JLG 1500AJP Operation And Safety Manual
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JLG 1500AJP Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
1500AJP
AS/NZS GB
ANSI
3121734
®
November 5, 2018 - Rev F

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 1500AJP AS/NZS GB ANSI 3121734 ® November 5, 2018 - Rev F...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 4 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.
  • Page 5 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 A POTENTIALLY HAZARDOUS SITUATION.
  • Page 6 Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.

  • Page 7: Revision Log

    FOREWORD REVISION LOG Original Issue A - September 22, 2016 Revision B - May 23, 2017 Revision C - March 23, 2018 Revision D - May 30, 2018 Revision E - June 29, 2018 - Revised Covers, Prop 65 Revision F - November 5, 2018 3121734...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS Function Check........2-13 SkyGuard Function Test.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE CAPACITY SELECT........4-6 4.11 FUNCTION SPEED CONTROL .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE KEYSWITCH IN GROUND MODE: ..... . 5-6 Platform or Boom Caught Overhead or Boom FUNCTION SPEED .
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SKYCUTTER ......... 7-12 SUPPLEMENTAL INFORMATION .
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature - Sheet 1 of 4 ....2-4 4-12.
  • Page 13 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 5-16. Capacity Mode Error Screen ......5-16 5-17.
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 8-15 Lubrication Specifications ......8-13 Beaufort Scale (For Reference Only).
  • Page 15 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121734...

  • Page 16: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 17: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 18: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 19: Trip And Fall Hazards

    • Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature, approved by JLG. ambient air temperature, and boom and platform position. • When two or more persons are in the platform, the operator Trip and Fall Hazards shall be responsible for all machine operations.

  • Page 20: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 21 SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE (Phase to Phase) in Feet (Meters) 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)

  • Page 22: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 23 Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind unless authorized by JLG. speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, •...
  • Page 24 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 25: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 26: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 27 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 28: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND nents or when performing welding on the machine. SEEK MEDICAL ATTENTION.
  • Page 29 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121734...

  • Page 30: Section 2. User Responsibilities, Machine Preparation, And Inspection

    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, The aerial platform is a personnel handling device; so it is neces- depressions, holes, or drop-offs exist.
  • Page 31 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 32: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance required by JLG Industries, Inc.
  • Page 33 Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121734...

  • Page 34: Basic Nomenclature - Sheet 1 Of 4

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 6. Tower Boom Fly Section 2. Jib 7. Tower Boom Mid Section 8. Tower Boom Base Section 3. Main Boom Fly Section 9. Turntable 4. Main Boom Mid Section 10.

  • Page 35: Basic Nomenclature - Sheet 2 Of 4

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Main Boom Mid Section 12. Main Boom Base Section 13. Main Boom Powertrack 14. Lift Cylinder Assembly 15. Link 16. Tower Boom Fly Section 17. Tower Boom Powertrack Figure 2-2. Basic Nomenclature - Sheet 2 of 4 3121734...

  • Page 36: Basic Nomenclature - Sheet 3 Of 4

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 18. Platform Control Console 19. LCD Display 20. Footswitch 21. Jib 22. Jib Lift Cylinder 23. Jib Rotator 24. Main Boom Fly Section 25. SkyGuard (If Equipped) 26. Cross Rail (If Equipped) Figure 2-3.

  • Page 37: Basic Nomenclature - Sheet 4 Of 4

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 27. Tire and Wheel 28. Axle 29. Frame 30. Drive Hub 31. Swing Bearing 32. Axle Extend Cylinder 33. Drive Motor Figure 2-4. Basic Nomenclature - Sheet 4 of 4 3121734...

  • Page 38: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. Daily Walk-Around Inspection – Perform as instructed. 6. Battery – Charge as required. The Pre-Start Inspection should include each of the following: 7. Fuel (Combustion Engine Powered Machines) – Add the 1.

  • Page 39: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Daily Walk-Around Inspection 3121734...
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-10 3121734...
  • Page 41 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121734 2-11...
  • Page 42 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Begin the "Walk-Around Inspection" at Item 1, as noted on the 6. Drive Motor, Brake, and Hub - No evidence of leakage. diagram. Continue checking each item in sequence for the condi- 7.

  • Page 43: Function Check

    IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER PLATFORM TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE ROPES INSPECTED/ SERVICED BY A QUALIFIED JLG MECHANIC. LOOSE OR MISADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH.

  • Page 44: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3. With the platform in the stowed position: 2. Activate the SkyGuard sensor: a. Drive the machine on a grade, not to exceed the rated a. SkyGuard - Apply approximately 50 lb (222 Nm) of gradeability, and stop to ensure the brakes hold.
  • Page 45 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 46: Section 3. Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL 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 THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 47: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Main Boom Telescope Provides extension and retraction TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR of the main boom. TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

  • Page 48: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Main Boom Telescope 3. Jib Swing 4. Jib Lift 5. Platform Rotate 6. Platform Leveling Override 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power Switch/Function Enable 9. Display Gauge 10. Platform/Ground Select 11.

  • Page 49: Override (Msso) (Ce Only)

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Main Boom Telescope 3. Jib Swing 4. Jib Lift 5. Platform Rotate 6. Platform Leveling Override 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power Switch/Function Enable 9. Display Gauge 10. Platform/Ground Select 11.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Jib Lift Provides raising and lowering of ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF the jib. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 6.
  • Page 51 WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE ble), and Diagnostic Trouble Codes (DTCs) POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES. from both the JLG Control System and the 7. Power/Emergency Stop Switch engine control system.

