JLG 1250AJP Operation And Safety Manual
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JLG 1250AJP 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
1250AJP
AS/NZS
ANSI
3121170
November 5, 2018 - Rev T
®

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 1250AJP AS/NZS ANSI 3121170 November 5, 2018 - Rev T ®...
  • 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 FOREWORD REVISION LOG Original Issue A - March 1, 2004 Revised Q - March 23, 2018 Revised B - May 4, 2005 Revised R - May 30, 2018 Revised C - January 12, 2006 Revised S - June 29, 2018 - Revised Covers, Prop 65 Revised D - May 9, 2006 Revised...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS Function Check........2-8 SkyGuard Function Test.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE AUXILIARY POWER OPERATION ..... 4-10 SkyGuard - SkyLine ....... 4-22 CAPACITY SELECT.
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE PIPE RACKS ......... . 6-3 Safety Precautions .
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Tire Replacement....... . . 7-35 Wheel and Tire Replacement .
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-4 Sheet 2 of 54-42 3-1.
  • Page 13 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121170...
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 7-19 Lubrication Specifications ......7-18 Beaufort Scale (For Reference Only).
  • Page 15 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121170...

  • 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 nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 29 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121170...
  • Page 30 @ 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 31: 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, drop-offs.

  • Page 32: 2.2 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. 3121170...
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Front Drive\Steer Wheels 2. Rear Drive\Steer Wheels 3. Tower Lift Cylinder 4. Ground Console 5. Tower Base Boom Section 6. Tower Mid Boom Section 7. Tower Fly Boom Section 8. Tower Boom Assembly 9.

  • Page 35: 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 36: Daily Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Daily Walk-Around Inspection 3121170...
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 5. Wheel/Tire Assemblies - Properly secured, no missing lug nuts. Inspect for worn tread, cuts, tears or other discrepan- cies. Inspect wheels for damage and corrosion. Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram.

  • Page 38: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the stowed position: a. Drive the machine on a grade, not to exceed the rated Perform the Function Check as follows: gradeability, and stop to ensure the brakes hold; 1.

  • Page 39: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test NOTE: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing. NOTE: Refer to Section 4.14 for additional information on SkyGuard 4. Disengage the SkyGuard sensor, release controls, then recy- operation.

  • Page 40: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 6. Have an assistant check to see that left front or right rear wheel remains elevated in position off of the ground. The front axles will oscillate when the boom is in the transport posi- 7.

  • Page 41: 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 42 @ 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 43: Ground Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Tower Lift Control Provides raising and lowering of the tower boom. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE 4.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Main Boom Telescope 3. Tower Boom Lift 4. Swing 5. Main Boom Lift 6. Jib Lift 7. Platform Leveling Override 8. Platform Rotate 9. Jib Swing 10. Platform/Ground Select Switch 11.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Main Boom Telescope 3. Tower Boom Lift 4. Swing 5. Main Boom Lift 6. Jib Lift 7. Platform Leveling Override 8. Platform Rotate 9. Jib Swing 10. Platform/Ground Select Switch 11.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Platform Rotate 11. Hourmeter Allows rotation of the platform. Registers the amount of time the machine has been in use, with engine running. By connecting into the oil pressure cir- 9. Jib Swing cuit of the engine, only engine run hours are recorded.
  • Page 47 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Auxiliary power only works if there is no engine oil pressure, and 14. Machine Safety System Override (MSSO) (CE is disabled if engine is running. Only) Functions will operate at a slower than normal rate because of Provides emergency override of function the reduced hydraulic flow.

  • Page 48: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 4. Engine Oil Temperature Indicator Indicates the temperature of the engine oil, which also (See Figure 3-3., Ground Control Indicator Panel) serves as engine coolant, is abnormally high and service is required.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Charging 4. High Engine Oil Temp. 7. Platform Capacity 2. Low Engine Oil Pressure 5. Glow Plug Indicator 8. Platform Overload 3. High Engine Coolant Temp. 6. Axles Set 9. Boom Control System Warning Figure 3-3.

