG Lift – Figure 4-2. Position of Least Backward Stability MAIN BOOM FULLY RETRACTED, ELEVATED 68 DEGREES MACHINE WILL "TIP OVER" IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE PLATFORM ROTATED 90 DEGREES SECTION 4 - MACHINE OPERATION .
SECTION 4 - MACHINE OPERATION 4.4 1. Turn key of Platform/Ground Select switch to the Ground position. ENGINE OPERATION NOTE: Initial starting should always be performed from the Ground Control station. 2. Pull the Power/Emergency Stop switch out. 3. Push the Engine Start switch until engine starts. Starting Procedure IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES.
SECTION 4 - MACHINE OPERATION NOTE: 6. From the Platform, pull the Power/Emergency Stop switch out. 2. Push Power/Emergency Stop switch in. 7. Push the Engine Start switch until engine starts. 3. Turn key of Platform/Ground Select switch to the Off position. Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE. Refer to Engine Manufacturer’s manual for detailed information.
SECTION 4 - MACHINE OPERATION • Engine Restart - When the engine shuts down, the operator will be permitted to cycle power and restart the engine for approximately 2 minutes of run time. After the 2 minutes of run time is complete, the operator may cycle power and restart the engine for an additional 2 minutes of run time. The operator can repeat this process until there is no more fuel available.
SECTION 4 - MACHINE OPERATION 4.5 TRAVELING (DRIVING) BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS. See Figure 4-3., Grade and Side Slopes NOTE: When the main boom is raised approximately 6 degrees above horizontal, the high drive function will automatically be in low drive. DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.
SECTION 4 - MACHINE OPERATION 0SJ 150 ADE R G SIDESLOPE LEVEL Figure 4-3.
SECTION 4 - MACHINE OPERATION 2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected. Traveling Forward and Reverse 1. At Platform Controls, pull out Emergency Stop switch, start engine, and activate footswitch. 2. Position Drive controller to Forward or Reverse as desired. 4.
SECTION 4 - MACHINE OPERATION 4.8 PLATFORM Platform Rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached. Platform Level Adjustment ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
SECTION 4 - MACHINE OPERATION Swinging the Boom TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED. NOTE: The axles must be fully extended to swing beyond the rear wheels (40 degrees).
SECTION 4 - MACHINE OPERATION Telescoping the Boom NOTE: Stowing/Swinging the Jib To swing the jib for stowage or machine usage, use the Jib Stow control to select Right or Left direction. The jib lock pin will also operate automatically while using the Jib Stow switch. The telescope function is not operable beyond the transport position if the axles are not fully extended. To extend or retract the main boom, use the Telescope Control Switch to select In or Out movement. Telescoping the Jib 4.
SECTION 4 - MACHINE OPERATION 2. Disconnect drive hubs by inverting disconnect cap. 4.11 EMERGENCY TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.) MAXIMUM TOWING GRADE 25%. DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED. 1.
SECTION 4 - MACHINE OPERATION 4.12 SHUT DOWN AND PARK 4.13 LIFTING AND TIE DOWN To shut down and park the machine, the procedures are as follows: See Figure 4-5. Lifting 1. Drive machine to a reasonably well protected area. 3. Push in the Emergency Stop at Platform Controls. 1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find out the Gross Vehicle Weight. 4. Push in the Emergency Stop at Ground Controls.
SECTION 4 - MACHINE OPERATION Tie Down 4.14 STOWING THE JIB FOR TRANSPORT 1. Place the boom in the stowed position with the axles retracted. WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. 1. Place the boom in the stowed position with the turntable locked. 2. Hold the Jib Swing control switch to the right until the platform will no longer swing. NOTE: Automatic platform leveling is disabled when stowing the jib. 3.
SECTION 4 - MACHINE OPERATION 6’10”/2.08 m 10’5”/3.18 m 17’3”/5.26 m 31’5”/9.58 m 11’7”/3.53 m 43’0”/13.11 m 1001125274 B Figure 4-5.
SECTION 4 - MACHINE OPERATION 47 46 ANSI & DUAL LANGUAGE 18 CE 22 ONLY 1701518 23 39 1500SJ 39 41 2 37 8 44 42 57 12 Figure 4-6.
