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JLG 1500SJ, Operation And Safety Manual

The JLG 1500SJ Operation And Safety Manual is an essential resource for owners and operators of this powerful aerial lift. This comprehensive manual provides detailed instructions for safe operation and maintenance. Download this manual for free from 88.208.23.73:8080 and ensure the utmost safety while using the JLG 1500SJ.

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3121261

– JLG Lift –

v

LIST OF FIGURES

FIGURE NUMBER - TITLE

PAGE

FIGURE NUMBER - TITLE

PAGE

2-1.

Basic Nomenclature - Sheet 1 of 3  . . . . . . . . . . . . . . . . . . . . 2-9

2-2.

Basic Nomenclature - Sheet 2 of 3  . . . . . . . . . . . . . . . . . . . 2-10

2-3.

Basic Nomenclature - Sheet 3 of 3  . . . . . . . . . . . . . . . . . . . 2-11

2-4.

Daily Walk-Around Inspection - Sheet 1 of 4  . . . . . . . . . 2-12

2-5.

Daily Walk-Around Inspection - Sheet 2 of 4  . . . . . . . . . 2-13

2-6.

Daily Walk-Around Inspection - Sheet 3 of 4  . . . . . . . . . 2-14

2-7.

Daily Walk-Around Inspection - Sheet 4 of 4  . . . . . . . . . 2-15

3-1.

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

3-2.

Ground Control Station with Machine Safety System 

Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3.

Ground Control Indicator Panel  . . . . . . . . . . . . . . . . . . . . . . 3-9

3-4.

Platform Control Console  . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12

3-5.

Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-20

3-6.

Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

4-1.

Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-5

4-2.

Position of Least Backward Stability  . . . . . . . . . . . . . . . . . . 4-6

4-3.

Grade and Side Slopes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-4.

Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-5.

Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-6.

Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-7.

Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-8.

Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-9.

Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-10.

Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-11.

Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-12.

Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

5-1.

Generation 1 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1

5-2.

Generation 2 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1

5-3.

LCD Panel  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-4.

Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-5.

Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-6.

Conditional Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-7.

CAN Communication Error Screen . . . . . . . . . . . . . . . . . . . 5-10

5-8.

Serviceable Fault Screen  . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-9.

Keyswitch in Ground Control Mode Screen  . . . . . . . . . . 5-14

5-10.

Keyswitch in Ground Control Mode with Operational 

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-11.

Operational Fault - No Graphics Screen . . . . . . . . . . . . . . 5-18

5-12.

Operational Fault - With Graphics Screen . . . . . . . . . . . . 5-20

5-13.

Operational Fault - Footswitch Open Screen . . . . . . . . . 5-22

5-14.

Out of Transport - Axles Retracted Screen. . . . . . . . . . . . 5-24

5-15.

Transport Swing Fault Screen  . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-16.

Backward Envelope Speed Reduction Fault Screen. . . 5-28

5-17.

Forward Envelope Violation Fault Screen . . . . . . . . . . . . 5-30

5-18.

Over/Under Moment Fault Screen . . . . . . . . . . . . . . . . . . . 5-32

5-19.

Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-20.

Manual Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-21.

Lanyard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-22.

Select Capacity Zone Screen  . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-23.

Machine Operating Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-24.

Keyswitch In Ground Mode Screen  . . . . . . . . . . . . . . . . . . 5-37

5-25.

Function Speed Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Summary of Contents for 1500SJ

Page 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Boom Lift Models 1500SJ 3121261 June 30 2017 ...

Page 2: ......

Page 3: ...e 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 ...

Page 4: ...LL HAVE AN 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 BACKGROUND INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY This is the Safety Alert Symbol It is used to alert you ...

Page 5: ...CTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office See addresses on inside of manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside U...

Page 6: ... Lift 3121261 REVISION LOG Original Issue April 25 2011 Revised May 23 2011 Revised November 10 2011 Revised September 10 2012 Revised September 4 2014 Revised January 5 2015 Revised May 23 2017 Revised June 30 2017 ...

Page 7: ...2 1 PERSONNEL TRAINING 2 1 Operator Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function Check 2 5 SkyGuard Function Test 2 7 Boom Control System Check Procedure 2 8 General 2 14 2 3 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 2 16 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND I...

Page 8: ...e Jib 4 16 4 10 FUNCTION SPEED CONTROL 4 16 4 11 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY 4 17 4 12 SKYGUARD OPERATION 4 17 4 13 EMERGENCY TOWING 4 18 4 14 SHUT DOWN AND PARK 4 19 4 15 LIFTING AND TIE DOWN 4 19 Lifting 4 19 Tie Down 4 20 4 16 STOWING THE JIB FOR TRANSPORT 4 20 SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 1 IDENTIFICATION 5 1 5 2 LCD DISPLAY PANEL 5 2 Description 5 2 5 3 GENERAT...

Page 9: ...Lamp On 5 42 Broken Cable 5 44 Platform Level 5 45 Platform Overload 5 46 Capacity Mode Error 5 47 Swing DTCs 5 48 Jib Unlocked 5 50 Jib Locked 5 51 Chassis Status 5 52 Machine Tilted Mode 5 55 Envelope Status 5 56 Machine Model Unknown 5 60 5 5 OPERATIONAL FAULT CODE LISTING 5 61 SECTION 6 EMERGENCY PROCEDURES 6 1 GENERAL 6 1 6 2 INCIDENT NOTIFICATION 6 1 6 3 EMERGENCY OPERATION 6 1 Operator Unab...

Page 10: ...0 7 6 SKYWELDER 7 10 Accessory Ratings 7 11 Generator Output 7 11 Welding Accessories 7 11 Safety Precautions 7 12 Preparation and Inspection 7 12 Operation 7 12 7 7 SOFT TOUCH 7 13 SECTION 8 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 8 1 INTRODUCTION 8 1 8 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA 8 1 Operating Specifications 8 1 Dimensional Data 8 2 Capacities 8 3 Tires 8 3 Engine Data 8 ...

Page 11: ...2 of 6 4 23 4 9 Decal Location Sheet 3 of 6 4 24 4 10 Decal Location Sheet 4 of 6 4 25 4 11 Decal Location Sheet 5 of 6 4 26 4 12 Decal Location Sheet 6 of 6 4 27 5 1 Generation 1 Boot Up Splash Screen 5 1 5 2 Generation 2 Boot Up Splash Screen 5 1 5 3 LCD Panel 5 2 5 4 Boot Up Splash Screen 5 4 5 5 Default Screen 5 6 5 6 Conditional Icons 5 8 5 7 CAN Communication Error Screen 5 10 5 8 Serviceabl...

Page 12: ...city Mode Error Screen 5 47 5 34 Swing DTC Screen 5 49 5 35 Jib Unlocked Screen 5 50 5 36 Jib Locked Screen 5 51 5 37 Axles Retracted Screen 5 52 5 38 Axles Extended Screen 5 53 5 39 Machine Tilted Mode Screen 5 55 5 40 Unrestricted Mode Screen 5 57 5 41 Restricted Mode Screen 5 58 5 42 Machine Model Unknown Screen 5 60 8 1 Oil Sampling Port 8 9 8 2 Engine Operating Temperature Specifications 8 10...