  • Page 50: Platform Station

    If the indicator remains lit, a boom control system fault or failure has been detected. If a failure is discovered, the system must be repaired by JLG authorized service personnel before the machine can be used.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Power/Emergency Stop 7. Lights 13. Platform Rotate 19. Platform Level Override 2. Engine Start / Aux Power 8. Jib Lift 14. Jib Stow Override 20. Axle Extend/Retract 3. Capacity Select 9. Soft Touch/SkyGuard Override 15.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Start/Auxiliary Power 4. Drive Orientation Override When pushed forward, the switch energizes the starter When the boom is swung over the rear tires or further in motor to start the engine. either direction, the Drive Orientation indicator will illumi- nate when the drive function is selected.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Main Telescope If equipped with SkyGuard, the switch enables functions cut out by the Sky- Allows extension and retraction of the main boom. guard system to be operated again, allowing the operator to resume use of 7.
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Soft Touch/SkyGuard Indicator (If Equipped) NOTE: To operate the Main Lift/Swing Joystick, pull up on the locking ring below the handle. Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When boom is positioned above transport position or telescoped 18. Steer Select out and any of the following switches, DRIVE SPEED/TORQUE SELECT or FUNCTION SPEED, are positioned to HIGH, high func- The action of the steering system is operator selectable. The tion speeds are automatically cut out and the machine contin- center switch position gives conventional front wheel steer- ues to operate at a lower speed.

  • Page 56: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 20. Axle Extend/Retract Platform Control Indicator Panel Allows the operator to extend or retract the axles. The axles (See Figure 3-5., Platform Control Indicator Panel) can only be extended or retracted while the machine is being driven forward or reverse.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Level System 6. Glow Plug 11. Drive Orientation 2. AC Generator 7. Enable 12. Axles Set 3. Platform Overload 8. Fuel Level 13. Boom Control System Warning 4. Platform Capacity 9. Creep Speed 5.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Platform Capacity Indicator 6. Glow Plug/Wait to Start Indicator NOTE: If the engine fails to start due to cold temperatures or excessive Indicates the maximum platform capacity selected for the amounts of smoke are produced on startup, wait for the glow platform.
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Footswitch/Enable Indicator NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more detailed information concerning the Low Fuel Indicator. 8. Fuel Level Indicator TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
  • Page 60 10. System Distress Indicator Indicates the platform is outside the operating area and The light indicates that the JLG Control System has detected operation of certain boom functions may be disabled (i.e. a malfunction and a Diagnostic Trouble Code has been set in lift, telescope).
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-20 3121170...
  • Page 62 @ 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 63: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in This machine is a mobile elevating work platform used to posi- both forward and reverse directions.

  • Page 64: Hydraulic System Warm Up

    Functions being operated when the warm up mode turns off will 4. All machine systems are functioning properly. remain in the creep speed until the function is re-initiated. 5. Proper tire pressure. 6. Machine is as originally equipped from JLG. 3121170...

  • Page 65: Envelope Control System

    SECTION 4 - MACHINE OPERATION Envelope Control System scope out without auto tower lift up) or the tower lift down switch (tower lift down without auto tower telescope in). A back- The Envelope Control System is the primary means of controlling ward tower path violation can be resolved by operating the tower the working positions of the tower and main boom within the lift up switch (tower lift up without auto tower telescope out) or...

  • Page 66: Tower Path Control System

    SECTION 4 - MACHINE OPERATION Tower Path Control System The Tower Path Control System uses the envelope control sensors to enhance the control of the tower boom for increased user effi- ciency and is used as an integral part of the envelope control sys- tem.

  • Page 67: Automatic Main Boom Control System

    SECTION 4 - MACHINE OPERATION Automatic Main Boom Control System TOWER LIFT UP - MAIN BOOM ABOVE 60° During tower lift up with the main boom already above 60°, the During combined tower lift and main lift functions, the control control system will delay automatic compensation of the main system will maintain the tower lift speed and automatically vary boom angle during tower lift until the main boom reaches...

  • Page 68: Controlled Angle

    SECTION 4 - MACHINE OPERATION Controlled Angle Swing Speed Proportioning The Controlled Boom Angle System minimizes the interaction of The boom control system sensors sense the distance the platform swing and drive functions with the envelope edges. This interac- is extended from the centerline of rotation, allowing higher tion is due to two factors.
  • Page 69 SECTION 4 - MACHINE OPERATION MAIN BOOM FULLY EXTENDED MACHINE WILL TIP OVER IN DIRECTION OF ARROWS IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE TOWER BOOM FULLY LOWERED TO FULLY RAISED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-2. Position of Least Forward Stability 3121170...
  • Page 70 SECTION 4 - MACHINE OPERATION 3121170...
  • Page 71 SECTION 4 - MACHINE OPERATION 3121170...