  • Page 52: Air Shutoff Valve (Asov) (If Equipped)

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Swing 15. Selective Catalyst Reduction (SCR) Button (If Equipped) Provides 360 degrees continuous turntable rotation. The Selective Catalyst Reduction (SCR) push button is used to initiate the Standstill Clean- ing mode. 16. Air Shutoff Valve (ASOV) (If Equipped) 13.

  • Page 53: Ground Control Indicator Panel

    2. Engine Error Indicator when fully extended. The light will go out when the axles are fully retracted. The light indicates that the JLG Control Sys- tem has detected an abnormal condition with the engine (a Diagnostic Trouble Code has been set in the system memory. The light will be solid for an engine warning condition or will flash for an engine shutdown condition.

  • Page 54: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. High Exhaust System Temperature (HEST) (If Equipped) 4. Axles Set 6. Platform Overload 2. Engine Error Indicator 5. Platform Capacity 7. Boom Control System Warning 3. Glow Plug Indicator Figure 3-3. Ground Control Indicator Panel 3121734...
  • Page 55 6. Platform Overload Indicator (If Equipped) fault or failure has been detected. If a failure is discovered, the system must be repaired by JLG authorized service per- Indicates the platform has been over- sonnel before the machine can be used.

  • Page 56: Ground Control Console Display Gauge - Machines Using Diesel Exhaust Fluid (Def)

    (See Figure 3-7., Ground Control Console Display Gauge) The Display Gauge shows engine hours, fuel level (if applicable), and Diagnostic Trouble Codes (DTCs) from both the JLG Control System and the engine control system. During machine start up, with no active DTCs in the control system, the splash screen will show for 3 seconds and then switch to main screen.

  • Page 57: Diagnostic Screen

    The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count played to show active faults.

  • Page 58: Ground Control Console Display Gauge

    SECTION 3 - MACHINE CONTROLS AND INDICATORS INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE FORWARD ARROW NAVIGATE BACK ARROW NAVIGATION BUTTONS Figure 3-7. Ground Control Console Display Gauge 3121734 3-13...

  • Page 59: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console 2. Steer Select The action of the steering system is opera- (See Figure 3-8., Platform Control Console) tor selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is for normal driving at maximum speeds.

  • Page 60: Platform Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1001156926 A 1702566 B 1702565 B 1705745 B 1702938 1705170 A 1705171 A 1. Drive Speed/Torque Select 7. Boom Control Select 13. Main Telescope 19. Soft Touch/SkyGuard Indicator 2. Steer Select 8. Power/Emergency Stop 14.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Horn A push-type HORN switch supplies electrical ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF power to an audible warning device when pressed. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL.
  • Page 62 When this occurs the only choices are to swing in the opposite matic, lift and telescope movements are coordi- direction or switch to automatic mode. nated by the JLG control system and the automatic platform leveling feature is active 8. Power/Emergency Stop during lift, telescope, swing, and drive movements.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS 9. Start/Auxiliary Power 11. Drive Orientation Override When pushed forward, the switch energizes the When the boom is swung over the rear tires starter motor to start the engine. or further in either direction, the Drive Orien- tation indicator will illuminate when the drive function is selected.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Drive Joystick, pull up on the lock- 13. Main Telescope ing ring below the handle. Provides extension and retraction of the main boom. 14. Lights (If Equipped) Operates accessory light packages if the NOTE: The DRIVE control levers are spring-loaded and will automati- machine is so equipped.
  • Page 65 SECTION 3 - MACHINE CONTROLS AND INDICATORS 16. Soft Touch/SkyGuard Override Switch (If equipped) NOTE: 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 The machine can be equipped with one of three options.
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS 19. Soft Touch/SkyGuard Indicator (If Equipped) 22. Function Speed Control Indicates the Soft Touch bumper is against an object or the This control affects the speed of main boom SkyGuard sensor has been activated. All controls are cut out telescope, jib telescope, and jib lift.

  • Page 67: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 3. Platform Overload Indicator (If Equipped) Indicates the platform has been over- (See Figure 3-9., Platform Control Indicator Panel) loaded. 1. Level System Fault Indicator Indicates a fault in the electronic leveling 4.

  • Page 68: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Level System 6. Glow Plug 11. Wire Rope Service 2. AC Generator 7. Enable 12. Drive Orientation 3. Platform Overload 8. Fuel Level 13. Axles Set 4. Platform Capacity 9. Creep Speed 14.
  • Page 69 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Tilt Alarm Warning Light 7. Footswitch/Enable Indicator IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE BY BLOCKING OR ANY OTHER MEANS.

  • Page 70: Fuel Level Indicator

    10. System Distress Indicator The light indicates that the JLG Control System has detected an abnormal condi- tion and a Diagnostic Trouble Code has been set in the system memory.
  • Page 71 If the indicator remains lit, a boom control system fault or failure has been detected. If a failure is discovered, 13. Axles Set Indicator the system must be repaired by JLG authorized service per- sonnel before the machine can be used. Indicates that the axles are fully extended.
  • Page 72 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 73: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION HYDRAULIC SYSTEM WARM UP This machine is a mobile elevating work platform used to posi- The control system monitors the hydraulic system in extremely tion personnel, along with their necessary tools and materials at cold temperatures and provides optimal performance by auto- work locations.

  • Page 74: Boom Operating Characteristics And Limitations

    Recognized faults within this system will result in control by the Electrical Retrieval System, reduced function speeds, and Boom 5. Machine is as originally equipped from JLG. Control System (BCS) warning light illumination. After retrieval the boom will be restricted from leaving the transport position until the fault is resolved.

