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Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 1500SJ PVC 2001 ANSI AS/NZS 31215063 November 22, 2019 - Rev A ®...
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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.
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FOREWORD FOREWORD The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var- ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard compliance information. This manual is a very important tool! Keep it with the machine at all times.
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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.
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FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations Compliance Information INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- • Product Safety Publica- TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions •...
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FOREWORD REVISION LOG Original Issue A - November 22, 2019 31215063...
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LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature - Sheet 1 of 3 ....2-4 5-8.
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LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 5-33. Capacity Mode Error Screen ......5-47 5-34.
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LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 Beaufort Scale (For Reference Only)....1-9 Inspection and Maintenance Table .
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LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE viii 31215063...
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR safe machine usage and maintenance.
SECTION 1 - SAFETY PRECAUTIONS Workplace Inspection • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including • Precautions to avoid all hazards in the work area must be recognition and avoiding hazards associated with their opera- taken by the user before and during operation of the machine.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection OPERATION • Do not operate this machine until the inspections and func- General tional checks as specified in Section 2 of this manual have been performed. • Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e.
SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con- traction. This may result in changes to the platform position approved by JLG. while the machine is stationary. Factors affecting thermal •...
SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. • This machine is not insulated and does not provide protection from contact or proximity to electrical current.
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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)
SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are • Ensure that the ground conditions are adequate to support rated for the voltage of the line being guarded. These barriers the maximum tire load indicated on the tire load decals shall not be part of (or attached to) the machine.
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SECTION 1 - SAFETY PRECAUTIONS • Before driving on floors, bridges, trucks, and other surfaces, • Wind speed can be significantly greater at height than at ground level. check allowable capacity of the surfaces. • Never exceed the maximum platform capacity as specified on •...
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SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 8.2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLAT- FORM BILLBOARD. Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions...
SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.
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 •...
SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help pro- MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT- TEN PERMISSION FROM THE MANUFACTURER.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The Mobile Elevating Work Platform (MEWP) is a personnel han- depressions, holes, and drop-offs exist.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Operator Responsibility Purpose and function of the machine controls and indicators at the platform and ground control stations; The operator must be instructed that he/she has the responsibil- Purpose, location, and function of the emergency controls; ity and authority to shut down the machine in case of a malfunc- Operating characteristics and limitations;...
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Before using each day; or User or Operator User or Operator Operation and Safety Manual whenever there’s an Operator change. Pre-Delivery Inspection (See Before each sale, lease, or rental delivery.
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 31215063...
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection Walk-Around Inspection – Perform as instructed. Battery – Charge as required. The Pre-Start Inspection should include each of the following: Fuel (Combustion Engine Powered Machines) – Add the Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- proper fuel as necessary.
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Platform Gate – Keep gate and surrounding area clean and unobstructed. Verify the gate closes properly and is not bent or damaged. Keep gate closed at all times except when entering/exiting the platform and loading/unloading mate- rials.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Walk-Around Inspection 31215063...
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-10 31215063...
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General Platform Control Console - Switches and levers return to neutral when activated and released, decals/placards secure and legible, control markings legible. Begin the Walk-Around Inspection at Item 1, as noted on the dia- gram.
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Hydraulic Pump - See Inspection Note. Air Shutoff Valve (ASOV) (If Equipped) - See Inspection Note. Ground Control Console - Switches and levers return to neutral when activated and released, decals/placards secure and legible, control markings legible.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check speed. Any difference would indicate delayed move- ment and loose wire ropes. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION, LOWER PLATFORM TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THE TO STOWED POSITION, SHUT DOWN MACHINE, AND HAVE WIRE ROPES INSPECTED/ OFF POSITION WHEN RELEASED.
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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION speed. Any difference would indicate delayed move- With the jib in line with the boom and locked, make sure the jib will not unlock unless: ment and loose wire ropes. a. The machine is in transport position (booms retracted; main boom below elevation [5 degrees]).
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test Once the sensor has been activated, verify the following conditions: NOTE: Refer to Section 4.10 for additional information on SkyGuard a. Telescope out function stops and telescope in function operation.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Boom Control System Check Procedure Perform the following check with no load (personnel or material) in the platform from the ground control console. Extend all axles fully. With the boom fully retracted, raise the boom off the boom rest to horizontal.
SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL CONTROLS AND INDICATORS NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND arise.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Jib Telescope Control TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Provides extension and retraction of the jib. TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.
SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Auxiliary power only works if there is no engine oil pressure, and is disabled if engine is running. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF Functions will operate at a slower than normal rate because of THE PLATFORM.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: With PLATFORM/GROUND SELECT switch in the center position, power is shut off to controls at both operating stations. WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES. Platform/Ground Select Switch Power/Emergency Stop Switch A three position, key operated switch sup-...
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Lift Control Boom Control System Test Button Provides raising and lowering The push button is used to test the of the main boom. boom control system and confirm that it is working properly. Machine Safety System Override (MSSO) (CE Only) Swing Control...
SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel ½ OAC02250 1. Battery Charge 6. Boom Control System Calibrated 11. Platform Overload 2. Boom Control System Warning 7. Generator 12. Wire Rope Service Indicator 3. System Distress 8. Glow Plug 13.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Battery Charge Indicator Drive and Steer Disable Indicator Indicates a problem in the battery or charging Indicates the Drive and Steer Disable function circuit, and service is required. has been activated. Boom Control System Warning Indicator Capacity Zone Indicator Indicates the platform is outside the operating area and operation of certain boom functions...
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Glow Plug Indicator Wire Rope Service Indicator Indicates the glow plugs are on. The glow When illuminated, the light indicates the wire plugs are automatically turned on with the ropes are loose or broken and must be repaired ignition circuit and remain on for approxi- or adjusted prior to use.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Station 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. Lights 20. Platform Rotate 3. Platform Leveling Override 9. Start/Auxiliary Power 15.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR can be used for positioning the machine in aisle ways or close to buildings.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Horn automatic platform leveling feature is active during lift, tele- scope, swing, and drive movements. A push-type HORN switch supplies electrical NOTE: • While operating lift up, the boom may also telescope out. power to an audible warning device when pressed.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Power/Emergency Stop Capacity Select A two-position red mushroom shaped switch This switch allows the operator to select supplies power to Platform Controls when between an operating envelope with a 500 lb. pulled out (on). When pushed in (off ), power is (227 kg for ANSI markets and 230 kg for CE and shut off to the platform controls.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: The DRIVE control levers are spring-loaded and will automati- Jib Lift cally return to neutral (OFF) position when released. Provides raising and lowering of the jib. Drive/Steer Push forward to drive forward, Soft Touch/SkyGuard Override Switch pull back to drive in reverse.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS tor to override the system that has experienced a cutout sit- Soft Touch/SkyGuard Indicator (If Equipped) uation. Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated. All controls are cut out until the override button is pushed.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. Main Lift/Swing Controller Provides main lift and swing.
SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel ½ 1. Boom Control System Warning 5. Tilt Alarm Warning 9. Glow Plug 13. Level System 17. Engine Error 2. System Distress 6. Generator 10. Fuel Level 14. Platform Overload 18.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Boom Control System Warning Indicator Capacity Zone Indicator Indicates the platform is outside the operating Indicates the maximum platform capacity area and operation of certain boom functions zone for the current position of the platform. may be disabled (i.e.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Tilt Warning Light and Alarm Creep Speed Indicator This red illuminator indicates that the chassis is When the Function Speed Control is turned to on a slope. If the boom is above horizontal and the creep position, the indicator acts as a the machine is on a slope, the tilt alarm warn- reminder that all functions are set to the slow-...
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Glow Plug Indicator extended past transport mode or elevated more than 8 degrees above horizontal. Indicates the glow plugs are operating. After Platform Overload Indicator turning on ignition, wait until light goes out before cranking engine.
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SECTION 3 - MACHINE CONTROLS AND INDICATORS Diesel Particulate Filter (DPF) Indicator Icon will illuminate when standstill exhaust system cleaning is required. Emissions Temperature Indicator Icon illuminates when the engine emissions con- trol sensor reaches a high temperature. 3-22 31215063...
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION BOOM OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a mobile elevating work platform used to posi- tion personnel, along with their necessary tools and materials at Capacities work locations. The primary operator control station is in the platform. From this Raising boom above horizontal with or without any load in plat- control station, the operator can drive and steer the machine in form, is based on the following criteria:...
SECTION 4 - MACHINE OPERATION Controlled Arc will function automatically, or when lifting up, telescope out will function automatically. When the Boom Control Switch is in the manual mode, lift and telescope functions are independent functions controlled by the operator. When the Boom Control Select switch is in the automatic mode, the Boom Control System automatically controls lift and tele- scope when the lift function is selected to move the platform...
