Oshkosh Corporation JLG H800AJ Operation And Safety Manual
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Oshkosh Corporation JLG H800AJ 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
H800AJ
S/N 0300000100 to
0300270863
AS/NZS
ANSI
3121769
®
August 26, 2020 - Rev D

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models H800AJ S/N 0300000100 to 0300270863 AS/NZS ANSI 3121769 ® August 26, 2020 - Rev D...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 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 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 •...
  • Page 6 FOREWORD REVISION LOG A - February 12, 2018 Original Issue B - June 29, 2018 Revised C - December 14, 2018 Revised D - August 26, 2020 Revised – JLG Lift – 3121769...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS FUNCTION CHECK........2-10 From the Ground Control Console with No Load in the GENERAL .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE POWERTRAIN OPERATING MODES....4-7 TOWING ..........4-20 HYBRID Mode .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Safety Precautions ....... . . 6-6 Engine Data .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally – JLG Lift – 3121769...
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-3 4-11.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally – JLG Lift – 3121769...
  • Page 13 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 .
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii – JLG Lift – 3121769...

  • Page 15: Section 1. Safety Precautions

    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.

  • Page 16: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS Workplace Inspection • An operator must not accept operating responsibilities until adequate training has been given by competent and autho- • Precautions to avoid all hazards in the work area must be rized persons. taken by the user before and during operation of the machine. •...

  • Page 17: Machine Inspection

    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.

  • Page 18: Trip And Fall Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature, ambient air temperature, and boom and platform position. approved by JLG. • When two or more persons are in the platform, the operator Trip and Fall Hazards shall be responsible for all machine operations.

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards • Before operating the machine, make sure all gates are closed and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 20 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 21: Tipping Hazards

    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 • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 22 SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions, including gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind platform. Keep all loads within the confines of the platform, unless authorized by JLG.
  • Page 23 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 24: Crushing And Collision Hazards

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

  • Page 25: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 26 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 27: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND nents or when performing welding on the machine. SEEK MEDICAL ATTENTION.
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 – JLG Lift – 3121769...

  • Page 29: 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 The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The aerial platform is a personnel handling device; so it is neces- depressions, holes, or drop-offs exist.

  • Page 30: 2.2 Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance required by JLG Industries, Inc.
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Chassis 2. Ground Console 3. Tower Lift Cylinder 4. Upright Level Cylinder 5. Upright 12 20 6. Main Boom Lift Cylinder 7. Master Cylinder 8. Main Boom Base Section 9. Main Boom Fly Section 10.
  • Page 32 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.

  • Page 33: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection Operation and Safety Manuals – Make sure a copy of the Operation and Safety Manual, AEM Safety Manual (ANSI The Pre-Start Inspection should include each of the following: markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage Cleanliness –...
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 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 obstructions. Refer to IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI- Section 4 for more specific operating instructions.

  • Page 35: Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Walk-Around Inspection Jib - See Inspection Note. Power Track - See Inspection Note. Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the con- All Hydraulic Cylinders - See Inspection Note.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Engine, Clutch Linkage, Integrated Motor Generator - See Tower Boom - No visible damage; wear pads secure. All cyl- Inspection Note. inders - rod end pins and barrel-end pins properly secured. Engine Battery - Proper electrolyte levels;...
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121769 – JLG Lift –...
  • Page 38 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-4. Daily Walk-Around Inspection (Sheet 3 of 3) 2-10 – JLG Lift – 3121769...

  • Page 39: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION FUNCTION CHECK From the Ground Control Console with No Load in the Platform: Ensure that all function controls and switches return to the "off" or neutral position when released. Operate all functions and ensure proper operation. Test the tower boom assembly sequencing as follows: a.
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION the tower boom horizontal limit switch at the end of the tower base boom section is fully extended. The DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED plunger is shown fully extended in Figure 2-6. b.
  • Page 41 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121769 – JLG Lift – 2-13...
  • Page 42 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-14 – JLG Lift – 3121769...

