Oshkosh Corporation 150HAX Operation And Safety Manual Download

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Operation and Safety Manual

ANSI

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

Boom Lift Models
150HAX

3121213

August 30, 2012

Summary of Contents for 150HAX

Page 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Boom Lift Models 150HAX 3121213 August 30 2012 ...

Page 2: ......

Page 3: ...e 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: ...LL HAVE AN ORANGE BACKGROUND INDICATES 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 A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO TECTION OF PROPERTY This is the Safety Alert Symbol It is used to alert you t...

Page 5: ...TS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office See addresses on inside of manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside US...

Page 6: ...FOREWORD d JLG Lift 3121213 REVISION LOG Original Issue July 19 2005 Revised August 8 2006 Revised November 30 2009 Revised August 30 2012 ...

Page 7: ...ng 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function Check 2 5 GENERAL 2 7 2 3 DAILY FUNCTIONAL CHECK 2 10 Axle Extension System 2 10 Axle Retraction System 2 11 Function Cut Outs and Restrictions 2 11 Tower Boom Sequence 2 13 Tower Boom Lift and Swing Systems 2 14 Tower Boom Telescope System 2 14 Main Boom Lif...

Page 8: ...stment 4 8 Platform Rotation 4 8 4 8 BOOM 4 9 Swinging the Boom 4 9 Raising and Lowering the Boom 4 10 Telescoping the Tower Boom 4 10 Telescoping the Main Boom 4 10 4 9 SHUT DOWN AND PARK 4 10 4 10 TIE DOWN AND LIFTING 4 11 Tie Down 4 11 Lifting 4 11 4 11 TOWING 4 11 SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL 5 1 5 2 INCIDENT NOTIFICATION 5 1 5 3 EMERGENCY TOWING PROCEDURES 5 1 5 4 EMERGENCY CONT...

Page 9: ... 2 2 Daily Walk Around Inspection Sheet 2 of 4 2 7 2 3 Daily Walk Around Inspection Sheet 3 of 4 2 8 2 4 Daily Walk Around Inspection Sheet 4 of 4 2 9 3 1 Ground Control Panel Sheet 1 of 3 3 3 3 2 Ground Control Panel Sheet 2 of 3 3 4 3 3 Ground Control Panel Sheet 3 of 3 3 5 3 4 Ground Control Remote Box 3 7 3 5 Platform Control Station 3 11 4 1 Position of Least Forward Stability 4 3 4 2 Positio...

Page 10: ...3758 4 15 4 2 Decal Installation S N 0300103758 to Present 4 19 6 1 Operating Specifications 6 1 6 2 Capacities 6 2 6 3 Cummins 4B3 9C 6 2 6 4 Cummins QSB4 5 NA 6 2 6 5 Tires 6 3 6 6 Dimensional Data 6 3 6 7 Hydraulic Oil 6 4 6 8 Mobilfluid 424 Specs 6 4 6 9 Mobil EAL 224 H Specs 6 5 6 10 Mobil DTE 13M Specs 6 5 6 11 Exxon Univis HVI 26 Specs 6 6 6 12 Critical Stability Weights 6 6 6 13 Lubricatio...

Page 11: ...e machine should not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc JLG FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS...

Page 12: ...riting by JLG Do not operate the machine in hazardous environments unless approved for that purpose by JLG Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine Machine Inspection Before machine operation perform inspections and func tional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine unt...

Page 13: ...form the opera tor shall be responsible for all machine operations Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area Supplies or tools which extend outside the platform are prohibited unless approved by JLG When driving always position boom over rear axle in line with the direction of travel Remember if boom is over the front axle s...

Page 14: ...use the boom assembly to enter or leave the plat form Use extreme caution when entering or leaving platform Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform closer to the ground for entry exit Face the machine maintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Electrocution H...

Page 15: ...nd its occupants their tools 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 Table 1 1 Minimum Approach Distances M A D Voltage Range Phase to Phase MINIMUM APPROACH DISTANCE in Feet Meters 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KVt...

