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 SERIOUS INJURY OR DEATH.
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 - May 24, 2002 Revised - October 7, 2013 Revised - June 14, 2002 Revised - September 11, 2014 Revised - November 1, 2002 Revised - January 15, 2003 Revised - May 3, 2005 Revised - August 30, 2005 Revised - January 12, 2006 Revised - June 19, 2006 Revised - July 17, 2006 Revised - December 1, 2006 Revised - April 11, 2007 Revised - June 19, 2008 Revised - November 19, 2009 Revised - August 30, 2010 Revised - November 3, 2010 Revised
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 ii PAGE Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-6 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 6.3 6.4 6.5 PAGE SECTION - PARAGRAPH, SUBJECT PAGE Engine Data - Deutz 2011 Prior to S/N 0300127698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Engine Data - Deutz 2011 S/N 0300127698 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Engine Data - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally.
LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE 2-1. 2-2. 2-3. 2-4. 3-1. 3-2. 3-3. 3-4. 3-5. 3-6. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . 2-8 Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . 2-9 Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . 2-10 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally.
LIST OF TABLES TABLE NUMBER - TITLE 1-1 1-2 2-1 4-1 4-2 6-1 6-2 6-3 6-4 6-5 6-6 6-7 6-8 6-9 6-10 6-11 6-12 6-13 6-14 6-15 6-16 6-17 6-18 6-19 7-1 3121141 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 - Prior to S/N 0300141473 . . . . . . . . . . . . .
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) 3121141 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 – 3121141
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, drop-offs. 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 Frequency Primary Responsibility Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operator and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 5. “Walk-Around” Inspection – Refer to Figure 2-2. and Figure 2-3. Pre-Start Inspection The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 7. Fuel (Combustion Engine Powered Machines) – Add the proper fuel as necessary. 2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION b. Check that all guards protecting the switches or locks are in place; IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. Function Check c. Operate all functions and check all limiting and cut-out switches; 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, jib straight, and platform level. 4. Extend the boom until it stops. 2-6 – JLG Lift – 5.
1. 2. 3. 4. 5. 6. 7. 3121141 – JLG Lift – 8. Fly Boom Section 9. Boom Assembly 10. Power Track 11. Jib 12. Platform 13. Platform Console Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3. Boom Sections/Uprights/Turntable - See Inspection Note. General Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) 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.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 12. Horizontal and Capacity Limit Switches - Switches operate properly. 14. Platform Rotator - See Inspection Note. 15. Jib Rotator - See Description. 13. Main Hydraulic Pump - See Inspection Note. Figure 2-4.
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 15° above horizontal and not extended beyond 12" [30.4 cm] on the1350SJP or 24" [60.9 cm] on the 1200SJP) 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: 2-12 – JLG Lift – 3121141
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL Ground Control Station NOTE: THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. If equipped, the Function Enable switch must be held down in order to operate Telescope, Swing, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions. (See Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 13 12 2 11 3 10 OR 1. 2. 3. 4. 5. 6. 7. 8. 9. 9 8 10. 11. 12. 13. Indicator Panel Boom Control System Test Button Telescope Swing Lift Platform/Ground Select Switch Hourmeter Power/Emergency Stop Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable Articulating Jib Platform Leveling Override Platform Rotate Jib Swing 7 1706911 A 4 5 6 Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Swing Control NOTE: Provides 360 degrees continuous turntable rotation. When Power/Emergency Stop switch is in the “ON” position and engine is not running, an alarm will sound, indicating Ignition is “ON”. 5. Lift Control Provides raising and lowering of the main boom. NOTE: With PLATFORM/GROUND SELECT switch in the center position, power is shut off to controls at both operating stations.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Auxiliary power only works if there is no engine oil pressure, and is disabled if engine is running. 10. Articulating Jib This switch provides raising and lowering of the jib. Functions will operate at a slower than normal rate because of the lesser flow of hydraulic fluid delivered. WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Low Engine Oil Pressure Indicator Ground Control Indicator Panel Indicates that engine oil pressure is below normal and service is required. (See Figure 3-2., Ground Control Indicator Panel) 1 2 3 4 5 6 3. High Engine Temperature Indicator Indicates that engine coolant temperature is abnormally high and service is required. 