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JLG 1250AJP, Operation And Safety Manual

The JLG 1250AJP operation and safety manual is essential for ensuring safe and efficient use of this powerful construction equipment. Download the manual for free from manualshive.com to access important information on operating procedures, safety guidelines, and maintenance instructions for the JLG 1250AJP.

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SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121170

7-23

Red = Filter Restricted; Filter Bypassed
Green = Filter Good; Not Restricted

Figure 7-9. Hydraulic Return Filter Condition Indicator - S/N 139396 to Present

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Summary of Contents for 1250AJP

Page 1: ...Safety Manual ANSI Original Instructions Keep this manual with the machine at all times AS NZS Boom Lift Models 1250AJP 3121170 November 5 2018 Rev T T o o r d e r g o t o D i s c o u n t E q u i p m...

Page 2: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 3: ...alifornia 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 we...

Page 4: ...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 t...

Page 5: ...TES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND INDICATES INFORMATION OR...

Page 6: ...INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 132...

Page 7: ...Revised H March 19 2008 Revised I November 19 2009 Revised J August 31 2010 Revised K August 18 2011 Revised L August 9 2012 Revised M September 11 2014 Revised N January 5 2015 Revised O May 23 2017...

Page 8: ...r Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 5 Daily Walk Around Inspection 2 6 Function Check 2 8 SkyGuard Function Test 2 9 2 3 OSCILLATING AXLE LOCKOUT...

Page 9: ...winging the Jib 4 21 4 12 FUNCTION SPEED CONTROL 4 21 4 13 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY 4 21 4 14 SKYGUARD OPERATION 4 22 SkyGuard 4 22 SkyGuard SkyLine 4 22 SkyGuard SkyEye 4 23 SkyGua...

Page 10: ...10 Operation 6 10 6 6 SKYWELDER 6 10 Accessory Ratings 6 11 Generator Output 6 11 Welding Accessories 6 11 Safety Precautions 6 12 Preparation and Inspection 6 12 Operation 6 12 6 7 SOFT TOUCH 6 13 6...

Page 11: ...JECT PAGE SECTION PARAGRAPH SUBJECT PAGE Tire Replacement 7 35 Wheel and Tire Replacement 7 35 Wheel Installation 7 35 7 5 SUPPLEMENTAL INFORMATION 7 37 SECTION 8 INSPECTION AND REPAIR LOG T o o r d e...

Page 12: ...ecal Location S N 0300141446 to Present CE Only Sheet 1 of 54 41 4 17 Decal Location S N 0300141446 to Present CE Only Sheet 2 of 54 42 4 18 Decal Location S N 0300141446 to Present CE Only Sheet 3 of...

Page 13: ...vi 3121170 LIST OF FIGURES FIGURE NUMBER TITLE PAGE FIGURE NUMBER TITLE PAGE This Page Left Blank Intentionally T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 14: ...ications S N 0300141446 to Present 7 2 7 3 Dimensional Data 7 3 7 4 Chassis Specifications 7 3 7 5 Capacities 7 4 7 6 Tire Specifications 7 4 7 7 Deutz BF4M2011 Specifications 7 5 7 8 Deutz TD2011L4 S...

Page 15: ...viii 3121170 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE This Page Left Blank Intentionally T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 16: ...of the machine has been completed under the supervision of an experienced and quali fied operator This section contains the responsibilities of the owner user oper ator lessor and lessee concerning s...

Page 17: ...in to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not...

Page 18: ...slippery substances from footwear and plat form floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any device i e cell phones two...

Page 19: ...e of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Hydraulic cylinders are subject to thermal expansion and con traction This may...

Page 20: ...all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slippery substances cleaned from footwear and the platform flo...

Page 21: ...r equip ment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less Table 1 1 Minimum Approach Distances...

Page 22: ...ork practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH ERWISE Tipping Hazards The...

Page 23: ...chine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions including gusts may exceed 28 mph 12 5 m s Factors affecting wind s...

Page 24: ...3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31...