SECTION 4 - MACHINE OPERATION Envelope Tracking NOTE: Boom Control System in Automatic Mode: When the boom is completely elevated along the edge of the backward stability region and the telescope in function is activated, lift down will automatically function until the boom is away from the edge of the backward stability region.
SECTION 4 - MACHINE OPERATION Platform Load Sensing System (LSS) CAPACITY SELECT The Platform Load Sensing System provides the platform capacity to The Boom Control System allows the operator to select the control system. operation in a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia markets) capacity restriction If the LSS system senses an overload condition, boom functions envelope or a 1000 lb.
SECTION 4 - MACHINE OPERATION JIB HORIZONTAL & FULLY EXTENDED MAIN BOOM FULLY EXTENDED MAIN BOOM ELEVATED 20 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED BEYOND THE LIMITS OF THE MAXIMUM OPERATING SLOPE Figure 4-1. Position of Least Forward Stability 31215063...
SECTION 4 - MACHINE OPERATION ENGINE OPERATION Starting Procedure NOTE: When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air den- IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. sity.
SECTION 4 - MACHINE OPERATION NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed posi- ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING tion, DO NOT OPERATE MACHINE. ANY LOAD.
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.
SECTION 4 - MACHINE OPERATION Fuel Reserve / Shut-Off System for approximately 2 minutes of run time. After the 2 min- utes of run time is complete, the operator may cycle power and restart the engine for an additional 2 minutes of run NOTE: Reference the Service and Maintenance Manual along with a time.
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 •...
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SECTION 4 - MACHINE OPERATION 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. 4-12 31215063...
SECTION 4 - MACHINE OPERATION Cancelling Maintenance Standstill After the cleaning process is complete, the engine will run 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"...
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 •...
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SECTION 4 - MACHINE OPERATION Table 4-1. Maintenance Standstill Cleaning Machine Hours Standstill Cleaning System Distress SCR Cleaning Since Last 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.
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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...
SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) See Figure 4-4., Grade and Side Slopes BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC- NOTE: When the main boom is raised approximately 6 degrees above TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF horizontal, the high drive function will automatically be in low TRAVEL.
SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse Match the black and white direction arrows At Platform Controls, pull out Emergency Stop on both platform con- switch, start engine, and activate footswitch. trol panel and the chas- sis to determine the direction the machine will travel.
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 (drive) axle, and in line with the direction of travel.
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. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM.
SECTION 4 - MACHINE OPERATION Swinging the Boom TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE NOTE: The axles must be fully extended to swing beyond the rear SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL. wheels (40 degrees).
SECTION 4 - MACHINE OPERATION Telescoping the Boom 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...
SECTION 4 - MACHINE OPERATION 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.
SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- Operator passes through path of sensor beam. nected. SkyGuard Function Table Boom Drive Drive Boom Boom Boom Basket Basket Steer Swing Lift Jib Lift Jib Tele...
SECTION 4 - MACHINE OPERATION 4.13 EMERGENCY TOWING 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.
SECTION 4 - MACHINE OPERATION 4.14 SHUT DOWN AND PARK 4.15 LIFTING AND TIE DOWN The preferred procedures to shut down and park the machine are See Figure 4-7. as follows: Lifting Drive machine to a reasonably well protected area. Refer to the Serial Number Plate, refer to the Specifications Ensure boom is fully retracted and lowered over rear axle.
SECTION 4 - MACHINE OPERATION Tie Down 4.16 STOWING THE JIB FOR TRANSPORT Place the boom in the stowed position with the axles retracted. WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO Hold the Jib Swing control switch to the right until the plat- THE BOOM REST.
SECTION 4 - MACHINE OPERATION 10’5”/3.18 m 6’10”/2.08 m 17’3”/5.26 m 31’5”/9.58 m 11’7”/3.53 m 43’0”/13.11 m 1001125274 D Figure 4-7. Lifting and Tie Down Chart 31215063 4-29...
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SECTION 4 - MACHINE OPERATION www.jlg.com ANS I & ANS I & DUAL DUAL LANG UAG E LANG UAG E Figure 4-11. Decal Location Sheet 4 of 6 31215063 4-33...
