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, COULD 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 SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. • Accident Reporting • Product Safety Publications • Current Owner Updates • Questions Regarding Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
FOREWORD REVISION LOG d Original Issue - May 4, 2005 Revised - September 1, 2005 Revised - March 7, 2006 Revised - July 17, 2006 Revised - March 12, 2007 Revised - March 30, 2007 Revised - January 6, 2009 Revised - November 6, 2009 Revised - December 12, 2009 Revised - July 26, 2010 Revised - June 21, 2012 – JLG Lift – 3121209
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT SECTION - 1 - SAFETY PRECAUTIONS 1.1 1.2 1.3 1.4 1.5 2.3 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Operator Training and Knowledge . . . . . . . . . . . 1-1 Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2 Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2 OPERATION . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 ii PAGE TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-6 Traveling Forward and Reverse. . . . . . . . . . . . . 4-7 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Loading From Ground Level . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 6.3 6.4 6.5 6.6 6.7 6.8 PAGE SECTION - PARAGRAPH, SUBJECT Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-10 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-29 Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6-3. Engine Operating Temperature Specifications - Ford Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14 6-4. Engine Operating Temperature Specifications - Ford Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL 1.2 This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.
SECTION 1 - SAFETY PRECAUTIONS • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual. • Use the machine in a manner which is within the scope of its intended application set by JLG. • All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.
SECTION 1 - SAFETY PRECAUTIONS 1.3 OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed. • Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. • Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the ground for entry/exit. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.
SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range (Phase to Phase) 0 to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11) Over 750 KV to 1000 KV 45 (14) NOTE: • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 11.
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 • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. • If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine. • Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
SECTION 1 - SAFETY PRECAUTIONS • Use the boom functions, not the drive function, to position the platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • 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.
SECTION 1 - SAFETY PRECAUTIONS 1.5 ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • 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. 3121209 – JLG Lift – • Charge batteries only in a well ventilated area.
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) 1-10 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 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. 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion. 4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs. 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 Pre-Start Inspection Primary Responsibility Frequency Before using each day; or whenever there’s an Operator change.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection The Pre-Start Inspection should include each of the following: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. (Domestic only) is enclosed in the weather resistant storage container. 5.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION ARTICULATING JIB ARTICULATING JIB LIFT CYLINDER ALL OTHER COMPONENTS ARE SIMILAR TO MODEL 800A ON PRECEDING PAGE Figure 2-2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 22,23,24 14,15,16,17,18,19,20 9 12 11 10 25 21 13 9,10 3,4,5 12 11 8 7 6 2 12 11 8 40 41 42 1 26 27 8 29 8 43 28 27 9 36 39 12 11 10 37,38 24,30,31,32,33 34,35 9,10 Figure 2-3.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION GENERAL 3. Rotator - See Inspection Note. 4. Rotator Motion Control Valve - See Inspection Note. 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. 5. Articulating Jib Boom - See Inspection Note. 6.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 13. Control Valve (Tank Compartment) - No loose or missing lug nuts, proper inflation (pneumatic). Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion. 14. Turntable Bearing and Pinion - No loose or missing hardware; no visible damage, evidence of proper lubrication. 15. Hydraulic Oil Medium Pressure Filter Housing - See Inspection Note. 16.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 30. Engine Air Filter - No loose or missing parts; no visible damage; element clean. 31. Battery - Proper electrolyte levels; cables tight, no visible damage or corrosion. 32. Engine Oil Supply - Full mark on dipstick; filler cap secure. 33. Muffler and Exhaust System - See Inspection Note. 39. Tower Boom - No visible damage; wear pads secure. All cylinders - rod end pins and barrel-end pins properly secured. 40.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 FUNCTION CHECK Perform a function check of all systems, once the walkaround inspection is complete, in an area free of overhead and ground level obstructions. A MACHINE MALFUNCTION COULD CAUSE DEATH OR SERIOUS INJURY. IF ANY MALFUNCTIONS OCCUR DURING THE FUNCTION TEST, DISCONTINUE OPERATION AND CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE. a.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION d. Raise the tower base boom to full height. Extend the tower fly boom a few feet. Check that the plunger on the tower boom horizontal limit switch at the end of the tower base boom section is fully extended. The plunger is shown fully extended in Figure 2-8. DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED b. Attempt to extend the tower fly boom.