Page 16: ...duced to a distance within the designed working dimensions of the insulating barrier This determination shall be made by a qualified per son in accordance with the employer local or governmental requirements for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE Tipping ...

Page 17: ...ne Do not tie off machine to any adjacent structure Do not operate the machine when wind conditions exceed 28 mph 12 5 m s Refer to Table 1 2 Beaufort Scale For Reference Only Do not increase the surface area of the platform or the load Increase of the area exposed to the wind will decrease stability Do not increase the platform size with unauthorized deck extensions or attachments If boom assembl...

Page 18: ... from striking or interfering with operating controls and per sons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised boom or platform Position barricades on floor if neces sary 1 4 TOWING LIFTING AND HAULING Never allow person...

Page 19: ...erforming welding or metal cutting operations precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine with the engine running Battery fluid is highly corrosive Avoid contact with skin and clothing at all times Charge batteries only in a well ventilated area ...

Page 20: ...d feltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentle breeze Leavesandsmallertwigsin constantmotion 4 13 18 5 5 7 9 Moderate breeze Dustand loose paperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Whistlingheardinoverheadwires Umbrella usebecomesdifficult 7 32 38 13 9 17 1 Near Gale ModerateGale Wholetreesinmotio...

Page 21: ...f the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles depressions holes drop offs 7 Means to avoid the hazards of unprotected electrical conductors...

Page 22: ...ons for further requirements for aerial work plat forms The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE ...

Page 23: ...ntInspection SeeNote Inservicefor3monthsor150hours whichever comesfirst or Outofserviceforaperiodofmorethan3months or Purchased used Owner Dealer orUser Qualified JLG Mechanic ServiceandMaintenance Manual and applicableJLG inspection form AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateof priorinspection Owner Dealer orUser FactoryQualified ServiceTechnician Recommended Serv...

Page 24: ...estic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 1 thru Figure 2 4 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 at the Full mark on the dipstick and the filler cap is secure 9 Hydr...

Page 25: ...ons are disabled when the Emergency Stop Button is activated 2 From the platform control console a Ensure that the control console is firmly secured in the proper location b Check that all guards protecting the switches or locks are in place c Operate all functions and check all limiting and cut out switches d Ensure that all machine functions are disabled when the Emergency Stop Button is pushed ...

Page 26: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 6 JLG Lift 3121213 Figure 2 1 Daily Walk Around Inspection Sheet 1 of 4 ...

Page 27: ...See Inspection Note 3 Axle Jack Extension Switches See Inspection Note decals in place and legible 4 All Hydraulic Cylinders No visible damage pivot pins and hydraulic hoses undamaged not leaking 5 Tie Rods and Steering Linkage No loose bent or missing parts no visible damage tie rod ends undamaged 6 Platform Assembly See Inspection Note Foot switch in good working order not modified disabled or b...

Page 28: ... and latches in working condition See Inspection Note 17 Control Valve Compartment See Inspection Note 18 Ground Controls Switches and controllers opera ble no visible damage placards secure and legible 19 Axle Jack Extension Switches See Inspection Note decals in place and legible 20 Main Boom Pivot Pin See Inspection Note 21 Manual Descent Valves and Pump Valve handles and pump handle properly s...

Page 29: ...o evi dence of leakage evidence of proper lubrication 27 Hydraulic Oil Supply Recommended oil level Check level with cold oil systems shut down machine in stowed position Cap secure and in place 28 Oil Filter Housing See Inspection Note 29 Hydraulic Oil Breather Element in place not clogged no visible signs of overflow 30 Fuel Supply Fuel filler cap secure Tank See Inspection Note 31 Platform Pivo...

Page 30: ... System WHEN RAISING FRAME TO OPERATE AXLE EXTENSION SYSTEM RAISE ONLY ONE JACK CYLINDER AT A TIME DO NOT RAISE BOTH CYLIN DERS AT THE SAME TIME AS THIS WILL CAUSE THE MACHINE TO BECOME UNSTABLE 1 From ground controls activate the machine hydraulic system 2 Position JACK cylinder switch on axle to DOWN and hold until wheels rise from the ground 3 Remove lock pin from left tie rod 4 Position EXTEND...