  • Page 43: From The Platform Control Console

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Check the high-drive cutout for the tower boom assembly as e. Attempt to lower the tower base boom while the tower follows: fly boom is extended. The tower base boom should not lower and the red boom malfunction light should illu- a.
  • Page 44 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Check the high-drive cutout for the main boom assembly as With the platform in the stowed position: follows: a. Drive the machine on a grade, not to exceed the rated a. Place machine on level surface with booms retracted gradeability, and stop to ensure the brakes hold;...

  • Page 45: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test NOTE: On machines equipped with SkyLine, reattach magnetic end of the cable to the bracket. NOTE: Refer to Section 4.10, Skyguard Operation for additional infor- If SkyGuard remains activated after function reversal or cutout, mation on SkyGuard operation.

  • Page 46: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST Carefully activate Swing control lever and return boom to (IF EQUIPPED stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- necessary to activate Drive to release cylinders.
  • Page 47 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Carefully activate SWING control lever and position boom over left side of machine. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.
  • Page 48 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-20 – JLG Lift – 3121769...

  • Page 49: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Indicates a potentially hazardous situation, which if THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 50: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS tery packs are, the faster it will blink. When the battery packs are close to being balanced and is equalizing, the light will TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR blink green.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS Charger Status The Charger Status LEDs give a visual TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR indicator of the status of each battery TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE charger.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Balance Indicator 2. Charger Status 3. Platform Rotate 4. Platform Leveling Override 5. Jib 6. Engine Start/Function Enable/Electric Mode 7. Power/Emergency Stop 8. Display Gauge 9. Platform/Ground Select 10. Machine Safety System Override (MSSO) (CE Only) 11.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS This switch provides raising and low- WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST ering of the jib. BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY. Power/Emergency Stop Switch A two-position red mushroom shaped switch NOTE: When Glow Plug Indicator is lighted (Yellow), wait until light...
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS Display Gauge NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope, Tower Telescope, and Platform Rotate control switches are Registers engine hours, fuel level (if applica- spring-loaded and will automatically return to neutral (off) ble), and Diagnostic Trouble Codes (DTCs) when released.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS Main Telescope Control TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT Provides extension and retraction of the main boom. AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE. WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.

  • Page 56: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel Low Fuel Level Indicator Indicates the fuel level is low. The Fuel (See Figure 3-2., Ground Control Indicator Panel) Reserve/Cut-Out System will shut the engine down (or allow it start and run for an addi- Engine Malfunction/Check Engine Indicator tional minute, depending upon machine setup) before the fuel tank is emptied.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Engine Malfunction/Check Engine 4. Glow Plug 6. Platform Overload 2. System Distress Indicator 5. Boom Malfunction 7. Drive and Steer Disable 3. Low Fuel Level Indicator Figure 3-2. Ground Control Indicator Panel 3121769 –...
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS Boom Malfunction Indicator Platform Overload Indicator (If Equipped) If the Boom Malfunction Indicator illumi- Indicates the platform has been overloaded. nates when attempting to activate a tower boom function, the function is being cutout Drive and Steer Disable Indicator (If Equipped) by tower boom limit switch.

  • Page 59: Ground Control Console Display Gauge

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Console Display Gauge (See Figure 3-6., Ground Control Console Display Gauge) The Display Gauge shows engine hours, fuel level (if applicable), and Diagnostic Trouble Codes (DTCs) from both the JLG Control System and the engine control system.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count played to show active faults.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS INDICATOR LAMP BATTERY LEVEL ENGINE HOURS NAVIGATE FORWARD ARROW NAVIGATE BACK ARROW NAVIGATION BUTTONS Figure 3-6. Ground Control Console Display Gauge 3121769 – JLG Lift – 3-13...