Page 25: ...ording to conditions of ground surface congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive...

Page 26: ...nserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid pos...

Page 27: ...ound for welding When performing welding or metal cutting operations pre cautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine...

Page 28: ...ays wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLO...

Page 29: ...SECTION 1 SAFETY PRECAUTIONS 1 14 3121170 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 30: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 31: ...ations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 6 The safest means to operate the mac...

Page 32: ...ial work platforms The fre quency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environ ment if the machine is used with increased freque...

Page 33: ...3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform An...

Page 34: ...erWheels 3 TowerLiftCylinder 4 GroundConsole 5 TowerBaseBoomSection 6 TowerMidBoomSection 7 TowerFlyBoomSection 8 TowerBoomAssembly 9 MainLiftCylinder 10 MainBaseBoomSection 11 MainBoomFlySection 12 M...

Page 35: ...Walk Around Inspection Perform as instructed 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine Oil Supply Ensure the engine oil level is...

Page 36: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 6 3121170 Daily Walk Around Inspection 0 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 37: ...placards secure and legible control markings legible 3 Boom Sections Turntable See Inspection Note 4 Swing Drive No evidence of damage 5 Wheel Tire Assemblies Properly secured no missing lug nuts Ins...

Page 38: ...functions and make sure the Boom Control System warning light does not come on d Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in 3 With the platform in the s...

Page 39: ...ctivated verify the following conditions a Telescope out function stops and telescope in function operates for a short duration b The horn sounds c If equipped with a SkyGuard beacon the beacon illumi...

Page 40: ...until left front wheel is on top of block 4 Carefully extend the boom just enough to get it out of the transport position 5 With boom in this position place Drive control lever to Reverse and careful...

Page 41: ...mbols and the corresponding functions 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 sy...

Page 42: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 43: ...ide Platform Rotate and Jib Swing functions 2 Main Boom Telescope Control Provides extension and retraction of the main boom 3 Tower Lift Control Provides raising and lowering of the tower boom 4 Swin...

Page 44: ...mLift 6 JibLift 7 PlatformLevelingOverride 8 PlatformRotate 9 JibSwing 10 Platform GroundSelectSwitch 11 Hourmeter 12 Power EmergencyStop 13 EngineStart AuxiliaryPower FunctionEnable 14 NotUsed 15 Air...

Page 45: ...atformLevelingOverride 8 PlatformRotate 9 JibSwing 10 Platform GroundSelectSwitch 11 Hourmeter 12 Power EmergencyStop 13 EngineStart AuxiliaryPower FunctionEnable 14 MachineSafetySystemOverride MSSO F...

Page 46: ...of time the machine has been in use with engine running By connecting into the oil pressure cir cuit of the engine only engine run hours are recorded The hourmeter registers up to 9 999 9 hours and c...

Page 47: ...ry Power Switch Function Enable To start the engine the switch must be held UP until the engine starts To use auxiliary power the switch must be held DOWN for duration of auxiliary pump use When the e...

Page 48: ...elow normal and ser vice is required 3 High Engine Temperature Indicator Indicates that engine coolant temperature is abnormally high and service is required 4 Engine Oil Temperature Indicator Indicat...

Page 49: ...ng 2 LowEngineOilPressure 3 HighEngineCoolantTemp 4 HighEngineOilTemp 5 GlowPlugIndicator 6 AxlesSet 7 PlatformCapacity 8 PlatformOverload 9 BoomControlSystemWarning Figure 3 3 Ground Control Indicato...

Page 50: ...platform to the ground If the indicator remains lit a boom control system fault or failure has been detected If a failure is discovered the system must be repaired by JLG authorized service personnel...

Page 51: ...JibLift 9 SoftTouch SkyGuardOverride 10 JibSwing 11 TowerBoomLift 12 SoftTouch SkyGuardIndicator 13 PlatformRotate 14 JibStowOverride 15 FunctionSpeedControl 16 MainLift Swing 17 DriveSpeed TorqueSele...

Page 52: ...r further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer con trol to act...

