JLG 1532R Operation And Safety Manual Download

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Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

ANSI

AS/NZS

Model(s)

1532R
1932R

P/N - 3121744

October 20, 2017

Summary of Contents for 1532R

Page 1: ...Operation and Safety Manual Original Instructions Keep this manual with the machine at all times ANSI AS NZS Model s 1532R 1932R P N 3121744 October 20 2017...

Page 2: ...NOTES...

Page 3: ...owners users operators lessors and lessees with the precautions and operating proce dures essential for the safe and proper machine operation for its intended purpose Due to continuous product improve...

Page 4: ...THIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL...

Page 5: ...ELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT...

Page 6: ...ift 3121744 REVISION LOG Original Issue of Manual July 14 2016 Manual Revised August 18 2016 Manual Revised September 27 2016 Manual Revised January 30 2017 Manual Revised February 21 2017 Manual Revi...

Page 7: ...11 Maintenance Hazards 1 11 Battery Hazards 1 12 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING 2 1 Operator Training 2 1 Training Supervision 2 2 Operator...

Page 8: ...System Fault Indicator 3 17 Alarm 3 17 Indoor Zone A Outdoor Zone B Operation Indicator 3 17 Indoor Zone A Outdoor Zone B Operation Mode Switch 3 17 Outdoor Indoor Operation Indicator 3 18 Outdoor Ind...

Page 9: ...5 OPERATOR MAINTENANCE 5 9 Scissor Arm Safety Prop 5 9 Hydraulic Oil Check Procedure 5 10 Delta Q Battery Charger 5 12 Green Power Battery Charger China Only 5 12 Eagle Performance Battery Charger 5...

Page 10: ...tion of Manual Descent Control 4 2 5 1 Scissor Arm Safety Prop 5 10 5 2 Hydraulic Oil Check Procedure 5 11 5 3 Hydraulic Oil Fill Procedure 5 11 5 4 Battery Fluid Level 5 14 5 5 Wheel Installation 5 1...

Page 11: ...e to operate The owner user operator lessor lessee of the machine must not accept operating responsibility until this manual has been read training is accomplished and operation of the machine has bee...

Page 12: ...achine is to be used in a manner which is within the scope of its intended application as determined by JLG All operating personnel must be familiar with the emer gency controls and emergency operatio...

Page 13: ...erformed as specified in Section 2 of this manual Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the mac...

Page 14: ...before moving the switch to the next function Operate controls with slow and even pressure Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform...

Page 15: ...he lanyard Attach only one 1 lanyard per lanyard anchorage point Enter and exit only through gate area Use extreme caution when entering or leaving platform Ensure that the platform assembly is fully...

Page 16: ...ols and their equipment 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 The minimum approach dista...

Page 17: ...the platform in the elevated position Before driving on floors bridges trucks and other surfaces check allowable capacity of the surfaces Never exceed the maximum work load as specified on the platfo...

Page 18: ...motionvisibleinsmoke 2 4 7 1 6 3 3 Lightbreeze Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperrais...

Page 19: ...or attachments If the scissor arm assembly or platform is caught so that one or more wheels are off the ground all persons must be removed before attempting to free the machine Use cranes forklift tru...

Page 20: ...nces in all drive speeds When driving in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in r...

Page 21: ...g machine mainte nance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to the...

Page 22: ...y unit in any way to affect stability Reference the Service and Maintenance Manual for the weights of critical stability items MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY...

Page 23: ...ground emergency controls and safety features Control labels instructions and warnings on the machine Rules of the employer and government regulations Use of approved fall protection equipment Enough...

Page 24: ...either the machine or the job site NOTE The Manufacturer or Distributor will provide qualified people for training assistance with the first unit s deliv ered and from that time forward as requested...

Page 25: ...iodofmorethan3 months orPurchasedused Owner Dealer orUser QualifiedJLG Mechanic ServiceandMaintenanceManualand applicableJLGinspectionform AnnualMachine Inspection seenotebelow Annually nolaterthan13m...

Page 26: ...peration and Safety Manuals Ensure that a copy of the Operation and Safety Manual AEM Safety Man ual ANSI markets only and ANSI Manual of Responsi bilities ANSI markets only is enclosed in the weather...

Page 27: ...PARATION AND INSPECTION 3121744 JLG Lift 2 5 10 Platform Gate Keep gate and surrounding area clean and unobstructed Check that gate closes properly and is not bent or damaged During operation keep gat...

Page 28: ...ARATION AND INSPECTION 2 6 JLG Lift 3121744 11 Lanyard Anchorage Points JLG Industries Inc recommends personnel in the platform wear a full body harness with a lanyard attached to an authorized lanyar...