SECTION 4 - MACHINE OPERATION ANSI, DUAL 31 LANGUAGE ONLY 33 50 9 51 BOTH SIDES BOTH SIDES 9 24 19 19 44 28 60 45 22 43 16 15 26 22 DECAL LOCATIONS FOR ANSI AND CE 15 DECAL LOCATIONS FOR DUAL LANGUAGE Figure 4-7.
SECTION 4 - MACHINE OPERATION 5 35 52 58 56 54 36 58 55 53 56 20 28 Figure 4-8.
SECTION 4 - MACHINE OPERATION 13 7 7 ANSI & CE ONLY! 21 29 23 64 AUS 29 26 25 11 16 DUAL LANGUAGE ONLY! 60 23 22 www.jlg.com 45 ANSI & 18 DUAL LANGUAGE 2 8 49 22 CE ONLY! 22 23 40 7 8 8 2 8 7 Figure 4-9.
SECTION 4 - MACHINE OPERATION 37 34 10 37 Figure 4-10.
SECTION 4 - MACHINE OPERATION 47 46 34 41 ANSI & 23 18 DUAL LANGUAGE 39 1500SJ 44 32 ANSI, DUAL LANGUAGE ONLY 39 30 17 8 2 37 Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION Table 4-1.
SECTION 4 - MACHINE OPERATION NOTES: 4-30 – JLG Lift – 3121261
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 SECTION 5. LCD DISPLAY PANEL - GENERATION 1 & 2 5.1 IDENTIFICATION The Operator can identify the Generation of the LCD Display Panel by the boot up splash screen that is displayed when the LCD screen is activated. Those screens are shown below. Figure 5-2. Generation 2 Boot Up Splash Screen Figure 5-1.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 5.2 LCD DISPLAY PANEL Description This machine utilizes an LCD display panel to assist the operator by supplying additional information during the operation of the machine. It is NOT a substitute for the Operation and Safety Manual, nor is it a replacement for thorough operational knowledge of the machine. Figure 5-3.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 5.3 GENERATION 1 LCD DISPLAY PANEL SCREENS Boot Up Splash Screen The Boot Up Splash Screen appears when the machine is first powered on. The screen contains several reminders for the operator prior to operation.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Capacity Select Reminder Attach Lanyard Reminder Read Operation and Safety Manual Reminder Figure 5-4.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Default Screen The Default Screen appears after the boot screen if there are no faults present in the JLG Control System. The display shows an indication of fuel level, battery voltage, and engine rpm. In addition, a check mark in a green circle indicates no serviceable faults are present. The LCD software version is also displayed for 5 seconds after initial bootup. NOTE: 3121261 In the example shown, the engine is not running.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Battery Voltage Engine RPM Fuel Level LCD Software Version No Serviceable Faults Present Figure 5-5.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Conditional Icons Several icons exist which may display below the line on the LCD panel on any screen if the operating condition they represent exists. These icons are Jib Unlocked, Jib Locked, Reduced Speed (turtle), Creep Speed (snail), Fault Code, Safety Alert Symbol, and No Serviceable Faults Present (check mark).
