JLG 740AJ Operation And Safety Manual
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JLG 740AJ Operation And Safety Manual

JLG 740AJ 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
740AJ
S/N 0300185828 to
Present
3121654
November 5, 2018 - Rev G

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Summary of Contents for JLG 740AJ

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 740AJ S/N 0300185828 to Present 3121654 November 5, 2018 - Rev G...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

  • Page 4: Safety Alert Symbols And Safety Signal Words

    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: Outside Usa

    Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.

  • Page 6: Revision Log

    FOREWORD REVISION LOG Original Issue A - March 31, 2014 Revised B - April 30, 2014 Revised C - June 10, 2014 Revised D - January 5, 2015 Revised E - August 3, 2015 Revised F - March 23, 2018 Revised G - November 5, 2018 3121654...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS FUNCTION CHECK........2-9 From Ground Control Station with No Platform GENERAL .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE ENGINE OPERATION ....... . . 4-5 4.12 TOWING .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE EMERGENCY TOWING PROCEDURES ....5-2 Tire Replacement ....... . 7-22 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) Wheel Replacement .
  • Page 10 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature ....... . . 2-5 4-8.
  • Page 11 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 12 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 13: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 14: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 15: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 16: Trip And Fall Hazards

    • During operation, occupants in the platform must wear a full • Supplies or tools which extend outside the platform are pro- body harness with a lanyard attached to an authorized lanyard hibited unless approved by JLG. anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

  • Page 17: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed • Use extreme caution when entering or leaving platform. Be and fastened in their proper position. sure that the boom is fully lowered. Refer to Section 2.5 for additional information on the proper use of the Fall Arrest Sys- tem.
  • Page 18 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 19: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 20 Keep all loads within the confines of the platform, mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Refer- unless authorized by JLG. ence Only). • Keep the chassis of the machine a minimum of 2 ft. (0.6m) •...
  • Page 21 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 22: 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 23: 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 24 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 25: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 26 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 27: 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 5. Enough knowledge of mechanical operation of the machine to recognize a malfunction or potential malfunction. The aerial platform is a personnel handling device; so it is neces- 6.

  • Page 28: 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 29 JLG inspection form (Recommended) Preventative Maintenance At intervals specified in Service and Maintenance Manuals. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121654...

  • Page 30: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-2. and Figure 2-3. The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7.
  • 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 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 Figure 2-2. Daily Walk-Around Inspection (Sheet 1 of 3) 3121654...

  • Page 33: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 4. Jib - See Inspection Note. 5. Dual Capacity Limit Switch (ANSI, Australia, if equipped); Begin the "Walk-Around Inspection" at Item 1, as noted on the Transport Position Limit Switch (CE) - Properly secured, no diagram.
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 13. Fuel Tank - See Inspection Note. 20. Tower Boom - No visible damage; wear pads secure. All cyl- inders - rod end pins and barrel-end pins properly secured. 14. Swing Drive Motor and Brake - See Inspection Note.

  • Page 35: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION FUNCTION CHECK 2. Raise tower base boom to approximately 40 degrees, then lower the tower boom back to the below horizontal position. Perform a function check of all systems, once the walk-around While raising and lowering tower boom assembly, observe inspection is complete, in an area free of overhead and ground position of the upright.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-10 3121654...
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121654 2-11...

  • Page 38: From Platform Control Station

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION From Platform Control Station c. Check adjustment of footswitch. Footswitch must be adjusted so that functions will operate when pedal is 1. Check control console is secure and all guards protecting the approximately at its center of travel.
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 5. Drive forward and reverse; check for proper operation. 8. Check the high-drive cutout for the main boom assembly as follows: 6. Steer left and right; check for proper operation. a. Place machine on level surface with booms retracted 7.
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 10. Check Tilt Alarm and Warning System as follows: 14. If equipped with 4-wheel steer, check rear steer left and right for proper operation. 15. If equipped, raise and lower articulating jib boom. Check for smooth operation.

  • Page 41: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test NOTE: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing. NOTE: Refer to Section 4.9 for additional information on SkyGuard 4. Disengage the SkyGuard sensor, release controls, then recy- operation.

  • Page 42: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST 8. 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 43: Inspection And Use Of Fall Arrest System

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION INSPECTION AND USE OF FALL ARREST SYSTEM THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTI- The external fall arrest system is designed to provide a lanyard attach FICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A point while allowing the operator to access areas outside the plat- COMPETENT PERSON.

  • Page 44: External Fall Arrest System Types

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION External Fall Arrest System Types Inspection Before Use The external fall arrest system must be inspected before each use of NOTE: There are two types of External Fall Arrest Systems - Transfastener the aerial work platform.