Page 13: ...s Accessories Relationship Table 7 2 8 1 Operating Specifications 8 1 8 2 Dimensional Data 8 2 8 3 Capacities 8 3 8 4 Tire Specifications 8 3 8 5 Deutz TD2011L4 Specifications 8 4 8 6 Deutz TCD2 9L4 Specifications 8 4 8 7 Critical Stability Weights 8 5 8 8 Hydraulic Oil 8 5 8 9 Mobilfluid 424 Specs 8 6 8 10 Mobil DTE 10 Excel 32 Specs 8 6 8 11 UCon Hydrolube HP 5046 8 7 8 12 Mobil EAL H 46 Specs 8...

Page 14: ...viii JLG Lift 3121261 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE This Page Left Blank Intentionally ...

Page 15: ...aining 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 ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any ques tions with regard to safety training inspection maintenance application and op...

Page 16: ...overnmental regulations as they pertain to your utilization 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 equip ment unless the application is approved in...

Page 17: ...m floor Keep 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 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 position ing personnel their ...

Page 18: ...quip ment 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 Hydraulic cylinders are subject to thermal expansion and con traction This may result in changes to the boom and or plat form position while the machine is stationary Factors affecting thermal movement can include the length of time the machin...

Page 19: ... 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 slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current ...

Page 20: ...nd its 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 1 1 Minimum Approach Distances M A D Voltage Range Phase to Phase MINIMUM APPROACH DISTANCE in Feet Meters 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KV...

Page 21: ... or governmental require ments for work practices 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 The user must be familiar with the surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform e...

Page 22: ...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 including gusts may exceed 28 mph 12 5 m s Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Refer to Table 1 2 Beaufort scale For Reference Only or use other me...

Page 23: ...e Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effo...

Page 24: ...operator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driv ing in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters o...

Page 25: ...ring 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 to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the mac...

Page 26: ...he machine Do not use machine as a ground for welding When performing welding or metal cutting operations pre cautions 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 Do not replace items critical to stability such as batteries or solid tires with items of...

Page 27: ...cts across the battery terminals Always wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing 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 Charge batteries only in a well ventilated area Avoid overfillin...

Page 28: ...SECTION 1 SAFETY PRECAUTIONS 1 14 JLG Lift 3121261 NOTES ...

Page 29: ...he employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes or drop offs exist 7 Means to avoid the hazards of unprotected electrical con du...

Page 30: ...ions for further requirements for aerial work platforms The fre quency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environ ment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE ...

Page 31: ...equentInspection SeeNote Inservicefor3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended Serviceand...

Page 32: ...d or replaced 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 5 Walk Around Inspection Refer to Figure 2 4 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine ...

Page 33: ...LY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION Function Check Perform the Function Check as follows 1 From the ground control console with no load in the plat form a Check that all guards protecting the switches or locks are in place b Operate all functions and ensure proper operation c Check auxiliary power and ensure p...

Page 34: ... telescope beyond transport mode lift up more than 6 above horizontal and swing beyond 40 from center functions are disabled with the axles retracted 5 With the jib inline with the boom and locked make sure the jib will not unlock unless a The machine is in transport position booms retracted main boom below elevation 5 degrees jib boom below 40 degrees axles retracted b The boom capacity select sw...

Page 35: ...n will sound until the SkyGuard sensor and footswitch are disengaged NOTE If the machine is equipped with both SkyGuard and Soft Touch functions will not reverse only stop NOTE If equipped ensure the SkyGuard beacon illuminates when Sky Guard is activated Disengage the SkyGuard sensor release controls recycle the foot switch make sure normal operation is available If SkyGuard remains activated aft...

Page 36: ...l 4 Extend the boom until it stops 5 Boom must stop on colored stripe matching the capacity indicator If the boom does not stop on the correct stripe the system must be repaired by JLG authorized Service Per sonnel before the machine can be used 6 Push and hold the gray Boom Control System Test Button on the ground control panel The lighting of the green Boom Control System Calibrated indicator in...

Page 37: ...NSPECTION 3121261 JLG Lift 2 9 Figure 2 1 Basic Nomenclature Sheet 1 of 3 1 Platform 2 SkyGuard If Equipped 3 Jib 4 Fly Boom Section 5 Outer Mid Boom Section 6 Inner Mid Boom Section 7 Base Boom Section 8 Boom Assembly 9 Lift Cylinder 10 Turntable 11 Chassis ...

Page 38: ... INSPECTION 2 10 JLG Lift 3121261 Figure 2 2 Basic Nomenclature Sheet 2 of 3 12 Platform 13 SkyGuard IfEquipped 14 CrossRail 15 PlatformControlConsole 16 PlatformLevelCylinder 17 PlatformRotator 18 JibFlyBoom 19 JibBaseBoom 20 JibLockCylinder 21 JibRotator ...

Page 39: ...ESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121261 JLG Lift 2 11 Figure 2 3 Basic Nomenclature Sheet 3 of 3 22 Turntable 23 DriveHub 24 RearDriveWheels 25 Frame 26 FrontDrive SteerWheels 27 GroundControlConsole ...

Page 40: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 12 JLG Lift 3121261 9 4 7 7 5 5 5 5 6 6 6 6 9 9 9 9 8 3 2 11 11 12 11 11 10 Figure 2 4 Daily Walk Around Inspection Sheet 1 of 4 ...

Page 41: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121261 JLG Lift 2 13 Figure 2 5 Daily Walk Around Inspection Sheet 2 of 4 ...

Page 42: ...d Gate latch and hinges in working condition 2 Platform Ground Control Consoles Switches and levers return to neutral decals placards secure and legible control markings legible 3 Boom Sections Turntable See Inspection Note 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 discrepan cies Inspect wheels for da...

Page 43: ...PECTION 3121261 JLG Lift 2 15 12 Hydraulic Pump See Inspection Note 13 Platform Rotator See Inspection Note 14 Jib Rotator and Jib Lock Cylinder See Inspection Note 15 SkyGuard If Equipped See Inspection Note Figure 2 7 Daily Walk Around Inspection Sheet 4 of 4 ...

Page 44: ... Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block 4 Carefully extend the boom just enough to get it out of the transport position 5 With boom in this position place Drive control lever to Reverse and carefully drive machine off of block and ramp 6 Have an assistant check to see that left front or right rear wheel re...

Page 45: ... by the ground controls for these symbols and the corresponding functions NOTE The indicator panels use different shaped 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 not corrected could result in serious injury or death This indicator will be red Indi...

Page 46: ...Control Station with Machine Safety System Override MSSO CE Only NOTE The Function Enable switch must be held down in order to operate Main Boom Telescope Swing Main Lift Jib Lift Platform Level Override Plat form Rotate and Jib Telescope functions 1 Indicator Panel The Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation 2 Jib Te...

Page 47: ... 6 5 4 3 Figure 3 1 Ground Control Station 1 IndicatorPanel 2 JibTelescopeControl 3 PlatformRotate 4 PlatformLevelingOverride 5 JibLift 6 EngineStart AuxiliaryPowerSwitch FunctionEnable 7 Power EmergencyStop 8 Hourmeter 9 Platform GroundSelect 10 Lift 11 Swing 12 Telescope 13 BoomControlSystemTest ...

