Oshkosh Corporation JLG 1200SJP Operation And Safety Manual Download Page 4 | Manualshive

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FOREWORD

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31215054

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT
IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK

-

GROUND.

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 INDI

-

RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death

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Summary of Contents for JLG 1200SJP

Page 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times AS NZS GB Models 1200SJP 1350SJP PVC 2001 31215054 October 1 2020 Rev C...

Page 2: ...ich are known to the State of California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service yo...

Page 3: ...Keep it with the machine at all times The purpose of this manual is to provide owners users operators lessors and lessees with the precautions and operating procedures essential for the safe and prop...

Page 4: ...VE AN ORANGE BACK GROUND 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 BACK...

Page 5: ...UCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Departme...

Page 6: ...FOREWORD d 31215054 REVISION LOG Original Issue A October 23 2019 Revision B June 26 2020 Revision C October 1 2020...

Page 7: ...ND MAINTENANCE 2 2 Pre Start Inspection 2 5 Daily Walk Around Inspection 2 6 Function Check 2 8 SkyGuard Function Test 2 9 Boom Control System Check Procedure 2 10 2 3 OSCILLATING AXLE LOCKOUT TEST IF...

Page 8: ...17 4 14 SHUT DOWN AND PARK 4 18 4 15 LIFTING AND TIE DOWN 4 18 Lifting 4 18 Tie Down 4 19 4 16 STOWING THE JIB FOR TRANSPORT 4 19 SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL 5 1 5 2 INCIDENT NOTIFICATI...

Page 9: ...ection 6 13 Operation 6 13 6 7 SOFT TOUCH 6 13 6 8 BOLT ON EXTERNAL FALL ARREST 6 14 Inspection Before Use 6 15 SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 1 INTRODUCTION 7 1 7 2 OPERATING...

Page 10: ...iv 31215054 TABLE OF CONTENTS...

Page 11: ...3 7 4 Capacities 7 3 7 5 Tire Specifications 7 4 7 6 Deutz BF4M2011 Specifications 7 4 7 7 Deutz TD2011L4 Specifications 7 5 7 8 Deutz TCD 2 9L4 Specifications 7 5 7 9 Caterpillar 3 4T Specifications...

Page 12: ...vi 31215054 LIST OF TABLES...

Page 13: ...on Sheet 1 of 7 4 21 4 9 Decal Location Sheet 2 of 7 4 22 4 10 Decal Location Sheet 3 of 7 4 23 4 11 Decal Location Sheet 4 of 7 4 24 4 12 Decal Location Sheet 5 of 7 4 25 4 13 Decal Location Sheet 6...

Page 14: ...viii 31215054 LIST OF FIGURES...

Page 15: ...ing is accomplished and operation 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 at...

Page 16: ...ontrols Read understand and obey all applicable employer local and governmental regulations as they pertain to your utilization and application of the machine WorkplaceInspection Precautions to avoid...

Page 17: ...mud oil grease and other 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 de...

Page 18: ...ry when operating machine Do not wear loose fitting clothing or long hair unre strained which may become caught or entangled in equip ment Persons under the influence of drugs or alcohol or who are su...

Page 19: ...p both feet firmly positioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slipper...

Page 20: ...ts occupants their tools and their 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 Tabl...

Page 21: ...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 Ensure that the g...

Page 22: ...machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions including gusts exceed specifications shown in section 7 2 of th...

Page 23: ...ibleinsmoke 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 Dustandloosepaperraised Smallb...

Page 24: ...nditions the operator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors Be aware of stopping distances in all drive...

Page 25: ...during machine maintenance are inserted 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 t...

Page 26: ...ms critical to stability such as batteries or solid tires with items of different weight or specification Do not modify the MEWP in any way to affect stability Refer to the Service and Maintenance Man...

Page 27: ...the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 7 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles...

Page 28: ...g understanding and following the manufacturer s operator s manual Prior to users authorization of an operator to use a specific model of MEWP the user shall ensure the operator is familiarized on the...

Page 29: ...eriodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13months...