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 GENERATION 1 LCD DISPLAY PANEL SCREENS Boot Up Splash Screen The Boot Up Splash Screen appears when the machine is first powered on. The screen contains several reminders for the opera- tor prior to operation.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Default Screen The Default Screen appears after the boot screen if there are no faults present in the JLG Control System. The display shows an indication of fuel level, battery voltage, and engine rpm. In addi- tion, a check mark in a green circle indicates no serviceable faults are present.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Battery Voltage Engine Fuel Level No Serviceable LCD Software Faults Present Version Figure 5-5. Default Screen 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Conditional Icons Several icons exist which may display below the line on the LCD panel on any screen if the operating condition they represent exists. These icons are Jib Unlocked, Jib Locked, Reduced Speed (turtle), Creep Speed (snail), Fault Code, Safety Alert Symbol, and No Serviceable Faults Present (check mark).
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 CAN Communication Error Screen The CAN Communication Error Screen appears if the JLG Control System senses that the communication connection between the LCD display and the Ground Control Module has been lost. In the lower right hand corner, 66?? will display in the numeric fault code area with a safety alert symbol.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code & Safety Alert Symbol Figure 5-7. CAN Communication Error Screen 5-10 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Serviceable Fault Indication Screen The Serviceable Fault Indication Screen appears if the JLG Control System has sensed a fault that may require service attention by a technician. As on the default screen, the display shows an indica- tion of the fuel level, battery voltage, and engine rpm.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Screen The Keyswitch in Ground Control Mode Icon will be displayed as long as the key is in the ground control position. The icons below the orange line will reflect the status of the machine.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Icon Figure 5-9. Keyswitch in Ground Control Mode Screen 5-14 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Keyswitch in Ground Control Mode Screen with Operational Faults The Keyswitch in Ground Control Mode Icon will be displayed as long as the key is in the ground control position. If any opera- tional faults are active, the refer to Operation Manual icon will be shown.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Refer to Operation Keyswitch in Ground Manual Icon Control Mode Icon Figure 5-10. Keyswitch in Ground Control Mode with Operational Faults 5-16 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - No Graphics Screen The Operational Fault Screen appears if the JLG Control System has sensed a fault that is due to operator error or a condition when the operator can be provided with additional information (i.e.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Reminder to Check Operation and Safety Manual No Serviceable Faults Present Figure 5-11. Operational Fault - No Graphics Screen 5-18 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - With Graphics Screen The Operational Fault Screen appears if the JLG Control System has sensed a fault that provides operational information. The dis- play shows an icon that represents the fault and available control options along with the fault code, which is displayed above the fault icon (Fault 2224 - Footswitch Selected Before Start is used as an example).
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Footswitch Open Screen The Footswitch Open Screen appears if the JLG Control System has sensed a fault that is due to the operator having the footswitch open. In this condition, no functions are operable as shown by the red X’s on the display screen.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Icon representing No Functions are Operational Icon Representing Footswitch Reminder No Serviceable Faults Present Figure 5-13. Operational Fault - Footswitch Open Screen 5-22 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Out of Transport - Axles Retracted The Out of Transport - Axles Retracted screen appears if the JLG Control System has sensed the boom has been moved out of the transport position with the axles retracted.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Yellow Highlights Indicate direction Control Switch can be Applied to Correct the Fault Condition Axles Retracted Icon - Extended Axles Will Flash Yellow Segments Indicate Directions that Joystick can be Applied to Correct the Fault Condition No Serviceable...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Transport Swing Fault Screen The Transport Swing Fault Screen appears when the 0038 - SWING ENVELOPE ENCROACHED - HYDRAULICS SUSPENDED operational fault is active, indicating that swing is restricted to +/ - 40 degrees from center while the axles are retracted.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Yellow Circle Indicates that Control Switch can be Applied in Either Fault Code Direction to Correct the Fault Condition Icon Representing Yellow Segments Transport Swing Indicate Directions Fault that Joystick can be (Extended Axles Applied to Correct the...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Envelope Speed Reduction Screen The Envelope Speed Reduction Screen appears if the JLG Control System has sensed that the boom is approaching the edge of the backward or forward operating envelope, which places all func- tions in proportionally reduced speed.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Icon Representing Back- ward Envelope Speed Reduction Indication Note: Opposite Side Will Highlight if Forward Envelope is near encroachment No Serviceable Turtle Icon Represents Faults Present Functions Operating at Reduced Speed Figure 5-16.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Envelope Violation Fault Screen The Envelope Violation Fault Screen appears if the JLG Control System has sensed that the boom is encroaching the edge of the forward or backward operating envelope (hydraulics are sus- pended).