Page 29: ...ches return to neutral position emergency stop switch functions properly Control markings legible 3 Hydraulic Pump Motor Control Valve Installation No unsupported wires or hoses no damaged or broken w...

Page 30: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 8 JLG Lift 3121744 Figure 2 1 Daily Walk Around Inspection Side Compartment Doors Open 2...

Page 31: ...ndle located at the left rear of the machine next to the battery char ger lowers the platform properly d Check that pot hole protection system bars are fully lowered when the platform is raised 2 From...

Page 32: ...settings in Table 2 3 NOTE When the tilt indicator warning is activated the following functions are affected drive and lift up functions are dis abled platform must be fully lowered stowed to drive Ta...

Page 33: ...CRIPTION This machine is a self propelled aerial work platform on top of an elevating scissor arm mechanism The Lift s intended pur pose is to position personnel with their tools and supplies at posit...

Page 34: ...ng personnel of potential hazards constituted by the operating characteristics and limitations of the machine See foreword for definitions of placard safety signal words 3 4 PLATFORM LOADING The platf...

Page 35: ...ontrol Station 2 Platform Control Station 3 Platform Manual Descent Control T Handle 4 AC Plug At Front of Machine For Platform AC Receptacle Outlet Box 5 AC Plug Battery Charger Input 6 Side Compartm...

Page 36: ...page 5 12 2 Connect the charger AC input plug to a grounded out let using a 3 wire heavy duty extension cord See Table 5 6 Battery Charger Specifications on page 5 6 for battery charger AC input spec...

Page 37: ...GROUND CONTROL STATION Figure 3 2 Ground Control Station 1 Ground Platform OFF Key Selector Switch 2 Platform Lift Lower Switch 3 Inverter ON OFF Switch If Equipped 4 Ground Emergency Stop Button 5 H...

Page 38: ...e machine overnight Platform Lift Lower Switch Item 2 Figure 3 2 A three position momentary contact lift control switch provides raising and lowering of the platform from the Ground Control Station Wh...

Page 39: ...latform using the machine man ual descent control ANSI Export Australia Japan All platform functions will be prevented Fully lower the platform from the ground controls or using the machine manual des...

Page 40: ...te the level of charge voltage remaining in the batteries NOTE When the battery voltage is low and will need a charge soon the YELLOW LED item 4 begin to flash Under normal operating conditions the BD...

Page 41: ...ow the platform ladder Look for the instruc tion decal located beside the release handle The lowering procedure is as follows 1 Locate the manual descent control T handle See Figure 3 4 KEEP HANDS AND...

Page 42: ...r Switch 5 Controller 6 Trigger Switch onfront of controller 7 Overload Indicator LSS if equipped 8 Tilt Indicator 9 Horn Button 10 Battery Discharge Indicator 11 System Fault Indicator 12 Alarm not s...

Page 43: ...w 4 Steer Control Switch and Direction Decal 5 Controller 6 Trigger Enable Switch 7 Overload Indicator LSS ifequipped 8 Tilt Indicator 9 Horn Button 10 Battery Discharge Indicator 11 System Fault Indi...

Page 44: ...ng between the Lift and Drive functions the joystick control must be returned to the neutral position for approximately 1 2 second before the function change is operable This toggle switch is used to...

Page 45: ...steer switch is a thumb operated switch located at the top of the control handle Depressing the switch to the right will steer the wheels to the right Depressing the switch to the left will steer the...

Page 46: ...e The drive system is proportional for additional drive speed push the joystick further from the neutral position in the direction of travel Releasing the trigger switch or return ing the joystick to...

Page 47: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121744 JLG Lift 3 15 Figure 3 7 Grade and Sideslope Definition LEVEL...

Page 48: ...ator is illuminated CE All functions will be prevented from the platform and ground controls Lower platform using the machine man ual descent control ANSI Export Australia Japan All platform functions...

Page 49: ...n Section 5 8 If the code cannot be cleared by the operator the machine will require service by a qualified JLG mechanic Alarm Item 12 This alarm mounted on the front of the platform control station w...

Page 50: ...LLOW indicator and the Indoor GREEN indicator displays which mode the machine is currently set to oper ate in Outdoor Indoor Operation Mode Switch CE AUS ONLY Item 14 Figure 3 6 This button will toggl...

Page 51: ...down on the lever slide the top handrails 2 until the locking mechanism pin clears the rear platform extension lock 3 2 Grasp the top handrails 2 of the extendible deck and push the extension out unti...

Page 52: ...and place on the floor of the platform NOTE Front deck extension top rail pins must be removed and deck extension top side rails slid towards rear of machine before lowering side rails Place pins in...

Page 53: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121744 JLG Lift 3 21 Figure 3 9 Platform Rails Fold Down Sequence 1 3 2 4...