Page 48: ...n with Machine Safety System Override MSSO CE Only 1 IndicatorPanel 2 JibTelescopeControl 3 PlatformRotate 4 PlatformLevelingOverride 5 JibLift 6 EngineStart AuxiliaryPowerSwitch FunctionEnable 7 Power EmergencyStop 8 Hourmeter 9 Platform GroundSelect 10 Lift 11 Swing 12 Telescope 13 BoomControlSystemTest 14 MachineSafetySystemOverride MSSO ...

Page 49: ...grade 5 Jib Lift Provides raising and lowering of the jib NOTE 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 WHEN USING AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP 6 Engine Start Aux...

Page 50: ...h engine running In the event of a fault the hourmeter also displays the three digit fault code Refer to the Service Manual for a listing of fault codes Additionally there is a small red indicator light that will blink when there is a fault on the machine to draw operator attention to the display NOTE With PLATFORM GROUND SELECT switch in the center position power is shut off to controls at both o...

Page 51: ...able rotation 12 Main Telescope Control Provides extension and retraction of the main boom 13 Boom Control System Test Button The push button is used to test the boom control system and confirm that it is working properly 14 Machine Safety System Override MSSO CE Only Provides emergency override of function controls that are locked out in the event of Load Sense System activation ...

Page 52: ...equired 4 Engine Oil Temperature Indicator Indicates the temperature of the engine oil which also serves as engine coolant is abnormally high and service is required 5 Glow Plug Indicator Indicates the glow plugs are operating After turning on ignition wait until light goes out before cranking engine 6 Axles Set Indicator Indicates that the axles are fully extended The indicator will flash as the ...

Page 53: ... NoAlternatorOutput 2 LowEngineOilPressure 3 HighEngineCoolantTemperature 4 EngineOilTemperature 5 GlowPlugIndicator 6 AxlesSet 7 PlatformCapacity 8 PlatformOverload 9 BoomControlSystemWarning 10 BoomControlSystemCalibrated Figure 3 3 Ground Control Indicator Panel ...

Page 54: ...pe Attempts to use the disabled functions cause the indicator to flash and an alarm to sound Immediately return the platform to the ground If the indicator remains lit a boom control system fault or failure has been detected If a failure is discovered the system must be repaired by JLG authorized service per sonnel before the machine can be used 10 Boom Control System Calibrated Indicator When the...

Page 55: ...iven as quietly as possible 2 Steer Select The action of the steering system is opera tor selectable The center switch position gives conventional front wheel steering with the rear wheels unaffected This is for normal driving at maximum speeds The forward position is for crab steering When in this mode both front and rear axles steer in the same direction which allows the chassis to move sideways...

Page 56: ...lect 3 PlatformLevelingOverride 4 AxleExtend Retract 5 Horn 6 IndicatorPanel 7 BoomControlSelect 8 Power EmergencyStop 9 Start AuxiliaryPower 10 CapacitySelect 11 DriveOrientationOverride 12 Drive Steer 13 MainTelescope 14 Lights 15 JibLift 16 SoftTouch SkyGuardOverride 17 JibStow 18 JibTelescope 19 SoftTouch SkyGuardIndicator 20 PlatformRotate 21 LockPinIndicator 22 FunctionSpeedControl 23 MainLi...

Page 57: ...e LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation Within about 2 seconds of pulling the Power Emergency Stop switch out the machine will perform a diagnostic check of the various electrical circuits and if everything is OK the platform alarm will beep once During this time the lights on the indicator panel will also blink...

Page 58: ...e disallowed direction will cause the BCS to flash When this occurs the only choices are to swing in the opposite direction or switch to automatic mode 8 Power Emergency Stop 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 Start Auxiliary Power When pushed forward the switch energizes t...

Page 59: ...n is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driving locate the black white orientation arrows on both the chassis and the plat form controls Move the drive controls in a direction match ing the directional arrows NOTE To operate the Drive Joystick pull up on the lock ing ring below the handle NOTE The DRIVE control l...

Page 60: ... equipped with SkyGuard the switch enables functions cut out by the Sky guard system to be operated again allowing the operator to resume use of machine functions If equipped with both Soft Touch and SkyGuard the switch operates like described above and allows the opera tor to override the system that has experienced a cutout situation UPON ACTIVATING THE JIB STOW CONTROL SWITCH A SLIGHT DELAY WIL...

Page 61: ...l work normally 20 Platform Rotate Allows the operator to rotate the platform to the left or right 21 Lock Pin Indicator When illuminated indicates the jib is centered and the jib lock pin is engaged When blinking indicates the jib is in the process of being stowed or centered The indica tor is off when the lock pin is disengaged and the jib is stowed machine in transport position 22 Function Spee...

Page 62: ...e NOTE The Main Boom Lift Swing joystick is spring loaded and will automatically return to neutral off position when released 23 Main Lift Swing Controller Provides main lift and swing Push forward to lift up pull backward to boom down Move right to swing right move left to swing left Moving the joystick activates switches to provide the functions selected ...

Page 63: ...E MACHINE RESET THE EMERGENCY STOP AND RESTART THE MACHINE IF THE FAULT PERSISTS RETURN THE PLATFORM TO THE STOWED POSITION USING MANUAL LEV ELING AS REQUIRED AND HAVE LEVELING SYSTEM REPAIRED 2 AC Generator If Equipped Indicates the generator is in operation 3 Platform Overload Indicator If Equipped Indicates the platform has been over loaded 4 Platform Capacity Indicator Indicates the maximum pl...

Page 64: ... 10 12 11 13 14 1 LevelSystem 2 ACGenerator 3 PlatformOverload 4 PlatformCapacity 5 TiltAlarmWarning 6 GlowPlug 7 Enable 8 FuelLevel 9 CreepSpeed 10 SystemDistress 11 CableService 12 DriveOrientation 13 AxlesSet 14 BoomControlSystemWarning Figure 3 5 Platform Control Indicator Panel ...

Page 65: ...arting the engine Indicates the glow plugs are operating After turning on ignition wait until light goes out before starting engine 7 Footswitch Enable Indicator TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOTTOM To operate any funct...

Page 66: ...el Indicator Indicates the level of fuel in the fuel tank 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 Figure 3 6 Fuel Level Indicator ...

Page 67: ...ation indicator will illumi nate 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 direc tion i e controls reversed situations 13 Axles Set Indicator Indicates that the axles are fully extended The indicator will flash as the axles are extending or retracting and be on solid when fully extended The light will go o...

Page 68: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 24 JLG Lift 3121261 NOTES ...

Page 69: ...tation The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Boom Lift and Swing and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so 4 2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities Raising boom above horizontal with or without any load in plat form is ...

Page 70: ... a predetermined arc equivalent to the percentage of extension i e If you start at 70 boom extension you will end up at approximately 70 boom extension no matter where you stop in the arc This means that when lifting down telescope in will function automatically or when lifting up telescope out will function automatically When the Boom Control Switch is in the manual mode lift and telescope functi...

Page 71: ...the edge of the backward stability region Boom Control System in Manual Mode The boom will stop when the end of the envelope is reached and the operator must acti vate lift and or telescope in the proper direction to bring the boom back into the envelope Controlled Angle The control system automatically maintains a constant elevated boom angle when swinging the turntable If the boom angle is at 30...