  • Page 72: Auxiliary Power Operation

    SECTION 4 - MACHINE OPERATION AUXILIARY POWER OPERATION CAPACITY SELECT The Auxiliary Power System provides a means of moving the plat- The Boom Control System allows the operator to select operation form in the event of an engine malfunction. This system uses an in a 500 lb.
  • Page 73 SECTION 4 - MACHINE OPERATION 3121170 4-11...

  • Page 74: Engine Operation

    2. After engine has had sufficient time to warm up, shut engine off. NOTE: Contact JLG Customer Service for operation under abnormal 3. Turn SELECT switch to PLATFORM. conditions. 4. From Platform, pull POWER/EMERGENCY STOP switch out,...

  • Page 75: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION Shutdown Procedure Air Shutoff Valve (ASOV) (If Equipped) Air Shutoff Valve (ASOV ) is an overspeed protection device mounted to the engine’s air intake system. When the valve is IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE actuated, it obstructs airflow intake and stops the engine.

  • Page 76: Fuel Reserve / Shut-Off System

    JLG Mechanic to verify your machine setup. The Fuel Shutoff System monitors the fuel in the tank and senses 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 77 The operator can repeat this process until there is no more fuel available. CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE. • Engine Stop - The engine will shut down. No restarts will be permitted until fuel is added to the tank.

  • Page 78: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) See Figure 4-7., Grade and Side Slopes NOTE: Refer to the Operating Specifications table for Gradeability and Sideslope ratings. All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and Traveling is limited by two factors: retracted.
  • Page 79 SECTION 4 - MACHINE OPERATION Figure 4-7. Grade and Side Slopes 3121170 4-17...

  • Page 80: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse Traveling on a Grade 1. At Platform Controls, pull out Emergency Stop switch, start When traveling a grade, maximum braking and traction are obtained engine, and activate footswitch. with the boom stowed, in position over the rear axle, and in line with the direction of travel.

  • Page 81: Steering

    SECTION 4 - MACHINE OPERATION STEERING Position the Platform/Level control switch Up or Down and hold until the desired platform position is obtained. Position thumb switch on Drive/Steer controller to RIGHT for Platform Rotation steering right, or to LEFT for steering left. To rotate the platform to the left or right, use the Platform Rotate EXTENDING THE AXLES control switch to select the direction and hold until desired posi-...

  • Page 82: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom Telescoping the Main Boom To swing boom, use Swing control to select Right or Left direc- NOTE: The telescope function is not operable beyond the transport tion. position if the axles are not fully extended. To extend or retract the main boom, use the Telescope Control Switch to select In or Out movement.

  • Page 83: Swinging The Jib

    SECTION 4 - MACHINE OPERATION Swinging the Jib 4.13 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) NOTE: For 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Australia markets) mode operation, the jib must be centered The Machine Safety System Override (MSSO) is and the Jib Swing function is not operable.

  • Page 84: 4.14 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.14 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 85: 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 Tower Boom Drive Drive Tower Tower Tower Boom Boom Boom Basket Basket Steer...

  • Page 86: 4.15 Emergency Towing

    SECTION 4 - MACHINE OPERATION 4.15 EMERGENCY TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H.

  • Page 87: 4.16 Shut Down And Park

    1. The weight of the machine is stamped on the serial number plate. If the plate is missing or illegible, call JLG Industries or 1. Drive machine to a reasonably well protected area. weigh the individual unit to find out the Gross Vehicle 2.