3121209 90° – JLG Lift – 90° CORRECT Figure 2-9. Boom Upright Positioning - Correct CORRECT UPRIGHT MUST BE 90° (VERTICAL) RELATIVE TO THE CHASSIS.
2-14 90° – JLG Lift – 90° INCORRECT Figure 2-10. Boom Upright Positioning - Incorrect INCORRECT TO AVOID TIPPING IF THIS OCCURS: -LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNCTIONS. HAVE CONDITION CORRECTED BY A TRAINED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION e. Attempt to lower the tower base boom while the tower fly boom is extended. The tower base boom should not lower and the red boom malfunction light should illuminate when pressing the tower down switch. DO NOT OPERATE MACHINE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION 2.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: 3. Ensure that all machine functions are disabled when the Emergency Stop Button is activated. 4. Check auxiliary power for proper operation. Operate each function control switch to ensure proper operation of the auxiliary power system. NOTE: c. With main boom in this position, raise the main base boom until the capacity indicator lights change back to the 1000 lb. (454 kg) indicator. Footswitch has a 7 second delay timer.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Check the Tilt Alarm and Warning System as follows: 9. Check the high-engine cutout for the main boom assembly as follows: a. Place machine on level surface with booms retracted and lowered. b. From the platform control, position DRIVE SPEED/ TORQUE SELECT switch to FAST (Forward Position). IF THE TILT ALARM AND WARNING SYSTEM DOES NOT OPERATE PROPERLY, DISCONTINUE OPERATION.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 13. Check that the platform level override operates properly. 2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 14. Check platform rotator for smooth operation and assure platform will rotate 90 degrees in both directions from centerline of boom. 15. If equipped with 4-wheel steer, check rear steer left and right for proper operation. 16. If equipped, raise and lower the articulating jib boom. Check for smooth operation. 17.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. 7. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground. 8. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels).
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-20 – JLG Lift – 3121209
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL Ground Control Station NOTE: Main Lift, Swing, Platform Level, Main Telescope, Platform Rotator and Auxiliary Power, Tower Telescope, Tower Lift, and jib control switches are spring-loaded and will automatically return to neutral (off) when released.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. Platform Rotate Platform Leveling Override Jib Power/Emergency Stop Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable Tower Telescope Hourmeter Platform/Ground Select Switch Swing Tower Lift Main Boom Lift Main Boom Telescope 2 12 3 OR 4 11 5 10 6 9 7 8 1706912 A Figure 3-1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 2. Platform Leveling Override WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Engine Start/Auxiliary Power Switch or Engine Start/ Auxiliary Power Switch /Function Enable. 6. Tower Telescope The TOWER TELESCOPE control switch provides extending and retracting of the tower boom when positioned to IN or OUT. This function works only when the tower boom is fully elevated (lift up). To start the engine, the switch must be held "UP" until the engine starts.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Platform/Ground Select Switch A three position, key operated switch supplies power to the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground controls are operable. NOTE: With the Platform/Ground Select Switch in the center position, power is shut off to controls at both operating stations.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 11. Main Lift Control The MAIN LIFT control switch provides raising and lowering of the main boom when positioned to UP or DOWN. 12. Main Telescope Control The MAIN TELESCOPE control switch provides extension and retraction of the boom, when positioned to IN or OUT. 1. 2. 3. 4. 5. 6. Battery Charging Low Engine Oil Pressure High Engine Water Temp. High Engine Oil Temp. Engine Malfunction Indicator Low Fuel 7. 8. 9. 10. 11. 12.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Discharging Indicator 5. Engine Malfunction Indicator Light (Ford Engines prior to S/N 62045) When illuminated indicates a problem in the battery or charging circuit, and service is required. 2. Engine Oil Pressure Indicator When illuminated indicates that engine oil pressure is below normal and service is required. 3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Boom Malfunction Indicator 9. Platform Overload (If equipped) If the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. The function is not permitted at the current boom configuration. If the Boom Malfunction Indicator is flashing or on steady without a boom function attempt, the upright is out of alignment or the monitoring system is in need of calibration.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Station 3. Main Lift/Swing Controller TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. A proportional dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lift down. Move right to swing right, move left to swing left. NOTE: 1.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 13 7 9 2 17 1 14 11 12 1702676-B 1704997 1702567 A 3 1. 