Page 31: ...for front axle to retract until the right axle is fully retracted Install right tie rod lock pin 7 Position JACK cylinder switch to UP to lower the machine wheels 8 Repeat steps 2 through 7 for rear axle Function Cut Outs and Restrictions 1 Platform Gate Interlock The engine will not start unless the platform gate is closed and latched 2 Swing Cut Out With axles retracted boom will only swing betw...

Page 32: ...izontal with machine on a 5 slope drive function is cut out and all other functions automati cally go into creep mode 7 Tower Boom Cut Outs Tower telescope and main lift are cut out unless tower lift is fully up Tower lift is cut out unless tower telescope is fully in and main lift is fully down 8 Main Boom Lift Cut Out When main boom lift is operating lift speed automati cally goes into the creep...

Page 33: ...evel ground and with the tower boom in the stowed position Identify the hydraulic valve switch adjacent to the tower lift cylinder at the bottom end rear of the tower base boom 2 Visually check the two valves in the turntable to ensure the plungers are fully extended SIDEVIEW MAINBOOMAND TOWERBOOMATTACH TOPVIEW BOOMATTACH TOTURNTABLE ...

Page 34: ...he red check light in the ground console should illuminate If the light does not come on contact a qualified service technician to further evaluate this condition before operating the machine 6 Fully retract the tower boom Lift the main boom several feet Attempt to lower the tower boom NOTE Tower Lift down should not work and the red check light in the ground console panel should illuminate If the...

Page 35: ...1 Activate hydraulic system Activate footswitch Operate TOWER BOOM TELESCOPE and hold controller Remove foot from footswitch motion should stop If it does not shut down machine and contact a qualified service technician 2 With hydraulic system and footswitch activated operate MAIN BOOM LIFT and hold control Remove foot from footswitch motion should stop If it does not shut down machine and contact...

Page 36: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 16 JLG Lift 3121213 NOTES ...

Page 37: ...he movable Ground Control Remote Box The remote box can be removed from the ground control station and is attached to the machine by a 50 foot 15 m cable This will allow the operator to control platform movement away from the machine to gain a better view of the platform location Ground Control Panel DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSON NEL IN THE PLATFORM EXCEPT IN AN EMERGENCY ...

Page 38: ...breaker returns interrupted power to the high engine function when depressed 5 Hourmeter An HOURMETER records the engine operating time 6 Voltmeter With the ignition switch in the ON position and before starting the engine the VOLTMETER indicates the con dition of the battery With the engine running the VOLT METER indicates output voltage of the alternator Normal reading for the voltmeter will be ...

Page 39: ...DICATORS 3121213 JLG Lift 3 3 Figure 3 1 Ground Control Panel Sheet 1 of 3 1 MasterSwitch 2 Platform GroundSelectSwitch 3 AxlesSetIndicator 4 HighEngine CircuitBreaker 5 Hourmeter 6 Voltmeter 7 OilPressureGauge 8 WaterTemperatureGauge ...

Page 40: ...ICATORS 3 4 JLG Lift 3121213 Figure 3 2 Ground Control Panel Sheet 2 of 3 1 MasterSwitch 2 Platform GroundSelectSwitch 3 Axles SetIndicator 4 HighEngine CircuitBreaker 5 Hourmeter 6 Voltmeter 7 OilPressureGauge 8 WaterTemperature Gauge ...

Page 41: ...3 JLG Lift 3 5 Figure 3 3 Ground Control Panel Sheet 3 of 3 1 N A 2 Platform Ground SelectSwitch 3 AxlesSetIndicator 4 High EngineCircuitBreaker 5 Hourmeter 6 Voltmeter 7 OilPressure Gauge 8 Water TemperatureGauge 9 TowerProximitySwitchCheckIndicator ...