  • Page 45: Inspecting Line Tenser

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Inspecting Line Tenser Cable tension is adjusted using the Line Tenser. The Line Tenser is the disc at the end of the cable (as shown in Figure 2-8. and Figure 2-9.). When proper tension is achieved, the disc will spin by hand.

  • Page 46: Inspecting Slip Indicator

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Inspecting Slip Indicator Shown below is the slip indicator with a gap, signifying external fall arrest system should be replaced immediately. The slip indicator is the short tube crimped beside the end connec- tion of the cable.
  • Page 47 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Transfastener 2. Bracket 3. Cable 4. Swage/Slip Indicator 5. Turnbuckle 6. Line Tenser Figure 2-12. Fall Arrest System - Transfastener Type 3121654 2-21...
  • Page 48 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Shuttle 2. Bracket 3. Cable 4. Swage/Slip Indicator 5. Turnbuckle 6. Line Tenser Figure 2-13. Fall Arrest System - Shuttle Type 2-22 3121654...

  • 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 TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE THE PLATFORM.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Switch/Function Enable 6. Hourmeter 7. Platform/Ground Select 8. Swing 9. Tower Lift 10. Main Boom Lift 11. Main Boom Telescope Figure 3-1.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Switch/Function Enable 6. Hourmeter 7. Platform/Ground Select 8. Swing 9. Tower Lift 10. Main Boom Lift 11. Main Boom Telescope 12.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When Power/Emergency Stop switch is in the “On” position and 5. Engine Start/ Auxiliary Power Switch /Function engine is not running, an alarm will sound, indicating Ignition is Enable “On”. To start engine, switch must be held "Up" until engine starts. To use auxiliary power, switch must be held “Down”...
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Hourmeter NOTE: When Platform/Ground Select Switch is in the center position, power is shut off to controls at Registers amount of time machine has both operating stations. Remove key to prevent been in use, with engine running. By controls from being actuated.

  • Page 55: Swing Control

    SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope, 9. Tower Lift Tower Telescope, Platform Rotate, and Auxiliary Power control switches are spring-loaded and will automatically return to neu- This switch provides raising and low- tral (off) when released.

  • Page 56: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 12. Machine Safety System Override (MSSO) 4. Engine Oil Temperature Indicator (Deutz, If Equipped) Provides emergency override of function controls that are locked out in the event of Indicates temperature of the engine oil, which Load Sense System activation.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. No Alternator Output 4. High Engine Oil Temperature 7. Platform Overload 2. Low Engine Oil Pressure 5. Glow Plug 8. Drive and Steer Disable 3. High Engine Coolant Temperature 6. Boom Malfunction Figure 3-3.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Boom Malfunction Indicator 7. Platform Overload Indicator. (If Equipped) If the Boom Malfunction Indicator illumi- Indicates platform has been overloaded. nates when attempting to activate a tower 8. Drive and Steer Disable Indicator (If equipped) boom function, the function is being cutout by tower boom limit switch.

  • Page 59: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console 2. Steer Select (If Equipped) When equipped with four wheel steering, the (See Figure 3-4.) action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaf- TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR fected.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Drive Speed / Torque Select 6. Engine Start / Aux Power 11. Lights 15. Soft Touch/SkyGuard Indicator 2. Steer Select 7. Fuel Select 12. Jib 16. Platform Rotate 3. Platform Level Override 8.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Engine Start/Auxiliary Power To start engine, switch must be held "UP" until ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF the engine starts. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL.
  • Page 62 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Drive Orientation Override NOTE: Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) position when released. When the boom is swung over the rear tires or further in either direction, the Drive Orienta- tion indicator will illuminate when the drive function is selected.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Main Boom Telescope 13. Soft Touch/SkyGuard Override Switch (If equipped) Provides extension and retraction of the main The machine can be equipped with one of three options. It boom. may have Soft Touch, SkyGuard, or both Soft Touch and Sky- Guard.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS 14. Tower Lift 17. Function Speed Control This switch provides for raising and lowering of This control affects the speed of telescope the tower boom when positioned to “up” or and platform rotate. Turning the knob all “down”.