  • Page 75: Tower Path Control System

    SECTION 4 - MACHINE OPERATION Boom position violations outside of the allowable envelope will The restricted functions due to forward tower envelope viola- result in reduced function speeds, BCS warning light illumination, tions are disallowing automatic tower lift up with tower lift up and restriction of functions.

  • Page 76: Automatic Boom Control System

    SECTION 4 - MACHINE OPERATION Automatic Boom Control System Slow Down System The Automatic Boom Control System uses the envelope control To reduce the machine dynamics and improve operator control, sensors to enhance the control of the main boom during tower the control system uses the envelope control sensors to slow lift functions.

  • Page 77: Controlled Boom Angle System

    SECTION 4 - MACHINE OPERATION Controlled Boom Angle System Swing Speed Proportioning The Controlled Boom Angle System uses the envelope control Swing Speed Proportioning uses the envelope control sensors to sensors to enhance the control of the boom by minimizing the improve the comfort, speed and control of the turntable swing interaction of swing and drive functions with the envelope function.

  • Page 78: Stability

    SECTION 4 - MACHINE OPERATION Stability CAPACITY SELECT Machine stability is based on two (2) conditions which are called The Boom Control System allows the operator to select FORWARD and BACKWARD stability. The machine’s position of operation in a 600 lb. (272 kg for ANSI markets and 270 least FORWARD stability is shown in Figure 4-1., and its position kg for CE and Australia markets) capacity restriction of least BACKWARD stability is shown in Figure 4-2.

  • Page 79: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION JIB HORIZONTAL MAIN BOOM HORIZONTAL & 600LB. CAPACITY - EXTENDED 833.6" (21174 MM) 1000LB. CAPACITY - EXTENDED 738.4" (18757 MM) MACHINE WILL "TIP OVER" IN THIS TOWER BOOM DIRECTION IF OVERLOADED OR FULLY ELEVATED OPERATED ON AN OUT-OF-LEVEL SURFACE TOWER BOOM AT 68 DEGREES...
  • Page 80 SECTION 4 - MACHINE OPERATION 3121734...

  • Page 81: Engine Operation

    NOTE: After turning on ignition, operator must wait until glow plug indicator light goes out NOTE: Contact JLG Customer Service for operation under abnormal before cranking engine. conditions. NOTE: Initial starting should always be per- formed from the Ground Control con- sole.

  • Page 82: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION 3. Push the Engine Start switch until engine starts. 8. Push the Engine Start switch until engine starts. NOTE: Footswitch must be in released (up) position before ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED starter will operate.
  • Page 83 SECTION 4 - MACHINE OPERATION Air Shutoff Valve (ASOV) (If Equipped) Air Shutoff Valve (ASOV ) is an overspeed protection device DO NOT USE ASOV AS AN ALTERNATIVE TO SHUTTING DOWN MACHINE PROPERLY. mounted to the engine’s air intake system. When the valve is actuated, it obstructs airflow intake and stops the engine.

  • Page 84: Fuel Reserve / Shut-Off System

    The Fuel Shutoff System monitors the fuel in the tank and senses more fuel available. when the fuel level is getting low. The JLG Control System auto- matically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

  • Page 85: Selective Catalytic Reduction (Scr) - Machines Using Diesel Exhaust Fluid (Def)4-13

    SECTION 4 - MACHINE OPERATION SELECTIVE CATALYTIC REDUCTION (SCR) - MACHINES Standstill Cleaning USING DIESEL EXHAUST FLUID (DEF) The following conditions must be met to perform Standstill Cleaning. Selective Catalytic Reduction (SCR) is an emissions control used in diesel engines and requires operator interaction to ensure •...
  • Page 86 SECTION 4 - MACHINE OPERATION 4. The Main Cleaning process will begin and last for approxi- mately 30 to 60 minutes. The following screen will show that the process has begun and includes a status bar that indi- cates the progress of the cleaning process. 4-14 3121734...

  • Page 87: Methods

    SECTION 4 - MACHINE OPERATION 5. After the cleaning process is complete, the engine will run Cancelling Maintenance Standstill for approximately 5 minutes to allow the Engine and Maintenance Standstill Cleaning will be stopped immediately if: Exhaust After Treatment (EAT) to cool down. The Indicator Gauge will display the "Regen Complete"...

  • Page 88: Unsuccessful Cleaning Event

    SECTION 4 - MACHINE OPERATION Unsuccessful Cleaning Event If there is an unsuccessful cleaning event, The SCR icon will show on the display gauge. Possible causes of an Unsuccessful Clean- ing Event are: • Engine is not warmed up • DEF tank is frozen •...

  • Page 89: Maintenance Standstill Cleaning

    Derate Comments Levels Light Light Cleaning 0-500 Between 500 and 1000 hours, clean- Normal None ing cycle can be initiated with JLG Operation 500-1000 analyzer. Standstill 1000-1100 None Required Engine coolant temperature must 0.5 Hz be >40° C and DEF must be thawed before cleaning can be initiated.
  • Page 90 SECTION 4 - MACHINE OPERATION Table 4-2. Cleaning When Crystallization is Detected During SCR Machine Hours Cleaning Crystallization after System Distress SCR Cleaning Initiation Derate Levels Crystallization Light Light Methods No Crystallization Normal Operation None Detected Crystallization Detected SCR Switch None Standstill Required or Analyzer...

  • Page 91: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC- TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF See Figure 4-5., Grade and Side Slopes - Sheet 2 of 2 TRAVEL.