Page 42: ...level functions to be operated b It should be noted that functions will operate at a slower than normal rate because of the lower gpm delivered NOTE When operating on auxiliary power do not operate more than one function at a time Simultaneous operation can overload the 12 volt auxiliary pump motor c Position PLATFORM GROUND SELECT SWITCH to GROUND d Position MASTER SWITCH to ON e Operate appropri...

Page 43: ...ure 3 4 Ground Control Remote Box 1 AuxiliaryPower 2 PlatformRotate 3 PlatformLeveling Override 4 Start 5 CreepSpeed 6 EmergencyStop 7 MainTelescope 8 Swing 9 TowerTelescope 10 TowerLift 11 MainLift 12 ManualDescentValves NotShown 13 FunctionEnable 14 PlatformOverload ...

Page 44: ...ep Speed Switch allows the operator to select a lower speed for machine functions when positioned to on 6 Emergency Stop Button The EMERGENCY STOP button supplies electrical power from the IGNITION ON relays to the START but ton when the button is pulled out and the MASTER SWITCH is in the ON position When depressed the but ton shuts off electrical power to the machine 7 Main Telescope Controller ...

Page 45: ... located on the left front of the machine turntable The manual descent valves should be used in the event of a total power failure to lower the work platform in the event of an emergency The valves permit the use of gravity to retract the tower boom and lower the main boom Refer to Section 6 for a complete description of the manual descent systems their application and their operation 13 Function ...

Page 46: ...e of the rocker switch will cause the machine to steer to the left and depressing the right side of the rocker switch will cause the machine to steer to the right WHEN DRIVING FORWARD AND OPERATING THE REAR STEER WHEELS THE REAR WHEELS WILL TURN IN THE OPPOSITE DIRECTION OF MACHINE TRAVEL I E DEPRESSING THE LEFT SIDE OF THE ROCKER SWITCH WILL CAUSE THE WHEELS TO TURN TO THE RIGHT 3 Tower Telescope...

Page 47: ...lugIndicator 6 Ignition EmergencyStopSwitch 7 MainTelescopeLever 8 TowerLiftLever 9 EngineDistressIndicator 10 MainLiftLever 11 BrokenChain 12 SwingLever 13 Axles SetIndicator 14 Horn 15 Steer Switch 16 Capacity Indicator 17 EngineSpeedSwitch 18 PumpVolumeSwitch 19 WheelSpeedSwitch 20 CreepSpeed Switch 21 ChassisOut ofLevelIndicator 22 RotateSwitch 23 AuxiliaryPowerSwitch 24 PlatformOverload ...

Page 48: ...erator of high engine coolant temperature or low oil pressure 10 Main Lift Controller The MAIN LIFT controller provides raising and lowering of the main boom when positioned to UP or DOWN 11 Broken Chain CE The red BROKEN CHAIN indicator light will illuminate to warn the operator of a broken fly extend chain in the main boom or a broken fly retract chain in the main boom 12 Swing Controller The SW...

Page 49: ...e main boom below horizontal HIGH ENGINE SPEED will oper ate with DRIVE TOWER TELESCOPE and TOWER LIFT With the main boom above horizontal and the appropriate function control handle at the end of its travel HIGH ENGINE SPEED will operate with TOWER LIFT and TOWER TELESCOPE 18 Pump Volume Switch The two position PUMP VOLUME control switch allows the operator to select high pump flow providing addi...

Page 50: ...otate the basket to the left or right when posi tioned to the desired direction 23 Auxiliary Power The AUXILIARY POWER control switch energizes the electrically operated hydraulic pump when actuated Switch must be held ON for duration of auxiliary pump use The auxiliary pump functions to provide sufficient oil flow to operate the basic machine system should the main pump or engine fail The auxilia...

Page 51: ...tch to OFF 24 Platform Overload If equipped Indicates the platform has been overloaded 25 Intercom Not Shown The machine is equipped with an intercom system that permits the operator in the platform to communicate with personnel on the ground The platform intercom is located to the right of the platform control console and is attached to the platform rail The ground intercom is located on the righ...