  • Page 88: Tie Down

    SECTION 4 - MACHINE OPERATION Tie Down 4.18 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 89 SECTION 4 - MACHINE OPERATION 9’-9”/2.97 m 6’-9”/2.06 m 16’-6”/5.03 m 15’-11”/4.85 m 21’-8”/6.60 m 37’-7”/11.46 m 1705838 B Figure 4-10. Lifting and Tie Down Chart 3121170 4-27...
  • Page 90 SECTION 4 - MACHINE OPERATION ANSI & DUAL LANGUAGE AUS ONLY ANSI & DUAL BOTH SIDES LANGUAGE AUS ONLY BOTH SIDES BOTH SIDES Figure 4-11. Decal Location Sheet 1 of 5 4-28 3121170...
  • Page 91 SECTION 4 - MACHINE OPERATION SECTION Figure 4-12. Decal Location Sheet 2 of 5 3121170 4-29...
  • Page 92 SECTION 4 - MACHINE OPERATION AUS ONLY ANSI ONLY! DECAL MOUNT FOR DOM DECAL MOUNT FOR DUAL LANGUAGE Figure 4-13. Decal Location Sheet 3 of 5 4-30 3121170...
  • Page 93 SECTION 4 - MACHINE OPERATION AUS ONLY ANSI & DUAL LANGUAGE ANSI & DUAL LANGUAGE AUS ONLY ANSI & DUAL LANGUAGE AUS ONLY TIER IVF VIEW Figure 4-14. Decal Location Sheet 4 of 5 3121170 4-31...
  • Page 94 SECTION 4 - MACHINE OPERATION CE ONLY ANSI & DUAL ANSI ONLY LANGUAGE DUAL LANGUAGE ONLY DANGER DANGER WARNING WARNING ANSI & DUAL LANGUAGE ONLY Figure 4-15. Decal Location Sheet 5 of 5 4-32 3121170...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - Prior to S/N 0300141446 English/ Item # ANSI Korean Chinese Portuguese French/English CE/Australian Japan Spanish 0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7 0274726-8 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - Prior to S/N 0300141446 English/ Item # ANSI Korean Chinese Portuguese French/English CE/Australian Japan Spanish 0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7 0274726-8 1702153 1705901 1704007 1704006 1703953 1703953 1703943 1705903 1703941 1703942...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - Prior to S/N 0300141446 English/ Item # ANSI Korean Chinese Portuguese French/English CE/Australian Japan Spanish 0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7 0274726-8 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972 1705511 1705511...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - Prior to S/N 0300141446 English/ Item # ANSI Korean Chinese Portuguese French/English CE/Australian Japan Spanish 0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7 0274726-8 4-36 3121170...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - S/N 0300141446 to Present English/ Item # ANSI Korean Chinese Portuguese French/English Australian Japan Spanish 0274722-F 0274723-E 0274724-E 0274725-E 0274727-E 1001114383-E 0274729-E 0274726-E 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - S/N 0300141446 to Present English/ Item # ANSI Korean Chinese Portuguese French/English Australian Japan Spanish 0274722-F 0274723-E 0274724-E 0274725-E 0274727-E 1001114383-E 0274729-E 0274726-E 1702153 1703953 1703953 1703943 1705903 1703941 1703942 1703944 1702868 1702868...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - S/N 0300141446 to Present English/ Item # ANSI Korean Chinese Portuguese French/English Australian Japan Spanish 0274722-F 0274723-E 0274724-E 0274725-E 0274727-E 1001114383-E 0274729-E 0274726-E 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1706062 1705511 1705511...
  • Page 102 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - S/N 0300141446 to Present English/ Item # ANSI Korean Chinese Portuguese French/English Australian Japan Spanish 0274722-F 0274723-E 0274724-E 0274725-E 0274727-E 1001114383-E 0274729-E 0274726-E 1001112551 1001223055 1001224048 1001224050 1001224049 1001223971 1001224053 4-40 3121170...
  • Page 103 SECTION 4 - MACHINE OPERATION Figure 4-16. Decal Location - S/N 0300141446 to Present - CE Only - Sheet 1 of 5 3121170 4-41...
  • Page 104 SECTION 4 - MACHINE OPERATION SECTION Figure 4-17. Decal Location - S/N 0300141446 to Present - CE Only - Sheet 2 of 5 4-42 3121170...
  • Page 105 SECTION 4 - MACHINE OPERATION 61 62 Figure 4-18. Decal Location - S/N 0300141446 to Present - CE Only - Sheet 3 of 5 3121170 4-43...
  • Page 106 SECTION 4 - MACHINE OPERATION Figure 4-19. Decal Location - S/N 0300141446 to Present - CE Only - Sheet 4 of 5 4-44 3121170...
  • Page 107 SECTION 4 - MACHINE OPERATION Figure 4-20. Decal Location - S/N 0300141446 to Present - CE Only - Sheet 5 of 5 3121170 4-45...
  • Page 108 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - S/N 0300141446 to Present - CE Only Item # Table 4-3. Decal Legend - S/N 0300141446 to Present - CE Only 0274728-G Item # 0274728-G 1705921 1701499 1705822 1701518 1705961 1701509 1705828 1701529...
  • Page 109 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - S/N 0300141446 to Present - CE Only Table 4-3. Decal Legend - S/N 0300141446 to Present - CE Only Item # Item # 0274728-G 0274728-G 1705511 1701501 1702773 1705864 3121170 4-47...
  • Page 110 SECTION 4 - MACHINE OPERATION NOTES: 4-48 3121170...