Page 53: ...the platform away from the obstacle that caused the shutdown situation If equipped with SkyGuard the switch enables functions cut out by the Sky guard system to be operated again allowing the operato...

Page 54: ...ic stop to stow the jib beside the boom for trans port 15 Function Speed Control Controls the speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed To adjust to creep t...

Page 55: ...er ing with the rear wheels unaffected This is for normal driv ing at maximum speeds The forward position is for crab steering When in this mode both front and rear axles steer in the same direction w...

Page 56: ...ol Indicator Panel 1 Level System Fault Indicator Indicates a fault in the electronic leveling system The fault indicator will flash and an alarm sound All functions will default to creep if the boom...

Page 57: ...PlatformOverload 4 PlatformCapacity 5 TiltAlarmWarning 6 GlowPlug 7 Enable 8 FuelLevel 9 CreepSpeed 10 SystemDistress 11 DriveOrientation 12 AxlesSet 13 BoomControlSystemWarning Figure 3 5 Platform C...

Page 58: ...E EXTENDING BOOM OR RAISING BOOM FROM THE TRANSPORT POSITION Indicates that the chassis is on a slope over 3 to 5 degrees depending upon boom angle If the boom is out of trans port position and the ma...

Page 59: ...ected within seven seconds or if a seven second lapse between ending one function and beginning the next func tion the enable light will go out and the footswitch must be released and depressed again...

Page 60: ...ther in either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to verify that the drive control is being oper ated in th...

Page 61: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 20 3121170 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 62: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 63: ...achine in both forward and reverse directions The operator can raise or lower the main or tower boom or swing the boom to the left or right Standard boom swing is 360 degree continuous left and right...

Page 64: ...ds and is indicated to the operator by flashing the creep light on the platform control panel Functions being operated when the warm up mode turns off will remain in the creep speed until the function...

Page 65: ...ight to flash and the platform alarm to sound Violations of the tower path with a healthy control system will cause the automatic combined operation of tower lift and tower telescope to be suspended A...

Page 66: ...ground and platform control panels use one function switch to control the tower User commands for tower lift up or tower lift down causes the control system to automatically intro duce the correct co...

Page 67: ...to 60 for the remainder of the tower lift down command TOWER LIFT UP MAIN BOOM ABOVE 60 During tower lift up with the main boom already above 60 the control system will delay automatic compensation o...

Page 68: ...com mands to maintain a constant boom angle relative to gravity Controlled boom angle is disabled with any envelope violation or failure Swing Speed Proportioning The boom control system sensors sens...

Page 69: ...orward Stability MACHINEWILLTIPOVERIN DIRECTIONOFARROWSIFOVERLOADED OROPERATED ONANOUT OF LEVELSURFACE MAINBOOM FULLYEXTENDED TURNTABLEROTATED 90DEGREESFROM STOWEDPOSITION TOWERBOOM FULLYLOWEREDTO FUL...

Page 70: ...1 of 2 JIB ELEVATED MACHINE WILL TIP OVER IN DIRECTION OF ARROW IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE MAIN BOOM FULLY ELEVATED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION TOWER BO...

Page 71: ...2 of 2 JIB ELEVATED MACHINE WILL TIP OVER IN DIRECTION OF ARROW IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE MAIN BOOM FULLY ELEVATED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION TOWER BO...

Page 72: ...nd the movements will momentarily stop and alternate between other functions as needed When operating Tower Lift the movements will alternate between tower lift tower telescope and main lift When oper...

Page 73: ...SECTION 4 MACHINE OPERATION 3121170 4 11 Figure 4 5 Range Diagram T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 74: ...ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL NOTE If the engine fails to start due to cold temperatures or excessive amounts of smoke are produced on startup wait for the glow plug wait to start indica...

Page 75: ...bstructs airflow intake and stops the engine Weekly tests are recommended to ensure the valve remains in good working condition 1 Start the engine running at idle 2 Open the red switch guard on ASOV t...