  • Page 92: Grade And Side Slopes - Sheet 1 Of 2

    SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Side Slopes - Sheet 1 of 2 4-20 3121734...

  • Page 93: Grade And Side Slopes - Sheet 2 Of 2

    SECTION 4 - MACHINE OPERATION Figure 4-5. Grade and Side Slopes - Sheet 2 of 2 3121734 4-21...

  • Page 94: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the 1. At Platform Controls, pull out Emergency Stop boom is swung beyond the rear drive tires and the machine may switch, start engine, and activate footswitch.

  • Page 95: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION Traveling on a Grade STEERING Position thumb switch on Drive/Steer controller to When traveling a grade, maximum braking and traction are obtained Right for steering right, or to Left for steering left. with the boom stowed, in position over the rear axle, and in line with the direction of travel.

  • Page 96: Platform

    SECTION 4 - MACHINE OPERATION PLATFORM Platform Rotation To rotate the platform to the left or right, use the Platform Level Adjustment Platform Rotate control switch to select the direc- tion and hold until desired position is reached. 4.10 BOOM ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM.

  • Page 97: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE To swing boom, use Swing control to select Right or SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL. Left direction. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE...

  • Page 98: Telescoping The Boom

    SECTION 4 - MACHINE OPERATION Telescoping the Boom 4.11 FUNCTION SPEED CONTROL This control affects the speed of main boom NOTE: The telescope function is not operable beyond the transport telescope, jib telescope, and jib lift. Turning the position if the axles are not fully extended. knob all the way counterclockwise until it clicks puts drive, main lift, platform rotate, and swing To extend or retract the main boom, use the Telescope...

  • Page 99: Skyguard™ Operation

    SECTION 4 - MACHINE OPERATION 4.13 SKYGUARD™ OPERATION SkyGuard SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- ation will reverse or cutout. The SkyGuard Function Table pro- vides more details on these functions. During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

  • Page 100: Skyguard - Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- nected. Operator passes through path of sensor beam. SkyGuard Function Table Drive Drive Tower Tower Tower Tower Boom Lift Boom Lift Boom Boom Basket...

  • Page 101: Emergency Towing

    SECTION 4 - MACHINE OPERATION 4.14 EMERGENCY TOWING 2. Disconnect drive hubs by inverting disconnect cap. 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.

  • Page 102: Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.15 SHUT DOWN AND PARK 4.16 LIFTING AND TIE DOWN To shut down and park the machine, the procedures are as fol- See Figure 4-8. lows: Lifting 1. Drive machine to a reasonably well protected area. 1.

  • Page 103: Tie Down

    SECTION 4 - MACHINE OPERATION Tie Down 4.17 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 2. Hold the Jib Swing control switch to the right until the plat- THE BOOM REST.

  • Page 104: Lifting And Tie Down Chart

    SECTION 4 - MACHINE OPERATION 8’ 4”/2.54 m 9’ 8”/2.95 m 18’ 0”/5.50 m 10’ 1"/3.08 m 23’ 6”/7.16 m 16’ 2“/4.94 m 39’ 8"/12.10 m 1001197350 C Figure 4-8. Lifting and Tie Down Chart 4-32 3121734...

  • Page 105: Decal Location Sheet 1 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Location Sheet 1 of 14 3121734 4-33...

  • Page 106: Decal Location Sheet 2 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Location Sheet 2 of 14 4-34 3121734...

  • Page 107: Decal Location Sheet 3 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Location Sheet 3 of 14 3121734 4-35...

  • Page 108: Decal Location Sheet 4 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Location Sheet 4 of 14 4-36 3121734...

  • Page 109: Decal Location Sheet 5 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Location Sheet 5 of 14 3121734 4-37...

  • Page 110: Decal Location Sheet 6 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-14. Decal Location Sheet 6 of 14 4-38 3121734...

  • Page 111: Decal Location Sheet 7 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-15. Decal Location Sheet 7 of 14 3121734 4-39...

  • Page 112: Decal Location Sheet 8 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-16. Decal Location Sheet 8 of 14 4-40 3121734...

  • Page 113: Decal Location Sheet 9 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-17. Decal Location Sheet 9 of 14 3121734 4-41...

  • Page 114: Decal Location Sheet 10 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-18. Decal Location Sheet 10 of 14 4-42 3121734...

  • Page 115: Decal Location Sheet 11 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-19. Decal Location Sheet 11 of 14 3121734 4-43...

  • Page 116: Decal Location Sheet 12 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-20. Decal Location Sheet 12 of 14 4-44 3121734...

  • Page 117: Decal Location Sheet 13 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-21. Decal Location Sheet 13 of 14 3121734 4-45...

  • Page 118: Decal Location Sheet 14 Of 14

    SECTION 4 - MACHINE OPERATION Figure 4-22. Decal Location Sheet 14 of 14 4-46 3121734...