2. 3. 4. 5. Power/Emergency Stop Horn Main Lift / Swing Telescope Drive/Steer 6 6. 7. 8. 9. 8 16 Function Speed Control Drive Speed / Torque Select Platform Rotate Platform Level Override 15 10. 11. 12. 13. 10 5 4 Articulating Jib (800AJ) Fuel Select Lights Steer Select 14. 15. 16. 17. Engine Start / Aux Power Tower Telescope Tower Lift Light Panel Figure 3-3.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 13 7 9 2 1 14 11 17 1702676-B 1704997 1702567 A 1702938 3 1. 2. 3. 4. 5. 3121209 6 8 19 16 1705170 A 15 18 10 12 4 5 Power/Emergency Stop 6. Function Speed Control 11. Fuel Select 16. Tower Lift 17. Drive Orientation Override Horn 7. Drive Speed / Torque Select 12. Lights Main Lift / Swing 8. Platform Rotate 13. Steer Select 18. Soft Touch Override Telescope 9. Platform Level Override 14. Engine Start / Aux Power 19.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Drive/Steer 7. Drive Speed/Torque Select Proportional single axis joystick is provided to control drive. Push forward to drive forward, pull back to drive in reverse. Steering is accomplished via a thumb-activated rocker switch on the end of the handle. Push on the left side of the switch to steer left, on right side to steer right. NOTE: Both drive and steer functions work in the opposite direction when the main boom is positioned over front of the chassis.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Work Lights (If Equipped) ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 9. Platform Leveling Override A three position switch allow the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situation such as ascending/ descending a grade.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 13. Steer Select (If Equipped) 14. Auxiliary Power 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 the best position for normal driving at maximum speeds. The forward position is for “crab” steering.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 16. Tower Telescope 18. Soft Touch Override Switch (If equipped) The three position center-off toggle switch provides for extending and retracting of the tower boom when positioned to IN or OUT. TOWER TELESCOPE must be fully RETRACTED before operating TOWER LIFT. (TOWER TELESCOPE should not function when TOWER LIFT is not fully elevated “UP”).
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 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. Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.
SECTION 3 - MACHINE CONTROLS AND INDICATORS light will go out and the footswitch must be released and depressed again to enable the controls. Releasing the footswitch removes power from all controls and applies the drive brakes. 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. 2.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 9 10 11 7 3 4 * 6 ** 1 2 5 8 * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. 2. 3. 4. 5. 6. 3-18 Enable 7. Creep Speed Engine Malfunction 8. Glow Plug Soft Touch 9. Tilt Alarm Warning AC Generator 10. Overload Fuel Level 11. Boom Malfunction Capacity Figure 3-5.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 9 10 11 * 6 1 1001107927 A 7 12 4 ** 2 5 8 * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. 2. 3. 4. 3121209 Enable 5. Fuel Level 9. Tilt Alarm Warning Engine Malfunction 6. Capacity 10. Overload Not Used 7. Creep Speed 11. Boom Malfunction AC Generator 8. Glow Plug 12. Drive Orientation Figure 3-6.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Soft Touch Indicator (If Equipped) 7. Creep Speed Indicator When illuminated (Yellow) the Soft Touch bumper is against an object. All controls are disabled until the override button is pushed, at which time controls are active in the Creep mode. Illuminated (Green) 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. 8. Glow Plug Indicator (If Equipped) 4.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Overload Indicator (If equipped) 12. Drive Orientation Indicator Indicates the platform has been overloaded. 11. Boom Malfunction Indicator When an audible alarm sounds and the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. This function is not permitted at the current boom configuration.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 – JLG Lift – 3121209
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 TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE. 4.3 ENGINE OPERATION NOTE: Initial starting should always be performed from the Ground Control station. Starting Procedure 4. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch to the upward position until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD. 1.
SECTION 4 - MACHINE OPERATION Figure 4-1.
SECTION 4 - MACHINE OPERATION Figure 4-2.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION Shutdown Procedure 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. IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION. 1. Remove all load and allow engine to operate at low speed setting for 3-5 minutes; this allows for further reduction of internal engine temperature. 2.
SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse 4.5 Depress the footswitch to steer machine, push switch left to steer left, to the right, to steer right. 1. At Platform Controls, pull out Emergency Stop switch, start engine, and activate footswitch. 2. Position Drive controller to FORWARD or REVERSE as desired. This machine is equipped with a Drive Orientation Indicator.