Page 76: ...be approximately 5 minutes of engine run time left If the system is in this condition and automatically shuts down the engine or the engine is manually shut down before the 5 minute run time is com pl...

Page 77: ...mplete the operator may cycle power and restart the engine for an additional 2 minutes of run time The operator can repeat this process until there is no more fuel available CONTACT A QUALIFIED JLG ME...

Page 78: ...WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED BEFORE DRIVING LOCATE THE BLACK WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS MOVE THE DRIVE CONTROLS I...

Page 79: ...SECTION 4 MACHINE OPERATION 3121170 4 17 Figure 4 7 Grade and Side Slopes T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 80: ...o determine the direc tion the machine will travel 2 Push and release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direct...

Page 81: ...maintain it s position To manually Level Up or Down Position the Platform Level control switch Up or Down and hold until the desired platform position is obtained Platform Rotation To rotate the platf...

Page 82: ...wer the Main Boom use Boom Lift control to select Up or Down movement Telescoping the Main Boom NOTE The telescope function is not operable beyond the transport position if the axles are not fully ext...

Page 83: ...swing the jib use the Jib Swing control to select Right or Left direction 4 12 FUNCTION SPEED CONTROL This control affects the speed of all boom functions and Platform Rotate When in the CCW maximum...

Page 84: ...tch are disengaged If the SkyGuard sensor remains activated after function reversal or cutout depress and hold the SkyGuard Override Switch to allow normal functions until the sensor is disengaged Con...

Page 85: ...Tower Tele In Boom Lift Up Boom Lift Down Boom Tele Out Boom Tele In Jib Lift Jib Swing Basket Level Basket Rotate R C R C R C C C C R R R C C C C C R IndicatesReversalisActivated C IndicatesCutoutis...

Page 86: ...TTED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 5 M P H 8 K M H MAXIMUM TOWING GRADE 25 DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Re...

Page 87: ...orm Controls to protect instruction placards warning decals and operating controls from hostile environment 4 17 LIFTING AND TIE DOWN See Figure 4 10 Lifting 1 The weight of the machine is stamped on...

Page 88: ...FOR TRANSPORT 1 Place the boom in the stowed position with the axles retracted 2 Hold the Jib Swing control switch to the right until the plat form will no longer swing NOTE The Jib Swing function is...

Page 89: ...CHINE OPERATION 3121170 4 27 1705838 B 37 7 11 46 m 21 8 6 60 m 15 11 4 85 m 9 9 2 97 m 6 9 2 06 m 16 6 5 03 m Figure 4 10 Lifting and Tie Down Chart T o o r d e r g o t o D i s c o u n t E q u i p m...

Page 90: ...H SIDES BOTH SIDES ANSI DUAL LANGUAGE AUS ONLY AUS ONLY ANSI DUAL LANGUAGE BOTH SIDES 23 47 46 22 22 30 8 2 34 18 39 39 32 7 37 18 18 41 60 60 Figure 4 11 Decal Location Sheet 1 of 5 T o o r d e r g o...

Page 91: ...SECTION 4 MACHINE OPERATION 3121170 4 29 36 34 10 A A SECTION A A 37 37 22 Figure 4 12 Decal Location Sheet 2 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 92: ...0 DECAL MOUNT FOR DOM DECAL MOUNT FOR DUAL LANGUAGE ANSI ONLY 52 58 63 66 62 61 9 51 31 33 50 51 9 19 43 45 44 24 19 22 28 59 28 20 59 59 26 16 15 15 Figure 4 13 Decal Location Sheet 3 of 5 T o o r d...

Page 93: ...US ONLY AUS ONLY ANSI DUAL LANGUAGE ANSI DUAL LANGUAGE ANSI DUAL LANGUAGE 37 48 18 12 22 22 22 67 23 18 8 2 7 46 27 42 57 47 18 60 60 35 TIER IVF VIEW 35 Figure 4 14 Decal Location Sheet 4 of 5 T o o...

