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Oshkosh Corporation 150HAX 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
150HAX
ANSI
3121213
®
August 30, 2012

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 150HAX ANSI 3121213 ® August 30, 2012...
  • Page 3 FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc.
  • Page 4 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 5 FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- • Accident Reporting • Standards and Regulations TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue - July 19, 2005 Revised - August 8, 2006 Revised - November 30, 2009 Revised - August 30, 2012 – JLG Lift – 3121213...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS GENERAL ......2-7 DAILY FUNCTIONAL CHECK .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 4 - MACHINE OPERATION SHUT-DOWN AND PARK ....4-10 4.10 TIE DOWN AND LIFTING .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE MAINTENANCE LIST OF FIGURES INTRODUCTION......6-1 2-1.
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES Minimum Approach Distances (M.A.D.) ..1-5 Beaufort Scale (For Reference Only) ..1-10 Inspection and Maintenance Table .

  • Page 11: Section 1. Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL PRE-OPERATION This section outlines the necessary precautions for proper Operator Training and Knowledge and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is estab- •...

  • Page 12: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine • Before machine operation, perform inspections and func- and in this manual. tional checks. Refer to Section 2 of this manual for •...

  • Page 13: Operation

    SECTION 1 - SAFETY PRECAUTIONS OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the •...

  • Page 14: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are • Use extreme caution when entering or leaving platform. closed and fastened in their proper position. Be sure that the boom is fully lowered. It may be neces- sary to telescope out to position the platform closer to the ground for entry/exit.

  • Page 15: Minimum Approach Distances (M.a.d.)

    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 16: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • The minimum approach distance may be reduced if insulat- ing barriers are installed to prevent contact, and the barriers • The user must be familiar with the surface before driving. are rated for the voltage of the line being guarded. These Do not exceed the allowable sideslope and grade while barriers shall not be part of (or attached to) the machine.

  • Page 17: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not elevate platform or drive with platform elevated • If boom assembly or platform is in a position that one or while on a sloping, uneven, or soft surface. more wheels are off the ground, all persons must be removed before attempting to stabilize the machine.

  • Page 18: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING • Use the boom functions, not the drive function, to position the platform close to obstacles. • Never allow personnel in platform while towing, lifting, or • Always post a lookout when driving in areas where vision hauling.

  • Page 19: Additional Hazards / Safety

    SECTION 1 - SAFETY PRECAUTIONS ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin • Do not use machine as a ground for welding. and clothing at all times. •...

  • Page 20: Beaufort Scale (For Reference Only)

    SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). Table 1-2. Beaufort Scale (For Reference Only) 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.

  • Page 21: 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 over- head obstructions, other moving equipment, and obsta- The aerial platform is a personnel handling device; so it is cles, depressions, holes, drop-offs.

  • Page 22: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT and maintenance required by JLG Industries, Inc.

  • Page 23: Inspection And Maintenance Table

    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 Operator and Safety Manual whenever there’s an Operator change. Pre-Delivery Inspection (See Before each sale, lease, or rental delivery.

  • Page 24: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection (Domestic only) is enclosed in the weather resistant storage container. The Pre-Start Inspection should include each of the follow- 5. “Walk-Around” Inspection – Refer to Figure 2-1. thru ing: Figure 2-4.

  • Page 25: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the transport (stowed) position: a. Drive the machine on a grade, not to exceed the Perform the Function Check as follows: rated gradeability, and stop to ensure the brakes 1.
  • Page 26 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Daily Walk-Around Inspection - Sheet 1 of 4 – JLG Lift – 3121213...

  • Page 27: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION GENERAL 3. Axle Jack/Extension Switches - See Inspection Note; decals in place and legible. Begin the "Walk-Around Inspection" at Item 1, as noted on the 4. All Hydraulic Cylinders - No visible damage; pivot diagram.
  • Page 28 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Drive Hub, Drive Motor and Drive Brake - See 17. Control Valve Compartment - See Inspection Note. Inspection Note. 18. Ground Controls - Switches and controllers opera- 10. Steer/Drive Wheel/Tire Assembly Properly ble;...
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 25. Boom Limit Switches - Properly secured; no damage 28. Oil Filter Housing - See Inspection Note. to cams or switches; cams free from excess dirt and 29. Hydraulic Oil Breather - Element in place; not grease.

  • Page 30: Daily Functional Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION DAILY FUNCTIONAL CHECK 1. From ground controls, activate the machine hydraulic system. A functional check of all systems should be performed, under 2. Position JACK cylinder switch on axle to DOWN and no load, once the walk-around inspection is complete, in an hold until wheels rise from the ground.