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Yellow Circle Indicates that Control Switch can be Applied in Either Yellow Half-Circle Indicates that Control Switch can be Applied in Only Direction to Correct the Fault Condition One Direction to Correct the Fault Condition Icon Representing Yellow Segments Envelope...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Operational Fault - Over/Under Moment Fault (DTC 0017/ 0018) The Over/Under Moment Fault Screen appears if the JLG Control System senses that the machine is in an over/under moment con- dition.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Numeric Fault Code Under/Over Moment Icon Forward and Rear Envelope Highlights Flash No Serviceable Faults Present Snail Icon Represents Functions Operating at Creep Speed Figure 5-18. Over/Under Moment Fault Screen 5-32 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 GENERATION 2 LCD DISPLAY PANEL SCREENS 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- yard attached to an authorized lanyard anchorage point, a reminder for the operator to read and understand the Operation...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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 DTC Tray Console Tray Machine Status Tray...
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 DIAGNOSTIC TROUBLE CODE (DTC) TRAY • CAN Bus Lost This tray shows the total number of DTC’s and the DTC Text. If • Take Foot Out there are multiple DTC’s, the operator can scroll through the DTC •...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 KeySwitch In Ground Mode: If the keyswitch is set to ground mode, the display shows the Key Switch in Ground Mode Image. Figure 5-24. Keyswitch In Ground Mode Screen 31215063 5-37...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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 5-27.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 BCS Lamp On NOTE: The available controls will be different among the different DTCs. The image below is ONLY for envelope violation. When the control system senses forward or backward envelope violation or moment violation conditions, the BCS Lamp will be ON.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Broken Cable shows a red octagon broken cable indicator in the machine sta- tus tray. When the control system senses a broken cable, the Broken Cable lamp on the platform panel is lit. When the lamp is lit, the display Figure 5-30.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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 5-32. Overload DTC Screen 5-46 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Swing DTCs When the machine is swung more than what it is allowed for in either left or right direction, the control system senses a swing fault. When a swing DTC is active, the display shows a machine image with green arc which indicates the allowed angle and the portion other than the green arc indicates the restricted area to show the swing DTC.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Jib Unlocked When the control system senses that jib pin is unlocked, the dis- play will show the Jib Unlocked image. Figure 5-35. Jib Unlocked Screen 5-50 31215063...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Jib Locked The display will show a different image on the machine status tray after 3 seconds have elapsed. When the boom control system senses jib is locked ONLY for the first time, the display will show the Jib Locked image on the machine status tray for 3 seconds.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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 5-38.
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 AXLES RETRACTED IN OUT OF TRANSPORT POSITION When the axles are retracted and the machine is in the out of transport position, the display will switch between axles extended and retracted every 0.5 seconds to tell the operator to extend the axles so the boom can be raised.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 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 5-39. Machine Tilted Mode Screen 31215063 5-55...
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Envelope Status Example 1: Platform is not at the edge of the envelope • When Unrestricted or Restricted mode is selected, the dis- play shows envelope image in the machine status tray. •...
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 • When operator switches from Unrestricted to Restricted Example 4: Restricted mode with envelope tilt condition mode, the envelope shrinks to indicate reduced operating • When on the Restricted envelope screen, if the operator envelope.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Machine Model Unknown 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 1500SJ nor Figure 5-42.
SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 OPERATIONAL FAULT CODE LISTING Table 5-1. Operational Fault Codes Fault Code Description EVERYTHING OK 0010 RUNNING AT CUTBACK - OUT OF TRANSPORT POSITION 0011 FSW OPEN 0012 RUNNING AT CREEP - CREEP SWITCH OPEN 0013 RUNNING AT CREEP - TILTED AND ABOVE ELEVATION 0014...
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SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2 Table 5-1. Operational Fault Codes Fault Code Description 2222 WAITING FOR FSW TO BE OPEN 2223 FUNCTION SWITCHES LOCKED - SELECTED BEFORE ENABLE 2224 FOOTSWITCH SELECTED BEFORE START FUNCTION SWITCHES LOCKED - SELECTED BEFORE AUX POWER FUNCTION SWITCHES LOCKED - SELECTED BEFORE START SWITCH START SWITCH LOCKED - SELECTED BEFORE KEYSWITCH MODEL CHANGED - HYDRAULICS SUSPENDED - CYCLE EMS...
SECTION 6 - EMERGENCY PROCEDURES SECTION 6. EMERGENCY PROCEDURES GENERAL FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL This section explains the steps to be taken in case of an emer- FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON- gency situation while operating.
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.