SECTION 4 - MACHINE OPERATION 4.7 PLATFORM Platform Level Adjustment Loading From Ground Level 1. Leveling UP. Depress footswitch To raise platform, position PLATFORM LEVEL control switch UP and hold until platform is level. 1. Position chassis on a smooth, firm and level surface. 2. If total load (personnel, tools and supplies) is less then rated capacity, distribute load uniformly on platform floor and proceed to work position. 2. Leveling DOWN.
SECTION 4 - MACHINE OPERATION DE GRA SIDE S LOPE LEVEL Figure 4-4.
SECTION 4 - MACHINE OPERATION 4.8 BOOM TRAVELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON THE SERIAL NUMBER PLACARD. (See Figure 4-2.) AN ORANGE TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE. DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT. DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.
SECTION 4 - MACHINE OPERATION Raising and Lowering the Tower Boom Raising and Lowering the Main Boom This machine will have two controls for the tower boom (two toggle switches), one controls tower lift, the other tower telescope. The switching system will sequence its LIFT and TELESCOPE functions as follows: 1. Depress footswitch and sequence while RAISING the TOWER BOOM from the fully lowered position.
SECTION 4 - MACHINE OPERATION Function of Tower Boom This machine will have two controls for the tower boom (two toggle switches), one controls tower lift, the other tower telescope. The switching system will sequence its LIFT and TELESCOPE functions as follows: 2. Sequence while LOWERING the TOWER BOOM from the fully elevated “up” position. a. TOWER TELESCOPE “in”. The TOWER BOOM must be fully retracted before the TOWER BOOM can be lowered. b.
SECTION 4 - MACHINE OPERATION 4.9 SHUT DOWN AND PARK 4.10 LIFTING AND TIE DOWN 1. Drive machine to a protected area. When transporting machine, boom must be in the stowed position mode, (booms lowered and retracted) with turntable lock pin engaged, and machine securely tied down to truck or trailer deck. Six tie down eyes are provided in the frame slab, one at each corner of the machine and 2 holes at the center of the frame. (See Figure 4-5., Machine Tie Down) 2.
SECTION 4 - MACHINE OPERATION NOTE: NOTE: Rig chains so as not to rub. Block rotator and platform. Secure platform w/o overtightening. Figure 4-5.
SECTION 4 - MACHINE OPERATION Figure 4-6.
SECTION 4 - MACHINE OPERATION NOTE: Crane and lifting devices, chains, slings, etc., must be capable of handling the gross machine weight. ABOVE IS MINIMUM WEIGHT. CHECK WEIGHT OF UNIT PRIOR TO LIFTING. NOTE: Lifting eyes are provided at the front and rear in the frame slab. Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated. 4.
SECTION 4 - MACHINE OPERATION 4.13 TOW BAR (IF EQUIPPED) 4. Position steer/tow selector valve for towing; pull valve knob OUT for towing. The machine is now in the towing mode. After towing the machine, complete the following: 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. 1.
SECTION 4 - MACHINE OPERATION Figure 4-7.
SECTION 4 - MACHINE OPERATION 4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY) Changing From Gasoline to LP Gas Description 1. Start engine from Ground Control Station. 2. Open hand valve on LP gas supply tank by turning counterclockwise. The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas. The system includes pressurized cylinders mounted on the frame, and the valves and switches needed to switch the fuel supply from gasoline to LP gas or from LP gas to gasoline.
SECTION 4 - MACHINE OPERATION 4.16 RE-SYNCHRONIZE UPRIGHT Releveling Valve A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90° (vertical) relative to the chassis (Refer to Figure 2.9 and Figure 2.10). This valve is located in the tank compartment area. Perform the following steps with the aid of an assistant: 1. Turn the key switch to the ground control position. 2. Start the engine. 3.
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 Figure 4-12.
SECTION 4 - MACHINE OPERATION Figure 4-13.
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 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-3.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION Table 4-4.
SECTION 4 - MACHINE OPERATION NOTES: 4-42 – JLG Lift – 3121209
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 After moving machine, complete the following procedures: 1. Position machine on a firm and level surface. 2. Chock wheels securely. 3. Engage drive hubs by reversing disconnect caps on hubs. 4. Remove chocks from wheels as needed. 5.4 EMERGENCY CONTROLS AND THEIR LOCATIONS The Ground Control Station is located on the right front side of the turntable.
SECTION 5 - EMERGENCY PROCEDURES 5. Position AUXILIARY POWER switch to ON and hold. 5.5 6. Release AUXILIARY POWER switch, selected control switch, lever or controller, and footswitch. Use of Ground Controls 7. Position POWER/EMERGENCY STOP switch to OFF. To activate auxiliary power from the ground control station: 1. Position PLATFORM/GROUND SELECT KEY SWITCH to GROUND. 2. Position POWER/EMERGENCY STOP switch to ON. EMERGENCY OPERATION KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION.