  • Page 31: Axle Retraction System

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Axle Retraction System Function Cut-Outs and Restrictions 1. From ground controls, activate the machine hydraulic 1. Platform Gate Interlock system. The engine will not start unless the platform gate is 2. Position JACK cylinder switch on axle to DOWN and closed and latched.
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 4. Tower Boom Horizontal Cut-Out 8. Main Boom Lift Cut-Out With the tower boom above horizontal, HIGH DRIVE and When main boom lift is operating, lift speed automati- 2 SPEED are cut out. In addition, with tower boom cally goes into the creep mode 18°...

  • Page 33: Tower Boom Sequence

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Tower Boom Sequence 2. Visually check the two valves in the turntable to ensure the plungers are fully extended 1. Place the machine on level ground and with the tower boom in the stowed position. Identify the hydraulic valve switch adjacent to the tower lift cylinder at the bottom end (rear) of the tower base boom.

  • Page 34: Tower Boom Lift And Swing Systems

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: If the plunger is not fully extended, contact a qualified ser- 6. Fully retract the tower boom. Lift the main boom several vice technician to further evaluate this condition before feet.

  • Page 35: Platform Leveling Systems

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Platform Leveling Systems 1. Activate hydraulic system. Activate footswitch. Operate TOWER BOOM TELESCOPE and hold controller. Check that platform automatic self-leveling system functions Remove foot from footswitch, motion should stop. If it properly during raising and lowering of boom.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-16 – JLG Lift – 3121213...

  • Page 37: Section 3. Machine Controls And Indicators

    CONTROLS AND INDICATORS be positioned to OFF to prevent draining the battery and burning ignition points. The Model 150HAX is equipped with control panels that use symbols and words to indicate control functions. On 1. Master Switch (Prior to S/N 46291) some machines, the control panels may use symbols only.
  • Page 38 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform/Ground Select Switch 6. Voltmeter three-position, center-off PLATFORM/GROUND With the ignition switch in the ON position, and before SELECT SWITCH supplies operating power to the con- starting the engine, the VOLTMETER indicates the con- trols on the platform control console, when positioned to dition of the battery.
  • Page 39 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Master Switch 2. Platform/Ground Select Switch 3. Axles Set Indicator 4. High Engine Circuit Breaker 5. Hourmeter 6. Voltmeter 7. Oil Pressure Gauge 8. Water Temperature Gauge Figure 3-1. Ground Control Panel - Sheet 1 of 3 3121213 –...
  • Page 40 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Master Switch 2. Platform/Ground Select Switch 3. Axles Set Indicator 4. High Engine Circuit Breaker 5. Hourmeter 6. Voltmeter 7. Oil Pressure Gauge 8. Water Temperature Gauge Figure 3-2. Ground Control Panel - Sheet 2 of 3 –...
  • Page 41 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. N/A 2. Platform/Ground Select Switch 3. Axles Set Indicator 4. High Engine Circuit Breaker 5. Hourmeter 6. Voltmeter 7. Oil Pressure Gauge 8. Water Temperature Gauge 9. Tower Proximity Switch Check Indicator Figure 3-3.

  • Page 42: Ground Control Remote Box

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Remote Box c. Position PLATFORM/GROUND SELECT SWITCH to GROUND. NOTE: If equipped, the Function Enable switch must be held d. Position MASTER SWITCH to ON. down in order to operate Main Boom Telescope, Tower e.
  • Page 43 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Auxiliary Power 2. Platform Rotate 3. Platform Leveling Override 4. Start 5. Creep Speed 6. Emergency Stop 7. Main Telescope 8. Swing 9. Tower Telescope 10. Tower Lift 11. Main Lift 12. Manual Descent Valves (Not Shown) 13.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Emergency Stop Button ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR The EMERGENCY STOP button supplies electrical SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE power from the IGNITION ON relays to the START but- ton when the button is pulled out and the MASTER THE LOAD/OCCUPANT TO SHIFT OR FALL.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Tower Lift Controller 13. Function Enable The TOWER LIFT controller provides raising and lower- If equipped, the enable switch must be held "DOWN" to ing of the tower boom when positioned to UP or DOWN. enable all boom controls when the engine is running.