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Jib Unlocked Creep Speed Software Version Numeric Fault Code Safety Alert Symbol No Serviceable Faults Present Jib Locked Reduced Speed Figure 5-6.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 CAN Communication Error Screen The CAN Communication Error Screen appears if the JLG Control System senses that the communication connection between the LCD display and the Ground Control Module has been lost. In the lower right hand corner, 66?? will display in the numeric fault code area with a safety alert symbol. The actual code cannot be displayed due to the communication error. Check the Service Manual for the specific fault code.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code & Safety Alert Symbol Figure 5-7.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Serviceable Fault Indication Screen The Serviceable Fault Indication Screen appears if the JLG Control System has sensed a fault that may require service attention by a technician. As on the default screen, the display shows an indication of the fuel level, battery voltage, and engine rpm. In the lower right hand corner, the numeric fault code with a safety alert symbol is displayed. Multiple faults will display in succession.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Battery Voltage Engine RPM Fuel Level Jib Unlocked Stored Serviceable Fault Fault Code (see Service Manual) Figure 5-8.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Screen The Keyswitch in Ground Control Mode Icon will be displayed as long as the key is in the ground control position. The icons below the orange line will reflect the status of the machine.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Icon Figure 5-9.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Screen with Operational Faults The Keyswitch in Ground Control Mode Icon will be displayed as long as the key is in the ground control position. If any operational faults are active, the refer to Operation Manual icon will be shown. Additionally, the numeric fault code will be displayed above the icon. The icons below the orange line will reflect the status of the machine.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Refer to Operation Manual Icon Keyswitch in Ground Control Mode Icon Figure 5-10.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - No Graphics Screen The Operational Fault Screen appears if the JLG Control System has sensed a fault that is due to operator error or a condition when the operator can be provided with additional information (i.e. functions are being slowed). The display shows a manual icon as a reminder to check the Operation and Safety Manual for the fault code, which is displayed above the manual icon.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Reminder to Check Operation and Safety Manual No Serviceable Faults Present Figure 5-11.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - With Graphics Screen The Operational Fault Screen appears if the JLG Control System has sensed a fault that provides operational information. The display shows an icon that represents the fault and available control options along with the fault code, which is displayed above the fault icon (Fault 2224 - Footswitch Selected Before Start is used as an example).
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Icon representing Operational Fault Jib Locked No Serviceable Faults Present Figure 5-12.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Footswitch Open Screen The Footswitch Open Screen appears if the JLG Control System has sensed a fault that is due to the operator having the footswitch open. In this condition, no functions are operable as shown by the red X’s on the display screen. This screen will remain until the operator releases the restricted function. The operator can then operate the function by pushing the footswitch and operating the function again.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Icon representing No Functions are Operational Icon Representing Footswitch Reminder No Serviceable Faults Present Figure 5-13.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Out of Transport - Axles Retracted The Out of Transport - Axles Retracted screen appears if the JLG Control System has sensed the boom has been moved out of the transport position with the axles retracted. The screen will remain until the operator operates one of the controls highlighted on the screen to correct the condition. In the lower right corner, a check mark in a green circle indicates there are no serviceable faults present.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Yellow Highlights Indicate direction Control Switch can be Applied to Correct the Fault Condition Axles Retracted Icon - Extended Axles Will Flash Yellow Segments Indicate Directions that Joystick can be Applied to Correct the Fault Condition No Serviceable Faults Present Figure 5-14.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Transport Swing Fault Screen The Transport Swing Fault Screen appears when the 0038 SWING ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED operational fault is active, indicating that swing is restricted to +/ - 40 degrees from center while the axles are retracted.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Yellow Circle Indicates that Control Switch can be Applied in Either Direction to Correct the Fault Condition Icon Representing Transport Swing Fault (Extended Axles will Flash) Yellow Segments Indicate Directions that Joystick can be Applied to Correct the Fault Condition No Serviceable Faults Present Figure 5-15.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Envelope Speed Reduction Screen The Envelope Speed Reduction Screen appears if the JLG Control System has sensed that the boom is approaching the edge of the backward or forward operating envelope, which places all functions in proportionally reduced speed. The proportionally reduced speed function is indicated by the turtle icon in the lower left corner of the screen.