Page 94: ...on Sheet 5 of 5 ANSI DUAL LANGUAGE ONLY DUAL LANGUAGE ONLY ANSI ONLY ANSI DUAL LANGUAGE CE ONLY AUS 29 11 6 6 16 13 23 23 WARNING WARNING DANGER DANGER 60 60 25 8 2 2 40 23 22 22 18 7 8 21 26 22 45 64...

Page 95: ...701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 170...

Page 96: ...05915 1705506 1705494 27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 28 1705168 1705168 1705334 1705899 1705908 1705333 1706770 1705330 29 1705181 1705181 1705478 1705900 1705919 1...

Page 97: ...1501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Table 4 1 Decal Legend Prior to S N 0300141446 Item ANSI 0274722 7 Korean 0274723 7 Chinese 02...

Page 98: ...4 1 Decal Legend Prior to S N 0300141446 Item ANSI 0274722 7 Korean 0274723 7 Chinese 0274724 7 Portuguese 0274725 7 English Spanish 0274726 8 French English 0274727 7 CE Australian 0274728 8 Japan 0...

Page 99: ...701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 170...

Page 100: ...02631 1702631 1702631 1702631 1702631 1702631 1702631 28 1001122369 1001122370 1001122371 1001122372 1001122373 1001122374 1706770 1001122375 29 1001122376 1001122377 1001122378 1001122379 1001122380...

Page 101: ...501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 Table 4 2 Decal Legend S N 0300141446 to Present Item ANSI 0274722 F Korean 0274723 E Chinese 0...

Page 102: ...001224050 1001224049 1001223971 1001224053 Table 4 2 Decal Legend S N 0300141446 to Present Item ANSI 0274722 F Korean 0274723 E Chinese 0274724 E Portuguese 0274725 E English Spanish 0274726 E French...

Page 103: ...4 MACHINE OPERATION 3121170 4 41 7 23 41 8 2 34 39 39 37 22 22 60 60 46 Figure 4 16 Decal Location S N 0300141446 to Present CE Only Sheet 1 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n...

Page 104: ...ON 4 MACHINE OPERATION 4 42 3121170 36 34 10 A A SECTION A A 37 37 22 Figure 4 17 Decal Location S N 0300141446 to Present CE Only Sheet 2 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t...

Page 105: ...INE OPERATION 3121170 4 43 60 58 63 66 9 51 33 50 51 9 24 22 52 61 62 28 20 44 Figure 4 18 Decal Location S N 0300141446 to Present CE Only Sheet 3 of 5 T o o r d e r g o t o D i s c o u n t E q u i p...

Page 106: ...OPERATION 4 44 3121170 253 23 37 48 22 41 8 2 7 27 42 57 22 22 60 60 35 46 44 35 Figure 4 19 Decal Location S N 0300141446 to Present CE Only Sheet 4 of 5 T o o r d e r g o t o D i s c o u n t E q u...

Page 107: ...NE OPERATION 3121170 4 45 Figure 4 20 Decal Location S N 0300141446 to Present CE Only Sheet 5 of 5 29 11 6 6 23 23 60 60 8 2 2 40 23 22 22 7 8 21 22 65 T o o r d e r g o t o D i s c o u n t E q u i p...

Page 108: ...6 1701529 7 1703811 8 1703814 9 1704277 10 1704412 11 12 13 14 15 16 17 18 19 20 1705921 21 1705822 22 1701518 23 1705961 24 1705828 25 26 27 1702631 28 1706770 29 1705468 30 31 32 33 34 1701505 35 17...

Page 109: ...44 1702773 45 46 1705864 47 48 49 50 51 52 53 Table 4 3 Decal Legend S N 0300141446 to Present CE Only Item CE 0274728 G 54 55 56 57 58 59 60 Table 4 3 Decal Legend S N 0300141446 to Present CE Only...

Page 110: ...SECTION 4 MACHINE OPERATION 4 48 3121170 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 111: ...anty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CON TROLS DO NOT LIFT A...

Page 112: ...machine 3 Use cranes forklifts or other equipment to stabilize motion of the machine to prevent a tip over as required 4 From the ground controls use the Auxiliary Power System to carefully free the...