  • Page 46: Platform Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Station WHEN DRIVING FORWARD AND OPERATING THE REAR STEER WHEELS, THE REAR WHEELS WILL TURN IN THE OPPOSITE DIRECTION OF MACHINE TRAVEL, I.E., DEPRESSING THE LEFT SIDE OF THE ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR ROCKER SWITCH WILL CAUSE THE WHEELS TO TURN TO THE RIGHT.
  • Page 47 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Leveling Override 2. Drive/Steer Lever 3. Tower Telescope Lever 4. Start 5. Choke/Glow Plug Indicator 6. Ignition/Emergency Stop Switch 7. Main Telescope Lever 8. Tower Lift Lever 9. Engine Distress Indicator 10.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Ignition/Emergency Stop Button 11. Broken Chain (CE) The IGNITION/EMERGENCY STOP button, when pulled The red BROKEN CHAIN indicator light will illuminate to out, supplies power to the start button. When warn the operator of a broken fly extend chain in the depressed, the button shuts off machine power in case main boom or a broken fly retract chain in the main of an emergency.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 15. Steer Switch 18. Pump Volume Switch The STEER control controls operation of the front steer The two-position PUMP VOLUME control switch allows wheels of the machine. When the steer switch is posi- the operator to select high pump flow, providing addi- tioned to RIGHT or LEFT, the machine will steer to the tional speed to machine functions when positioned to...
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 21. Chassis Out of Level (Tilt Alarm) Warning Light (Red) 23. Auxiliary Power. A warning light on the control console that lights when The AUXILIARY POWER control switch energizes the the chassis is on a severe slope. electrically-operated hydraulic pump when actuated.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS Auxiliary power is primarily intended for platform lowering 24. Platform Overload (If equipped) in the event of primary power failure. However, auxiliary power may be used for platform positioning when operat- Indicates the platform has been overloaded. ing in close quarters in the following sequence: 25.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: For engine starting, the footswitch must be in the released (up) position. Footswitch must be actuated in order for controls to function. NOTE: The platform gate must be latched in order to operate the machine.

  • Page 53: Section 4. Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom. Capacities The JLG Lift has a primary operator Control Station in the The boom can be raised above horizontal with or without any platform.

  • Page 54: Engine Operation

    SECTION 4 - MACHINE OPERATION 4. Place ENGINE SPEED control switch on platform con- trol console to LOW position. TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD NOTE: Footswitch must be in released (pedal up) position before MACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE. starter will operate.
  • Page 55 SECTION 4 - MACHINE OPERATION The position of Least Forward Stability is with the tower boom fully elevated and fully retracted, with the main boom fully extended at horizontal over the side of the machine. Figure 4-1. Position of Least Forward Stability 3121213 –...
  • Page 56 SECTION 4 - MACHINE OPERATION – JLG Lift – 3121213...

  • Page 57: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION Shutdown Procedure TRAVELING (DRIVING) DO NOT DRIVE WITH BOOMS EXTENDED OR ABOVE HORIZONTAL IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUT- EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE. DOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION.
  • Page 58 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Sideslope – JLG Lift – 3121213...

  • Page 59: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse STEERING To steer machine using front steer wheels, position STEER 1. Depress footswitch and position DRIVE controller/con- control switch on platform control console to RIGHT for trav- trol lever to FORWARD and hold for the duration of for- eling right, or to LEFT for traveling left.

  • Page 60: Platform

    SECTION 4 - MACHINE OPERATION PLATFORM Platform Level Adjustment Loading From Ground Level 1. Leveling UP . To raise platform, position LEVEL control switch to UP and hold until platform is level. 1. Position chassis on a smooth, firm and level surface. 2.

  • Page 61: Boom

    SECTION 4 - MACHINE OPERATION BOOM TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP MACHINE. A RED TILT ALARM WARNING LIGHT IS LOCATED ON THE CONTROL Swinging the Boom CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE (5°...

  • Page 62: Raising And Lowering The Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Boom SHUT-DOWN AND PARK 1. Drive machine to a reasonably well protected area. To raise or lower boom, position LIFT controller (standard controls) or control lever (hydraulic controls) to UP or 2.

  • Page 63: 4.10 Tie Down And Lifting

    SECTION 4 - MACHINE OPERATION 4.10 TIE DOWN AND LIFTING SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING Tie Down LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER. When transporting machine, boom must be in the stowed 4.11 TOWING mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck.
  • Page 64 SECTION 4 - MACHINE OPERATION Figure 4-4. Lifting Diagram 4-12 – JLG Lift – 3121213...
  • Page 65 SECTION 4 - MACHINE OPERATION Figure 4-5. Decal Installation- Sheet 1 of 2 3121213 – JLG Lift – 4-13...
  • Page 66 SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Installation- Sheet 2 of 2 4-14 – JLG Lift – 3121213...