Page 52: ...t switch disconnects power to the ignition switch when the gate is not latched 27 Footswitch Not Shown A safety feature makes it necessary to depress the foot switch to allow operation of the controls TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER ATE WHEN PEDAL IS APPROXIMATELY AT ITS CE...

Page 53: ...rm Con trol Station Ground Controls operate boom lift telescope swing and rotate and are to be used only in an emergency to lower the platform to the ground should the operator in the platform be unable to do so 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS Capacities The boom can be raised above horizontal with or without any load in the platform if 1 Machine is positioned on a smooth firm and le...

Page 54: ...NE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL 4 Place ENGINE SPEED control switch on platform con trol console to LOW position NOTE Footswitch must be in released pedal up position before starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE NOTE The platform gate must be latched in order to operate the machine A platform gat...

Page 55: ...ON 3121213 JLG Lift 4 3 Figure 4 1 Position of Least Forward Stability Thepositionof Least ForwardStability iswith thetowerboomfullyelevated and fully retracted with themainboomfullyextendedathorizontalover thesideof themachine ...

Page 56: ...ft 3121213 Figure 4 2 Position of Least Backward Stability The position of Least Backward Stability is with the tower boom fully elevated and fully extended with the main boom fully elevated and fully retracted over the side of the machine ...

Page 57: ...VE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED ON CAUTION PLACARD AT PLATFORM ASSURE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGINNING ANY EXTENDED TRAVELING AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE TO UPSET TRAVEL GRADES IN LOW DRIVE SPEED...

Page 58: ...SECTION 4 MACHINE OPERATION 4 6 JLG Lift 3121213 Figure 4 3 Grade and Sideslope ...

Page 59: ...T and position the ENGINE SPEED PUMP VOLUME and WHEEL SPEED switches to HIGH 6 Prior to stopping the machine position ENGINE SPEED DRIVE SPEED and WHEEL SPEED switches to LOW 7 For going up grades position WHEEL SPEED switch to LOW and HIGH ENGINE switch to HIGH 4 5 STEERING To steer machine using front steer wheels position STEER control switch on platform control console to RIGHT for trav eling ...

Page 60: ...7 kg or less for a single capacity machine proceed with adding weight If total weight in platform is 1 000 lbs 454 kg or less for dual capacity machine and machine is within proper capacity location distribute load uniformly on platform floor and proceed to work position Platform Level Adjustment 1 Leveling UP To raise platform position LEVEL control switch to UP and hold until platform is level 2...

Page 61: ...ILT ALARM WARNING LIGHT ILLUMINATES WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTEND ING OR RAISING MAIN BOOM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED TO AVO...

Page 62: ...sition MAIN BOOM TELESCOPE controller to IN or OUT and hold until plat form reaches desired position 4 9 SHUT DOWN AND PARK 1 Drive machine to a reasonably well protected area 2 Position HIGH ENGINE speed control switch on Plat form Console to LOW 3 Assure main boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured 4 Remove all load and allow engine...

Page 63: ...cessary to lift the machine using an over head or mobile crane it is very important that the lifting devices are attached only to the designated lifting eyes and that the turntable lock pin is engaged A lifting tie down eye is provided at each of the four corners of the machine frame When lifting the machine each of the four chains or slings used for lifting the machine must be adjusted individual...

Page 64: ...SECTION 4 MACHINE OPERATION 4 12 JLG Lift 3121213 Figure 4 4 Lifting Diagram ...

Page 65: ...SECTION 4 MACHINE OPERATION 3121213 JLG Lift 4 13 Figure 4 5 Decal Installation Sheet 1 of 2 ...

Page 66: ...SECTION 4 MACHINE OPERATION 4 14 JLG Lift 3121213 Figure 4 6 Decal Installation Sheet 2 of 2 ...

Page 67: ...700584 1700584 1700584 1700584 1700584 1700584 3 1701509 1701509 1701509 1701509 1701509 1701509 1701509 4 3251813 5 1704277 6 1703518 1693292 1693294 1701600 1701791 7 8 1702868 9 1703953 10 1701501 1701501 1701501 1701501 1701501 1701501 1701501 11 12 1701504 1701504 1701504 1701504 1701504 1701504 1701504 13 1701500 1701500 1701500 1701500 1701500 1701500 1701500 14 1701499 1701499 1701499 1701...