  • Page 119: Decal Legend

    SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend English/ ANSI French/English Korean Chinese Portuguese Japan Australia Item # Spanish 1001197316-D 1001197318-D 1001197319-H 1001197320-D 1001197321-D 1001197322-D 1001197324-D 1001197325-H 1001197323-D 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701505 1701505 1701505 1701505 1701505...
  • Page 120 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend English/ ANSI French/English Korean Chinese Portuguese Japan Australia Item # Spanish 1001197316-D 1001197318-D 1001197319-H 1001197320-D 1001197321-D 1001197322-D 1001197324-D 1001197325-H 1001197323-D 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412...
  • Page 121 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend English/ ANSI French/English Korean Chinese Portuguese Japan Australia Item # Spanish 1001197316-D 1001197318-D 1001197319-H 1001197320-D 1001197321-D 1001197322-D 1001197324-D 1001197325-H 1001197323-D 1001131269 1001131269 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001197350 1001197350 1001197350...
  • Page 122 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend English/ ANSI French/English Korean Chinese Portuguese Japan Australia Item # Spanish 1001197316-D 1001197318-D 1001197319-H 1001197320-D 1001197321-D 1001197322-D 1001197324-D 1001197325-H 1001197323-D 1001229782 4-50 3121734...
  • Page 123 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 124: Section 5 - Lcd Display Panel

    SECTION 5 - LCD DISPLAY PANEL SECTION 5. LCD DISPLAY PANEL DESCRIPTION This machine utilizes an LCD display panel to assist the operator by supplying additional information during the operation of the machine. It is NOT a substitute for the Operation and Safety Man- ual, nor is it a replacement for thorough operational knowledge of the machine.

  • Page 125: Boot Up Splash Screen

    SECTION 5 - LCD DISPLAY PANEL BOOT UP SPLASH SCREEN When the machine is first powered on, the JLG boot up splash screen appears followed by three reminder screens. There is a reminder for the operator to wear a full body harness with a lan-...

  • Page 126: Lanyard Screen

    SECTION 5 - LCD DISPLAY PANEL Figure 5-4. Lanyard Screen Figure 5-5. Select Capacity Zone Screen 3121734...

  • Page 127: Machine Operating Screen

    SECTION 5 - LCD DISPLAY PANEL MACHINE OPERATING SCREEN images and trays. Each tray provides different machine informa- tion. After the reminder screens, the Machine Operating Screen will appear. The Machine Operating Screen consists of different 0 /0 DTC Tray Console Tray Icons Tray Machine Status Tray...

  • Page 128: Diagnostic Trouble Code (Dtc) Tray

    SECTION 5 - LCD DISPLAY PANEL Diagnostic Trouble Code (DTC) Tray • Key Switch Ground Mode • CAN Bus Lost This tray shows the total number of DTC’s and the DTC Text. If there are multiple DTC’s, the operator can scroll through the DTC •...

  • Page 129: Keyswitch In Ground Mode

    SECTION 5 - LCD DISPLAY PANEL KEYSWITCH IN GROUND MODE: If the keyswitch is set to ground mode, the display shows the Key Switch in Ground Mode Image. Figure 5-7. Keyswitch In Ground Mode Screen 3121734...

  • Page 130: Function Speed

    SECTION 5 - LCD DISPLAY PANEL 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 5-8.

  • Page 131: Can Bus Lost

    SECTION 5 - LCD DISPLAY PANEL CAN BUS LOST NOTE: There is no way to get the active DTCs so, the previously active DTCs will be scrolling along with the CAN Bus Communication When the control system senses a communication loss with any lost DTC.

  • Page 132: Take Foot Out

    SECTION 5 - LCD DISPLAY PANEL 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 5-10. Take Foot Out Screen 3121734...

  • Page 133: Put Foot In

    SECTION 5 - LCD DISPLAY PANEL PUT FOOT IN When put foot in DTC is active, the display shows Put Foot In image in the machine status tray. When the operator operates the machine without putting his foot on switch, Put Foot In DTC becomes active after timeout. Figure 5-11.

  • Page 134: Boom Control System (Bcs) Lamp On

    SECTION 5 - LCD DISPLAY PANEL BOOM CONTROL SYSTEM (BCS) LAMP ON NOTE: The available controls will be different among the different DTCs. The image below is ONLY for envelope violation. When the boom control system senses the platform is outside the operating area, the BCS Lamp will be ON.

  • Page 135: Bcs Lamp Screen

    SECTION 5 - LCD DISPLAY PANEL Figure 5-12. BCS Lamp Screen 5-12 3121734...

  • Page 136: Wire Rope Service

    SECTION 5 - LCD DISPLAY PANEL 5.10 WIRE ROPE SERVICE lamp is lit, the display shows a red octagon wire rope service indi- cator in the machine status tray. When the control system senses a loose or broken wire rope, the Wire Rope Service lamp on the platform panel is lit.

  • Page 137: Platform Level

    SECTION 5 - LCD DISPLAY PANEL 5.11 PLATFORM LEVEL this lamp is lit, the display shows a red octagon platform level DTC indicator in the machine status tray. Whenever the control system senses a DTC with the platform level, the platform level lamp is lit on the platform console. When Figure 5-14.

  • Page 138: Platform Overload

    SECTION 5 - LCD DISPLAY PANEL 5.12 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 5-15. Overload DTC Screen 3121734 5-15...

  • Page 139: Capacity Mode Error

    SECTION 5 - LCD DISPLAY PANEL 5.13 CAPACITY MODE ERROR completely telescoped out, and changes the capacity to Restricted mode), the capacity mode indicator icon will flash in If the operator selects the incorrect capacity mode for the jib con- the Machine Status tray every second.

  • Page 140: Chassis Status

    SECTION 5 - LCD DISPLAY PANEL 5.14 CHASSIS STATUS shown on the left side of the display or machine status tray. This image will be shown until the axles are extended. Axles Retracted In Transport Position When the axles are retracted regardless of engine state, the dis- play shows the following screen.

  • Page 141: Axles Extended

    SECTION 5 - LCD DISPLAY PANEL Axles Extended Engine state, the Axles Extended image will show up on the machine status tray for first 3 seconds. When the axles are extended for the first time (meaning previous state is retracted and current state is extended), regardless of the Figure 5-18.