  • Page 62: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF (See Figure 3-7.) THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Platform Leveling Override TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE...
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1702676-B 1001222709 B 1702567 A 1702938 100 1 1 4443 3 A 12 11 1. Drive Speed / Torque Select 6. Drive Orientation Override 10. Jib 14. Soft Touch/SkyGuard Indicator 11. Soft Touch/SkyGuard Override 15.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS Horn Drive Orientation Override A push-type Horn switch supplies electrical When the boom is swung over the rear tires or power to an audible warning device when pressed. further in either direction, the Drive Orienta- tion indicator will illuminate when the drive Power/Emergency Stop Switch function is selected.
  • Page 65 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Lift, Swing, and Drive control levers are spring-loaded and will Main Boom Telescope automatically return to neutral (off) position when released. Provides extension and retraction of the main NOTE: To operate the Drive joystick, pull up on the lock- boom.
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS Soft Touch/SkyGuard Override Switch (If equipped) Tower Telescope The machine can be equipped with one of three options. It This switch provides for extending and retract- may have Soft Touch, SkyGuard, or both Soft Touch and Sky- ing of the tower boom when positioned to in Guard.
  • Page 67 SECTION 3 - MACHINE CONTROLS AND INDICATORS Soft Touch/SkyGuard Indicator (If Equipped) NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. Indicates the Soft Touch bumper is against an object or the NOTE: SkyGuard sensor has been activated.

  • Page 68: Platform Console Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console Indicator Panel IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, (See Figure 3-8., Platform Console Indicator Panel) RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.
  • Page 69 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. AC Generator 5. Footswitch/Enable 9. Boom Malfunctgion 2. Overload 6. Battery Charge 10. Drive Orientation 3. Tilt 7. Creep 11. Low Fuel Level 4. Glow Plug/Wait to Start 8. System Distress Figure 3-8. Platform Console Indicator Panel 3121769 –...
  • Page 70 SECTION 3 - MACHINE CONTROLS AND INDICATORS Footswitch/Enable Indicator Battery Charge Indicator To operate any function, the footswitch must This indicator lights to show the state-of- be depressed and the function selected within charge of the battery packs.. seven seconds. The enable indicator shows that the controls are enabled.
  • Page 71 SECTION 3 - MACHINE CONTROLS AND INDICATORS Boom Malfunction Indicator Drive Orientation Indicator When an audible alarm sounds and the Boom When the boom is swung beyond the rear Malfunction Indicator illuminates when drive tires or further in either direction, the attempting to activate a tower boom function, Drive Orientation indicator will illuminate the function is being cutout by tower boom limit switch.
  • Page 72 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-24 – JLG Lift – 3121769...

  • Page 73: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION Load is within manufacturer’s rated capacity. All machine systems are functioning properly. This machine is a mobile elevating work platform used to posi- tion personnel, along with their necessary tools and materials at Machine is as originally equipped from JLG work locations.
  • Page 74 SECTION 4 - MACHINE OPERATION BOOM FULLY EXTENDED AT HORIZONTAL (0 DEGREES) TOWER BOOM AT MAX ANGLE AND FULLY RETRACTED Figure 4-1. Position of Least Forward Stability – JLG Lift – 3121769...
  • Page 75 SECTION 4 - MACHINE OPERATION MAIN BOOM FULLY RETRACTED AND FULLY ELEVATED TOWER BOOM FULLY RETRACTED AND LOWERED MACHINE WILL UPSET IN THIS DIRECTION IF OPERATED ON AN OUT-OF-LEVEL SURFACE LEVEL SURFACE Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2) 3121769 –...
  • Page 76 SECTION 4 - MACHINE OPERATION Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2) – JLG Lift – 3121769...

  • Page 77: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION Turn key of Platform/Ground Select switch to Ground. NOTE: Initial starting should always be per- formed from the Ground Control con- sole. Pull the Power/Emergency Stop switch to On. Push the Engine Start switch until engine starts. 1001223567 B Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING...

