Page 1
Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) 1532R 1932R P/N - 3121744 ANSI AS/NZS October 20, 2017 ®...
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating proce- dures 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 noti- fication. Contact JLG Industries, Inc. for updated information.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROP- COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ERTY. ORANGE BACKGROUND. – JLG Lift – 3121744...
• Questions Regarding NOTICE uct 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 Contact: THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.
JLG Industries, Inc. • Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to your utili- zation and application of the machine.
Operate controls with slow and even pressure. • Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. – JLG Lift – 3121744...
• Prior to operation, ensure all gates and rails are fastened and secured in their proper position. • JLG Industries, Inc. recommends that all persons in the plat- form wear a full body harness with a lanyard attached to an authorized lanyard anchorage point while operating this machine.
• Never exceed the maximum work load as specified on the Over 750 KV to 1000 KV 45 (14) platform. Keep all loads within the confines of the platform, unless authorized by JLG. NOTE: This requirement shall apply except where employer, local or govern- mental regulations are more stringent.
32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. – JLG Lift – 3121744...
• Keep hands and limbs out of the scissor arm assembly dur- ing operation and when elevated without safety prop engaged. • Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bot- tom of platform when lifting or lowering platform. 3121744 – JLG Lift –...
Page 20
• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all operations. • Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, conges- tion, visibility, slope, location of personnel, and other fac- tors. 1-10 – JLG Lift – 3121744...
• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. 3121744 – JLG Lift – 1-11...
• Reference the Service and Maintenance Manual for the • Charge batteries only in a well ventilated area. weights of critical stability items. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 1-12 – JLG Lift – 3121744...
• Means to avoid the hazards of unprotected electrical conductors. • Specific job requirements or machine application. • Reading and understanding the Operation and Safety Manual. 3121744 – JLG Lift –...
Table 2-1 explains the periodic machine inspections and main- son in an open area free of obstructions until the trainee has tenance recommended by JLG Industries, Inc. Consult local reg- developed the ability to safely control and operate the machine.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. NOTICE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
9. Function Check – Once the “Walk-Around” Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstruc- tions. Refer to Section 3 for more specific instructions on the operation of each function. – JLG Lift – 3121744...
Page 27
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 10. Platform Gate - Keep gate and surrounding area clean and unobstructed. Check that gate closes properly and is not bent or damaged. During operation keep gate closed. Self-Closing Swing Gate Chain Gate 3121744 – JLG Lift –...
Page 28
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION 11. Lanyard Anchorage Points - JLG Industries, Inc. recommends personnel in the platform wear a full body harness with a lanyard attached to an authorized lanyard anchorage point (1). Lanyard Attach Points –...
Ensure that all guards protecting switches are in place. c. Operate all switch functions, drive/lift mode select switch, and horn button. d. Operate all platform joystick functions to ensure proper operation of drive, lift, steer, and enable trigger switch operation. 3121744 – JLG Lift –...
This section provides the necessary information needed to understand controls and their functions. This JLG Lift has a primary operator control station in the plat- form. From this control station, the operator can drive and steer the machine in both forward and reverse directions, raise and lower the platform.
4. AC Plug - At Front of Machine - For Platform AC Receptacle Outlet Box 5. AC Plug - Battery Charger Input 6. Side Compartment Doors (Both Sides) 7. Side Compartment Door Latch Location (Both Sides) Figure 3-1. Location of Machine Controls. 3121744 JLG Lift –...
2. Connect the charger AC input plug to a grounded out- let using a 3 wire heavy duty extension cord. (See Table 5-6, “Battery Charger Specifications,” on page 5-6, for battery charger AC input specifications.). – JLG Lift – 3121744...
A two- position, red, mushroom-shaped emergency stop switch, when positioned to ON with the key selector switch positioned to ground, furnishes operating power to the ground control station – JLG Lift – 3121744...
ANSI Export/Australia/Japan: All platform functions will be prevented. Fully lower the platform from the ground controls or using the machine manual descent control. Reduce the weight in the platform to not exceed the rated workload indicated on the capacity decal. 3121744 JLG Lift –...
2. Grasp the T-handle and slowly pull out to lower the scissor arms/platform, when the platform is lowered to desired level, allow the T-handle to return to it’s closed position. Figure 3-4. Location of Manual Descent Control (Left Rear of Machine) 3121744 JLG Lift –...
10. Battery Discharge Indicator 11. System Fault Indicator 12. Alarm (not shown, located on bottom of box) 13. Indoor-Zone A (CE)/Outdoor-Zone B (CE) Indicators 14. Indoor-Zone A/Outdoor-Zone B - Select Switch (CE) Figure 3-5. Platform Control Station 3-10 – JLG Lift – 3121744...