  • Page 65: Platform Console Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console Indicator Panel 2. Platform Overload (If equipped) Indicates platform has been overloaded. (See Figure 3-5., Platform Console Indicator Panel) 1. Tilt Alarm Warning Light and Alarm 3. Boom Malfunction Indicator This red illuminator indicates chassis is on an When an audible alarm sounds and the Boom excessive slope.
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Tilt 5. Enable 9. AC Generator 2. Overload 6. Glow Plug 10. Drive Orientation 3. Boom Malfunction 7. Low Fuel 11. Creep 4. Capacity 8. System Distress Figure 3-5. Platform Console Indicator Panel 3-18 3121654...
  • Page 67 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Capacity Indicator 5. Footswitch/Enable Indicator Indicates maximum platform capacity for cur- To operate any function, the footswitch must rent platform position. Restricted capacities be depressed and the function selected within are permitted at restricted platform positions seven seconds.
  • Page 68 8. System Distress Indicator the proper direction (i.e. controls reversed situations). The light indicates the JLG Control System has 11. Creep Speed Indicator detected an abnormal condition and a Diag-...
  • Page 69 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 70: Section 4 - Machine Operation

    4. Proper tire pressure. boom. 5. Machine is as originally equipped from JLG The primary operator control station is in the platform. From this Stability control station, the operator can drive and steer the machine in both forward and reverse directions.
  • Page 71 SECTION 4 - MACHINE OPERATION AT HORIZONTAL (0 DEGREES) MACHINE WILL UPSET IN THIS TOWER BOOM DIRECTIO N IF OVERLO ADED AT MAX ANGLE O R O PERATED O N AN O UT-OF-LEVEL SURFACE. LEVEL SURFACE Figure 4-1. Position of Least Forward Stability 3121654...
  • Page 72 SECTION 4 - MACHINE OPERATION RETRACTED AND FULLY RETRACTED TOWER BOOM FULLY 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) 3121654...
  • Page 73 SECTION 4 - MACHINE OPERATION Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2) 3121654...

  • Page 74: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION 2. Pull the Power/Emergency Stop switch to On. NOTE: Initial starting should always be per- formed from the Ground Control station. 3. Push the Engine Start switch until engine starts. Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

  • Page 75: Shutdown Procedure

    The Fuel Shutoff System monitors fuel in the tank and senses tion, DO NOT OPERATE MACHINE. when the fuel level is getting low. The JLG Control System auto- matically shuts the engine down before the fuel tank is emptied Shutdown Procedure unless the machine is set up for Engine Restart.

  • Page 76: Traveling (Driving)

    All ratings for Gradeability and Sideslope are based on the machine’s boom being in the stowed position, fully lowered, and retracted. CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE. Traveling is limited by two factors: •...
  • Page 77 SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Sideslopes 3121654...

  • Page 78: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND 1. At Platform Controls, pull out Emergency Stop LEVEL SURFACE. switch and activate footswitch. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

  • Page 79: Steering

    SECTION 4 - MACHINE OPERATION 1. Match the black and STEERING white direction arrows on both platform con- Position thumb switch on Drive/Steer controller to trol panel and the chas- Right for steering right, or to Left for steering left. sis to determine the PLATFORM direction the machine...

  • Page 80: Boom

    SECTION 4 - MACHINE OPERATION BOOM Swinging the Boom To swing boom, use Swing control switch to select Right or Left direction. AN ORANGE TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE. DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT.

  • Page 81: Raising And Lowering The Tower Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Tower Boom Telescoping the Main Boom To raise or lower the Tower Boom, depress footswitch, To extend or retract the main boom, use the Main position Tower Lift controller Up or Down, and hold Telescope Control Switch to select In or Out move- until the desired height is reached.

  • Page 82: Skyguard Operation

    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.

  • Page 83: Skyguard Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard SkyEye Reattach magnetic end of cable to bracket if it becomes discon- nected. Operator passes through path of sensor beam. SkyGuard Function Table Tower Boom Drive Drive Tower Boom Boom Boom Basket Basket Steer Swing Lift Lift...

  • Page 84: 4.10 Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.10 SHUT DOWN AND PARK 1. Drive machine to a protected area. 2. Assure boom is fully retracted and lowered over rear (Drive) axle; all access panels and doors closed and secured. 3. Remove all load and allow engine to operate 3-5 minutes at idle to permit reduction of engine internal temperatures.

  • Page 85: 4.11 Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.11 LIFTING AND TIE DOWN Tie Down See Figure 4-5. Lifting WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. 1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find 1.
  • Page 86 SECTION 4 - MACHINE OPERATION "A" Dimension Steer Axle To Center Of Gravity 52" (1320 mm) LIFT HERE (SPREADER BAR REQUIRED) CENTER G RAVITY "A" L ROTATION Figure 4-5. Lifting Chart 3121654 4-17...