Page 54: ...ection the platform control station can be secured to it s mounting plate see Figure 3 10 Also the side compartment doors can be secured by plac ing a padlock through the holes provided just below the...

Page 55: ...reader bar and four equal length straps or chains capable of supporting the full gross weight of the machine see Figure 3 12 Lift only using the lifting lugs provided at the four corners of the machin...

Page 56: ...owed position with the machine securely tied down to the truck or trailer deck There are two tie down and one lift lugs located at the front and two tie down lift lugs on the rear of the machine See F...

Page 57: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121744 JLG Lift 3 25 Figure 3 13 Tie Down and Lift Lug Locations...

Page 58: ...the Emergency Stop switch in 2 Open the right side compartment door and locate the main hydraulic control valve 3 Perform the following to set the drive motor control valve to tow mode On the drive co...

Page 59: ...the platform controls DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 3 Rescue equipment can be used to remove the plat form occupant s Cranes and forklifts can be used to stabilize mo...

Page 60: ...m ladder Look for the instruc tion decal located beside the release handle The lowering procedure is as follows 1 Locate the manual descent control T handle See Figure 4 1 KEEP HANDS AND ARMS OUT OF T...

Page 61: ...8 811005 AUSTRALIA 61 2 65 811111 E mail productsafety jlg com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any w...

Page 62: ...SECTION 4 EMERGENCY PROCEDURES 4 4 JLG Lift 3121744 NOTES...

Page 63: ...ation and maintenance of this machine The maintenance portion of this section is intended as informa tion to assist the machine operator to perform daily mainte nance tasks only and does not replace t...

Page 64: ...G MaximumOperatingTiltAngle Grade FronttoBack platformfullyelevated Sideslope SidetoSide 0 0 3 75 1 50 Outdoor 1 75 Indoor 0 0 3 75 1 50 Outdoor 1 75 Indoor MaximumDriveSpeed FWD REV Stowed SecondstoD...

Page 65: ...ndBearingPressure 115psi 8 09kg cm2 100psi 7 03kg cm2 125psi 8 79kg cm2 GroundClearance PHPRetracted PHPDeployed 2 76 in 7cm 0 81in 2 0cm 2 76 in 7cm 0 81in 2 0cm BreakOverAngle Grade 11 2 20 11 2 20...

Page 66: ...FORCE Platform Fully Extended Max Capacity MAXIMUM OPERATING WIND SPEED ANSI JPN CSA 1532R 600lb 272Kg 250lb 113Kg 2 100lb 445N 28mph 12 5m s CE AUS 275Kg 120Kg Indoor 2Persons 115Kg 400N 0m s 125Kg...

Page 67: ...ail 77 7in 197cm 63 53in 161 4cm FoldingRailsDown 78 72in 200cm 64 55in 163 37cm FoldingRailsDown OverallMachineWidth 32in 81 3cm OverallMachineLength 68 67in 174 4cm PlatformSize Length Inside 62 65i...

Page 68: ...sePolarity OutputShortCircuit ACOverload DCOverload Delta Q 85 270VAC 100VAC 240VACRMS 50 60Hz 7 5A IP66NEMA4Type4 40 F 40 C to149 F 65 C 24V 36V 27 1A 1A 24V ElectronicProtection AutoReset CurrentLim...

Page 69: ...n tain the same required additives or be of comparable vis cosities Table 5 7 Critical Stability Weights COMPONENT 1532R 1932R WheelandTireAssembly each 26 9lb 12 2kg Wheel Tire and Drive Assembly eac...

Page 70: ...erviceclassificationGL 5or MIL SpecMIL L 2105 HO JLGRecommends Mobil Mobilfluid424 MobilEALENVIRONSYNH32 MobilSHCHYDRAULICEAL32 NOTE EALandSHCarecompatiblewitheachother Table 5 11 Hydraulic Oil Specif...

Page 71: ...s on the right side of the machine To engage the safety prop 1 From the Ground Control Station raise the platform far enough to allow the safety prop to be engaged 2 Rotate the prop assembly clockwise...

Page 72: ...ent door there is a cutout 1 which allows viewing of the hydraulic oil tank marking 2 The res ervoir is marked with a MAX maximum marking 2 The MIN marking 3 is the bottom edge of the cutout on the do...

Page 73: ...ntervals are based on machine operations under normal conditions For machines used in multi shift operations and or exposed to hostile environments or conditions lubrication fre quencies must be incre...

Page 74: ...BER LED Flashing Green Power Battery Charger China Only Battery Charging YELLOW LED AGM Flashes Quickly FLOODED Remains ON AGM FLOODED Flashes Slowly Charge Complete GREEN LED ON Fault Indicator RED L...