  • Page 111: Section 5 - 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 112: Platform Or Boom Caught Overhead Or Boom Movement Prevented By Boom Control System

    SECTION 5 - 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 113: 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 114 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121170...
  • Page 115 @ 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 116: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Fall Arrest Platform (36" x 72") √ √ √ Fall Arrest Platform (36" x 96") √ Pipe Racks √ √ SkyCutter™ √...
  • Page 117 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Platform MMR**, Platform MTR*, SkyCutter™, SkyGlazier™, Pipe Racks SkyPower™ Soft Touch SkyWelder™ 4’ Platform, Pipe Racks, Platform SkyCutter™ SkyPower™...

  • Page 118: Fall Arrest Platform

    TENANCE MANUAL). FALL ARREST PLATFORM NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform.

  • Page 119: Capacity Specifications (Australia Only)

    SECTION 6 - ACCESSORIES Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform. • Do not exit platform over rails or stand on rails. Max. Platform Capacity Max. Capacity in Racks • Do not drive machine without material secured (With Max.

  • Page 120: Skycutter

    SECTION 6 - ACCESSORIES SKYCUTTER™ Safety Precautions DO NOT OVERLOAD PLATFORM. DE-RATE THE PLATFORM BY 70 LBS (32 KG) WHEN PLASMA CUTTER IS IN PLATFORM. • Check for cracked welds and damage to plasma supports. • Check for secure installation of cutter and bracket. •...

  • Page 121: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Amperes Input @ Plasma Gas Flow/ Rated Cutting Spec. Rated Output Rated Output, 60 kVa/kW Plasma Gas Max. OCV Pressure Capacity @ 10 IPM Hz, 1-Phase 120 Volts ±10% 27 A @ 91 VDC @ 20% 28.8 max;...

  • Page 122: Skyglazier

    SECTION 6 - ACCESSORIES SKYGLAZIER™ Capacity Specifications Max. Platform Capacity Capacity Zone * Max. Tray Capacity (With Max. Weight in Tray) 500 lbs 150 lbs 250 lbs (227 kg) (68 kg) (113 kg) 550 lbs 150 lbs 250 lbs (250 kg) (68 kg) (113 kg) 600 lbs...

  • Page 123: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Preparation and Inspection • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. ENSURE PANEL IS SECURED WITH STRAP. • Ensure strap is not torn or frayed. Operation DO NOT OVERLOAD TRAY OR PLATFORM.

  • Page 124: Skypower

    SECTION 6 - ACCESSORIES SKYPOWER™ All power regulation components are located in a watertight box connected by cable to the generator. The generator supplies power when running at the specified speed with the power switch on (switch is located on platform). A three-pole, 30 Amp circuit breaker protects the generator from overload.

  • Page 125: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions SKYWELDER™ DO NOT OVERLOAD PLATFORM. • Ensure no personnel are beneath platform. • This factory-installed option is available only on specified models. • Keep lanyard attached at all times. • Do not use electrical tools in water. •...

  • Page 126: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Welding Amps Input At Rated Load Output (50/60 Hz) Maximum Open Welding Mode Input Power Rated Output Amperage Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2 V, 15.7 35% Duty Cycle 3- phase 5-250 A 79 VDC...

  • Page 127: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Use correct rod size and current settings. • Do not use electrical cords without ground. • Do not use electrical tools in water. DO NOT OVERLOAD PLATFORM. • Do not weld to the platform. •...

  • Page 128: Soft Touch

    SECTION 6 - ACCESSORIES SOFT TOUCH BOLT-ON EXTERNAL FALL ARREST The bolt-on external fall arrest system is designed to provide a lan- A padding kit is mounted to the platform rails and to a frame sus- yard attach point while allowing the operator to access areas outside pended below the platform.