  • Page 87: 4.12 Towing

    SECTION 4 - MACHINE OPERATION 4.12 TOWING 3. Disconnect drive hubs by inverting disconnect cap. 4. Position steer/tow selector valve for towing; pull valve knob The machine is not equipped with a tow package. Refer to Sec- out for towing. The machine is now in towing mode. tion 5 for emergency towing procedures.
  • Page 88 SECTION 4 - MACHINE OPERATION Figure 4-6. Tow Bar 3121654 4-19...

  • Page 89: Oscillating Axle Lockout Test (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.14 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOP- PING THE ENGINE. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUC- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- TIONS MUST BE FOLLOWED.

  • Page 90: Changing From Lp Gas To Gasoline

    SECTION 4 - MACHINE OPERATION Changing From LP Gas to Gasoline 4.16 RE-SYNCHRONIZE UPRIGHT Re-leveling Valve 1. With engine operating on LP under a no-load con- dition, position FUEL SELECT switch at Platform A pull type control valve allows the operator to adjust the upright Control Station to GASOLINE position.
  • Page 91 SECTION 4 - MACHINE OPERATION 6. Lower tower boom fully and continue to hold down the switch to Tower Down for an additional 20 seconds. 7. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis. Figure 4-7.

  • Page 92: 4.17 Air Compressor

    SECTION 4 - MACHINE OPERATION 4.17 AIR COMPRESSOR Daily Operation Normal Startup Procedure Before Starting: 1. Check compressor oil level. 1. Check compressor oil level - top up if necessary. 2. Check for any leaks or loose bolts. 2. Air service valve (beside the compressor) closed. 3.
  • Page 93 SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 1 of 5 4-24 3121654...
  • Page 94 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 2 of 5 3121654 4-25...
  • Page 95 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 3 of 5 4-26 3121654...
  • Page 96 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 4 of 5 3121654 4-27...
  • Page 97 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Installation - Sheet 5 of 5 4-28 3121654...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend Table 4-1. Decal Legend Item # ANSI French Item # ANSI French 0274483-C 0274488-C 0274484-5 1001114464-C 0274483-C 0274488-C 0274484-5 1001114464-C 1702868 1704000 1701499 1701499 1701499 1701499 1703797 1703924 1705921 1705921 1705336 1705347 1705822 1705822...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend Table 4-1. Decal Legend Item # ANSI French Item # ANSI French 0274483-C 0274488-C 0274484-5 1001114464-C 0274483-C 0274488-C 0274484-5 1001114464-C 1001096141 1705977 1705977 1705977 1703959 1001131269 1703959 1703959 1705351 1705429 1001131269 1700584 1001131269 1001112551...
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  • Page 101: Section 5 - Emergency Procedures

    REQUIRED, AND ALL CONTROLS ARE OPERATING CORRECTLY. JLG Industries, Inc. must be notified immediately of any incident EMERGENCY OPERATION involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and pro- Operator Unable to Control Machine vided with all necessary details.

  • Page 102: 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 103: Machine Safety System Override (Msso) Ce Only

    NOTE: If MSSO functionality is used, the fault indicator will flash and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician. NOTE: No functional checks of the MSSO system are necessary. The JLG Control system will set a Diagnostic Trouble Code if control switch is faulty.
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  • Page 105: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES SKYPOWER™ The SkyPower™ system supplies AC power to the platform through an AC receptacle to run tools, lights, cutting, and weld- ing equipment. All power regulation components are located in a watertight box connected by cable to the generator.

  • Page 106: 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 107: Introduction

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications mation to the operator for proper operation and maintenance of this machine.

  • Page 108: Dimensional Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Dimensional Data Capacities Table 7-2. Dimensional Data Table 7-3. Capacities Turning Radius (Outside) 4.42 m (14 ft- 6 in) Fuel Tank Approx. 147.6 L (39 gal) Turning Radius (Inside) 2.13 m (11 ft) Hydraulic Tank Approx.

  • Page 109: Engine Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-5. Deutz TD 2.9 Specifications Fuel Ultra Low Sulfur Diesel (15 ppm) Table 7-4. Deutz D2011L04 Specifications Output 50 kW (67 hp) Type Liquid Cooled (Oil) Torque 234 Nm (173 ft-lb) @ 1800 rpm Fuel Diesel Oil Capacity (Crankcase)

  • Page 110: Tires

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Table 7-6. GM 3.0L Table 7-7. Tire Specifications Fuel Gasoline or Gasoline/LP Gas No. of Cylinders Load Size Type Ply Rating Pressure Range Gasoline 83 hp @ 3000 rpm 15-625 pneumatic 6.5 bar 75 hp @ 3000 rpm (95psi)