Page 30: ...54 Figure 2 1 Basic Nomenclature 1 Front Steer Wheels 2 Rear Drive Wheels 3 Lift Cylinder 4 Ground Console 5 Base Boom Section 6 Inner Mid Boom Section 7 Outer Mid Boom Section 8 Fly Boom Section 9 Bo...

Page 31: ...ANSI markets only is enclosed in the weather resistant storage container 5 Walk Around Inspection Perform as instructed 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the p...

Page 32: ...ting the platform and loading unloading materials 14 Lanyard Attach Points During operation occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anc...

Page 33: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 31215054 2 7 Walk Around Inspection...

Page 34: ...d or blocked Latch stop and hinges in working condition 2 SkyGuard See Inspection Note 3 Platform Control Console Switches and levers return to neutral when activated and released decals placards secu...

Page 35: ...ions should extend retract together at the same rate of speed Any difference would indicate delayed move ment and loose wire ropes IF DELAYED MOVEMENT IS DETECTED IN WIRE ROPE OPERATION LOWER PLATFORM...

Page 36: ...erial in the platform from the ground control station 1 Extend all axles fully 2 With the boom fully retracted raise the boom off the boom rest to horizontal 3 Position the jib horizontal jib straight...

Page 37: ...eam 3 Once the sensor has been activated 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 S...

Page 38: ...gine 3 Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block 4 Carefully extend the boom just enough to get it o...

Page 39: ...the operator to different types of operational situations that could arise The meaning of those symbols are explained below Indicates a potentially hazardous situation which if not corrected could re...

Page 40: ...ontrol Station without MSSO 1 IndicatorPanel 2 BoomControlSystemTestButton 3 Telescope 4 Swing 5 Lift 6 Platform GroundSelectSwitch 7 Hourmeter 8 Power EmergencyStop 9 EngineStart AuxiliaryPower 10 Ar...

Page 41: ...Control Station with MSSO 1 IndicatorPanel 2 BoomControlSystemTestButton 3 Telescope 4 Swing 5 Lift 6 Platform GroundSelectSwitch 7 Hourmeter 8 Power EmergencyStop 9 EngineStart AuxiliaryPower 10 Arti...

Page 42: ...Panel 2 BoomControlSystemTestButton 3 Telescope 4 Swing 5 Lift 6 Platform GroundSelectSwitch 7 Hourmeter 8 Power EmergencyStop 9 EngineStart AuxiliaryPower 10 ArticulatingJib 11 PlatformLevelingOverri...

Page 43: ...l The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation 2 Boom Control System Test Button The push button is used to test the...

Page 44: ...Stop switch is in the On position and engine is not running an alarm will sound indicating Ignition is On WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF...

Page 45: ...jib ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANTS TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOU...

Page 46: ...emergency override of function controls that are locked out in the event of Load Sense System activation 15 Air Shutoff Valve ASOV If Equipped The red LED ASOV light indicates when the valve has been...

Page 47: ...isable 4 CapacityZoneIndicator 5 BoomControlSystemCalibrated 6 Generator 7 FuelGauge 8 GlowPlugs 9 PlatformOverload 10 AxlesSet 11 WireRopeService 12 EngineError 13 BoomControlSystemWarning 14 Emissio...

Page 48: ...or 2 3 sec onds when the key is positioned to the ON position to act as a self test 3 Drive and Steer Disable Indicator Indicates the Drive and Steer Disable function has been activated 4 Capacity Zon...

Page 49: ...he light indicates the wire ropes are loose or broken and must be repaired or adjusted prior to use 12 Engine Error Indicator Indicates a fault with the engine and service is required 13 Boom Control...

Page 50: ...ect 2 SteerSelect 3 PlatformLevelOverride 4 AxleExtend Retract 5 Horn 6 IndicatorPanel 7 BoomControlSelect IfEquipped 8 Power EmergencyStop 9 EngineStart AuxiliaryPower 10 CapacitySelectSwitch 11 Driv...

Page 51: ...position gives maximum torque for rough terrain and climbing grades The center position allows the machine to be driven as qui etly as possible 2 Steer Select The action of the steering system is oper...