Page 72: ...operator to select operation in a 500 lb 227 kg for ANSI markets and 230 kg for CE and Australia markets capacity restriction envelope or a 1000 lb 454 kg for ANSI markets and 450 kg for CE and Australia markets capacity restriction envelope The operator selects the desired capacity restriction by positioning the Capacity Select switch on the platform console The Capacity Indicator shows the capac...

Page 73: ...3121261 JLG Lift 4 5 Figure 4 1 Position of Least Forward Stability MAINBOOM ELEVATED20DEGREES JIBHORIZONTAL FULLYEXTENDED MACHINEWILL TIPOVER INTHIS DIRECTIONIFOVERLOADEDOR OPERATEDONAN OUT OF LEVELSURFACE MAINBOOM FULLYEXTENDED ...

Page 74: ... 3121261 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 JIB FULLY EXTENDED PLATFORM ROTATED 90 DEGREES ...

Page 75: ...l conditions NOTE Initial starting should always be per formed from the Ground Control sta tion 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 MIN UTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL NOTE After turning on ignition operator must wait until glow plug ...

Page 76: ... must be in released up position before starter will operate If starter operates with footswitch in the depressed posi tion DO NOT OPERATE MACHINE Shutdown Procedure IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE 1 Remove all load and allow engine to operate at low speed for 3 5 minutes this allows further reduction of intern...

Page 77: ...d the engine will react according to machine setup Setup options are as follows Engine One Restart When the engine shuts down the operator will be permitted to cycle power and restart the engine once with approximately 2 minutes of run time After the 2 minute run time is complete or if the engine is shut down by the operator prior to the completion of the 2 minute run time it cannot be restarted u...

Page 78: ...OOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED BEFORE DRIVING LOCATE THE BLACK WHITE ORIENTATION ARROWS ON BOTH THE CHASSI...

Page 79: ...SECTION 4 MACHINE OPERATION 3121261 JLG Lift 4 11 G R A D E LE V E L S ID E S L O P E 1500SJ Figure 4 3 Grade and Side Slopes ...

Page 80: ... tires and the machine may Drive Steer in the opposite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both platform con trol panel and the chas sis to determine the direction the machine will travel 2 Push and release the Drive Orientation Over ride switch Within 3 second...

Page 81: ...ility IF THE BOOM IS OVER THE FRONT STEER AXLE DIRECTION OF STEER AND DRIVE MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS 4 6 STEERING Position thumb switch on Drive Steer controller to Right for steering right or to Left for steering left 4 7 EXTENDING THE AXLES NOTE The boom must be oriented between the rear wheels to extend or retract the axles The operator must be driving the mac...

Page 82: ...Position the Platform Level control switch Up or Down and hold until the desired platform position is obtained Platform Rotation To rotate the platform to the left or right use the Platform Rotate control switch to select the direc tion and hold until desired position is reached 4 9 BOOM A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLO...

Page 83: ...TOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMER GENCY STOP SWITCH TO STOP THE MACHINE Swinging the Boom NOTE The axles must be fully extended to swing beyond the rear wheels 40 degrees To swing boom use Swing control to select Right or Left direction WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS PARTITIONS AND EQ...

Page 84: ...the jib use the Jib Telescope Con trol Switch to select In or Out movement 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 auto matically while using the Jib Stow switch 4 10 FUNCTION SPEED CONTROL This control affects the speed of main boom telescope jib telescope and jib lift Turn...

Page 85: ...used to provide enhanced control panel protection When the SkyGuard sensor is activated functions that were in use at the time of actuation will reverse or cutout The table below outlines these functions Table 4 1 SkyGuard Function Table Main Lift Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lift Up Tower Lift Down Platform Level Platform Rotate Jib Lift Jib Rotate Jib Tele R...

Page 86: ...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 Retract lower and position boom in travel position lock turntable 2 Disconnect drive hubs by inverting disconnect cap 3 Reconnect the drive hubs by inverting the disconnect cap when towing is complete Figure...

Page 87: ...ecessary cover Platform Controls to protect instruction placards warning decals and operating controls from hostile environment 4 15 LIFTING AND TIE DOWN See Figure 4 6 Lifting 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 2 Place the boom in the stowed position with the turntable locked 3 Rem...

Page 88: ... the platform using straps or chains of adequate strength and attached to the designated tie down points 4 16 STOWING THE JIB FOR TRANSPORT 1 Place the boom in the stowed position with the axles retracted 2 Hold the Jib Swing control switch to the right until the plat form will no longer swing NOTE Automatic platform leveling is disabled when stowing the jib 3 Push and hold the platform rotate swi...

Page 89: ...SECTION 4 MACHINE OPERATION 3121261 JLG Lift 4 21 1001125274 D 17 3 5 26 m 6 10 2 08 m 10 5 3 18 m 43 0 13 11 m 11 7 3 53 m 31 5 9 58 m 10 0 3 05 m Figure 4 6 Lifting and Tie Down Chart ...

Page 90: ...SECTION 4 MACHINE OPERATION 4 22 JLG Lift 3121261 2 A N S I D U A L LA N G U A G E C E O N L Y 22 1701518 39 37 8 39 57 42 12 46 47 1500S J 18 41 44 23 Figure 4 7 Decal Location Sheet 1 of 6 ...

Page 91: ... LL O C A T IO N SF O RA N S I A N DC E 15 26 BO T H S ID E S BO T H S ID E S 44 60 43 45 24 9 51 33 31 50 9 19 A N S I D U A L LA N G U A G EO N L Y 22 28 19 22 D E C A LL O C A T IO N SF O RD U A LLA N G U A G E 15 16 Figure 4 8 Decal Location Sheet 2 of 6 ...

Page 92: ...SECTION 4 MACHINE OPERATION 4 24 JLG Lift 3121261 35 56 58 58 52 54 5 56 55 53 28 20 36 Figure 4 9 Decal Location Sheet 3 of 6 ...

Page 93: ... Lift 4 25 A N S I D U A L LA N G U A G E C E O N L Y D U A LLA N G U A G E O N L Y A N S I C EO N L Y A U S 7 7 13 8 2 8 2 45 60 11 25 49 26 29 21 18 23 16 29 22 64 22 23 23 22 40 8 7 8 7 www jlg com Figure 4 10 Decal Location Sheet 4 of 6 ...

Page 94: ...SECTION 4 MACHINE OPERATION 4 26 JLG Lift 3121261 37 37 10 34 Figure 4 11 Decal Location Sheet 5 of 6 ...

Page 95: ...ION 4 MACHINE OPERATION 3121261 JLG Lift 4 27 A N S I D U A L LA N G U A G E 8 2 37 39 17 30 39 34 32 44 41 23 18 46 47 1500S J A N S I D U A L LA N G U A G EO N L Y Figure 4 12 Decal Location Sheet 6 of 6 ...

Page 96: ... 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 17055980 17055980...

Page 97: ...508 1705907 1705915 1705506 1705494 27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 28 1001125175 1001122370 1001122371 1001122372 1001122373 1001122374 1001125177 1001122375 1001125177 29 1001125176 1001122377 1001122378 1001122379 1001122380 1001122381 1001125178 1001122382 1001125178 30 1001131269 1700584 1700584 1700584 31 1001130584 1706751 1706751 1706751 1706751 1706751 1...