  • Page 142: Axles Retracted In Out Of Transport Position

    SECTION 5 - LCD DISPLAY PANEL Axles Retracted In Out of Transport Position Axles In Transient State When the axles are retracted and the machine is in out of trans- When the operator is extending or retracting the axles, the Axles port position, the display will switch between axles extended and In Transient State screen will show and the arrows showing axle retracted every 0.5 seconds to tell the operator to extend the...

  • Page 143: Machine Tilted Mode

    SECTION 5 - LCD DISPLAY PANEL 5.15 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 5-20. Machine Tilted Mode Screen 5-20 3121734...

  • Page 144: Envelope Status

    SECTION 5 - LCD DISPLAY PANEL 5.16 ENVELOPE STATUS • The display shows animated boom length and boom angle information along with the envelope. Example 1: Platform is not at the edge of the envelope • Boom movement is proportional to the envelope bound- •...

  • Page 145: Unrestricted Mode Screen

    SECTION 5 - LCD DISPLAY PANEL 0 /0 Figure 5-21. Unrestricted Mode Screen 5-22 3121734...

  • Page 146: Restricted Mode Screen

    SECTION 5 - LCD DISPLAY PANEL 0 /0 Figure 5-22. Restricted Mode Screen 3121734 5-23...
  • Page 147 SECTION 5 - LCD DISPLAY PANEL • When operator switches from Unrestricted to Restricted • Display shows animated boom length and boom angle mode, the envelope shrinks to indicate reduced operating information along with the new envelope. envelope. • Boom movement is proportional to envelope boundaries. Example 2: Platform is edge of the envelope •...

  • Page 148: Machine Model Unknown

    1500SJ, nor 1850SJ the display will show the Machine Model Unknown image on the machine status tray. As soon as the machine is powered up, the control system checks the model of the machine and if the model is neither 1500AJP, Figure 5-23. Machine Model Unknown Screen 3121734...

  • Page 149: Selective Catalytic Reduction (Scr) Cleaning

    The SCR Warning Icon will display when cleaning is required. Refer to Section 4 for more information. The SCR Cleaning Icon will display when: • JLG Control System requests cleaning • Crystallization is detected • The machine is in cleaning mode •...

  • Page 150: Scr Cleaning Screen - Sheet 1 Of 2

    SECTION 5 - LCD DISPLAY PANEL DEF Level SCR Cleaning Icon SCR Warning Icon Figure 5-24. SCR Cleaning Screen - Sheet 1 of 2 3121734 5-27...

  • Page 151: Scr Cleaning Screen - Sheet 2 Of 2

    SECTION 5 - LCD DISPLAY PANEL DEF Level SCR Cleaning Icon SCR Warning Icon HEST Warning Icon Figure 5-25. SCR Cleaning Screen - Sheet 2 of 2 5-28 3121734...
  • Page 152 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 153: Section 6 - Emergency Procedures

    BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR- RECTLY. JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is EMERGENCY OPERATION evident, the factory should be contacted by telephone and pro- vided with all necessary details.

  • Page 154: Platform Or Boom Caught Overhead Or Boom Movement Prevented By Boom Control System

    SECTION 6 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead or Boom Movement EMERGENCY TOWING PROCEDURES Prevented by Boom Control System Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorpo- Lowering the boom onto an object or structure may cause the rated.

  • Page 155: Machine Safety System Override (Msso)(Ce Only)

    NOTE: If the MSSO functionality 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.
  • Page 156 SECTION 6 - EMERGENCY PROCEDURES NOTES: 3121734...

  • Page 157: Section 7 - Accessories

    SECTION 7 - ACCESSORIES SECTION 7. ACCESSORIES Table 7-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) SkyPower™ (7500W) √ √ √ √ √ √ √ SkyPower™ (4000W) √ √ √ √ √ √ √ SkyWelder™ √ √ √...

  • Page 158: Options/Accessories Relationship Table

    SECTION 7 - ACCESSORIES Table 7-2. Options/Accessories Relationship Table COMPATIBLE WITH INTERCHANGABLE ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH ( note 1) WITH (note 2) SkyPower (7500 watt generator SkyGlazier, SkyWelder, and Air line to platform) SkyCutter SkyWelder ( Stick welder) SkyPower SkyCutter Soft Touch, Pipe Jacks/Racks, SkyGlazier...

  • Page 159: Skypower

    SECTION 7 - ACCESSORIES CE Specs: 3-phase, 240-volt, 7.5kw, 18.3-amps, 1.0-pf INSTALLING OR REMOVING APPROVED ACCESSORIES OR CHANGING PLATFORM SIZE REQUIRES RECALIBRATION OF THE BOOM CONTROL SYSTEM (SEE SERVICE AND MAIN- 1-phase, 240 volt, 6.0kw, 26-amps, 1.0-pf TENANCE MANUAL). 1-phase, 120 volt, 6.0kw, 50-amps, 1.0-pf SKYPOWER™...

  • Page 160: Safety Precautions

    SECTION 7 - ACCESSORIES Safety Precautions SKYWELDER™ • Do not over load platform. The welder is capable of TIG and Stick welding and is capable at producing 200 Amps at 100% duty cycle or 250 Amps at 50% • Make sure no personnel are beneath platform. duty cycle.

  • Page 161: Skywelder™ - Sheet 1 Of 2

    SECTION 7 - ACCESSORIES WELDER WELDER SUPPORT FIRE EXTINGUISHER WELD LEADS Figure 7-1. SkyWelder™ - Sheet 1 of 2 3121734...