SECTION 6 - EMERGENCY PROCEDURES MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) The Machine Safety System Override (MSSO) is only to be used to retrieve an operator that is pinned, trapped, or unable to operate the machine and function controls are locked out from the platform due to a platform overload sit- uation.
SECTION 7 - ACCESSORIES PIPE RACKS INSTALLING OR REMOVING APPROVED ACCESSORIES OR CHANGING PLATFORM SIZE REQUIRES RECALIBRATION OF THE BOOM CONTROL SYSTEM (SEE SERVICE AND MAIN- TENANCE MANUAL). FALL ARREST PLATFORM NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information.
SECTION 7 - 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.
SECTION 7 - 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. •...
SECTION 7 - 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.
SECTION 7 - 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.
SECTION 7 - 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. •...
SECTION 7 - 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...
SECTION 7 - ACCESSORIES Safety Precautions • Do not use electrical cords without ground. • Do not use electrical tools in water. • Do not weld to the platform. DO NOT OVERLOAD PLATFORM. • Do not ground through the platform. •...
SECTION 7 - ACCESSORIES SOFT TOUCH BOLT-ON EXTERNAL FALL ARREST A padding kit is mounted to the platform rails and to a frame sus- The bolt-on external fall arrest system is designed to provide a lan- pended below the platform. Limit switches deactivate platform yard attach point while allowing the operator to access areas outside functions when the padded framework contacts an adjacent the platform.
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.
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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-...
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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 7-2. Bolt On Fall Arrest System 7-16 31215063...
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.
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 8-5. Deutz TD2011L4 Specifications Table 8-6. Deutz TCD2.9L4 Specifications Type Liquid Cooled Type Liquid Cooled Number of Cylinders Number of Cylinders Bore 3.7 in. (94 mm) Bore 3.6 in. (92 mm) Stroke 4.4 in.
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil OIL SAMPLING Table 8-7. Hydraulic Oil See Figure 8-1., Oil Sampling Port. Hydraulic System This machine is equipped with an oil sampling valve to allow for S.A.E. Viscosity Operating verification of hydraulic oil condition. Refer to the Service Manual Grade Temperature Range for Oil Sampling procedures.
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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.
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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...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 8-13. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Viscosity at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index NOTE: Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 8-1. Oil Sampling Port 31215063...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 8-2. Engine Operating Temperature Specifications 8-10 31215063...
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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 EMPERATURE BOUNDARIES OUT LINED IN T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENT S OF T HE HYDRAULIC SYST EM.
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL NOTE: The following numbers correspond to those in Figure 8-4., Oper- CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED ator Maintenance and Lubrication Diagram. TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Swing Gearbox 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.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Return Filter Hydraulic Charge Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 300 hours Interval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator thereafter or as indicated by condition indicator.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Suction Strainers (In Tank) FULL LEVEL (HOT OIL) FULL LEVEL (COLD OIL) Lube Point(s) - 2 Lube Point(s) - Fill Cap Interval - Every 2 years or 1200 hours of operation. Capacity - Standard 31 gallons (117 liters) Remove and clean at time of hydraulic oil change.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE A. Oil Change w/Filter - Deutz TD2011 B. Oil Change w/Filter - Deutz TCD2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element Capacity - 2.4 Gallon (8.9 L) Capacity - Lube - EO 5 Quarts (4.5 L) Cooling System...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE A. Fuel Filter - Deutz TD2011 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 600 hours of operation 31215063 8-19...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fuel Strainer TD2011 Fuel Pre-Filter TCD2.9 Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation 8-20 31215063...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Radiator Coolant TCD2.9 A. Air Filter - Deutz TD2011 Lube Point(s) - Fill Cap Lube Point(s) - Replaceable Element Capacity - 3.2Gallon (12.1 L) Interval - Every 6 months or 300 hours of operation or as Lube - Anti-Freeze indicated by the condition indicator Interval - Check level daily;...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Air Filter - Deutz TCD2.9 Platform Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and then every year or 600 hours of operation thereafter Boom Lube Point(s) - Apply to wear pad contact paths Lube - Super Lube®...
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Optional Fuel Filter/Water Separator Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of operation 31215063 8-23...
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE TIRES & WHEELS recommend that replacement tires have the following characteris- tics: Tire Damage • Equal or greater ply/load rating and size of original • Tire tread contact width equal or greater than original For polyurethane foam filled tires, JLG Industries, Inc.
SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE.
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SECTION 8 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION Table 8-15. Wheel Torque Chart 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. 45 ft.
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