Page 98: ...5511 1705511 1705511 1705511 1705511 37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Table 4 2 Decal Legend Item ANSI 1001125140 B Korean 0274723 B Chinese 0274724 B Portuguese 0274725 B English Spanish 0274726 B French English 0274727 B CE 1001125143 B Japan 0274729 B Australia 1001125141 B ...

Page 99: ...3 54 55 56 57 58 59 60 61 62 63 64 1001112551 Table 4 2 Decal Legend Item ANSI 1001125140 B Korean 0274723 B Chinese 0274724 B Portuguese 0274725 B English Spanish 0274726 B French English 0274727 B CE 1001125143 B Japan 0274729 B Australia 1001125141 B ...

Page 100: ...SECTION 4 MACHINE OPERATION 4 32 JLG Lift 3121261 NOTES ...

Page 101: ...RATION 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 1 Generation 1 Boot Up Splash Screen Figure 5 2 Generation 2 Boot Up Splash Screen ...

Page 102: ...ion 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 Man ual nor is it a replacement for thorough operational knowledge of the machine Figure 5 3 LCD Panel ...

Page 103: ...eration There is a reminder for the operator to wear a full body harness with a lanyard attached to an authorized lanyard anchorage point a reminder for the operator to read and understand the Operation and Safety Manual and a reminder for the operator to select the desired capacity range of the machine In addition the display also uses a yellow circle and arrows to indicate the location of the Ca...

Page 104: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 4 JLG Lift 3121261 Figure 5 4 Boot Up Splash Screen AttachLanyard Reminder CapacitySelect Reminder ReadOperationand SafetyManual Reminder ...

Page 105: ...e no faults present in the JLG Control System The display shows an indication of fuel level battery voltage and engine rpm In addi tion a check mark in a green circle indicates no serviceable faults are present The LCD software version is also displayed for 5 sec onds after initial bootup NOTE In the example shown the engine is not running ...

Page 106: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 6 JLG Lift 3121261 Figure 5 5 Default Screen Fuel Level Engine RPM NoServiceable FaultsPresent Battery Voltage LCDSoftware Version ...

Page 107: ...veral 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 ...

Page 108: ...D DISPLAY PANEL GENERATION 1 2 5 8 JLG Lift 3121261 Figure 5 6 Conditional Icons Safety Alert Symbol NoServiceable FaultsPresent Software Version Creep Speed Jib Unlocked Jib Locked Reduced Speed Numeric Fault Code ...

Page 109: ...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 This screen will remain until the condition is corrected ...

Page 110: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 10 JLG Lift 3121261 Figure 5 7 CAN Communication Error Screen Numeric FaultCode SafetyAlert Symbol ...

Page 111: ...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 Check the Service Manual for the specific fault code In addition the locked unlocked status of the jib is displayed on the lower left corner of the screen NOTE The fault indication can be shown regardless of the in...

Page 112: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 12 JLG Lift 3121261 Figure 5 8 Serviceable Fault Screen Fuel Level Engine RPM StoredServiceableFault FaultCode seeServiceManual Jib Unlocked Battery Voltage ...

Page 113: ...3121261 JLG Lift 5 13 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 ...

Page 114: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 14 JLG Lift 3121261 Figure 5 9 Keyswitch in Ground Control Mode Screen KeyswitchinGround ControlModeIcon ...

Page 115: ...Keyswitch in Ground Control Mode Icon will be displayed as long as the key is in the ground control position If any opera tional 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 ...

Page 116: ...N 5 LCD DISPLAY PANEL GENERATION 1 2 5 16 JLG Lift 3121261 Figure 5 10 Keyswitch in Ground Control Mode with Operational Faults RefertoOperation ManualIcon Numeric FaultCode KeyswitchinGround ControlModeIcon ...

Page 117: ...ormation 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 In the lower right hand corner a check mark in a green circle indicates no sys tem faults are present If a system fault is present the numeric fault code with a caution symbol is displayed Multiple faults will dis...

Page 118: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 18 JLG Lift 3121261 Figure 5 11 Operational Fault No Graphics Screen RemindertoCheck OperationandSafety Manual Numeric FaultCode NoServiceable FaultsPresent ...

Page 119: ...layed above the fault icon Fault 2224 Footswitch Selected Before Start is used as an example In the lower right hand corner a check mark in a green circle indicates no serviceable faults are present If a ser viceable fault is present the numeric fault code with a safety alert symbol is displayed Multiple faults will display in succession Check the Service Manual for the specific fault code In addi...

Page 120: ...CTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 20 JLG Lift 3121261 Figure 5 12 Operational Fault With Graphics Screen Iconrepresenting OperationalFault Numeric FaultCode NoServiceable FaultsPresent Jib Locked ...

Page 121: ...d 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 foot switch and operating the function again In the lower right hand corner a check mark in a green circle indicates no serviceable faults are present If a serviceable fault is present the numeric fault code with a safety alert symbol is ...

Page 122: ... PANEL GENERATION 1 2 5 22 JLG Lift 3121261 Figure 5 13 Operational Fault Footswitch Open Screen IconrepresentingNo Functions areOperational Numeric FaultCode NoServiceable FaultsPresent IconRepresenting Footswitch Reminder ...

Page 123: ...th 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 If a serviceable fault is present the numeric fault code with a safety alert symbol is displayed Multiple faults will display in succession Check th...

Page 124: ... of Transport Axles Retracted Screen AxlesRetracted Icon Extended AxlesWillFlash NoServiceable FaultsPresent YellowHighlightsIndicatedirectionControlSwitch canbeAppliedtoCorrecttheFaultCondition YellowSegments IndicateDirections thatJoystickcanbe AppliedtoCorrectthe FaultCondition ...

Page 125: ... the axles are retracted This screen will remain until the operator operates one of the controls high lighted on the screen to correct the condition the axles are extended or the turntable swings away from the limit In the lower right hand corner a check mark in a green circle indicates no serviceable faults are present If a system fault is present the numeric fault code with a safety alert symbol...

Page 126: ...t Screen IconRepresenting TransportSwing Fault ExtendedAxles willFlash YellowCircleIndicatesthatControlSwitchcanbeAppliedinEither DirectiontoCorrecttheFaultCondition NoServiceable FaultsPresent YellowSegments IndicateDirections thatJoystickcanbe AppliedtoCorrectthe FaultCondition Numeric FaultCode ...

Page 127: ...h places all func tions in proportionally reduced speed The proportionally reduced speed function is indicated by the turtle icon in the lower left corner of the screen In the lower right hand corner a check mark in a green circle indicates no serviceable faults are present If a serviceable fault is present the numeric fault code with a safety alert symbol is displayed Multiple faults will display...

Page 128: ...gure 5 16 Backward Envelope Speed Reduction Fault Screen IconRepresentingBack wardEnvelope SpeedReduction Indication Note OppositeSide WillHighlightif ForwardEnvelope isnear encroachment NoServiceable FaultsPresent TurtleIconRepresents FunctionsOperatingatReducedSpeed ...

Page 129: ...ended This screen will remain until the operator operates one of the controls highlighted on the screen to correct the condition In the lower right hand corner a check mark in a green circle indi cates no serviceable faults are present If a serviceable fault is present the numeric fault code with a safety alert symbol is dis played Multiple faults will display in succession Check the Ser vice Manu...