  • Page 78: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION From Platform, pull Power/Emergency Stop Turn Platform/Ground Select switch to Off. switch out. Refer to Engine Manufacturer’s manual for detailed information. Push the Engine Start switch until engine starts. Engine Warmup When it is below 32°F (0°C), the clutch is disengaged from the engine when started.

  • Page 79: Powertrain Operating Modes

    SECTION 4 - MACHINE OPERATION POWERTRAIN OPERATING MODES The engine drives the IMG to generate electricity to charge the battery pack and also drive the hydraulic pumps to provide The powertrain system consists of the engine, clutch, Integrated energy needed to operate boom functions and drive functions. Motor Generator (IMG), and hydraulic pumps.

  • Page 80: Electric Mode

    SECTION 4 - MACHINE OPERATION ELECTRIC Mode Switching Between Modes In Electric mode, the engine does not run and the If the selection switch is changed from HYBRID Mode to ELECTRIC clutch is disengaged. The machine operates all Mode position while the engine is running, the clutch will disen- functions using battery power only to drive the gage and the engine will stop automatically.

  • Page 81: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND See Figure 4-4., Grade and Sideslopes LEVEL SURFACE. NOTE: Refer to the Operating Specifications table for Gradeability and Sideslope ratings. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.
  • Page 82 SECTION 4 - MACHINE OPERATION LEVEL Figure 4-4. Grade and Sideslopes 4-10 – JLG Lift – 3121769...

  • Page 83: Traveling Forward And Reverse

    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 and activate footswitch. trol panel and the chas- sis to determine the direction the machine will travel.

  • Page 84: Traveling On A Grade

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

  • Page 85: 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 EMER- GENCY STOP TO STOP THE MACHINE. A RED TILT WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE.

  • Page 86: Raising And Lowering The Tower Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Tower Boom b. The Tower lift “down” will only operate when the Tower Boom is fully retracted. This machine has two controls for the tower boom (two toggle switches), one controls tower lift, the other tower telescope. The switching system will sequence its Lift and Telescope functions as follows: Sequence while raising the Tower Boom from the fully low-...

  • Page 87: Raising And Lowering The Main Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Main Boom SHUT DOWN AND PARK To raise or lower the Main Boom, position the Main Drive machine to a protected area. Boom Lift switch to Up or Down until the desired Assure boom is fully retracted and lowered over rear (Drive) height is reached.

  • Page 88: Battery Charging

    SECTION 4 - MACHINE OPERATION BATTERY CHARGING The machine incorporates two battery chargers (primary and a ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET. DO secondary) which operate on 220V or 110V. Both chargers oper- NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH NON-INSULATED ate initially and the primary does the finish charging.

  • Page 89: Machine Safety System Override (Msso)

    SECTION 4 - MACHINE OPERATION MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE SkyGuard ONLY) The Machine Safety System Override (MSSO) is used to override function controls for Emergency Platform Retrieval only. Refer to Section 5.5, MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) for operating procedures. 4.10 SKYGUARD OPERATION OAC00110 OAC00110...
  • Page 90 SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye OAC00130 AC00130 OAC00140 OAC00140 Reattach magnetic end of cable to bracket if it becomes discon- Operator passes through path of sensor beam. nected. Table 4-1. SkyGuard Function Table Tower Tower Tower Boom Boom Boom Boom...

  • Page 91: 4.11 Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.11 LIFTING AND TIE DOWN Tie Down See Figure 4-6. Lifting WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. Refer to the Serial Number Plate, refer to the Specifications NOTE: section of this manual, or weigh the individual unit to find Putting the platform in certain positions for transporting may...
  • Page 92 SECTION 4 - MACHINE OPERATION 81.05” 58.14” [2059mm] [1477mm] 1001233452A Figure 4-6. Lifting Chart 4-20 – JLG Lift – 3121769...