Page 113: ...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 wil...

Page 114: ...SECTION 5 EMERGENCY PROCEDURES 5 4 3121170 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 115: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

Page 116: ...sory Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x72 FallArrestPlatform 36 x96 PipeRacks SkyCutter SkyGlazier SkyPower SkyWelder SoftTouch Bolt OnExternalFallArrest 36 x72 B...

Page 117: ...yGlazier SkyGlazier SkyPower 4 Platform PipeRacks Platform MTR SoftTouch SkyCutter SkyWelder SkyPower SkyCutter SkyGlazier SkyWelder SkyWelder SkyPower SkyCutter 4 Platform PipeRacks Platform MTR Soft...

Page 118: ...se by one person Personnel must use fall protection at all times A full body harness is required with lanyard not to exceed 6 ft 1 8 m in length that limits the maximum arrest force to 900 lbs 408 kg...

Page 119: ...e racks are secured to the platform rails Replace torn or frayed tie down straps Operation 1 To prepare racks for loading remove locking pins rotate each rack 90 degrees from stowed to working positio...

Page 120: ...welds and damage to plasma supports Check for secure installation of cutter and bracket Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Use this option only...

Page 121: ...See the Miller Plasma Cutter Owner s Manual PN 3128420 for more information Spec RatedOutput AmperesInput RatedOutput 60 Hz 1 Phase kVa kW PlasmaGas PlasmaGasFlow Pressure RatedCutting Capacity 10IPM...

Page 122: ...city Max Platform Capacity With Max Weight in Tray 500lbs 227kg 150lbs 68kg 250lbs 113kg 550lbs 250kg 150lbs 68kg 250lbs 113kg 600lbs 272kg 150lbs 68kg 250lbs 113kg 750lbs 340kg 150lbs 68kg 440lbs 200...

Page 123: ...REA EXPOSED TO THE WIND WILL DECREASE STABILITY LIMIT PANEL AREA TO 32 SQ FT 3 SQ M Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Remove tray when not in u...

Page 124: ...ning 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 Generator Output ANSI Specifications 3 phase...

Page 125: ...ng used Do not overload circuit Preparation and Inspection Ensure generator is secure Check condition of belt and wiring Operation Start the engine then turn on the generator See the Miller Generator...

Page 126: ...p and stinger stored in the platform Fire extinguisher Welding Mode Input Power Rated Output Welding Amperage Range Maximum Open Circuit Voltage Amps Input At Rated Load Output 50 60 Hz 230 V 460 V 57...

Page 127: ...correct polarity of leads Wear proper welding apparel Use correct rod size and current settings Do not use electrical cords without ground Do not use electrical tools in water Do not weld to the platf...

Page 128: ...he platform through the gate area only The system is designed for use by one person Personnel must use fall protection at all times A full body harness is required with lanyard not to exceed 6 ft 1 8...

Page 129: ...EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTI FICATION THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A QUALIFIED PERSON OTHER THAN THE USER Inspection Before Use T...

Page 130: ...g No cracks or signs of wear are acceptable Any signs of corrosion requires replacement Attaching Hardware Inspect all attaching hardware to ensure there are no missing components and hardware is prop...

Page 131: ...0 I 8 7 1 2 3 4 6 9 5 Figure 6 2 Bolt On External Fall Arrest System 1 BellevilleWasher 2 Washer 3 HexNut 4 JamNut 5 LHBracket 6 AttachmentRing 7 Cable 8 RHBracket 9 Decal T o o r d e r g o t o D i s...

Page 132: ...al Prior to SN 0300201017 3121172 Illustrated Parts Manual SN 0300201017 to Present 3121737 Troubleshooting Guide 3128411 Troubleshooting CD 3128444 7 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA T...

Page 133: ...tformHeight Restricted 125ft 38 1m Max HorizontalPlatformReach Unrestricted 63ft 2in 19 3m Max HorizontalPlatformReach Restricted 53ft 2in 16 2m UpandOverHeight 60ft 7in 18 5m MainBoomRange AtMaximumU...