Page 130: ...Thesideof theenvelope beingviolated willbeilluminated YellowCircleIndicatesthatControlSwitchcanbeAppliedinEither DirectiontoCorrecttheFaultCondition NoServiceable FaultsPresent YellowSegments IndicateDirections thatJoystickcanbe AppliedtoCorrectthe FaultCondition YellowHalf CircleIndicatesthatControlSwitchcanbeAppliedinOnly OneDirectiontoCorrecttheFaultCondition ...

Page 131: ...until the operator operates one of the controls high lighted on the screen to correct the condition In the lower left corner of the screen the Super Creep snail icon will be displayed to show that all functions will operate in Super Creep mode until the condition is corrected In the lower right hand corner a check mark in a green circle indicates no serviceable faults are present If a serviceable ...

Page 132: ...RATION 1 2 5 32 JLG Lift 3121261 Figure 5 18 Over Under Moment Fault Screen Under Over MomentIcon ForwardandRear Envelope HighlightsFlash NoServiceable FaultsPresent SnailIconRepresents FunctionsOperatingatCreepSpeed Numeric FaultCode ...

Page 133: ...llowed by three reminder screens There is a reminder for the operator to wear a full body harness with a lan yard attached to an authorized lanyard anchorage point a reminder for the operator to read and understand the Operation and Safety Manual and a reminder for the operator to select the desired capacity range of the machine Each reminder screen will show for 3 seconds Figure 5 19 Boot Up Spla...

Page 134: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 34 JLG Lift 3121261 Figure 5 20 Manual Screen Figure 5 21 Lanyard Screen Figure 5 22 Select Capacity Zone Screen ...

Page 135: ...g Screen After the reminder screens the Machine Operating Screen will appear The Machine Operating Screen consists of different images and trays Each tray provides different machine informa tion Figure 5 23 Machine Operating Screen DTCTray Console Tray Icons Tray MachineStatus Tray ...

Page 136: ...with a gray arrow NOTE The green and gray console arrows shown in the examples in this section may be different depending upon machine setup and specific operating conditions ICONS TRAY The Icons Tray shows engine RPM plus Creep and Super Creep modes The RPM level is represented in bars MACHINE STATUS TRAY The Machine Status Tray is used to display different images based on the machine status Thes...

Page 137: ...D DISPLAY PANEL GENERATION 1 2 3121261 JLG Lift 5 37 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 Keyswitch In Ground Mode Screen ...

Page 138: ...Lift 3121261 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 Function Speed Icons ...

Page 139: ... BLAM Chassis UGM or Jib Control Mod ule the display will show a CAN Communication lost until the communications are reset NOTE 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 communi cations to reset Figure 5 26 CAN Bus Lost Screen ...

Page 140: ...NERATION 1 2 5 40 JLG Lift 3121261 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 Take Foot Out Screen ...

Page 141: ... 5 41 Put Foot In When the operator operates the machine without putting his foot on switch Put Foot In DTC becomes active after timeout When put foot in DTC is active the display shows Put Foot In image in the machine status tray Figure 5 28 Put Foot In Screen ...

Page 142: ...tion 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 hazard ous situation The DTCs that triggered this BCS Lamp will be scrolled in the DTC tray NOTE The available controls will be different among the different DTCs The image below is ONLY for envelope violation ...

Page 143: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 3121261 JLG Lift 5 43 Figure 5 29 BCS Lamp Screen ...

Page 144: ...ft 3121261 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 shows a red octagon broken cable indicator in the machine sta tus tray Figure 5 30 Broken Cable Screen ...

Page 145: ...m Level Whenever the control system senses a DTC with the platform level the platform level lamp is lit on the platform console When this lamp is lit the display shows a red octagon platform level DTC indicator in the machine status tray Figure 5 31 Level System DTC Screen ...

Page 146: ...EL GENERATION 1 2 5 46 JLG Lift 3121261 Platform Overload When the boom control system senses that the platform is over loaded the Platform Overload indicator on the platform console will be lit Figure 5 32 Overload DTC Screen ...

Page 147: ...ts the incorrect capacity mode for the jib con figuration 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 Capacity Mode Error Screen ...

Page 148: ...d 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 Swing DTC will be displayed on the DTC tray with the num ber and system distress icon Available functions on the machine are shown with green arrows Functions that are not available are grayed out RPM and speed restriction icon will be display...

Page 149: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 3121261 JLG Lift 5 49 Figure 5 34 Swing DTC Screen ...

Page 150: ...ON 5 LCD DISPLAY PANEL GENERATION 1 2 5 50 JLG Lift 3121261 Jib Unlocked When the control system senses that jib pin is unlocked the dis play will show the Jib Unlocked image Figure 5 35 Jib Unlocked Screen ...

Page 151: ...n 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 The display will show a different image on the machine status tray after 3 seconds have elapsed Figure 5 36 Jib Locked Screen ...

Page 152: ... IN TRANSPORT POSITION When the axles are retracted regardless of engine state the dis play shows the following screen The Axles Retracted image is shown on the left side of the display or machine status tray This image will be shown until the axles are extended Figure 5 37 Axles Retracted Screen ...

Page 153: ... 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 Axles Extended Screen ...

Page 154: ...LES 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 ...

Page 155: ...RATION 1 2 3121261 JLG Lift 5 55 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 Machine Tilted Mode Screen ...

Page 156: ...e 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 The display shows animated boom length and boom angle information along with the envelope Boom movement is proportional to the envelope bound aries Platform location is always shown at the end of the boom Mode Boom Platform E...

Page 157: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 3121261 JLG Lift 5 57 Figure 5 40 Unrestricted Mode Screen ...

Page 158: ...SECTION 5 LCD DISPLAY PANEL GENERATION 1 2 5 58 JLG Lift 3121261 Figure 5 41 Restricted Mode Screen ...

Page 159: ...t is less than what the machine is configured for then the envelope will shrink further to show that the new envelope Display shows animated boom length and boom angle information along with the new envelope Boom movement is proportional to envelope boundaries Platform location is always at the end of the boom Example 4 Restricted mode with envelope tilt condition When on the Restricted envelope s...

Page 160: ...ne 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 1850SJ the display will show the Machine Model Unknown image on the machine status tray Figure 5 42 Machine Model Unknown Screen ...

Page 161: ...VATION 0014 CHASSISTILTSENSOROUTOFRANGE 0015 LOADSENSORREADINGUNDERWEIGHT 0016 ENVELOPEENCROACHED HYDRAULICSSUSPENDED 0017 OVERMOMENT HYDRAULICSSUSPENDED 0018 UNDERMOMENT HYDRAULICSSUSPENDED 0030 RUNNINGATCREEP PLATFORMSTOWED 0035 APUACTIVE 0037 JIBUNLOCKEDOUTOFTRANSPORT HYDRAULICSSUSPENDED 0038 SWINGENVELOPEENCROACHED HYDRAULICSSUSPENDED 2211 FSWINTERLOCKTRIPPED 2212 DRIVELOCKED JOYSTICKMOVEDBEFO...