  • Page 162: Skywelder™ - Sheet 2 Of 2

    SECTION 7 - ACCESSORIES ON/OFF SWITCH OUTPUT LIGHT OVERTEMP LIGHT WELD PROCESS REMOVE COVER SELECTOR SWITCH TO SELECT VOLTAGE. AMPERAGE ADJUSTMENT VOLTAGE TO BE SET CONTROL (5-250 AMPS) AT 220/230 VAC REMOTE AMPERAGE CONTROL RECEPTACLE Figure 7-2. SkyWelder™ - Sheet 2 of 2 3121734...

  • Page 163: Accessory Ratings

    SECTION 7 - ACCESSORIES Accessory Ratings Table 7-3. Welding Characteristics Welding Amps Input At Rated Load Output. 50/60 Hz Welding Maximum Open Input Power Rated Output Amperage Mode Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2V. 30.5 15.7 35% Duty Cycle...

  • Page 164: Preparation And Inspection

    SECTION 7 - ACCESSORIES • Do not weld to platform. PIPE RACK • Do not ground through the platform. Pipe Racks provide a means of storage of pipe or conduit inside • Do not use a high frequency arc starter with TIG welder. the platform to help prevent rail damage and optimize platform utility.
  • Page 165 SECTION 7 - ACCESSORIES NOTE: Platform shown in phantom OVERRIDE SWITCH for clarity. OVERRIDE INDICATOR LIGHT RAIL BUMPER LIMIT SWITCH SOFT TOUCH RAIL & BUMPER SOFT TOUCH FRAME LIMIT SWITCH Figure 7-3. Soft Touch 3121734...

  • Page 166: Skyglazier

    SECTION 7 - ACCESSORIES SKYGLAZIER™ The SkyGlazier™ allows glaziers to efficiently position panels. The WITH THE SKYGLAZIER INSTALLED, THE ORIGINAL PLATFORM CAPACITY RATINGS glazier package consists of a tray that extends from the bottom of ARE REDUCED AS SHOWN IN TABLE 7-4, SPECIFICATIONS FOR SKYGLAZIER™. DO NOT the platform.

  • Page 167: Specifications

    SECTION 7 - ACCESSORIES Specifications Preparation and Inspection Check for cracked welds and damage to tray. Make sure tray is Table 7-4. Specifications for SkyGlazier™ properly secured to platform. Rated Rated Manua Check to ensure strap is not torn or frayed. Mark Capacity Wind...

  • Page 168: Skycutter

    SECTION 7 - ACCESSORIES SKYCUTTER duty cycle or 14A at 92 VDC @ 60% duty cycle. The Plasma Cutter will be capable of cutting up to a thickness of Accessory Ratings 3/8 in. metal and is capable of producing 27A at 92 VDC @ 35% Table 7-5.

  • Page 169: Safety Precautions

    SECTION 7 - ACCESSORIES Safety Precautions • Do not cut platform. • Do not ground through the platform. • Wear proper cutting apparel. DO NOT OVER LOAD PLATFORM. • Do not drive machine while connecting external air/gas sources. • Preparation and Inspection DE RATE THE PLATFORM BY 70LBS/32KG WHEN PLASMA CUTTER IS IN THE PLAT- •...

  • Page 170: Fall Arrest Platform

    FALL ARREST PLATFORM BOLT-ON EXTERNAL FALL ARREST NOTE: Refer to JLG External Fall Arrest System manual (P/N-3128935) The bolt-on external fall arrest system is designed to provide a lan- for more detailed information. yard attach point while allowing the operator to access areas outside the platform.

  • Page 171: Inspection Before Use

    SECTION 7 - ACCESSORIES Inspection Before Use The external fall arrest system must be inspected before each use of IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE the aerial work platform. Replace components if there are any signs DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY of wear or damage.

  • Page 172: Bolt-On External Fall Arrest Cable Tension

    SECTION 7 - ACCESSORIES • Cable: Inspect cable for proper tension, broken strands, kinks, or • Attachment Ring: No cracks or signs of wear are acceptable. Any any signs of corrosion. signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure GAP SHOWING: GAP SHOWING: there are no missing components and hardware is properly tight-...

  • Page 173: Bolt-On External Fall Arrest System

    SECTION 7 - ACCESSORIES 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 7-5. Bolt-On External Fall Arrest System 3121734 7-17...
  • Page 174 SECTION 7 - ACCESSORIES NOTES: 7-18 3121734...
  • Page 175 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 176: Section 8 - General Specifications & Operator Maintenance

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 8. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS AND PERFORMANCE DATA This section of the manual provides additional necessary infor- mation to the operator for proper operation and maintenance of Operating Specifications this machine.

  • Page 177: Dimensional Data

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-1. Operating Specifications Dimensional Data Weight Distribution: 28,881 lbs./27,749 lbs. Table 8-2. Dimensional Data Axles Deployed or Retracted (Front/Rear) (13,100 kg/12,587 kg) Turning Radius (Axles Retracted) Ground Bearing Pressure - Maximum 123 psi (8.65 kg/cm Outside 31 ft.

  • Page 178: Capacities

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-2. Dimensional Data Capacities Table 8-3. Capacities Horizontal Reach over end Unrestricted Capacity Zone 65 ft. 8 in. (20.01 m) Hydraulic Oil Tank 93 Gal. (352 L) Restricted Capacity Zone 57 ft. 8 in. (17.57 m) Fuel Tank 45 Gal.

  • Page 179: Engine Data

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Major Component Weights Table 8-5. Engine Data - Deutz TD 3.6L Type Turbo-charged Diesel DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT Number of Cylinders OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT Bore 3.9 in.