SECTION 5 - EMERGENCY PROCEDURES Operator Unable to Control Machine Platform or Boom Caught Overhead IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE: DO NOT OPERATE WITH PRIMARY POWER SOURCE (ENGINE OR ELECTRIC MOTOR) IF PERSONS ARE PINNED OR TRAPPED. USE AUXILIARY POWER INSTEAD.
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 6-1. Operating Specifications Boom Elevation - 800A Above Grade Below Grade +80 ft.(24.38 m) -15 ft.-7 in. (4.75 m) Boom Elevation - 800AJ Above Grade Below Grade Max. Ground Bearing Pressure Max. Tire Load Table 6-2. Tire Specifications Size Type Ply Rating +80 ft.(24.38 m) -13 ft.- 1 in. (3.99 m) IN 385/65D 19.5 pneumatic 16 H 95PSI (6.5 Bar) 84 psi. (5.9 kg/cm2) IN 445/55D 19.5 pneumatic 16 H 85 PSI (6.0 Bar) 15 X 19.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Data Table 6-4. Ford LRG-425 Specifications Table 6-3. Capacities Fuel Tank Approx. 40 gallons (151.4 liters) Hydraulic Tank Approx. 40 gallons (151.4 liters) Hydraulic System (Including Tank) 77 Gal. (291.4 L) Drive Hub (Prior to S/N 83332) 17 ounces (0.5 L) Drive Hub (S/N 83332 to Present) 44 ounces (1.3 L) Drive Brake (S/N 8332 to Present) 2.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-5. Deutz F4M2011F Specifications Table 6-6. Deutz D2011L04 Specifications Type Liquid Cooled (Oil) Type Liquid Cooled (Oil) Fuel Diesel Fuel Diesel Oil Capacity Cooling System Crankcase Total Capacity 5 Quarts (4.5 L) 11 Quarts (10.5 L) w/Filter 16 Quarts (15 L) Oil Capacity Cooling System Crankcase Total Capacity 5 Quarts (4.5 L) 11 Quarts (10.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-7. Caterpillar 3044C/3.4 Type Cylinders Bore Stroke Aspiration Compression ratio Displacement Firing Order Table 6-8. Isuzu 4JB1 Four Stroke Cycle 4 in-line 3.70 inch (94 mm) Water-cooled Oil Capacity (w/filter) 8.5 Quarts (8.0 L) Cooling System (Engine Only) 5.8 quarts (5.5 L) 4.72 inch (120 mm) Idle RPM turbocharged Low RPM 1800 19:1 High RPM 2800 203 in3 (3.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Table 6-9. GM 3.0L Fuel No. of Cylinders Gasoline or Gasoline/LP Gas BHP Gasoline LP 83 hp @ 3000 rpm 75 hp @ 3000 rpm Bore 4.0 in. (101.6 mm) Stroke 3.6 in. (91.44 mm) Displacement Oil Capacity w/filter Minimum Oil Pressure at idle Hot Compression Ratio Firing Order Max. RPM 6-6 Table 6-10. Hydraulic Oil 4 181 cu.in. (3.0 L, 2966 cc) 4.5 qts. (4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations. Table 6-11. Mobilfluid 424 Specs Table 6-12. Mobil DTE 13M Specs ISO Viscosity Grade #32 Specific Gravity 0.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-13. Mobil EAL 224H Specs Type Synthetic Biodegradable ISO Viscosity Grade 32/46 Specific Gravity .922 Pour Point, Max -25°F (-32°C) Flash Point, Min. 428°F (220°C) Operating Temp. 0 to 180°F (-17 to 162°C) Weight 7.64 lb. per gal. (0.9 kg per liter) Table 6-14. UCon Hydrolube HP-5046 NOTE: 6-8 37 cSt at 100° C 8.4 cSt Viscosity Index 213 Synthetic Biodegradable 1.082 Pour Point, Max -58°F (-50°C) pH 9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-16. Quintolubric 888-46 Table 6-15. Exxon Univis HVI 26 Specs Specific Gravity Pour Point Flash Point 32.1 Density 0.91 @ 15°C (59°F) -76°F (-60°C) Pour Point <-20°C (<-4°F) 217°F (103°C) Flash Point 275°C (527°F) Fire Point 325°C (617°F) Viscosity at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index 376 Autoignition Temperature NOTE: Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-17. Critical Stability Weights - 800A COMPONENTS DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY. Tire & Wheel Size (Foam Filled Only) Engine Counterweight Wheel Hubs Platform 6-10 – JLG Lift – LBS. KG. 365/65D19.5 565 255 445/55D19.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-18. Critical Stability Weights - 800AJ COMPONENTS Tire & Wheel Size (Foam Filled Only) Engine Counterweight Wheel Hubs Platform Size 3121209 LBS. KG. 365/65D19.5 565 255 445/55D19.5 675 305 15 X 19.5 565 255 18 X 19.5 675 305 Ford 600 209 Deutz 534 242 Isuzu 463 210 GM w/pumps 1030 468 Turntable 4805 2180 Rear 218 99 Front 2WD 110 99 Front 4WD 218 99 6 FT. (1.83 M) 205 93 8 FT. (2.