Page 162: ...UXPOWER 236 FUNCTIONSWITCHESLOCKED SELECTEDBEFORESTARTSWITCH 237 STARTSWITCHLOCKED SELECTEDBEFOREKEYSWITCH 259 MODELCHANGED HYDRAULICSSUSPENDED CYCLEEMS 2513 GENERATORMOTIONCUTOUTACTIVE 2514 BOOMPREVENTED DRIVESELECTED 2515 DRIVEPREVENTED BOOMSELECTED 2516 DRIVEPREVENTED ABOVEELEVATION 2517 DRIVEPREVENTED TILTED ABOVEELEVATION 2521 JIBSWINGPREVENTED IN1000 MODE Table 5 1 Operational Fault Codes Fa...

Page 163: ...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 PLATFORM CON TROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING COR RECTLY 6 3 EMERGENCY OPERATION Operator Unable to...

Page 164: ...bject Movement of the boom can be regained by observing the following 1 Shut off the engine 2 Rescue platform occupants prior to freeing machine 3 Use cranes forklifts or other equipment to stabilize motion of the machine as required 4 From the ground control position use the Auxiliary Power System to carefully raise the boom off the object 5 Once clear restart the engine and return the platform t...

Page 165: ...ity is used the fault indicator will flash and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician NOTE No functional checks of the MSSO system are necessary The JLG Control system will set a Diagnostic Trouble Code if the control switch is faulty To operate the MSSO 1 From the ground control console place the Platform Ground Select switch in the...

Page 166: ...SECTION 6 EMERGENCY PROCEDURES 6 4 JLG Lift 3121261 NOTES ...

Page 167: ...S 3121261 JLG Lift 7 1 SECTION 7 ACCESSORIES Table 7 1 Available Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x96 PipeRacks SkyCutter SkyGlazier SkyPower SkyWelder SoftTouch ...

Page 168: ...Racks Platform MTR SoftTouch SkyGlazier SkyGlazier SkyPower 4 Platform PipeRacks Platform MTR SoftTouch SkyCutter SkyWelder SkyPower SkyCutter SkyGlazier SkyWelder SkyWelder SkyPower SkyCutter 4 Platform PipeRacks Platform MTR SoftTouch SkyGlazier SoftTouch SkyPower PipeRacks SkyCutter SkyGlazier SkyWelder Note1 Anynon Sky accessorynotlistedunder INCOMPATIBLEWITH isassumedtobecompatible Note2 Canb...

Page 169: ...rea only The system is designed for use by one person Personnel must use 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 lbs 408 kg for the trans fastener type and 1350 lbs 612 kg for the shuttle type fall arrest system Safety Precautions DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE P...

Page 170: ...els Preparation and Inspection Ensure racks are secured to the platform rails Replace torn or frayed tie down straps Operation 1 To prepare racks for loading remove locking pins rotate each rack 90 degrees from stowed to working position then secure with locking pins 2 Loosen and remove tie down straps Place material on racks with weight evenly distributed between both racks 3 Route the tie down s...

Page 171: ...MA CUTTER IS IN PLATFORM Check for cracked welds and damage to plasma supports Check for secure installation of cutter and bracket Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Use this option only on approved models Keep lanyard attached at all times Use correct cutting settings Do not use electrical cords without ground Do not use electrical tools in ...

Page 172: ...rator then turn on the plasma cutter See the Miller Plasma Cutter Owner s Manual PN 3128420 for more information Spec RatedOutput AmperesInput RatedOutput 60 Hz 1 Phase kVa kW PlasmaGas PlasmaGasFlow Pressure RatedCutting Capacity 10IPM Max OCV 120Volts 10 20A 27A 91VDC 20 DutyCycle 28 8max 0 30 3 4kVa 3 2kW AirorNitrogenOnly 90 120psi 621 827kPa 4 5cfm 129L Min 60psi 414kPa 3 8in 10mm 400VDC 120V...

Page 173: ...ications Capacity Zone Max Tray Capacity Max Platform Capacity With Max Weight in Tray 500lbs 227kg 150lbs 68kg 250lbs 113kg 550lbs 250kg 150lbs 68kg 250lbs 113kg 600lbs 272kg 150lbs 68kg 250lbs 113kg 750lbs 340kg 150lbs 68kg 440lbs 200kg 1000lbs 454kg 250lbs 113kg 500lbs 227kg Refertothecapacitydecalsinstalledonthemachineforcapac ityzoneinformation Required Platform Type Side Entry Max Dimensions...

Page 174: ...LOCATED ON TRAY AN INCREASE OF THE AREA EXPOSED TO THE WIND WILL DECREASE STABILITY LIMIT PANEL AREA TO 32 SQ FT 3 SQ M Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Remove tray when not in use Use this option only on approved models Preparation and Inspection Check for cracked welds and damage to tray Ensure tray is properly secured to platform Ensure ...

Page 175: ...he generator supplies power when running at the specified speed with the power switch on switch is located on platform A three pole 30 Amp circuit breaker protects the generator from overload Generator Output ANSI Specifications 3 phase 240 V 60 Hz 7 5 kW 1 phase 240 V 120 V 60 Hz 6 kW CE Specifications 3 phase 240 V 7 5 kW 18 3 A 1 0 pf 1 phase 240 V 6 0 kW 26 A 1 0 pf 1 phase 120 V 6 0 kW 50 A 1...

Page 176: ...s in water Use correct voltage for tool being used Do not overload circuit Preparation and Inspection Ensure generator is secure Check condition of belt and wiring Operation Start the engine then turn on the generator See the Miller Generator Technical Manual PN 3121677 for more information 7 6 SKYWELDER SkyWelder is capable of TIG and Stick welding producing 200 Amps at 100 duty cycle or 250 Amps...

Page 177: ...ssories 12 ft welding leads with clamp and stinger stored in the platform Fire extinguisher Welding Mode Input Power Rated Output Welding Amperage Range Maximum Open Circuit Voltage Amps Input At Rated Load Output 50 60 Hz 230 V 460 V 575 V kVa kW Stick SMAW TIG GTAW 3 phase 280Ampat31 2V 35 DutyCycle 5 250A 79VDC 32 17 13 15 7 10 200Ampat28V 100 DutyCycle 20 11 8 10 3 6 4 1 phase 200Ampat28V 50 D...

Page 178: ...anyard attached at all times Ensure correct polarity of leads Wear proper welding apparel Use correct rod size and current settings Do not use electrical cords without ground Do not use electrical tools in water Do not weld to the platform Do not ground through the platform Do not use a high frequency arc starter with TIG welder Preparation and Inspection Connect ground clamp to metal being welded...

Page 179: ... a frame sus pended below the platform Limit switches deactivate platform functions when the padded framework contacts an adjacent structure A button on the platform console allows override of the system OVERRIDE INDICATOR LIGHT OVERRIDE LIGHT RAIL BUMPER LIMIT SWITCH SUSPENDED FRAME AND RAIL BUMPER LIMIT SWITCH ...

Page 180: ...SECTION 7 ACCESSORIES 7 14 JLG Lift 3121261 NOTES ...

Page 181: ...ntenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 3121262 Illustrated Parts Manual 3121263 8 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA Operating Specifications Table 8 1 Operating Specifications Capacity ANSI Unrestricted Restricted 500lbs 227kg 1000lbs 454kg Capacity CE Australia Unrestricted Restricte...