Page 68: ...0037 26 1702153 27 28 3251243 29 30 31 1701502 1701502 1701502 1701502 1701502 1701502 1701502 32 1701503 1701503 1701503 1701503 1701503 1701503 1701503 33 1703162 1703162 1703162 1703162 1703162 1703162 1703162 34 1701527 1701527 1701527 1701527 1701527 1701527 1701527 35 Table 4 1 Decal Installation Prior to S N 0300103758 Item ANSI 0257251 2 Dutch 0252864 2 French 0252079 2 German 0252862 2 It...

Page 69: ...1703514 1703509 1703513 45 1701596 1703510 1703507 1703515 1703512 1703516 46 47 1701428 1701428 1701428 1701428 1701428 1701428 1701428 48 1701427 1701427 1701427 1701427 1701427 1701427 1701427 49 1701426 1701426 1701426 1701426 1701426 1701426 1701426 50 51 1702300 1702300 1702300 1702300 1702300 1702300 1702300 52 1705336 53 1702631 1702631 1702631 1702631 1702631 1702631 1702631 Table 4 1 Dec...

Page 70: ...52523 3252523 3252523 55 1703456 1703456 1703456 1703456 1703456 1703456 1703456 56 1704096 57 1707014 58 59 Table 4 1 Decal Installation Prior to S N 0300103758 Item ANSI 0257251 2 Dutch 0252864 2 French 0252079 2 German 0252862 2 Italian 0252863 2 Spanish 0253267 2 UK 0252078 4 ...

Page 71: ...1700584 1700584 1700584 1700584 1700584 3 1701509 1701509 1701509 1701509 1701509 1701509 1701509 4 3251813 5 1704277 6 1703518 1693292 1693294 1701600 1701791 7 8 1702868 9 1703953 10 1701501 1701501 1701501 1701501 1701501 1701501 1701501 11 1701505 12 1701504 1701504 1701504 1701504 1701504 1701504 1701504 13 1701500 1701500 1701500 1701500 1701500 1701500 1701500 14 1701499 1701499 1701499 170...

Page 72: ...037 26 1702153 27 28 3251243 29 30 31 1701502 1701502 1701502 1701502 1701502 1701502 1701502 32 1701503 1701503 1701503 1701503 1701503 1701503 1701503 33 1703162 1703162 1703162 1703162 1703162 1703162 1703162 34 1701527 1701527 1701527 1701527 1701527 1701527 1701527 35 Table 4 2 Decal Installation S N 0300103758 to Present Item ANSI 0257251 2 Dutch 0252864 2 French 0252079 2 German 0252862 2 I...

Page 73: ...08 1703514 1703509 1703513 45 1701596 1703510 1703507 1703515 1703512 1703516 46 47 1701428 1701428 1701428 1701428 1701428 1701428 1701428 48 1701427 1701427 1701427 1701427 1701427 1701427 1701427 49 1701426 1701426 1701426 1701426 1701426 1701426 1701426 50 51 1702300 1702300 1702300 1702300 1702300 1702300 1702300 52 1705336 53 1702631 1702631 1702631 1702631 1702631 1702631 Table 4 2 Decal In...

Page 74: ...2523 3252523 3252523 55 1703456 1703456 1703456 1703456 1703456 1703456 1703456 56 1704096 57 1707014 58 59 Table 4 2 Decal Installation S N 0300103758 to Present Item ANSI 0257251 2 Dutch 0252864 2 French 0252079 2 German 0252862 2 Italian 0252863 2 Spanish 0253267 2 UK 0252078 4 ...

Page 75: ...eration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 10 FT 3 M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 5 3 EMERGENCY TOWING PROCEDURES RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING B...