4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Platform Overload Indicator (If Equipped) Platform Station Indicates the platform has been overloaded. (See Figure 3-3., Platform Control Console - Prior to S/N 79596, Figure 3-4., Platform Control Console - S/N 79596 to 93078, and Figure 3-5., Platform Control Console - w/Boom Control Select) 8. Boom Control System Warning Indicator Indicates the platform is outside the operating area and operation of certain boom functions may be disabled (i.e.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Start/Auxiliary Power 4. Drive Orientation Override When pushed forward, the switch energizes the starter motor to start the engine. When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 17 18 19 20 21 1 2 3 4 1705175 A 1705171 A 16 1. 2. 3. 4. 5. Power/Emergency Stop Engine Start / Aux Power Capacity Select Drive Orientation Override Drive/Steer 15 6. 7. 8. 9. Telescope Lights Jib Lift Soft Touch Override 14 13 12 11 10. 11. 12. 13. Jib Swing Axle Extend/Retract Soft Touch Indicator Platform Rotate 10 14. 15. 16. 17. 9 8 7 5 6 Jib Stow Override Function Speed Control Main Lift / Swing Drive Speed / Torque Select 18.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 18 17 19 11 20 21 1 2 3 4 1705744 A 1705745 B 1702938 1705171 A 16 1. 2. 3. 4. 5. Power/Emergency Stop Engine Start / Aux Power Capacity Select Drive Orientation Override Drive/Steer 15 6. 7. 8. 9. Telescope Lights Jib Lift Soft Touch Override 14 10. 11. 12. 13. 13 12 Jib Swing Axle Extend/Retract Soft Touch Indicator Platform Rotate 1705170 A 10 14. 15. 16. 17.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 18 19 11 20 21 22 1 2 3 4 1706741A 17 1705744 A 1705745 B 1702938 1705171 A 16 1. 2. 3. 4. 5. 3-10 Power/Emergency Stop Engine Start / Aux Power Capacity Select Drive Orientation Override Drive/Steer 15 6. 7. 8. 9. 10. 14 13 12 1705170 A 10 9 8 7 6 Telescope 11. Axle Extend/Retract 15. Function Speed Control 12. Soft Touch Indicator 16. Main Lift / Swing Lights Jib Lift 13. Platform Rotate 17.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Main Telescope NOTE: This control allows extension and retraction of the main boom. The Jib Swing function is not operable when the Capacity Select control is in the 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Australia markets) position. 10. Jib Swing 7. Lights (If Equipped) This switch operates accessory light packages if the machine is so equipped. This switch allows the operator to rotate the jib to the left or right. 11.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 14. Jib Stow Override NOTE: This switch allows the operator to rotate the jib to the right past the electronic stop to stow the jib under the boom for transport. When boom is positioned above transport position or telescoped out and any of the following switches, DRIVE SPEED/TORQUE SELECT or FUNCTION SPEED, are positioned to HIGH, high function speeds are automatically cut out and the machine continues to operate at a lower speed. 15.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 18. Steer Select When equipped with four wheel steering, the action of the steering system is operator 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 as it goes forward.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 21. Indicator Panel Manual Mode: The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation. 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. 22.
SECTION 3 - MACHINE CONTROLS AND INDICATORS default to creep if the boom is extended past transport mode (24 inches [61 cm] 1200; 12 inches [30.5 cm] 1350) or elevated more than 15° above horizontal. Platform Control Indicator Panel (See Figure 3-6. or Figure 3-7.) NOTE: The platform control indicator panel uses different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 2 14 13 3 12 * 4 5 6 7 ** 11 10 9 8 * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. 2. 3. 4. 5. 3-16 Level System 6. Glow Plug 11. Cable Service AC Generator 7. Enable 12. Drive Orientation Platform Overload 8. Fuel Level 13. Axles Set Platform Capacity 9. Creep Speed 14. Boom Control System Warning Tilt Alarm Warning 10. System Distress Figure 3-6.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 2 14 13 3 12 * 4 5 6 7 ** 11 10 9 8 * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. 2. 3. 4. 5. 3121141 Level System 6. Glow Plug 11. Cable Service AC Generator 7. Enable 12. Drive Orientation Platform Overload 8. Fuel Level 13. Axles Set Platform Capacity 9. Creep Speed 14. Boom Control System Warning Tilt Alarm Warning 10. System Distress Figure 3-7.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Tilt Alarm Warning Light and Alarm 7. Footswitch/Enable Indicator Indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above transport position. If lit when the boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuous operation.