Page 134: ...30 4cm GroundClearance Chassis 25 5in 64 7cm Table 7 4 Chassis Specifications MaximumTravelGradeWithboominstowed position Gradeability 45 MaximumTravelGradeWithboominstowed position SideSlope 5 Turni...

Page 135: ...10 0 5quarts 0 5liters 10 Table 7 6 Tire Specifications Size 445 50D710 LoadRange J PlyRating 18 FoamFill PolyurethaneHD 55Durometer Foam Diameter 46 45in 117 9cm Width 18in 45 7cm RimSize 15x28 Tire...

Page 136: ...r TotalCapacity 5Quarts 4 5L 11Quarts 10 5L 16Quarts 15L AverageFuelConsumption 1 1gph 4 1lph IdleEngineRPM 1200 MidEngineRPM 1800 HighEngineRPM 2475 Table 7 8 Deutz TD2011L4 Specifications Type Liqui...

Page 137: ...CoolantCapacity System 3 2Gallon 12 1L AverageFuelConsumption 1 2gph 4 1lph Min LowEngineRPM 1200 MidEngineRPM 1800 Max HighEngineRPM 2500 Table 7 10 Caterpillar 3 4T Type LiquidCooled Antifreeze Numb...

Page 138: ...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 Table 7 11 Hydraulic...

Page 139: ...166 C Viscosity at40 C 33cSt at100 C 6 6cSt at100 F 169SUS at210 F 48SUS cpat 20 F 6 200 ViscosityIndex 140 Table 7 14 UCon Hydrolube HP 5046 Type Synthetic Biodegradable SpecificGravity 1 082 PourPoi...

Page 140: ...76 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity Table 7 16 Mobil EAL H 46 Specs Type Synthetic Biodegradable ISO Viscosity Grade 46 Density at 15 C 874 Pour Poi...

Page 141: ...L Viscosity at40 C 43 3cSt at100 C 7 7cSt ViscosityIndex 149 Table 7 18 Component Weights Component Pounds Kilograms Tire Wheel 867 393 DriveHub Motor 275 5 123 EngineAssembly 1275 579 MainBoom 5186 2...

Page 142: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121170 7 11 Figure 7 1 Engine Operating Temperature Specifications T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 143: ...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 HYDRAULIC FLUID OPERATI...

Page 144: ...esistant Mobilfluid424 55 145 X MobilDTE10Excel32 32 164 X X UnivisHVI26 26 376 X MobilEALHydraulicOil 47 176 X X X MobilEALEnvirosynH46 49 145 X X X Quintolubric888 46 50 185 X X X X Readilybiodegrad...

Page 145: ...FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ENGINE WILL START AND OPERATE UNAIDED A...

Page 146: ...HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE E...

Page 147: ...ONS OPERATOR MAINTENANCE 7 16 3121170 Figure 7 6 Operator Maintenance and Lubrication Diagram Deutz 2011 CAT Engines 4 4 4 4 5 8 15 19 9 1 11A 12 10A 14 2 3 6 7 18 17A T o o r d e r g o t o D i s c o...

Page 148: ...FICATIONS OPERATOR MAINTENANCE 3121170 7 17 Figure 7 7 Operator Maintenance and Lubrication Diagram Deutz 2 9 Engine 4 4 4 4 5 8 13 9 1 11B 10B 2 3 6 7 18 17B 16 T o o r d e r g o t o D i s c o u n t...

Page 149: ...ace all filters at the same time 1 Swing Bearing Remote Lube Lube Point s 2 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hours of operation Table 7 19 Lubrication Specifications...

Page 150: ...es 2 3 L Lube GL 5 Interval Check level every 150 hrs Change every 1200 hours of operation Fill to cover ring gear 3 Swing Brake Lube Point s Fill Plug Capacity 2 7 ounces 80 ml Lube DTE24 Interval Ch...