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 NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 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) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
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 AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 120 F(49 C) 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) ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
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 Figure 6-9.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.3 NOTE: OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 69., Operator Maintenance and Lubrication Diagram. It is recommended as a good practice to replace all filters at the same time. 1. Swing Bearing - Internal Ball Bearing Table 6-19. Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Bearings 3. Wheel Drive Hub Lube Point(s) - Repack Capacity - A/R Lube - MPG Interval - Every 2 years or 1200 hours of operation 6-22 Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.5 L) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter 5. Hydraulic Charge Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 3121209 – JLG Lift – Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank 7. Suction Strainers Lube Point(s) - Fill Cap Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L) System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Ford 9. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 3121209 – JLG Lift – Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts(10.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - Isuzu 12. Oil Change w/Filter - GM Lube Point(s) - Fill Cap/Spin-on Element Capacity - 8.5 qt. (8.0L) engine; 5.3 qt. (5.L) cooler Lube - EO Interval - Change oil after first 50 and every 200 hrs. there after. Change oil filter after 50hrs. and every 400 hrs. there after. Comments - Check level daily/Change in accordance with engine manual. 11.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Fuel Filter - Deutz 13. Fuel Filter - Ford Lube Point(s) - Replaceable Element Interval - Every Year or 1200 hours of operation Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 15. Fuel Filter - Isuzu Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 16.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 17. Fuel Filter (Gasoline) - GM 19. Electronic Pressure Regulator (LP only) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 18. Air Filter Interval - 3 Months or 150 hours of operation Comments - Drain oil build up. Refer to Section 6.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.4 20. Fuel Filter (Propane) - GM Engine 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 Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.6, Propane Fuel Filter Replacement For pneumatic tires, JLG Industries, Inc.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE • 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE 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.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. The tightening of the nuts should be done in stages. Following the recommended sequence, tighten nuts per wheel torque chart. 6.5 DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR (PRIOR TO S/N 0300134626) Table 6-20. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 70 ft. lbs. (95 Nm) 170 ft. lbs. (225 Nm) 300 ft. lbs. (405 Nm) 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Push in the Emergency Switch once the engine stops. 6. Remove the retainer clip for the LPG fuel temperature sensor and remove the sensor from the regulator body. 5. Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR. NOTE: Have a small container ready to collect oil that will drain freely from the regulator at this point. 7.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.6 PROPANE FUEL FILTER REPLACEMENT Installation Removal 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 2. Disconnect the negative battery cable. 1. Install the mounting plate to lock off O-ring seal. 3. Slowly loosen the Filter housing and remove it. 2. If equipped, install the retaining bolt seal. 4.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1 1 7 7 8 8 2 13 9 3 9 3 10 10 4 OR 5 4 5 11 6 11 12 1. 2. 3. 4. 5. Electric Lock Off Solenoid Mounting Plate Housing Seal Filter Magnet Filter Housing 6. 7. 8. 9. Seal Electrical Connector Fuel Outlet O-ring 10. 11. 12. 13. Filter Fuel Inlet Retaining Bolt Ring Figure 6-10.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF 6.8 THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.
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 3121209 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia JLG Latino Americana Ltda. Rua Eng. Carlos Stevenson, 80-Suite 71 13092-310 Campinas-SP Brazil +55 19 3295 0407 +61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000 +49 (0)421 69 350 20 +49 (0)421 69 350 45 JLG France SAS Z.I.