Page 52: ...perform a diagnostic check of the various electrical circuits and if everything is OK the platform alarm will beep once During this time the lights on the indicator panel will also blink once as a bu...

Page 53: ...actuated Switch must be held on for duration of auxiliary pump use The auxiliary pump functions to provide suffi cient oil flow to operate the basic machine functions should the main pump or engine f...

Page 54: ...n boom 14 Lights SkySense Mute If Equipped Operates accessory light packages if the machine is so equipped If machine is equipped with SkySense the switch will mute the SkySense speakers 15 Jib Lift P...

Page 55: ...activated All controls are cut out until the override button is pushed For Soft Touch controls are then active in the Creep Mode or for SkyGuard controls will work normally 19 Platform Rotate Allows...

Page 56: ...E The Main Boom Lift Swing joystick is spring loaded and will automatically return to neutral off position when released 22 Main Lift Swing Controller Provides main lift and swing Push forward to lift...

Page 57: ...ityZoneIndicator 4 TiltAlarm Warning 5 Generator 6 CreepSpeed 7 FootswitchEnable 8 FuelGauge 9 GlowPlugs 10 LevelSystemFaultIndicator 11 EmissionsFailure 12 PlatformOverload 13 AxlesSet 14 WireRopeSer...

Page 58: ...drive control is being operated in the proper direction i e controls reversed situations 3 Capacity Zone Indicator Indicates the maximum platform capacity zone for the current position of the platform...

Page 59: ...the indicator acts as a reminder that all functions are set to the slow est speed 7 Footswitch Enable Indicator To operate any function the footswitch must be depressed and the function selected with...

Page 60: ...xtended The indi cator will flash as the axles are extending or retracting and be solid when fully extended The indicator icon will go out when the axles are fully retracted 14 Wire Rope Service Indic...

Page 61: ...54 3 23 17 Diesel Particulate Filter DPF Indicator Icon will illuminate when standstill exhaust system cleaning is required 18 Emissions Temperature Indicator Indicator illuminates when the engine emi...

Page 62: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 24 31215054...

Page 63: ...and Traveling of this man ual for specific requirements The machine has a Ground Control Station that can override the Platform Control Station Ground controls operate all functions except Drive and...

Page 64: ...ely 70 boom extension no matter where you stop in the arc This means that when lifting down telescope in will function automatically or when lifting up telescope out will function automatically When t...

Page 65: ...ontrol system sensors sense the distance the platform is extended from the turntable allowing higher swing speeds with the boom retracted and gradually slower swing speeds as the boom is extended Plat...

Page 66: ...54 Figure 4 1 Position of Least Forward Stability TELESCOPE FULLY EXTENDED TURNTABLEROTATED 90 DEGREES FROM STOWED POSITION MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED BEYOND THE...

Page 67: ...ILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL NOTE Diesel Engines Only After turning on ignition operator must wait until glow plug indicator light goes out before cranking engine 1 Tu...

Page 68: ...ime to warm up shut engine off 5 Turn Platform Ground Select switch to the Platform position 6 From Ground Control Console pull Power Emergency Stop switch out 7 From the Platform Control Console pull...

Page 69: ...air intake system When the valve is actuated it obstructs airflow intake and stops the engine Weekly tests are recommended to ensure the valve remains in good working condition 1 Start the engine runn...

Page 70: ...nce a second and there will 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...

Page 71: ...he 2 min utes of run time is complete 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 avail...

Page 72: ...Mainte nance Standstill Cleaning is cleaning requested by the engine on the regular maintenance interval NOTE The system will reset the maintenance interval back to zero hours after Standstill or Main...

Page 73: ...Ground Console for 3 seconds The Indicator Gauge will display the following screen 4 The Main Cleaning process will begin and last for approxi mately 30 to 60 minutes The following screen will show t...

Page 74: ...Standstill Cleaning can be started by one of two methods by using the Analyzer or the DPF button on the Ground Console All the same conditions as outlined under Standstill Cleaning must be met Cancel...