Page 151: ...just starts to flow out of check port NOTE After S N 0300134389 machines may be built with either Bonfigli oli or Reggiana Riduttori wheel drive hubs B Wheel Drive Hub Bonfiglioli S N 100128 to Prese...

Page 152: ...position and Check port at 3 o clock position Pour lubricant into fill port until it just starts to flow out of check port 5 Hydraulic Return Filter See Figure 7 8 Hydraulic Return Filter Condition I...

Page 153: ...ATOR MAINTENANCE 7 22 3121170 A Red FilterRestricted FilterBypassed B Green FilterGood NotRestricted Figure 7 8 Hydraulic Return Filter Condition Indicator Prior to S N 139396 T o o r d e r g o t o D...

Page 154: ...RATOR MAINTENANCE 3121170 7 23 Red FilterRestricted FilterBypassed Green FilterGood NotRestricted Figure 7 9 Hydraulic Return Filter Condition Indicator S N 139396 to Present T o o r d e r g o t o D i...

Page 155: ...24 3121170 6 Hydraulic Charge Filter or Lube Point s Replaceable Element Interval Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator if equipped T o o r...

Page 156: ...al Change after first 50 hours and every 300 hours thereafter 8 Hydraulic Oil Lube Point s Fill Cap Capacity 55 gallons 208 liters Tank Lube HO Interval Check level daily Change every 2 years or 1200...

Page 157: ...n Remove and clean at time of hydraulic oil change 10 A Oil Change w Filter Deutz 2011 Lube Point s Fill Cap Spin on Element Capacity 11 Quarts 10 5 L w Filter Lube EO Interval Check level daily chang...

Page 158: ...Filter Deutz TCD2 9 Lube Point s Fill Cap Spin on Element Capacity 2 4 Gallon 8 9 L Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level...

Page 159: ...eutz 2011 Engine Dipstick MAXIMUMOIL LEVEL NOTE Hotoilchecksshouldbemadeaperiodof5minutesaftertheenginehasbeenshutdown MINIMUMLEVELOIL HOT MAXIMUMLEVELOIL HOT MINIMUMLEVELOIL COLD MAXIMUMLEVELOIL COLD...

Page 160: ...Fuel Filter Deutz 2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation B Fuel Filter Deutz TCD2 9 Lube Point s Replaceable Element Interval Every year or 500 hours of o...

Page 161: ...Deutz 2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation 13 Fuel Pre Filter TCD2 9 Lube Point s Replaceable Element Interval Drain water daily Change every year or 50...

Page 162: ...y Capacity 10 5 Quarts 10 L Lube EO Interval Check level daily change every 150 hours or three months whichever comes first Adjust final oil level by mark on dipstick 15 Fuel Filter Water Separator CA...

Page 163: ...tor Coolant TCD2 9 Lube Point s Fill Cap Capacity 3 2Gallon 12 1 L Lube Anti Freeze Interval Check level daily change every 1000 hours or 2 years whichever comes first 17 A Air Filter Deutz 2011 CAT D...

Page 164: ...B Air Filter Deutz TCD2 9 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indi cated by the condition indicator Comments Check Dust Valve daily 18 Platform Fil...

Page 165: ...oses sidewall or tread area cords in the tire measures must be taken to remove the JLG product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyu...

Page 166: ...lated to the pressure recommended by JLG Due to size variations between tire brands both tires on the same axle should be the same Wheel and Tire Replacement The rims installed on each product model h...

Page 167: ...e nuts should be done in stages Follow ing the recommended sequence tighten nuts per wheel torque chart 4 Wheel nuts should be torqued before first road use and after each wheel removal Check and torq...

Page 168: ...less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on tes...

Page 169: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 38 3121170 NOTES T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 170: ...PAIR LOG 3121170 8 1 SECTION 8 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 8 1 Inspection and Repair Log Date Comments T o o r d e r g o t o D i s c o u...

Page 171: ...SECTION 8 INSPECTION AND REPAIR LOG 8 2 3121170 Table 8 1 Inspection and Repair Log Date Comments T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 172: ...3121170 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 173: ...Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wiscons...

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