  • Page 129: Inspection Before Use

    SECTION 6 - 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 130 SECTION 6 - 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 131 SECTION 6 - 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 6-2. Bolt-On External Fall Arrest System 6-16 3121170...

  • Page 132: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. 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 Table 7-1.
  • Page 133 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications - Prior to S/N 0300141446 Table 7-2. Operating Specifications - S/N 0300141446 to Present Maximum Wind Speed 28 mph (12.5 m/s) JibPLUS Length 8ft. (2.44m) Maximum Manual Force 400 N Horizontal Motion 125°...

  • Page 134: Dimensional Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Chassis Table 7-3. Dimensional Data Table 7-4. Chassis Specifications Overall Width Maximum Travel Grade With boom in stowed Axles Retracted 8ft. 2in. (2.49 m) position (Gradeability) 12ft. 6in. (3.8 m) Axles Extended Maximum Travel Grade With boom in stowed 5°...

  • Page 135: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Tires Table 7-6. Tire Specifications Table 7-5. Capacities Size 445/50D710 Hydraulic Tank 53.3 gallons (201.7 liters) Load Range Fuel Tank 31 gallons (117 liters) Ply Rating Hydraulic System 65.4 gallons (247.5 liters) Foam Fill Polyurethane HD (55 Durometer) Foam Drive Hub...

  • Page 136: Engine Data - Deutz 2011 Prior To S/N 0300127698

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data - Deutz 2011 Prior to S/N 0300127698 Engine Data - Deutz 2011 S/N 0300127698 to Present Table 7-7. Deutz BF4M2011 Specifications Table 7-8. Deutz TD2011L4 Specifications Type Liquid Cooled Type Liquid Cooled Number of Cylinders Number of Cylinders...

  • Page 137: Engine Data - Caterpillar

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data - Deutz TCD2.9L4 Engine Data - Caterpillar Table 7-9. Deutz TCD2.9L4 Specifications Table 7-10. Caterpillar 3.4T Type Liquid Cooled Type Liquid Cooled, Antifreeze Number of Cylinders Number of Cylinders Bore 3.6 in.

  • Page 138: Hydraulic Oil

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of differ- ent brands or types, as they may not contain the same required addi- Table 7-11. Hydraulic Oil Specifications tives or be of comparable viscosities.
  • Page 139 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-14. UCon Hydrolube HP-5046 Table 7-13. Mobil DTE 10 Excel 32 Specs Type Synthetic Biodegradable ISO Viscosity Grade Specific Gravity 1.082 Specific Gravity 0.877 Pour Point, Max -58°F (-50°C) Pour Point, Max -40°F (-40°C) Flash Point, Min.
  • Page 140 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-15. Exxon Univis HVI 26 Specs Table 7-16. Mobil EAL H 46 Specs Specific Gravity 32.1 Type Synthetic Biodegradable Pour Point -76°F (-60°C) ISO Viscosity Grade Flash Point 217°F (103°C) Density at 15° C .874 Viscosity Pour Point...
  • Page 141 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Major Component Weights Table 7-17. Mobil EAL 46 Specs Table 7-18. Component Weights Type Synthetic Biodegradable Component Pounds Kilograms ISO Viscosity Grade Tire & Wheel Density at 15° C Drive Hub & Motor 275.5 Pour Point -27°F (-33°C)
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-1. Engine Operating Temperature Specifications 3121170 7-11...
  • Page 143 SECTION 7 - 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 144 SECTION 7 - 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 145 ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND...
  • Page 146 (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES AMBIENT TEMPERATURE 110°...
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11A,12 15,19 Figure 7-6. Operator Maintenance and Lubrication Diagram - Deutz 2011/CAT Engines 7-16 3121170...
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-7. Operator Maintenance and Lubrication Diagram - Deutz 2.9 Engine 3121170 7-17...