  • Page 67: Decal Installation - Prior To S/N 0300103758

    SECTION 4 - MACHINE OPERATION Table 4-1. Decal Installation - Prior to S/N 0300103758 Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 1706948 3252523 3252523 3252523 3252523 3252523 3252523 1700584 1700584 1700584 1700584 1700584 1700584 1700584...
  • Page 68 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Installation - Prior to S/N 0300103758 Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 1703805 1701488 1701488 1701488 1701488 1701488 1701488 1701488 1700981 1700981 1700981 1700981 1700981 1700981...
  • Page 69 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Installation - Prior to S/N 0300103758 Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 1701436 1701484 1701484 1701484 1701484 1701484 1701484 1701895 1701483 1701483 1701483 1701483 1701483 1701483...
  • Page 70 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Installation - Prior to S/N 0300103758 Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 3252523 3252523 3252523 3252523 3252523 3252523 1703456 1703456 1703456 1703456 1703456 1703456 1703456 1704096...

  • Page 71: Decal Installation - S/N 0300103758 To Present

    SECTION 4 - MACHINE OPERATION Table 4-2. Decal Installation - S/N 0300103758 to Present Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 3252523 3252523 3252523 3252523 3252523 3252523 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1701509...
  • Page 72 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Installation - S/N 0300103758 to Present Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 1703805 1701488 1701488 1701488 1701488 1701488 1701488 1701488 1700981 1700981 1700981 1700981 1700981 1700981...
  • Page 73 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Installation - S/N 0300103758 to Present Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 1701436 1701484 1701484 1701484 1701484 1701484 1701484 1701895 1701483 1701483 1701483 1701483 1701483 1701483...
  • Page 74 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Installation - S/N 0300103758 to Present Item # ANSI Dutch French German Italian Spanish 0257251-2 0252864-2 0252079-2 0252862-2 0252863-2 0253267-2 0252078-4 3252523 3252523 3252523 3252523 3252523 3252523 1703456 1703456 1703456 1703456 1703456 1703456 1703456 1704096...

  • Page 75: Section 5. Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL This section explains the steps to be taken in case of an FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE emergency situation while operating. AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS.

  • Page 76: Emergency Controls And Their Locations

    SECTION 5 - EMERGENCY PROCEDURES 3. Connect suitable equipment, remove chocks, and move machine. CHECK MACHINE DAILY TO MAKE SURE IGNITION/EMERGENCY STOP After moving machine, complete the following procedures: BUTTON IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE. 1.

  • Page 77: Manual Descent And Retraction

    SECTION 5 - EMERGENCY PROCEDURES To activate auxiliary power from the platform: 6. Position MASTER SWITCH to OFF. 1. Position PLATFORM/GROUND SELECT SWITCH to Manual Descent and Retraction PLATFORM. The manual descent valves are used, in the event of total 2.

  • Page 78: Emergency Operation

    SECTION 5 - EMERGENCY PROCEDURES EMERGENCY OPERATION 2. Other qualified personnel on the platform may use the platform controls with regular or auxiliary power. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT Use of Ground Controls FUNCTION NORMALLY. KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SIT- 3.

  • Page 79: Section - 6 - General Specifications & Operator

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary Table 6-1. Operating Specifications information to the operator for proper operation and mainte- Maximum Work Load (Capacity) nance of this machine.

  • Page 80: Capacities

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine NOTE: RPM Tolerances are ± 100. Table 6-2. Capacities Fuel Tank 68 gallons (257 liters) Table 6-3. Cummins 4B3.9C Hydraulic Oil Tank 124 gallons (469 liters) Horsepower 76 @ 2500 RPM, no load Hydraulic System 150 gallons (568 liters) Fuel...

  • Page 81: Tires

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Dimensional Data Table 6-5. Tires Table 6-6. Dimensional Data Turning Radius (Outside) Size Type Pressure w/axles retracted 24 ft. 2 in. (7.4 meters) 445/65R22.5 Foam-Filled w/axles extended 27 ft. 2 in. (8.3 meters) Length Stowed w/main boom fully retracted and 39 ft.

  • Page 82: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If Table 6-7.Hydraulic Oil use of hydraulic oil other than Mobilfluid 424 is desired, con- Hydraulic System Operating...

  • Page 83: Mobil Eal 224 H Specs

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-9. Mobil EAL 224 H Specs Table 6-10. Mobil DTE 13M Specs Type Biodegradable Vegetable Oil Petroleum Base Type ISO Viscosity Grade 32/46 ISO Viscosity Grade Specific Gravity .922 Specific Gravity .877 -25°F (-32°C) Pour Point, Max...