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Icon Representing Backward Envelope Speed Reduction Indication Note: Opposite Side Will Highlight if Forward Envelope is near encroachment No Serviceable Faults Present Turtle Icon Represents Functions Operating at Reduced Speed Figure 5-16.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Envelope Violation Fault Screen The Envelope Violation Fault Screen appears if the JLG Control System has sensed that the boom is encroaching the edge of the forward or backward operating envelope (hydraulics are suspended). This screen will remain until the operator operates one of the controls highlighted on the screen to correct the condition.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Yellow Circle Indicates that Control Switch can be Applied in Either Direction to Correct the Fault Condition Yellow Half-Circle Indicates that Control Switch can be Applied in Only One Direction to Correct the Fault Condition Icon Representing Envelope Violation Fault Note: The side of the envelope being violated will be illuminated Yellow Segments Indicate Directions that Joystick can be Applied to Correct the Fault Condition No Serviceable Faults Pres
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Over/Under Moment Fault (DTC 0017/ 0018) The Over/Under Moment Fault Screen appears if the JLG Control System senses that the machine is in an over/under moment condition. This screen may also display without a Fault Code when the Boom Control System indicator light is lit. This screen will remain until the operator operates one of the controls highlighted on the screen to correct the condition.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Under/Over Moment Icon Forward and Rear Envelope Highlights Flash No Serviceable Faults Present Snail Icon Represents Functions Operating at Creep Speed Figure 5-18.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 5.4 GENERATION 2 LCD DISPLAY PANEL SCREENS Boot up Splash Screen When the machine is first powered on, the JLG boot up splash screen appears followed by three reminder screens.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Figure 5-20. Manual Screen Figure 5-22. Select Capacity Zone Screen Figure 5-21.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 images and trays. Each tray provides different machine information. Machine Operating Screen After the reminder screens, the Machine Operating Screen will appear. The Machine Operating Screen consists of different DTC Tray Console Tray Machine Status Tray Icons Tray Figure 5-23.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 • CAN Bus Lost DIAGNOSTIC TROUBLE CODE (DTC) TRAY This tray shows the total number of DTC’s and the DTC Text. If there are multiple DTC’s, the operator can scroll through the DTC List to the end. When the tray is empty, this means there are no active DTC’s. • Take Foot Out • Put Foot In • BCS Lamp On • Broken Cable CONSOLE TRAY This tray represents the platform console information.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 KeySwitch In Ground Mode: If the keyswitch is set to ground mode, the display shows the Key Switch in Ground Mode Image. Figure 5-24.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Function Speed If there is no function speed restriction, a gray snail is shown. If the machine is in Creep Mode, a green snail icon is shown. If the machine is in Super Creep Mode, the green snail icon will flash. Figure 5-25.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 NOTE: CAN Bus Lost When the control system senses a communication loss with any of the control modules (BLAM, Chassis, UGM, or Jib Control Module), the display will show a CAN Communication lost until the communications are reset. There is no way to get the active DTCs so, the previously active DTCs will be scrolling along with the CAN Bus Communication lost DTC. This DTC needs to be cleared in order for the communications to reset. Figure 5-26.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Take Foot Out When the footswitch is pressed and the control system senses a Take Foot Out DTC, the displays shows the Take Foot Out image in the machine status tray. Figure 5-27.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 When put foot in DTC is active, the display shows Put Foot In image in the machine status tray. Put Foot In When the operator operates the machine without putting his foot on switch, Put Foot In DTC becomes active after timeout. Figure 5-28.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 NOTE: BCS Lamp On The available controls will be different among the different DTCs. The image below is ONLY for envelope violation. When the control system senses forward or backward envelope violation or moment violation conditions, the BCS Lamp will be ON. When the BCS Lamp is ON, the display shows a red octagon image in the machine status tray indicating a potentially hazardous situation.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Figure 5-29.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 shows a red octagon broken cable indicator in the machine status tray. Broken Cable When the control system senses a broken cable, the Broken Cable lamp on the platform panel is lit. When the lamp is lit, the display Figure 5-30.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 this lamp is lit, the display shows a red octagon platform level DTC indicator in the machine status tray. Platform Level Whenever the control system senses a DTC with the platform level, the platform level lamp is lit on the platform console. When Figure 5-31.