Page 75: ...t in progress Other engine faults are active The Gauge will display Regen Failed screen as shown If the cleaning event has failed the process must be repeated DPFFilter Replacement due to Ash Load The...

Page 76: ...PF Filter ExchangeIndicator Engine Error Indicator Derate NormalOperation 100 None FilterExchangeRequired 100 None WarningLevel 105 Blinking None WarningLevel 110 Blinking Continuous MachineplacedinCr...

Page 77: ...50 1 Standstill Required 650 750 None Enginecoolanttemperature mustbe 40 Candmachine mustbeingroundstation mode 2 Warning Level 750 775 Continuous MachineplacedinCreep andDTCactive 3 ShutOff Level 775...

Page 78: ...ours oruntilthesootload reaches109 WarningLevel 109 to125 or 25Hours SwitchinJLGMachine or JLGAnalyzer Continuous MachineplacedinCreep andDTCactive WillremaininWarning level Derate for25 hoursoruntilt...

Page 79: ...SECTION 4 MACHINE OPERATION 31215054 4 17 GRADE LEVEL S IDES LOPE w w w jlg c om Figure 4 4 Grade and Side Slopes...

Page 80: ...egrees above horizontal the high drive function will automatically be in low drive DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE WITHIN THE LIMITS OF THE MAXIMUM OP...

Page 81: ...control panel and the chassis to 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 arr...

Page 82: ...ESULT IN DEATH OR SERIOUS INJURY NOTE When the Boom Control Select Switch is in the Manual mode Platform leveling only functions during Main Lift operation When the Boom Control Select Switch is in th...

Page 83: ...IZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH C...

Page 84: ...n To swing the jib use the Jib Swing control to select Right or Left direction 4 10 FUNCTION SPEED CONTROL This control knob affects the speed of Telescope Jib Swing Jib Lift and Platform Rotate funct...

Page 85: ...l sensor and footswitch 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 sens...

Page 86: ...e Reverse Steer Swing Boom LiftUp Boom Lift Down Boom Tele Out Boom TeleIn Jib Lift Jib Swing Basket Level Basket Rotate R C R C R R R R C C C C C R IndicatesReversalisActivated C IndicatesCutoutisAct...

Page 87: ...LURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 5 MPH 8 KM H MAXIMUM TOWING GRADE 25 DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower...

Page 88: ...ELEVATED BUT SHALL NOT BE EXTENDED IT IS THE OPERATOR S RESPONSIBILITY TO ENSURE ALL SAFETY PRECAUTIONS IN SECTION 1 OF THIS MAN UAL ARE FOLLOWED FOR EACH UNIQUE SITUATION 4 15 LIFTING AND TIE DOWN S...

Page 89: ...s on the boom using straps or chains of adequate strength 4 16 STOWING THE JIB FOR TRANSPORT 1 Place the boom in the stowed position with the axles retracted 2 Hold the Jib Swing control switch to the...

Page 90: ...ON 4 28 31215054 1705096 F R R 23 9 7 24 m 1200SJP 34 11 10 64m 1200SJP 18 7 5 66 m 38 11 11 86 m 1350SJP 1100SB 11 2 3 40 m 27 9 8 46 m 1350SJP 1100SB 7 10 2 39 m 10 9 3 28 m 10 0 3 05 m Figure 4 7 L...

Page 91: ...SECTION 4 MACHINE OPERATION 31215054 4 29 30 31 23 20 3 101 105 5 26 13 23 21 36 25 209 204 253 O AC 02790 Figure 4 8 Decal Location Sheet 1 of 6...

Page 92: ...SECTION 4 MACHINE OPERATION 4 30 31215054 28 10 106 35 18 34 35 106 205 36 27 15 102 206 16 208 205 39 O AC 02800 C E ONLY Figure 4 9 Decal Location Sheet 2 of 6...

Page 93: ...SECTION 4 MACHINE OPERATION 31215054 4 31 4 25 23 19 209 204 105 101 3 23 40 238 4 30 31 O AC 02811 Figure 4 10 Decal Location Sheet 3 of 6...