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 11. Cable Service Indicator 14. Boom Control System Warning Indicator When illuminated, the light indicates the boom cables are loose or broken and must be repaired or adjusted immediately. 12. Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected.
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom. 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. The operator can raise or lower the upper or lower boom or swing the boom to the left or right.
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 (See Figure 4-1.), and its position of least BACKWARD stability is shown in (See 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 4.4 3. Turn SELECT switch to PLATFORM. ENGINE OPERATION NOTE: 4. From Platform, pull POWER/EMERGENCY STOP switch out, then push the ENGINE START switch until engine starts. Initial starting should always be performed from the Ground Control station. NOTE: 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 • 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 Figure 4-1.
SECTION 4 - MACHINE OPERATION 4.5 . NOTE: TRAVELING (DRIVING) When the upper boom is raised approximately 15 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. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
SECTION 4 - MACHINE OPERATION 1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel. 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. 2. Push and release the Drive Orientation Override switch.
SECTION 4 - MACHINE OPERATION Figure 4-3.
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 Swinging the Jib 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 EQUIPMENT. Raising and Lowering the Boom NOTE: The lift function is not operable above 15 degrees above horizontal if the axles are not fully extended. To raise or lower the Boom, use Boom Lift control to select Up or Down movement. NOTE: For 1000 lb.
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. and Figure 4-6. Lifting 1. Drive machine to a reasonably well protected area. 1. Call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight. 2. Ensure boom is lowered over rear drive axle. 3. Push in the Emergency Stop at Platform Controls. 2. Place the boom in the stowed position with the turntable locked. 4.
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. NOTE: 2. Hold the Jib Swing control switch to the right until the platform will no longer swing. Prior to loading the machine onto a trailer, it will be necessary to rotate the turntable 180 degrees to provide better weight distribution.
SECTION 4 - MACHINE OPERATION Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION Figure 4-7.
SECTION 4 - MACHINE OPERATION Figure 4-8.
SECTION 4 - MACHINE OPERATION Figure 4-9.
SECTION 4 - MACHINE OPERATION Figure 4-10.
SECTION 4 - MACHINE OPERATION 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 Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 4 - MACHINE OPERATION Table 4-2.
SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating. 5.2 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 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead 5.4 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION 6.2 This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-2. Operating Specifications - S/N 0300141473 to Present Maximum Work Load (Capacity) - ANSI Unrestricted Restricted 500 lb (227 kg) 1000 lb. (454 kg) Maximum Work Load (Capacity)CE & Australia Unrestricted Restricted 500 lb (230 kg) 1000 lb. (450 kg) Max.Vertical Platform Height (Unrestricted) 1200SJP 1350SJP 120 ft. (36.6 m) 135 ft. (41.2 m) Max.Vertical Platform Height (Restricted) 1200SJP 1350SJP 115 ft. (35.1 m) 125 ft. (38.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-4. Chassis Specifications Chassis Maximum Wind Speed Table 6-4. Chassis Specifications Maximum Travel Grade With boom in stowed position (Gradeability) 45% Maximum Travel Grade With boom in stowed position (Side Slope) 5° Turning Radius (Axles Retracted) Outside Inside Turning Radius (Axles Extended) Inside Outside Max Tire Load 1200SJP 1350SJP Max Ground Bearing Pressure 1200SJP 1350SJP Maximum Drive Speed Max.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Engine Data - Deutz 2011 Prior to S/N 0300127698 Table 6-7. Deutz BF4M2011 Specifications Table 6-6. Tire Specifications 6-4 Size 445/50D710 Type Liquid Cooled Load Range J Number of Cylinders 4 Ply Rating 18 Bore 3.7 in. (94 mm) Load Rating 26,500 lbs. @ 100 psi (12020 kg @ 6.9 Bar) Stroke 4.4 in. (112 mm) Foam Fill Polyurethane HD (55 Durometer) Foam Total Displacement 190 cu. in.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data - Deutz 2011 S/N 0300127698 to Present Engine Data - Deutz TCD2.9L4 Table 6-8. Deutz TD2011L4 Specifications Table 6-9. 