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Platform Overload When the boom control system senses that the platform is overloaded, the Platform Overload indicator on the platform console will be lit. Figure 5-32.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Capacity Mode Error If the operator selects the incorrect capacity mode for the jib configuration (i.e., if the operator is in Unrestricted mode with the jib completely telescoped out, and changes the capacity to Restricted mode), the capacity mode indicator icon will flash in the Machine Status tray every second. Figure 5-33.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Swing DTCs When the machine is swung more than what it is allowed for in either left or right direction, the control system senses a swing fault. When a swing DTC is active, the display shows a machine image with green arc which indicates the allowed angle and the portion other than the green arc indicates the restricted area to show the swing DTC. Displays shows operator to extend the axles by flashing the axles.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Figure 5-34.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Jib Unlocked When the control system senses that jib pin is unlocked, the display will show the Jib Unlocked image. Figure 5-35.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 The display will show a different image on the machine status tray after 3 seconds have elapsed. Jib Locked When the boom control system senses jib is locked ONLY for the first time, the display will show the Jib Locked image on the machine status tray for 3 seconds. Figure 5-36.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 shown on the left side of the display or machine status tray. This image will be shown until the axles are extended. Chassis Status AXLES RETRACTED IN TRANSPORT POSITION When the axles are retracted regardless of engine state, the display shows the following screen. The Axles Retracted image is Figure 5-37.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 AXLES EXTENDED When the axles are extended for the first time (meaning previous state is retracted and current state is extended), regardless of the Engine state, the Axles Extended image will show up on the machine status tray for first 3 seconds. Figure 5-38.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 AXLES RETRACTED IN OUT OF TRANSPORT POSITION When the axles are retracted and the machine is in the out of transport position, the display will switch between axles extended and retracted every 0.5 seconds to tell the operator to extend the axles so the boom can be raised.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Machine Tilted Mode When the control system senses the chassis is on an excessive slope, the display will show the Machine Tilted image in the machine status tray. Figure 5-39.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Envelope Status Example 1: Platform is not at the edge of the envelope • When Unrestricted or Restricted mode is selected, the display shows envelope image in the machine status tray. • The color code for the envelope matches the capacity select decals on the machine. • When the control system senses that the axles are fully extended, the selected envelope shows up on the machine status tray.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Figure 5-40.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Figure 5-41.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 • When operator switches from Unrestricted to Restricted mode, the envelope shrinks to indicate reduced operating envelope. Example 2: Platform is edge of the envelope • When Unrestricted or Restricted mode is selected, the display flashes snail image at a rate of 0.5 seconds in the machine status tray. • The envelope color will match the weight mode selected.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 1850SJ the display will show the Machine Model Unknown image on the machine status tray. Machine Model Unknown As soon as the machine is powered up, the control system checks the model of the machine and if the model is neither 1500SJ nor Figure 5-42.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 5.5 OPERATIONAL FAULT CODE LISTING Table 5-1.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Table 5-1.
SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES 6.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 6.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.
SECTION 6 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead 6.4 If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine. EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7.1 INTRODUCTION 7.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications Maximum Wind Speed Table 7-2. Dimensional Data 28 mph (12.5 m/s) Maximum Manual Force 90 lbs. (400 N) Maximum System Voltage 12 volts Maximum Main Relief Hyd. Pressure 4600 psi (317 Bar) Dimensional Data Table 7-2. Dimensional Data Turning Radius (Axles Retracted) Outside Inside 22 ft. 6 in. (6.8 m) 14 ft. 5 in. (4.4 m) Turning Radius (Axles Extended) Inside Outside 8 ft. (2.4 m) 19 ft. 4 in. (5.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 7-3. Capacities Hydraulic Oil Tank Table 7-4. Tire Specifications 55 gal. (208 L) Fuel Tank - Standard 31 gal. (117 L) Fuel Tank - Optional 52.8 gal. (200 L) Drive Hub Bonfiglioli Reggiana Riduttori 2.1 quarts (2 liters) ± 10% 0.5 quarts (0.5 liters) ± 10% 3121261 – JLG Lift – Size 445/50D710 Load Range J Ply Rating 18 Foam Fill Polyurethane HD (55 Durometer) Foam Diameter 46.45 in. (117.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-5. Deutz TD2011L4 Specifications Table 7-6. Deutz TCD2.9L4 Specifications Type Liquid Cooled Type Liquid Cooled Number of Cylinders 4 Number of Cylinders 4 Bore 3.7 in. (94 mm) Bore 3.6 in. (92 mm) Stroke 4.4 in. (112 mm) Stroke 4.3 in. (110 mm) Total Displacement 190 cu. in. (3108 cm3) Total Displacement 178 cu. in. (2925 cm3) Compression Ratio 17.