  • Page 93: Towing

    SECTION 4 - MACHINE OPERATION TOWING TOW BAR (IF EQUIPPED) The machine is not equipped with a tow package. Refer to Sec- tion 5 for emergency towing procedures. 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.
  • Page 94 SECTION 4 - MACHINE OPERATION Figure 4-7. Tow Bar 4-22 – JLG Lift – 3121769...

  • Page 95: 4.10 Re-Synchronize Upright

    SECTION 4 - MACHINE OPERATION 4.10 RE-SYNCHRONIZE UPRIGHT Position steer/tow selector valve for towing; pull valve knob out for towing. The machine is now in the towing mode. Releveling Valve After towing the machine, complete the following: A pull type control valve allows the operator to adjust the upright Actuate steer/tow selector valve for steering;...
  • Page 96 SECTION 4 - MACHINE OPERATION Lower the tower boom fully and con- tinue to hold down the switch to Tower Down for an additional 20 sec- onds. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis. Figure 4-8.
  • Page 97 SECTION 4 - MACHINE OPERATION FRONT OF MACHINE ENGINE SIDE VIEW SEE DETAIL A 24 27 DETAIL A TANK SIDE VIEW FRONT OF MACHINE Figure 4-9. Decal Installation - Sheet 1 of 19 3121769 – JLG Lift – 4-25...
  • Page 98 SECTION 4 - MACHINE OPERATION FRONT VIEW REAR VIEW Figure 4-10. Decal Installation - Sheet 2 of 19 4-26 – JLG Lift – 3121769...
  • Page 99 SECTION 4 - MACHINE OPERATION FRONT OF MACHINE TOP VIEW Figure 4-11. Decal Installation - Sheet 3 of 19 3121769 – JLG Lift – 4-27...
  • Page 100 SECTION 4 - MACHINE OPERATION INSIDE ACCESS DOOR ENGINE SIDE VIEW TANK SIDE VIEW Figure 4-12. Decal Installation - Sheet 4 of 19 4-28 – JLG Lift – 3121769...
  • Page 101 SECTION 4 - MACHINE OPERATION INSIDE ACCESS DOOR ENGINE SIDE VIEW TANK SIDE VIEW Figure 4-13. Decal Installation - Sheet 5 of 19 3121769 – JLG Lift – 4-29...
  • Page 102 SECTION 4 - MACHINE OPERATION INSIDE ACCESS DOOR ENGINE SIDE VIEW HOOD DECALS CE MARKET ONLY TANK SIDE VIEW Figure 4-14. Decal Installation - Sheet 6 of 19 4-30 – JLG Lift – 3121769...
  • Page 103 SECTION 4 - MACHINE OPERATION ENGINE SIDE VIEW HOOD DECALS AUS MARKET ONLY TANK SIDE VIEW Figure 4-15. Decal Installation - Sheet 7 of 19 3121769 – JLG Lift – 4-31...
  • Page 104 SECTION 4 - MACHINE OPERATION FRONT VIEW REAR VIEW ANSI, ANSI EXPORT, CSA, JAPAN, CHINA HOOD DECALS Figure 4-16. Decal Installation - Sheet 8 of 19 4-32 – JLG Lift – 3121769...
  • Page 105 SECTION 4 - MACHINE OPERATION FRONT VIEW REAR VIEW CE ONLY HOOD DECALS Figure 4-17. Decal Installation - Sheet 9 of 19 3121769 – JLG Lift – 4-33...
  • Page 106 SECTION 4 - MACHINE OPERATION FRONT VIEW REAR VIEW AUS ONLY HOOD DECALS Figure 4-18. Decal Installation - Sheet 10 of 19 4-34 – JLG Lift – 3121769...
  • Page 107 SECTION 4 - MACHINE OPERATION TYPICAL BOTH SIDES TYPICAL BOTH SIDES ANSI, ANSI EXPORT, CSA, JAPAN, CHINA CE & AUS ONLY BOOM UPRIGHT Figure 4-19. Decal Installation - Sheet 11 of 19 3121769 – JLG Lift – 4-35...
  • Page 108 SECTION 4 - MACHINE OPERATION CE & AUS MARKETS ANSI, ANSI EXPORT, CSA, JAPAN, CHINA FRONT PLATFORM DECALS Figure 4-20. Decal Installation - Sheet 12 of 19 4-36 – JLG Lift – 3121769...