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data - Caterpillar Hydraulic Oil Table 6-10. Caterpillar 3.4T Specifications Type Liquid Cooled, Antifreeze Number of Cylinders 4 Bore 3.7 in. (94 mm) Stroke 4.7 in. (120 mm) Total Displacement 201 cu. in. (3294 cm3) Compression Ratio 19.5:1 Firing Order 1-3-4-2 Output 73.7hp (55 kW) Oil Capacity 10.5 Quarts (10 L) Average Fuel Consumption 1.36 gph (5.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-12. Mobilfluid 424 Specs Table 6-13. Mobil DTE 13M 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) 3121141 #32 Specific Gravity 0.877 Pour Point, Max -40°F (-40°C) Flash Point, Min. 330°F (166°C) Viscosity Viscosity Brookfield, cP at -18°C ISO Viscosity Grade at 40° C 33cSt 2700 at 100° C 6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-14. UCon Hydrolube HP-5046 Table 6-15. Mobil EAL H 46 Specs Type Synthetic Biodegradable Type Synthetic Biodegradable Specific Gravity 1.082 ISO Viscosity Grade 46 Pour Point, Max -58°F (-50°C) Specific Gravity .910 pH 9.1 Pour Point -44°F (-42°C) Flash Point 500°F (260°C) at 0° C (32° F) 340 cSt (1600SUS) Operating Temp.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-16. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity NOTE: 3121141 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-17. Component Weights Major Component Weights Component Pounds Kilograms 1200 Counterweight 5494 2492 T/T Assy. (less Cwt) 9450 4286 Table 6-17. Component Weights Component Pounds Kilograms Tire & Wheel 867 393 Drive Hub & Motor 275.
SECTION 6 - 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 6 - 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 6 - 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) 80 F(27 C) 70 F(21 C) ENGINE SPECIFICATIONS 60 F(16 C) 50 F(10 C) 40 F(4 C) 30 F(-1 C) 20 F(-7 C) ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
SECTION 6 - 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.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE AMBIENT AIR TEMPERATURE 120° F (49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F (43° C) 100° F (38° C) PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100° F (38° C) OR ABOVE.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-5.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 1. Swing Bearing - Remote Lube OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 6-5., Lubrication and Maintenance Point Location. Table 6-18. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.
SECTION 6 - 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. 3121141 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTE: After S/N 0300134389 machines may be built with either Bonfiglioli or Reggiana Riduttori wheel drive hubs. B: Wheel Drive Hub (S/N 100131 to Present) 4. A. Wheel Drive Hub (Prior to S/N 100131) 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to Present) 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 position. Pour lubricant into fill port until it just starts to flow out of check port. 3121141 – JLG Lift – 5.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7. Hydraulic Oil 8. Suction Strainers (In Tank) FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation. Remove and clean at time of hydraulic oil change. Lube Point(s) - Fill Cap Capacity - 55 gallons (208 liters) Tank Lube - HO Interval - Check level daily. Change every 2 years or 1200 hours of operation.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. A. Oil Change w/Filter - Deutz 2011 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. 3121141 – JLG Lift – Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL LEVEL MINIMUM LEVEL OIL HOT MAXIMUM LEVEL OIL HOT MINIMUM LEVEL OIL COLD MAXIMUM LEVEL OIL COLD MAXIMUM OIL LEVEL NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 6-6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. A. Fuel Filter - Deutz 2011 B. Fuel Filter - Deutz TCD2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. Fuel Strainer -Deutz 2011 12. Fuel Pre-Filter TCD2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 13. Oil Change w/Filter - CAT 14. Fuel Filter - CAT Lube Point(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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 15. Radiator Coolant TCD2.9 16. A. Air Filter - Deutz 2011 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Air Filter - Deutz TCD2.9 17.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 • any damage to the bead area cords of the tire TIRES & WHEELS 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. Tire Damage For pneumatic tires, JLG Industries, Inc.
SECTION 6 - 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 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-19. Wheel Torque Chart 6.5 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 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1.
SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1.
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 3121141 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.