Page 94: ...SECTION 4 MACHINE OPERATION 4 32 31215054 4 107 6 9 3 3 O AC 02821 Figure 4 11 Decal Location Sheet 4 of 6...

Page 95: ...ACHINE OPERATION 31215054 4 33 104 207 17 8 33 38 209 204 108 22 36 29 101 101 105 41 17 202 208 209 209 208 24 104 104 105 O AC 02830 AUS ONLY AUS ONLY DUAL LANGUAGE ONLY Figure 4 12 Decal Location S...

Page 96: ...215054 19 23 28 40 4 25 209 204 5 26 13 23 28 25 209 204 40 O AC 02840 DE CAL LOCATIONS FOR S TE E L HOOD OPTION GB MAR KE T ONLY ANS I AND DUAL LANGUAGE ANS I AND DUAL LANGUAGE GB MAR KE T ONLY Figur...

Page 97: ...1706064 1706098 1706062 7 1705351 1705427 1705430 1705905 1705910 1705429 1705426 8 1705492 9 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511 10 3252347 1705828 15 91403230 91403230 91...

Page 98: ...2774 1702774 28 1702773 1702773 1702773 1702773 1702773 1702773 1702773 1702773 29 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 30 1705864 1705864 1705864 1705864 1705864 1705864 17...

Page 99: ...7035 1705906 1705915 1705505 1705493 204 1703953 1703945 1703943 1705903 1703941 1703942 1703944 205 1702868 1705969 1001116846 1705967 1704001 1704000 206 1001231315 1001231317 1001231321 1001231319...

Page 100: ...SECTION 4 MACHINE OPERATION 4 38 31215054 10 19 3 101 105 5 22 15 19 21 26 21 209 208 6 O AC 02791 Figure 4 14 Decal Location CE Only Sheet 1 of 6...

Page 101: ...SECTION 4 MACHINE OPERATION 31215054 4 39 210 106 7 14 106 6 26 17 102 208 28 12 O AC 02801 Figure 4 15 Decal Location CE Only Sheet 2 of 6...

Page 102: ...SECTION 4 MACHINE OPERATION 4 40 31215054 19 3 105 101 19 6 4 238 209 208 21 10 O AC 02810 Figure 4 16 Decal Location CE Only Sheet 3 of 6...

Page 103: ...SECTION 4 MACHINE OPERATION 31215054 4 41 4 107 11 9 3 3 O AC 02822 Figure 4 17 Decal Location CE Only Sheet 4 of 6...

Page 104: ...SECTION 4 MACHINE OPERATION 4 42 31215054 104 207 8 24 27 209 18 26 101 101 105 208 209 209 208 20 104 104 105 208 O AC 02831 Figure 4 18 Decal Location CE Only Sheet 5 of 6...

Page 105: ...SECTION 4 MACHINE OPERATION 31215054 4 43 19 6 4 21 209 6 21 209 O AC 02841 DE CAL LOCATIONS FOR S TE E L HOOD OPTION Figure 4 19 Decal Location CE Only Sheet 6 of 6...

Page 106: ...12 1706770 17 91403230 18 1705980 19 1200SJP 1705178 19 1350SJP 1705167 20 1705096 21 1200SJP 0272523 21 1350SJP 0272522 22 1001253993 24 1705364 25 26 4420051 27 1001197408 28 1001180690 101 1701499...

Page 107: ...h an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE...

Page 108: ...operating any controls on the 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...

Page 109: ...ality is used the fault indicator is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician NOTE No functional checks of the MSSO system are necessar...

Page 110: ...SECTION 5 EMERGENCY PROCEDURES 5 4 31215054...

Page 111: ...able Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x72 FallArrestPlatform 36 x96 PipeRacks SkyCutter SkyGlazier SkyPower 7 5kW Generator 4kW SkyWelder Sk...

Page 112: ...PlatformMTR SkySense SkyGlazier SkyGlazier SkyPower 4 Platform PipeRacks PlatformMTR SkySense SkyCutter SkyWelder SkyPower SkyCutter SkyGlazier SkyWelder SkyWelder SkyPower SkyCutter 4 Platform PipeRa...