  • Page 180: Hydraulic Oil

    2700 hydraulic system service. at 40° C 55 cSt NOTE: Aside from JLG recommendations, it is not advisable to mix oils at 100° C 9.3 cSt of different brands or types, as they may not contain the same Viscosity Index required additives or be of comparable viscosities.

  • Page 181: Mobil Dte 10 Excel 32 Specs

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-9. Mobil DTE 10 Excel 32 Specs Table 8-10. UCon Hydrolube HP-5046 ISO Viscosity Grade Type Synthetic Biodegradable Specific Gravity 0.877 Specific Gravity 1.082 Pour Point, Max Pour Point, Max -58°F (-50°C) -40°F (-40°C) Flash Point, Min.

  • Page 182: Mobil Eal H 46 Specs

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-11. Mobil EAL H 46 Specs Table 8-12. Mobil EAL 46 Specs Type Synthetic Biodegradable Type Synthetic Biodegradable ISO Viscosity Grade ISO Viscosity Grade Density at 15° C .874 Density at 15° C Pour Point -49°F (-45°C) Pour Point...

  • Page 183: Exxon Univis Hvi 26 Specs

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-14. Quintolubric 888-46 Table 8-13. Exxon Univis HVI 26 Specs Density Specific Gravity 32.1 0.92 g/cm Pour Point -76°F (-60°C) Pour Point <-30°C (<-22°F) Flash Point 217°F (103°C) Flash Point 300°C (572°F) Viscosity Fire Point 360°C (680°F)

  • Page 184: Engine Operating Temperature Specifications

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 8-1. Engine Operating Temperature Specifications 3121734...

  • Page 185: Hydraulic Oil Operation Chart - Sheet 1 Of 2

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE HYDRAULIC FLUID OPERATION CHART MACHINE OPERAT ION USING NON-JLG APPROVED HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF T HE T EMPERAT URE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMAT URE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.

  • Page 186: Hydraulic Oil Operation Chart - Sheet 2 Of 2

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fluid Properties Base Classifications Mobilfluid 424 Mobil DTE 10 Excel 32 Univis HVI 26 Mobil EAL Hydraulic Oil Mobil EAL Envirosyn H46 Quintolubric 888-46 * Readily biodegradable classification indicates one of the following: CO2 Conversion >...
  • Page 187 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9,10 11,18 Figure 8-4. Maintenance and Lubrication Diagram 8-12 3121734...

  • Page 188: Maintenance And Lubrication

    Engine (crankcase) API CJ-4 Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within -45° to Lube® 450°F (-43° to 232° C). JLG P/N 3020042. Lube Point(s) - 3 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hours of operation Comments - Apply grease and rotate in 45 degree intervals until bearing is completely lubricated.
  • Page 189 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Gearbox 3. Wheel Drive Hub Lube Point(s) - Level/Fill Plug Capacity - 2.6 quarts (2.5 liters) ± 10% Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Lube Point(s) - Fill Plug Capacity - 3 qt.
  • Page 190 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter 5. Hydraulic Tank Breather Interval - Change after first 50 hrs. and every 6 months or 300 Lube Point(s) - Replaceable Element hrs. thereafter. Interval - Change after first 50 hours and every 6 months or 300 hours thereafter.
  • Page 191 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Charge Filter 7. High Pressure Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 6 months or Interval - Change after first 50 hours and every 6 months or 300 hours thereafter.
  • Page 192 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Hydraulic Oil 9. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap Capacity - 93 Gallons (352 liters) Tank to Full Mark Lube Point(s) - Fill Cap/Spin-on Element 124 Gallons (469.3 L) System Capacity - 9.4 Quarts (8.9 L) Lube - HO Lube - EO...
  • Page 193 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. Fuel Pre-Filter 10. Fuel Filter - Deutz Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every year or 500 hours of operation Interval - Every year or 500 hours of operation 8-18 3121734...
  • Page 194 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Air Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments - Check dust valve for dirt daily 13.
  • Page 195 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 15. Diesel Exhaust Fluid (DEF) (If Equipped) 16. DEF Supply Module Filter (If Equipped) Interval - 500 hours or 2 years, whichever comes first Lube Point - Fill Cap Lube - DEF Capacity - 5.7 gal.
  • Page 196 SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 17. Platform Filter 18. Optional Fuel Filter/Water Separator Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation Lube Point - Replaceable Element Interval - Change after first 50 hours and then every year or 600 hours of operation, whichever comes first 3121734 8-21...

  • Page 197: Tires & Wheels

    Tire Replacement Tire Damage JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular For polyurethane foam filled tires, JLG Industries, Inc.

  • Page 198: Wheel Replacement

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement 1. Start all wheel bolts by hand to prevent cross threading. DO NOT use a lubricant on threads. The rims installed on each product model have been designed for 2. Tighten wheel bolts in the following sequence: stability requirements which consist of track width, tire pressure, and load capacity.

  • Page 199: Wheel Torque Chart

    SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-16. Wheel Torque Chart SUPPLEMENTAL INFORMATION TORQUE SEQUENCE The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC 1st Stage 2nd Stage 3rd Stage and is only applicable to CE machines. 35 ft.
  • Page 200 SECTION 9 - INSPECTION AND REPAIR LOG SECTION 9. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 9-1. Inspection and Repair Log Date Comments 3121734...
  • Page 201 SECTION 9 - INSPECTION AND REPAIR LOG Table 9-1. Inspection and Repair Log Date Comments 3121734...
  • Page 203 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

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