Page 182: ...5 8in 18 81m PlatformHeight UnrestrictedCapacity RestrictedCapacity 150ft 1in 45 75m 130ft 2in 39 67m Table 8 1 Operating Specifications HorizontalReachfromcenterlineofrota tion UnrestrictedCapacity RestrictedCapacity 80ft 24 38m 64ft 11in 19 79m HorizontalReachoverend UnrestrictedCapacity RestrictedCapacity 72ft 4in 24 38m 57ft 3in 17 45m HorizontalReachoverside UnrestrictedCapacity RestrictedCap...

Page 183: ...quarts 0 5liters 10 Table 8 4 Tire Specifications Size 445 50D710 LoadRange J PlyRating 18 FoamFill PolyurethaneHD 55Durometer Foam Diameter 46 45in 117 9cm Width 18in 45 7cm RimSize 15x28 Tire WheelWeight 867lbs 393kg MaxTireLoad 28600lbs 12973kg Size 445 65 24 Type SolidorSolidNon Marking Diameter 45 3in 115 1cm Width 17 3in 43 9cm RimSize 12 00 24 Tire WheelWeight Solid 960lbs 435 4kg Tire Whee...

Page 184: ...ystem w Filter TotalCapacity 5Quarts 4 5L 11Quarts 10 5L 16Quarts 15L AverageFuelConsumption 1 2gph 4 1lph IdleEngineRPM 1200 MidEngineRPM 1800 HighEngineRPM 2475 Table 8 6 Deutz TCD2 9L4 Specifications Type LiquidCooled NumberofCylinders 4 Bore 3 6in 92mm Stroke 4 3in 110mm TotalDisplacement 178cu in 2925cm FiringOrder 1 3 4 2 Output 74 2hp 55 4kW OilCapacity 2 4Gallon 8 9L CoolantCapacity System...

Page 185: ...em service NOTE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities Table 8 7 Critical Stability Weights Components LBS KG Counterweight 9500 4309 Tire Wheel 867 393 Tire Wheel 960 435 4 DriveHub Motor 275 5 123 SwingDrive 290 132 CompleteEngineAssembly 1275 579 CompleteBoom ...

Page 186: ... procedures Table 8 9 Mobilfluid 424 Specs SAE Grade 10W30 Gravity API 29 0 Density Lb Gal 60 F 7 35 Pour Point Max 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 8 10 Mobil DTE 10 Excel 32 Specs ISOViscosityGrade 32 SpecificGravity 0 877 PourPoint Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at100 C...

Page 187: ... pH 9 1 Viscosity at0 C 32 F 340cSt 1600SUS at40 C 104 F 46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 Table 8 12 Mobil EAL H 46 Specs Type SyntheticBiodegradable ISOViscosityGrade 46 SpecificGravity 910 PourPoint 44 F 42 C FlashPoint 500 F 260 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 45cSt at100 C 8 0cSt ViscosityIndex 153 ...

Page 188: ...LG Lift 3121261 Table 8 13 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity ...

Page 189: ...SECTION 8 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121261 JLG Lift 8 9 Figure 8 1 Oil Sampling Port ...

Page 190: ...SECTION 8 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 8 10 JLG Lift 3121261 Figure 8 2 Engine Operating Temperature Specifications ...

Page 191: ...NG NON JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE HYDRAULIC FLUID OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM HYDRAULIC FLUID OPERATION CHART Figure 8 3 Hydraulic Oil Operation Chart Sheet 1 of 2 ...

Page 192: ...SECTION 8 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 8 12 JLG Lift 3121261 4 4 9B 13 4 17 4 5 19 12 14 7 8 1 10A 10B 11 9A 16A 16B 15 2 3 18 6 Figure 8 4 Operator Maintenance and Lubrication Diagram ...

Page 193: ... s 2 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hours of operation Table 8 14 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excel lentwaterresistanceandadhesivequalities andbeingofextremepressuretype TimkenOK40poundsminimum EPGL ExtremePressureGearLube oil meetingAPIserviceclassificationGL 5orMIL SpecMIL L 2105...

Page 194: ...e 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 3 Swing Brake 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 ...

Page 195: ...t 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 B Wheel Drive Hub Reggiana Riduttori Lube Point s Level Fill Plug Capacity 0 5 quarts 0 5 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 3 o clock posit...

Page 196: ...ube Point s Replaceable Element Interval Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator 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 ...

Page 197: ... 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 8 Suction Strainers In Tank Lube Point s 2 Interval Every 2 years or 1200 hours of operation Remove and clean at time of hydraulic oil change FULLLEVEL HOTOIL FULLLEVEL COLDOIL ...

Page 198: ... 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 B Oil Change w Filter Deutz TCD2 9 Lube Point s Fill Cap Spin on Element Capacity 2 4 Gallon 8 9 L Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark o...

Page 199: ...INTENANCE 3121261 JLG Lift 8 19 10 A Fuel Filter Deutz TD2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation B Fuel Filter Deutz TCD2 9 Lube Point s Replaceable Element Interval Every year or 600 hours of operation ...

Page 200: ... 8 20 JLG Lift 3121261 11 Fuel Strainer TD2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation 12 Fuel Pre Filter TCD2 9 Lube Point s Replaceable Element Interval Drain water daily Change every year or 600 hours of operation ...

Page 201: ... s Fill Cap Spin on Element Capacity 10 5 Quarts 10 L Lube EO Interval Check level daily change every 150 hours or three months whichever comes first Adjust final oil level by mark on dipstick 14 Fuel Filter CAT Lube Point s Replaceable Element Interval Drain water daily Change every year or 600 hours of operation ...

Page 202: ... 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 16 A Air Filter Deutz TD2011 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator ...

Page 203: ...of operation or as indi cated by the condition indicator Comments Check Dust Valve daily 17 Platform Filter Lube Point s Replaceable Element Interval Change after first 50 hours and then every year or 600 hours of operation thereafter 18 Boom Lube Point s Apply to wear pad contact paths Lube Super Lube Interval As needed Refer to the Service Manual for detailed procedures ...

Page 204: ... GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 8 24 JLG Lift 3121261 19 Optional Fuel Filter Water Separator Lube Point s Replaceable Element Interval Drain water daily Change every year or 600 hours of operation ...

Page 205: ... any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire 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 Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer...

Page 206: ...E DANGEROUS 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 wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torq...

Page 207: ...ed sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is sub jec...

Page 208: ...SECTION 8 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 8 28 JLG Lift 3121261 NOTES ...

Page 209: ...SECTION 9 INSPECTION AND REPAIR LOG 3121261 JLG Lift 9 1 SECTION 9 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 9 1 Inspection and Repair Log Date Comments ...

Page 210: ...SECTION 9 INSPECTION AND REPAIR LOG 9 2 JLG Lift 3121261 Table 9 1 Inspection and Repair Log Date Comments ...

Page 211: ... form Mfg Model ______________________________________________________________________ Serial Number ____________________________________________________________________ Previous Owner __________________________________________________________________ Address _________________________________________________________________________ __________________________________________________________________...

Page 212: ......

Page 213: ......

Page 214: ...erhude Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia S R L Via Po 22 20010 Pregnana Milanese MI Italy 39 0 2 9359 5210 39 0 2 9359 5211 Email ricambi jlg com JLG EMEA B V Polaris Avenue 63 2132 JH Hoofdorf The Netherlands 3...

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