  • Page 109 SECTION 4 - MACHINE OPERATION CE & AUS ONLY ANSI, ANSI EXPORT, CSA, JAPAN, CHINA PLATFORM DECALS Figure 4-21. Decal Installation - Sheet 13 of 19 3121769 – JLG Lift – 4-37...
  • Page 110 SECTION 4 - MACHINE OPERATION CE & AUS ONLY ANSI, ANSI EXPORT, CSA, JAPAN, CHINA DECAL PANEL ANSI, ANSI EXPORT, CSA, JAPAN, CHINA PLATFORM CONSOLE Figure 4-22. Decal Installation - Sheet 14 of 19 4-38 – JLG Lift – 3121769...
  • Page 111 SECTION 4 - MACHINE OPERATION PLATFORM DECALS Figure 4-23. Decal Installation - Sheet 15 of 19 3121769 – JLG Lift – 4-39...
  • Page 112 SECTION 4 - MACHINE OPERATION FUEL TANK DECALS ALL MARKETS ENGINE RADIATOR SUPPORT Figure 4-24. Decal Installation - Sheet 16 of 19 4-40 – JLG Lift – 3121769...
  • Page 113 SECTION 4 - MACHINE OPERATION 12 VOLT ELECTRICAL BOX HYDRAULIC TANK DECALS HYDRAULIC TANK DECALS ANSI EXPORT, CSA, CE, AUS, JAPAN, CHINA ANSI ONLY IMG CONTROL BOX Figure 4-25. Decal Installation - Sheet 17 of 19 3121769 – JLG Lift – 4-41...
  • Page 114 SECTION 4 - MACHINE OPERATION FRONT VIEW UNDER HOOD DECALS BATTERY BOXES & CHARGERS Figure 4-26. Decal Installation - Sheet 18 of 19 4-42 – JLG Lift – 3121769...
  • Page 115 SECTION 4 - MACHINE OPERATION FRONT VIEW UNDER HOOD DECALS BATTERY BOXES & CHARGERS Figure 4-27. Decal Installation - Sheet 19 of 19 3121769 – JLG Lift – 4-43...
  • Page 116 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend Item # ANSI Korean Chinese Spanish Portuguese French Japanese 1001223542-D 1001223546-B 1001223548-B 1001223549-B 1001223550-B 1001223547-B 1001223544-D 1001223545-B 1001223543-D 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701501 1701501 1701501 1701501 1701501 1701501 1701501...
  • Page 117 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend Item # ANSI Korean Chinese Spanish Portuguese French Japanese 1001223542-D 1001223546-B 1001223548-B 1001223549-B 1001223550-B 1001223547-B 1001223544-D 1001223545-B 1001223543-D 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1704277 1704277 1704277 1704277 1704277 1704277 1704277...
  • Page 118 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend Item # ANSI Korean Chinese Spanish Portuguese French Japanese 1001223542-D 1001223546-B 1001223548-B 1001223549-B 1001223550-B 1001223547-B 1001223544-D 1001223545-B 1001223543-D 1001131269 1001131269 1001174449 1001174449 1001174449 1001174449 1001174449 1001174449 1001174449 1001174449 1001174449 1001223055 1001224048 1001224050 1001224049 1001224052...
  • Page 119 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend Item # ANSI Korean Chinese Spanish Portuguese French Japanese 1001223542-D 1001223546-B 1001223548-B 1001223549-B 1001223550-B 1001223547-B 1001223544-D 1001223545-B 1001223543-D 1001232893 1001233452 1001233452 1001233452 1001233452 1001233452 1001233452 1001233452 1001233452 1001233452 1001204510 1001204510 1001117307 1001117307 1001117307 1001117307...
  • Page 120 SECTION 4 - MACHINE OPERATION 4-48 – JLG Lift – 3121769...