(Item 2) NOTE: When selecting between the Lift and Drive functions the joystick control must be returned to the neutral position for approximately 1/2 second before the function change is operable. 3-12 – JLG Lift – 3121744...
ON posi- switch to the left will steer the wheels to the left. tion. Joystick Controller - The control handle controls two functions: drive and lift. 3121744 JLG Lift – 3-13...
The drive system is proportional, for additional drive speed push the joystick further from the neutral position in the direction of travel. Releasing the trigger switch or return- ing the joystick to center will stop machine movement. 3-14 – JLG Lift – 3121744...
Fully lower the platform from the ground controls or using the machine manual descent control. Reduce the weight in the platform to not exceed the rated workload indicated on the capacity decal. 3-16 – JLG Lift – 3121744...
Outdoor If the code cannot be cleared by the operator, the machine will mode (Zone B) will restrict platform opera- require service by a qualified JLG mechanic. tions if operating machine outside rated wind speed specifications. 3121744 JLG Lift –...
2. Grasp the top handrails (2) of the extendible deck and push the extension out until it hits the stops and the locking mechanism pin is locked into one of the for- ward platform extension locks (4) or (5). Figure 3-8. Platform Deck Extension 3121744 JLG Lift – 3-19...
NOTE: Front deck extension top rail pins must be removed and deck extension top side rails slid towards rear of machine before lowering side rails. Place pins in the lower holes of the extension side top rails before folding main platform side rails down. 3-20 – JLG Lift – 3121744...
6. Chock at least two wheels when parking the machine Figure 3-10. Securing Control Station to Platform for an extended period of time. 3-22 – JLG Lift – 3121744...
5, Machine Specifications for machine gross weight). LIFTING THE MACHINE FROM THE SIDES USING A FORK TRUCK IS NOT REC- OMMENDED BY JLG. IN THE EVENT THAT THE MACHINE NEEDS TO BE LIFTED FROM THE SIDES CAUTION MUST BE USED TO AVOID JAMMING THE POT HOLE PROTECTION BARS UP AGAINST THE FRAME.
(See Figure 3-13.) Figure 3-12. Lifting Machine Using Spreader Bar and Lift Lug Locations 1. Four (4) equal length chains or 2. Spreader Bar Assembly. lifting straps. 3-24 – JLG Lift – 3121744...
Page 57
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-13. Tie Down and Lift Lug Locations 3121744 JLG Lift – 3-25...
4. On the main valve body, to release the brakes, push Figure 3-14. Hydraulic Brakes - Manual Disengage. the BLACK brake override button (2) in, (there is a (Inside Right Side Compartment Door) detent which will hold the valve in place). 3-26 – JLG Lift – 3121744...
DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY. 3. Rescue equipment can be used to remove the plat- form occupant(s). Cranes and forklifts can be used to stabilize motion of the machine. 3121744 – JLG Lift –...
2. Grasp the T-handle and slowly pull out to lower the scissor arms/platform, when the platform is lowered to desired level, allow the T-handle to return to it’s closed position. Figure 4-1. Location of Manual Descent Control (Left Rear of Machine) – JLG Lift – 3121744...
SECTION 4 - EMERGENCY PROCEDURES INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, JLG must be contacted by telephone and provided with all necessary details.
The maintenance portion of this section is intended as informa- tion to assist the machine operator to perform daily mainte- nance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual. 3121744 – JLG Lift –...
Indoor - 2 Persons + 70 Kg 400 N 0 m/s CE/AUS 120 Kg 125 Kg Outdoor - 1 Person + 45 Kg 200 N 12.5 m/s NOTE: (1) Maximum Platform Capacity includes platform and platform extension. – JLG Lift – 3121744...
Electronic Protection-Auto Reset Electronic Protection-Auto Reset Electronic Protection-Auto Reset Output Short Circuit: Current Limited Electronic Protection-Auto Reset Electronic Protection-Auto Reset Branch Circuit Protection Current Limited AC Overload: Current Limited DC Overload: Current Limited Current Limited Current Limited – JLG Lift – 3121744...
50° F to 210° F (+10° C to +99° C) 20W-20 NOTE: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not con- tain the same required additives or be of comparable vis- cosities.
Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or Flash Point, Min. 442° F (228° C) 514° F (268° C) MIL-Spec MIL-L-2105. VISCOSITY SPECIFICATIONS JLG Recommends - Mobil - Mobilfluid 424 at 40° C 55 cSt 33.1 cSt Mobil EAL ENVIRONSYN H 32 at 100° C 9.3 cSt...
3. Lower the platform until the safety prop rests against the safety prop stop on the arm set below it, stopping all downward movement of the platform/scissor arm assembly. 3121744 – JLG Lift –...
Fill until oil level is close to the MAX marking (3), but not over the MAX marking. Prop Disengaged NOTE: Care should be taken not to introduce any impurities (dirt, water, etc.) while cap is removed. Figure 5-1. Scissor Arm - Safety Prop 5-10 – JLG Lift – 3121744...
Figure 5-2. Hydraulic Oil Check Procedure Figure 5-3. Hydraulic Oil Fill Procedure NOTE: Recommended lubricating intervals are based on machine operations under normal conditions. For machines used in multi-shift operations and/or exposed 3121744 – JLG Lift – 5-11...
• DO NOT fill to bottom of vent tubes. connector on top of the batteries inside the battery compart- ment and pull halves apart. • DO NOT allow fluid level to go below the top of the plates when charging or operating. 5-14 – JLG Lift – 3121744...
• If more than one discrepancy exists in any quadrant of the JLG as an approved replacement. Please refer to the JLG Parts wheel (within 90 degrees of one another).
The vibration total value to which the hand-arm system is sub- jected does not exceed 2,5 m/s2. The highest root mean square value of weighted acceleration to which the whole body is sub- jected does not exceed 0,5 m/s2. 3121744 – JLG Lift – 5-17...
The more detailed three to five digit code numbers in the DTC column of the following tables are only indicated on a JLG hand- held diagnostic analyzer connected to the machine, or on the Ground Control Station - MDI indicator, if equipped.
Page 84
• Alternately, there may be difficulty with the Elevation Angle Sensor that causes the Control System to improperly believe the platform is stowed. 5-22 – JLG Lift – 3121744...
Page 85
FUNCTION PROBLEM – HORN PERMA- None • Horn Prevented • Horn Switch in the Platform Control Box was closed during NENTLY SELECTED power-up. Release or repair the switch to clear the message. 3121744 – JLG Lift – 5-23...
Page 86
FUNCTION PROBLEM – STEER LEFT None • DriveState = PREVENTED • Steer Left Switch in the Platform Control Box was closed dur- PERMANENTLY SELECTED ing power-up. Release or repair the switch to clear the mes- sage. 5-24 – JLG Lift – 3121744...
Page 87
DRIVE & LIFT UP PREVENTED – CHAR- None • DriveState = PREVENTED • Driving and Lifting are not possible since the vehicle is charg- GER CONNECTED • LiftUpState = PREVENTED ing and it is configured to prevent all motion. 3121744 – JLG Lift – 5-25...
Page 88
• Alternately, there may be difficulty with the Elevation Angle Sensor that causes the Control System to improperly believe the platform is elevated. 5-26 – JLG Lift – 3121744...
Page 89
4236 POWER MODULE TOO COLD - MODULE None • DriveState = PREVENTED • Heatsink temperature below -40° F(-40°C). SHUTDOWN • LiftUpState = PREVENTED • Possible Cause: • Controller is operating in an extreme environment. 3121744 – JLG Lift – 5-27...
Page 90
• The Ground Module's VSW voltage was measured to be more HIGH • LiftDownState = MAX than 32V. This may be caused by loose battery terminal, severely discharge batteries, a damaged battery, or an improper wire harness connection. 5-28 – JLG Lift – 3121744...
Page 91
• The Ground Module momentarily measured excessively high UNPLUG CHARGER • LiftDownState = MAX battery voltage (VBAT) (>32.0V) and entered SafeMode to protect system devices. This may be due to improper battery charging or incorrect voltage batteries being used. 3121744 – JLG Lift – 5-29...
Page 92
• The Ground Module momentarily measured excessively high ING DISCHARGE Lift Up = PREVENTED battery voltage (VBAT) (>32.0V) and entered SafeMode. This Drive = PREVENTED may be due to improper battery charging or incorrect voltage batteries being used. 5-30 – JLG Lift – 3121744...
SECTION 6 - INSPECTION AND REPAIR LOG SECTION 6. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 6-1. Inspection and Repair Log DATE COMMENTS 3121744 – JLG Lift –...
Page 94
SECTION 6 - INSPECTION AND REPAIR LOG Table 6-1. Inspection and Repair Log DATE COMMENTS – JLG Lift – 3121744...