  • Page 111: Critical Stability Weights

    When temperatures remain consistently below -7° C (20° F), JLG Industries recommends use of Mobil DTE13. Tire & Wheel Size (Foam Filled Only) 15-625 Aside from JLG recommendations, it is not advisable to mix oils of differ- Counterweight Turntable 2180...
  • Page 112 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-10. Mobilfluid 424 Specs Table 7-11. Mobil DTE 13M Specs SAE Grade 10W30 ISO Viscosity Grade Gravity, API 29.0 Specific Gravity 0.877 Density, Lb/Gal. 60°F 7.35 Pour Point, Max -40°C (-40°F) Pour Point, Max -46°F (-43°C) Flash Point, Min.
  • Page 113 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-12. Mobil EAL 224H Specs Table 7-13. UCon Hydrolube HP-5046 Type Synthetic Biodegradable Type Synthetic Biodegradable ISO Viscosity Grade 32/46 Specific Gravity 1.082 Specific Gravity .922 Pour Point, Max -50°C (-58°F) Pour Point, Max -32°C (-25°F) Flash Point, Min.
  • Page 114 ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
  • Page 115 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS N O T E : AMBIENT AIR TEMPERATURES 110°...
  • Page 116 -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
  • Page 117 (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...
  • Page 118 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7,8,9,10 Figure 7-5. Maintenance and Lubrication Diagram 7-12 3121654...

  • Page 119: Maintenance And Lubrication

    Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within -43° to Capacity - A/R Lube® 232° C (-45° to 450°F). JLG P/N 3020042. Lube - MPG Interval - Every 3 months or 150 hours of operation Comments - Remote Access LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS.
  • Page 120 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Drive Hub 3. Swing Drive Hub Lube Point(s) - Level/Fill Plug Capacity - 0.5 L (17 oz) - 1/2 Full Lube - EPGL Interval - Check level every 3 months or 150 hours of opera- tion;...
  • Page 121 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter 5. Hydraulic Charge Filter Interval - Change after first 50 hours and every 6 months or Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator.

  • Page 122: Hydraulic Tank

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank 7. Oil Change w/Filter - Deutz D2011 Lube Point(s) - Fill Cap Lube Point(s) - Fill Cap/Spin-on Element Capacity - 151 L (40 gal) Tank; 291.4 L (77 gal) System Capacity - 10.5 L (11 qt) Crankcase Lube - HO Lube - EO...
  • Page 123 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD LEVEL MAXIMUM LEVEL OIL COLD NOTE: Hot oil checks should be made a period of 5 minutes after engine has been shut down. Figure 7-6.
  • Page 124 B. Oil Change w/Filter - Deutz TD2.9 8. Oil Change w/Filter - GM Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965) Capacity - 9.0 L (9.6 qt) Capacity - 4.25 L (4.5 qt) w/filter Lube - EO...
  • Page 125 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Fuel Filter - Deutz D2011 B. Fuel Filter - Deutz TD2.9 (On Hydraulic Tank) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation Interval - Change in accordance with engine manual 3121654 7-19...

  • Page 126: Air Filter

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE C. Fuel Filter - Deutz TD2.9 (On Engine) 11. Air Filter Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indi- Interval - Change in accordance with engine manual cated by the condition indicator 10.
  • Page 127 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Air Filter (Deutz TD 2.9) 12. Fuel Filter (Propane) - GM Engine Interval - 3 months or 150 hours of operation Lube Point(s) - Replaceable Element Comments - Replace filter. Refer to Section 7.5, Propane Fuel Interval - Every 6 months or 300 hours of operation or as Filter Replacement indicated by the condition indicator...

  • Page 128: Tires & Wheels

    Tire Replacement Air pressure for pneumatic tires must be equal to the air pressure stenciled on the side of the JLG product or rim decal for safe and JLG recommends a replacement tire be the same size, ply and brand proper operational characteristics.

  • Page 129: Wheel Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement 2. Tighten nuts in the following sequence: Rims installed on each product model have been designed for stabil- ity requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommen- dations, may result in an unsafe condition regarding stability.

  • Page 130: Propane Fuel Filter Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL FILTER REPLACEMENT Removal 1. Relieve propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2. Disconnect negative battery cable. 3. Slowly loosen filter housing and remove it. 4. Pull filter housing from electric lock off assembly. 5.

  • Page 131: Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Installation PROPANE FUEL SYSTEM PRESSURE RELIEF REINSTALL FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE RISK OF FIRE AND PERSONAL INJURY, RELIEVE PROPANE FUEL SYSTEM 1.

  • Page 132: 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 134 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

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