  • Page 121: Section 5 - Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. 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.

  • Page 122: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead EMERGENCY TOWING PROCEDURES If the platform or boom becomes jammed or snagged in over- Towing this machine is prohibited, unless properly equipped. head structures or equipment, do the following: However, provisions for moving the machine have been incorpo- rated.
  • Page 123 SECTION 5 - EMERGENCY PROCEDURES Pull out the Power/Emergency Stop control. Start the engine. Press and hold the MSSO switch and the control switch for the desired function. 3121769 – JLG Lift –...
  • Page 124 SECTION 5 - EMERGENCY PROCEDURES – JLG Lift – 3121769...

  • Page 125: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Fall Arrest Platform (36" x 96")     Fall Arrest Platform (36" x 72")     Pipe Racks ...
  • Page 126 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Platform MMR**, Platform MTR*, Pipe Racks SkyPower™ SkyCutter, SkyGlazier, SkyWelder Soft Touch 4’ Platform, Pipe Racks, Platform SkyGlazier™ SkyPower™...

  • Page 127: Fall Arrest Platform

    SECTION 6 - ACCESSORIES FALL ARREST PLATFORM PIPE RACKS NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform.

  • Page 128: Capacity Specifications (Australia Only)

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

  • Page 129: Skyglazier

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

  • Page 130: Safety Precautions

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

  • Page 131: Skypower

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

  • Page 132: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Preparation and Inspection • Ensure generator is secure. • Check condition of belt and wiring. DO NOT OVERLOAD PLATFORM. Operation • Ensure no personnel are beneath platform. Start the engine, then turn on the generator. •...

  • Page 133: Skywelder

    SECTION 6 - ACCESSORIES SKYWELDER™ Generator Output Engine Speed of 1800 rpm +/- 10%. ANSI Specifications: • 3-phase: 240 V, 60 Hz, 7.5 kW • 1-phase: 240 V/120 V, 60 Hz, 6 kW CE Specifications: • 3-phase: 400 V, 50 Hz, 7.5 kW •...

  • Page 134: Accessory Ratings

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

  • Page 135: Preparation And Inspection

    SECTION 6 - ACCESSORIES SOFT TOUCH • Use correct rod size and current settings. • Do not use electrical cords without ground. A padding kit is mounted to the platform rails and to a frame sus- • Do not use electrical tools in water. pended below the platform.
  • Page 136 SECTION 6 - ACCESSORIES OVERRIDE SWITCH OVERRIDE SWITCH OVERRIDE INDICATOR LIGHT OVERRIDE INDICATOR LIGHT RAIL BUMPER RAIL BUMPER LIMIT SWITCH LIMIT SWITCH SOFT TOUCH RAIL SOFT TOUCH RAIL & BUMPER & BUMPER SOFT TOUCH FRAME LIMIT SWITCH SOFT TOUCH FRAME LIMIT SWITCH Figure 6-1.

  • Page 137: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS AND PERFORMANCE DATA This section of the manual provides additional necessary infor- mation to the operator for proper operation and maintenance of Operating Specifications this machine.

  • Page 138: Tires

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Batteries Table 7-1. Operating Specifications Ground Clearance 11" (28 cm) The machine has two (2) separate battery systems: 12V and 84V. Machine Height Stowed 9 ft. 9.5 in.(2.98 m) The 12V system powers the control modules (e.g., UGM), hydraulic Machine Length (Stowed) 36 ft.-6 in.

  • Page 139: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Data Table 7-4. Capacities Table 7-5. Kubota D1305 Fuel Tank Approx. 25 gallons (94.6 liters) Fuel Diesel Hydraulic Tank Approx. 40 gallons (151.4 liters) No. of Cylinders Hydraulic System (Including Tank) 65 Gal.