Page 75: ...ging 30 60 90 RED LED ON Charge Complete GREEN LED ON No Battery Detected 30 RED Blinking Overall Timer Shutdown 30 60 90 RED LEDs Blinking Internal OverTemp Shutdown 30 90 RED LEDs Blink ing 1 AC Vol...

Page 76: ...Y DISTILLED WATER TO BATTERIES WHEN ADDING DISTILLED WATER TO THE BATTERIES A NON METALLIC CONTAINER AND OR FUNNEL MUST BE USED Check the electrolyte level of the batteries often adding only distilled...

Page 77: ...be the same size and brand as originally installed on the machine or offered by JLG as an approved replacement Please refer to the JLG Parts Manual for the part number of the approved tires for a part...

Page 78: ...n the slotted nuts The proper procedure for attaching wheels is as follows 1 If not already installed install shaft key 5 to shaft and align with wheel keyway install wheel and hub 3 onto tapered shaf...

Page 79: ...ure level at the work platform is 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 Equipm...

Page 80: ...SECTION 5 GENERAL SPECIFICATIONS AND MAINTENANCE 5 18 JLG Lift 3121744 5 7 DECAL INSTALLATION Figure 5 6 1532R 1932R Machine Decal Installation See Table 5 12 1...

Page 81: ...016 1704016 7 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 8 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 9 1705679 1705720 1705679 10 1705686 170...

Page 82: ...1001212291 1001212291 1001212291 1001212291 23 1001212292 1001212292 1001212292 1001212292 1001212292 1001212292 1001212292 1001212292 1001212292 24 1001212293 1001212293 1001212293 1001212293 100121...

Page 83: ...h on the platform indicator panel when a fault occurs The more detailed three to five digit code numbers in the DTC column of the following tables are only indicated on a JLG hand held diagnostic anal...

Page 84: ...EVENTED LiftUpState PREVENTED Driving and lift up are not possible since the platform is ele vated and the chassis is not level 006 LIFT UP PREVENTED MAX HEIGHT ZONE A None None LiftUpState PREVENTED...

Page 85: ...eState PREVENTED The Drive Cutout functionality is enabled and the Platform is Elevated above the Calibrated Cutout Height 211 POWER CYCLE None 2_1 No Motion restrictions This Help Message is issued a...

Page 86: ...clear the message 223 FUNCTION PROBLEM DRIVE LIFT ACTIVE TOGETHER None 2_2 MoveState LIFT DriveState PREVENTED LiftUpState PREVENTED LiftDownState PREVENTED The Drive Lift Selector Switch indicates th...

Page 87: ...GroundMode then LiftUpState PREVENTED LiftDownState PREVENTED LiftSwitch UporDown intheGroundControlBoxwasclosed during power up Release or repair the switch to clear the message 232 GROUND LIFT UP DO...

Page 88: ...wed in the stowed position Refer to LSS functionality for Lift and Drive restrictions 256 DRIVE PREVENTED POTHOLE NOT ENGAGED PF 500ms On 500ms Off GND 500ms On 500ms Off 2_5 DriveState PREVENTED Whil...

Page 89: ...NTED Heatsink temperature above 203 F 95 C Possible Cause Controller is operating in an extreme environment Excessive load on vehicle Improper mounting of controller 4235 POWER MODULE TOO HOT REDUCED...

Page 90: ...ted batteries or poor power connections 442 BATTERYVOLTAGETOOHIGH SYSTEM SHUTDOWN None 4_4 Enter SafeMode LiftDownState MAX The Ground Module measured excessively high battery volt age VBAT 32 0V andd...

Page 91: ...Blown B fuse or main contactor not closed 4475 POWER MODULE BDI FAULT None 4_4 DriveState PREVENTED LiftUpState PREVENTED PumpBDIFaultSet BDIPercentagechargeat0 whenthe pump was activated Effect Shutd...

Page 92: ...ft Down PREVENTED Lift Up PREVENTED Drive PREVENTED The Ground Module momentarily measured excessively high battery voltage VBAT 32 0V and entered SafeMode This may be due to improper battery charging...

Page 93: ...ECTION 6 INSPECTION AND REPAIR LOG 3121744 JLG Lift 6 1 SECTION 6 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 6 1 Inspection and Repair Log DATE COMMENTS...

Page 94: ...SECTION 6 INSPECTION AND REPAIR LOG 6 2 JLG Lift 3121744 Table 6 1 Inspection and Repair Log DATE COMMENTS...

Page 95: ...form Mfg Model ______________________________________________________________________ Serial Number ___________________________________________________________________ Previous Owner ________________...

Page 96: ......

Page 97: ......

Page 98: ...itterhude Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852...

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