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Major Component Weights Hydraulic Oil Table 7-8. Hydraulic Oil Hydraulic System Operating Temperature Range DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY. Table 7-7. Critical Stability Weights S.A.E. Viscosity Grade +0° to + 180° F (-18° to +83° C) 10W KG.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OIL SAMPLING Table 7-10. Mobil DTE 13M Specs See Figure 7-1., Oil Sampling Port. This machine is equipped with an oil sampling valve to allow for verification of hydraulic oil condition. Refer to the Service Manual for Oil Sampling procedures. ISO Viscosity Grade #32 Specific Gravity 0.877 Pour Point, Max -40°F (-40°C) Flash Point, Min. Table 7-9.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-11. UCon Hydrolube HP-5046 Type Table 7-12. Mobil EAL H 46 Specs Synthetic Biodegradable Type Specific Gravity 1.082 ISO Viscosity Grade 46 Pour Point, Max -58°F (-50°C) Specific Gravity .910 pH 9.1 Viscosity 3121261 Synthetic Biodegradable Pour Point -44°F (-42°C) Flash Point 500°F (260°C) at 0° C (32° F) 340 cSt (1600SUS) Operating Temp.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-13. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity NOTE: 7-8 at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index 376 Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-1.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120° F(49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F(43° C) 100° F(38° C) 90° F(32° C) ENGINE SPECIFICATIONS SUMMER GRADE FUEL 80° F(27° C) 70° F(21° C) 60° F(16° C) 50° F(10° C) 40° F(4° C) 30° F(-1° C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82°C) OR ABOVE. 180° F (82° C) (HYD. OIL TANK TEMP.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-4.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7.3 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 7-4., Operator Maintenance and Lubrication Diagram. Table 7-14. Lubrication Specifications. LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. 1.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Gearbox 3. Swing Brake Lube Point(s) - Fill Plug Capacity - 79 ounces (2.3 L) Lube - GL-5 Interval - Check level every 150 hrs/Change every 1200 hours of operation. Fill to cover ring gear. 7-14 Lube Point(s) - Fill Plug Capacity - 2.7 ounces (80 ml) Lube - DTE24 Interval - Check level every 150 hrs/Change every 1200 hours of operation.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B: Wheel Drive Hub - Reggiana Riduttori 4. A. Wheel Drive Hub - Bonfiglioli Lube Point(s) - Level/Fill Plug Capacity - 2.1 quarts (2 liters) ± 10% Lube - EPGL Interval - Change after first 150 hours then every 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 8 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 5. Hydraulic Return Filter 6. Hydraulic Charge Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator 7-16 Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7. Hydraulic Oil 8. Suction Strainers (In Tank) FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Fill Cap Capacity - Standard 31 gallons (117 liters) Optional 52.8 gallons (200 liters) Lube - HO Interval - Check level daily. Change every 2 years or 1200 hours of operation. 3121261 – JLG Lift – Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation. Remove and clean at time of hydraulic oil change.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. A. Oil Change w/Filter - Deutz TD2011 B. Oil Change w/Filter - Deutz TCD2.9 Lube Point(s) - Fill Cap/Spin-on Element Capacity 5 Quarts (4.5 L) Cooling System 11 Quarts (10.5 L) w/Filter 16 Quarts (15 L) Total Capacity Lube - EO Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on dipstick. 7-18 – JLG Lift – Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. A. Fuel Filter - Deutz TD2011 B. Fuel Filter - Deutz TCD2.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. Fuel Strainer TD2011 12. Fuel Pre-Filter TCD2.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 13. Radiator Coolant TCD2.9 14. A. Air Filter - Deutz TD2011 Lube Point(s) - Fill Cap Capacity - 3.2Gallon (12.1 L) Lube - Anti-Freeze Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Air Filter - Deutz TCD2.9 15. Platform Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and then every year or 600 hours of operation thereafter 16.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7.4 • any damage to the bead area cords of the tire TIRES & WHEELS If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria. Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-15. Wheel Torque Chart 7.4 TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 45 ft. lbs. (60 Nm) 100 ft. lbs. (140 Nm) 180 ft. lbs. (252 Nm) SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. 4. Wheel nuts should be torqued before first road use and after each wheel removal.
SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 7-26 – JLG Lift – 3121261
SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1.
SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1.
TRANSFER OF OWNERSHIP Title:____________________________________________________________________ Name: ___________________________________________________________________________ Who in your organization should we notify? Country: _____________________________ Telephone: (_______) ________________________ _________________________________________________________________________________ Address: _________________________________________________________________________ Current Owner: __________________
Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 USA (717) 485-5161 (717) 485-6417 3121261 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 JLG Latino Americana Ltda. Rua Eng.