Page 76: ...IS IN PLACE AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE Ground Control Station The Ground Control Station is located on the front right side of the turntable The controls on this panel provide the means for overriding the platform controls and for controlling the platform level platform rotate tower boom lift tower boom telescope main boom lift main boom telescope swing creep spe...

Page 77: ...XILIARY POWER switch and appropriate control switch or controller 6 Position MASTER SWITCH to OFF Manual Descent and Retraction The manual descent valves are used in the event of total power failure to retract the tower boom and lower the main boom using gravity To operate the manual descent system proceed as follows 1 Remove manual descent pump handle from inside bat tery access door 2 Open manua...

Page 78: ...onnel on the platform may use the platform controls with regular or auxiliary power DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY 3 Prior to removing platform occupants cranes forklift trucks or other equipment which may be available are to be used to stabilize motion of the machine in case machine controls are inadequate or malfunction when used Platform or Boom Caught Overhead I...

Page 79: ...ce and Maintenance Manual ANSI 3120679 Service and Maintenance Manual CE 3120817 Illustrated Parts Manual ANSI 3120679 Illustrated Parts Manual CE 3120812 6 2 OPERATING SPECIFICATIONS Table 6 1 Operating Specifications MaximumWork Load Capacity Unrestricted Restricted FrenchSpec 500lb 230kg 1000lb 450kg 585lb 265kg MaximumTravelGrade Gradeablility with boominstowedposition SeeFigure4 3 30 MaximumT...

Page 80: ...rts 9 5liters w o filter Cooling System System 21 4quarts 20 2liters Engine 7 4quarts 7 0liters Radiator 14 0quarts 13 2liters 21 4quarts 20 2liters 7 4quarts 7 0liters 14 0quarts 13 2liters Table 6 3 Cummins 4B3 9C Horsepower 76 2500RPM noload Fuel Diesel LowRPM 1800 HighRPM 2500 Alternator 60Amp belt driven Battery 85Amphour 550CCA 12volts Table 6 4 Cummins QSB4 5 NA Horsepower 80 2200RPM noload...

Page 81: ...nal Data Turning Radius Outside w axlesretracted w axlesextended 24ft 2in 7 4meters 27ft 2in 8 3meters LengthStowed w mainboomfullyretractedand platforminnormal position w mainboomtelescopedout and platformtiltedtostowatminimum height 39ft 5in 12 0meters 41ft 7in 12 7meters Machine Width w axlesretracted w axlesextended 11ft 6in 3 5meters 18ft 0in 5 5meters Wheelbase 18ft 0in 5 5meters ...

Page 82: ...LG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired con tact JLG Industries for proper recommendations Table 6 7 Hydraulic Oil Hydraulic System Operating Temperature Range SAE Viscosity Grade 0 to 23 F 18 to 5 C 10W 0 to 210 F ...

Page 83: ...nt Min 428 F 220 C Weight 7 64 lb per gal 0 9 kg per liter Viscosity at 104 F 40 C 37 cSt at 212 F 100 C 8 4 cSt Viscosity Index 213 Operating Temp 0 180 F 17 162 C Note Must be stored above 32 F 14 C Table 6 10 Mobil DTE 13M Specs Type Petroleum Base ISO Viscosity Grade 32 Specific Gravity 877 Pour Point Max 40 F 40 C Flash Point Min 330 F 166 C Viscosity at 104 F 40 C 33 cSt at 212 F 100 C 6 5 c...

Page 84: ...cific Gravity 32 1 Pour Point 76 F 60 C Flash Point 217 F 103 C Viscosity at 40 C 25 8 cSt at 100 C 9 3 cSt Viscosity Index 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity Table 6 12 Critical Stability Weights LB KG Counterweight 3285 1490 Tire WheelAssembly 1020 494 Engine 680 308 8ft Platform 295 134 ...

Page 85: ... turntable just behind the fuel tank If the serial number plate is missing the machine serial number is stamped on the left side of the frame below the turntable bearing In addition the last five dig its of the serial number are stamped on the top of the fly end of each of the tower boom and main boom sections Figure 6 1 Serial Number Locations LAST5DIGITSOF SERIAL NUMBER STAMPED SERIALNUMBERSTAMP...