  • Page 149: Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE 1. Swing Bearing - Remote Lube NOTE: The following numbers correspond to those in Figure 7-6., Oper- ator Maintenance and Lubrication Diagram - Deutz 2011/CAT Engines. Table 7-19. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350°...
  • Page 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Gearbox 3. Swing Brake Lube Point(s) - Fill Plug Lube Point(s) - Fill Plug Capacity - 79 ounces (2.3 L) Capacity - 2.7 ounces (80 ml) Lube - GL-5 Lube - DTE24 Interval - Check level every 150 hrs/Change every 1200 Interval - Check level every 150 hrs/Change every 1200 hours of operation.
  • Page 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. A. Wheel Drive Hub (Prior to S/N 100128) B: Wheel Drive Hub - Bonfiglioli (S/N 100128 to Present) Lube Point(s) - Level/Fill Plug Lube Point(s) - Level/Fill Plug Capacity - 0.5 liters (1/2 full) Capacity - 2.1 quarts (2 liters) ±...
  • Page 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to Pres- 5. Hydraulic Return Filter ent) (See Figure 7-8., Hydraulic Return Filter Condition Indicator - Prior to S/N 139396 and Figure 7-9., Hydraulic Return Filter Condition Indicator - S/N 139396 to Present) Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours...
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE A - Red = Filter Restricted; Filter Bypassed B - Green = Filter Good; Not Restricted Figure 7-8. Hydraulic Return Filter Condition Indicator - Prior to S/N 139396 7-22 3121170...
  • Page 154 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Red = Filter Restricted; Filter Bypassed Green = Filter Good; Not Restricted Figure 7-9. Hydraulic Return Filter Condition Indicator - S/N 139396 to Present 3121170 7-23...
  • Page 155 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Charge Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator (if equipped) 7-24 3121170...
  • Page 156 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7. Main Valve Filter 8. Hydraulic Oil FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours thereafter 1705511 B Lube Point(s) - Fill Cap Capacity - 55 gallons (208 liters) Tank...
  • Page 157 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Suction Strainers (In Tank) 10. A. Oil Change w/Filter - Deutz 2011 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts (10.5 L) w/Filter Lube - EO Interval - Check level daily; change every 500 hours or six Lube Point(s) - 2 months, whichever comes first.
  • Page 158 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Oil Change w/Filter - Deutz TCD2.9 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 Gallon (8.9 L) Lube - EO Interval - Check level daily; change every 500 hours or six months, whichever comes first.
  • Page 159 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD LEVEL MAXIMUM LEVEL OIL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 7-10.
  • Page 160 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. A. Fuel Filter - Deutz 2011 B. Fuel Filter - Deutz TCD2.9 Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation Interval - Every year or 500 hours of operation 3121170 7-29...
  • Page 161 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Fuel Strainer - Deutz 2011 13. Fuel Pre-Filter TCD2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 500 hours of operation Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 7-30 3121170...
  • Page 162 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Oil Change w/Filter - CAT 15. Fuel Filter/Water Separator - CAT Lube Point(s) - Replaceable Element Lube Point(s) - Fill Cap/Spin-on Element (element can be Interval - Drain water daily; Replace element every year or 600 accessed from below engine tray) hours of operation Capacity - 10.5 Quarts (10 L)
  • Page 163 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 16. Radiator Coolant TCD2.9 17. A. Air Filter -Deutz 2011/CAT DEUTZ 2011 Lube Point(s) - Fill Cap Capacity - 3.2Gallon (12.1 L) Lube - Anti-Freeze Interval - Check level daily; change every 1000 hours or 2 years, whichever comes first.
  • Page 164 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as Interval - Every 6 months or 300 hours of operation or as indi- indicated by the condition indicator cated by the condition indicator Comments - Check Dust Valve daily...

  • Page 165: Tires & Wheels

    TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pres- sure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.

  • Page 166: Tire Replacement

    Tire Replacement dations, may result in an unsafe condition regarding stability. JLG recommends a replacement tire be the same size, ply and brand Wheel Installation as originally installed on the machine. Please refer to the JLG Parts...
  • Page 167 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1. Start all nuts by hand to prevent cross threading. DO NOT 3. The tightening of the nuts should be done in stages. Follow- use a lubricant on threads or nuts. ing the recommended sequence, tighten nuts per wheel torque chart.

  • Page 168: Supplemental Information

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A) For combustion engine powered machines, guaranteed Sound...
  • Page 169 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 7-38 3121170...
  • Page 170 SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121170...
  • Page 171 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121170...
  • Page 172 3121170...
  • Page 173 @ 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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