  • Page 84: Critical Stability Weights

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-11. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Table 6-12. Critical Stability Weights Pour Point -76°F (-60°C) Flash Point 217°F (103°C) Counterweight 3285 1490 Viscosity Tire & Wheel Assembly 1020 at 40°...

  • Page 85: Serial Number Locations

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations the machine serial number is stamped on the left side of the frame, below the turntable bearing. In addition, the last five dig- its of the serial number are stamped on the top of the fly end of For machine identification, a serial number plate is affixed to the each of the tower boom and main boom sections.
  • Page 86 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120° F(49° C) NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 110° F(43° C) 100° F(38° C) 90° F(32° C) 80° F(27° C) SUMMER GRADE 70° F(21° C) FUEL ENGINE 60° F(16° C) SPECIFICATIONS 50°...
  • Page 87 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82°C) OR ABOVE. 180° F (82° C) (HYD. OIL TANK TEMP.) AMBIENT AIR TEMPERATURE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE 120°...
  • Page 88 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-4. Operator Maintenance & Lubrication Diagram 6-10 – JLG Lift – 3121213...

  • Page 89: Operator Maintenance

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE NOTE: It is recommended as a good practice to replace all filters at the same time. NOTE: The following numbers correspond to those in Figure 6- 1. Torque Hubs 4., Operator Maintenance & Lubrication Diagram. Table 6-13.
  • Page 90 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Steer Spindles 3. Tie Rod Center Pivot Links Lube Point(s) - 4 Grease Fittings Lube Point(s) - 2 Grease Fittings Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation 6-12...
  • Page 91 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Steer Cylinder Barrel Ends 5. Steer Cylinder Rod Ends Lube Point(s) - 2 Grease Fittings Lube Point(s) - 2 Grease Fittings Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation 3121213...
  • Page 92 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Extending Axles 7. Swing Bearing Gear Lube Point(s) - N/A Lube Point(s) - N/A Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation Comments - Apply by brush Comments - Apply by brush...
  • Page 93 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Lower Master Cylinder Barrel End 9. Tower Boom Lift Cylinder Barrel End Lube Point(s) - 1 Grease Fitting Lube Point(s) - 1 Grease Fitting Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation...
  • Page 94 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Swing Bearing 12. Platform Hinges Lube Point(s) - 2 Grease Fitting Lube Point(s) - 2 Grease Fittings Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation Comments - Remote Fitting on Left Rear of Turntable 13.
  • Page 95 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Platform Rotate Pivot/Rotator Worm Gear Lube Point(s) - 2 Grease Fittings on pivot; 1 Grease Fit- ting on worm gear Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation 15.
  • Page 96 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 16. Level Cylinder Rod End 18. Engine Crankcase Lube Point(s) - 1 Grease Fitting Lube Point(s) - Fill Cap/Drain Plug Capacity - A/R Capacity - 10 quarts (9.5 L) w/o filter Lube - MPG Lube - EO Interval - Every 3 months or 150 hrs of operation Comments - Check daily.
  • Page 97 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 19. Engine Oil Filter 21. Main Boom Extend Chain Sheave Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align access holes in mid and fly boom 22.
  • Page 98 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 23. Main Boom Retract Chain Sheave 25. Tower Boom Pivot Pin Lube Point(s) - 1 Grease Fitting Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Align with access hole in base boom.
  • Page 99 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 26. Level Links 27. Upper Master Cylinder Rod End Lube Point(s) - 3 Grease Fitting Lube Point(s) - 1 Grease Fitting Capacity - A/R Capacity - A/R Lube - MPG Lube - MPG Interval - Every 3 months or 150 hrs of operation Interval - Every 3 months or 150 hrs of operation Comments -...
  • Page 100 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 28. Upper Master Cylinder Barrel End 30. Hydraulic Oil Lube Point(s) - Fill Cap/Drain Plug Capacity - A/R Lube - HO Interval - Check daily. Change every 2 years or 1200 hours Comments - On new machines, those recently over- hauled, or after changing hydraulic oil, operate all sys- tems a minimum of two complete cycles and recheck oil...
  • Page 101 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 32. Air Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 3121213 – JLG Lift – 6-23...

  • Page 102: Tires & Wheels

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE TIRES & WHEELS • any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria, the tire Tire Inflation must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria.
  • Page 103 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque.

  • Page 104: Wheel Torque Chart

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/...

  • Page 105: Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121213 – JLG Lift –...
  • Page 106 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121213...
  • Page 110 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121213 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I.

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