Page 86: ...38 C 110 F 43 C 120 F 49 C ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY AMBIENT AIR TEMPERATURE SAE 15W 40 SAE 10W 30 SAE 5W 30 SUMMER GRADE FUEL WINTER GRADE FUEL NO OPERATION BELOW THIS AMBIENT TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE Figure 6 2 Engine Operating Temperature Specifications Cu...

Page 87: ...E THIS AMBIENT TEMPERATURE DO NOT START UP 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 EXXON UNIVIS HVI 26 MOBIL DTE 13 NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LE...

Page 88: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 10 JLG Lift 3121213 Figure 6 4 Operator Maintenance Lubrication Diagram ...

Page 89: ...erval Check oil level at side plug on hub weekly Change after first 3 months or 150 hours then every 2 years or 1200 hours of operation Comments Place Fill port at 12 o clock position and pour lubricant into fill port until it just starts to flow out of check port when it s at the 3 o clock position Table 6 13 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehaving aminimumdripp...

Page 90: ...G Lift 3121213 2 Steer Spindles Lube Point s 4 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 3 Tie Rod Center Pivot Links Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation ...

Page 91: ... Lift 6 13 4 Steer Cylinder Barrel Ends Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 5 Steer Cylinder Rod Ends Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation ...

Page 92: ... 3121213 6 Extending Axles Lube Point s N A Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Apply by brush 7 Swing Bearing Gear Lube Point s N A Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Apply by brush ...

Page 93: ... 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Fitting on Left Rear of Turntable 9 Tower Boom Lift Cylinder Barrel End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Fitting on Left Rear of Turntable ...

Page 94: ...te Fitting on Left Rear of Turntable 11 Lower Master Cylinder Rod End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 12 Platform Hinges Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 13 Platform Door Latch Lube Point s N A Capacity A R Lube EO Interval Every 3 months or 150 hrs of op...

Page 95: ...ate Pivot Rotator Worm Gear Lube Point s 2 Grease Fittings on pivot 1 Grease Fit ting on worm gear Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 15 Platform Level Links Lube Point s 3 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation ...

Page 96: ...Lube MPG Interval Every 3 months or 150 hrs of operation 17 Level Cylinder Barrel End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 18 Engine Crankcase Lube Point s Fill Cap Drain Plug Capacity 10 quarts 9 5 L w o filter Lube EO Comments Check daily Refer to Engine Manual for Change interval ...

Page 97: ... Point s N A Capacity N A Lube Chain Lube Interval Every 2 years or 1200 hours of operation 21 Main Boom Extend Chain Sheave Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Align access holes in mid and fly boom 22 Main Boom Lift Cylinder Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation ...

Page 98: ... R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Align with access hole in base boom 24 Main Boom Pivot Pin Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation 25 Tower Boom Pivot Pin Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation ...

Page 99: ... 6 21 26 Level Links Lube Point s 3 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 27 Upper Master Cylinder Rod End Lube Point s 1 Grease Fitting Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments ...

Page 100: ...ty A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments 30 Hydraulic Oil Lube Point s Fill Cap Drain Plug Capacity A R Lube HO Interval Check daily Change every 2 years or 1200 hours Comments On new machines those recently over hauled or after changing hydraulic oil operate all sys tems a minimum of two complete cycles and recheck oil level in reservoir 31 Hydraulic Filter Interva...

Page 101: ... 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121213 JLG Lift 6 23 32 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator ...

Page 102: ...ies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as ...

Page 103: ...l mounting torque WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wre...

Page 104: ...plicable 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 Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of t...

Page 105: ...ECTION 7 INSPECTION AND REPAIR LOG 3121213 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerial Number _______________________________________ Table 7 1 Inspection and Repair Log Date Comments ...

Page 106: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121213 Table 7 1 Inspection and Repair Log Date Comments ...

Page 107: ...r rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Previous Owner ___________________________________________________________ Address _________________________________________________________________ ___________________________________________________...

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Page 110: ...5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technol...

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