  • Page 140: Hydraulic Oil

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of differ- ent brands or types, as they may not contain the same required addi- tives or be of comparable viscosities. If use of hydraulic oil other than Table 7-6.
  • Page 141 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-9. UCon Hydrolube HP-5046 Table 7-8. Mobil DTE 10 Excel 32 Specs Type Synthetic Biodegradable ISO Viscosity Grade Specific Gravity 1.082 Specific Gravity 0.877 Pour Point, Max -58°F (-50°C) Pour Point, Max -40°F (-40°C) Flash Point, Min.
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-10. Mobil EAL 224H Specs Table 7-11. Exxon Univis HVI 26 Specs Type Synthetic Biodegradable Specific Gravity 32.1 ISO Viscosity Grade 32/46 Pour Point -76°F (-60°C) Specific Gravity .922 Flash Point 217°F (103°C) Pour Point, Max -25°F (-32°C)

  • Page 143: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-12. Critical Stability Weights COMPONENTS LBS. Tire & Wheel Size 15-625 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT (Foam Filled Only) 18 -625 OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY.
  • Page 144 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTICE: MACHINE OPERATION USING NON-JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "ENGINE OIL OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE. 1001222023 B Figure 7-1.
  • Page 145 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1001228397 B Figure 7-2. Hydraulic Oil Operating Temperature Specifications - Sheet 1 of 2 3121769 – JLG Lift –...
  • Page 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fluid Base Properties Classification NOTICE: MACHINE OPERATION USING NON-JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE "HYDRAULIC FLUID OPERATION CHART" MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC SYSTEM.
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8,9,10,11 Figure 7-4. Maintenance and Lubrication Diagram 3121769 – JLG Lift – 7-11...

  • Page 148: Maintenance And Lubrication

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MAINTENANCE AND LUBRICATION Swing Bearing - Internal Ball Bearing NOTE: The following numbers correspond to those in Figure 7-4., Main- tenance and Lubrication Diagram. Table 7-13. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel- lent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 149 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Drive Hub Oil Change w/Filter Lube Point(s) - Level/Fill Plug Capacity - 17 oz. (0.5 L) - 1/2 Full Lube - EPGL Lube Point(s) - Fill Cap/Spin-on Element Interval - Check level every 3 months or 150 hrs of operation; Capacity - 6 qt.
  • Page 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fuel Filter/Water Separator Fuel Strainer Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Drain water daily; Change every year or 600 hours of Interval - Change every year or 600 hours of operation operation 7-14 –...
  • Page 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Radiator Swing Drive Hub Lube Point(s) - Fill Cap Lube - Anti-Freeze Coolant (Refer to Engine Manual for com- patible coolants) Capacity - 6 qt. (5.7 L) Lube Point(s) - Level/Fill Plug Capacity - 43 oz.
  • Page 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Return Filter Hydraulic Charge Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Interval - Change after first 50 hrs. and every 6 months or 300 hrs.
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Tank Air Filter Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indi- cated by the condition indicator Lube Point(s) - Fill Cap Capacity - 25 gallons (94.5 L) total capacity, 21 gallons (79.5 L) to Full Mark on Sight Gauge;...

  • Page 154: Tires & Wheels

    SECTION 7 - 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 155: Wheel Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation It is extremely important to apply and maintain proper wheel The rims installed on each product model have been designed for mounting torque. stability requirements which consist of track width, tire pressure, and load capacity.
  • Page 156 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tighten nuts in the following sequence: The tightening of the nuts should be done in stages. Follow- ing the recommended sequence, tighten nuts per wheel torque chart. Table 7-14. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage...

  • Page 157: Supplemental Information

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A) For combustion engine powered machines, guaranteed Sound...
  • Page 158 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 7-22 – JLG Lift – 3121769...

  • Page 159: Section 8 - Inspection And Repair Log

    SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121769 – JLG Lift –...
  • Page 160 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments – JLG Lift – 3121769...
  • Page 164 3121769 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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