Page 113: ...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 m in length that limits the maximu...

Page 114: ...reparationand Inspection Ensure 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...

Page 115: ...TTER IS IN PLATFORM Check for cracked 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 o...

Page 116: ...e generator then turn on the plasma cutter See the Miller Plasma Cutter Owner s Manual PN 3128420 for more information Spec RatedOutput AmperesInput RatedOutput 60 Hz 1 Phase kVa kW PlasmaGas PlasmaGa...

Page 117: ...cifications Capacity Zone Max Tray Capacity Max Platform Capacity With Max Weight in Tray 500lb 227kg 150lb 68kg 250lb 113kg 550lb 250kg 150lb 68kg 250lb 113kg 600lb 272kg 150lb 68kg 250lb 113kg 750lb...

Page 118: ...TED ON TRAY AN INCREASE OF THE AREA 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...

Page 119: ...run tools lights cutting and welding equipment All power regulation components are located in a watertight box connected by cable to the generator The generator supplies power when running at the spec...

Page 120: ...y Precautions DO NOT OVERLOAD PLATFORM Ensure no personnel are beneath platform This factory installed option is available only on specified models Keep lanyard attached at all times Do not use electr...

Page 121: ...duty cycle or 250 Amps at 50 duty cycle This accessory receives power from the SkyPower system Generator Output Engine Speed of 1800 rpm 10 ANSI Specifications 3 phase 240 V 60 Hz 7 5 kW 1 phase 240 V...

Page 122: ...e MaximumOpen CircuitVoltage Amps InputAt Rated LoadOutput 50 60 Hz 230V 460 V 575V kVa kW Stick SMAW TIG GTAW 3 phase 280Ampat31 2V 35 DutyCycle 5 250A 79VDC 32 17 13 15 7 10 200Ampat28V 100 DutyCycl...

Page 123: ...rd attached at all times Ensure 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 i...

Page 124: ...RESPONSIBILITY TO BE AWARE OF THEIR SURROUNDINGS AT ALL TIMES DE RATE THE PLATFORM BY 10 LB 4 5 KG PER BAR WHEN INSTALLED ON THE PLAT FORM 20 LB 9 KG OR 30 LB 14 KG TOTAL NOTE SkySense is not active...

Page 125: ...Sense slows a machine s function to creep speed when it is a certain distance away from an object known as the warning zone If the machine continues to approach the object and moves into the stop zone...

Page 126: ...e warning zone and will reduce function speed to creep Flash fre quency correlates to proximity of object LED Red Machine is in SkySense stop zone and all machine functions will cease LED Flashing Red...

Page 127: ...with headlights tail lights or chassis illumination lights options AND the SkySense option the Mute switch will be located in the alternate position 3 See Figure 6 1 SkySense Platform Panel Indicators...

Page 128: ...SECTION 6 ACCESSORIES 6 18 31215054 SkySenseCoverage Areas Sensor Cones shown are approximations for reference only Level1 2 Bar Level2 3 Bar...

Page 129: ...not move platform during use of the external fall arrest system DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM BE CAREFUL WHEN ENTERING EXITING THE PLATFORM AT ELEVATION IF THE EXTERNA...

Page 130: ...no signs of fractures Inspect brackets for any damage Attachment Ring No cracks or signs of wear are acceptable Any signs of corrosion requires replacement Attaching Hardware Inspect all attaching har...

Page 131: ...TION 6 ACCESSORIES 31215054 6 21 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 Dec...

Page 132: ...SECTION 6 ACCESSORIES 6 22 31215054...

Page 133: ...ule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 31215055 Illustrated Parts Manual 31215056 7 2 OPERATING SPECIFICATIONS Table 7 1 Operati...

Page 134: ...ringPressure 1200SJP 1350SJP 100psi 7 03kg cm2 105psi 7 38kg cm2 MaximumDriveSpeed 3 25mph 5 2km h Max HydraulicSystemPressure 4600psi 317Bar Table 7 1 Operating Specifications MaximumWindSpeed 28mph...

Page 135: ...208liters FuelTank Standard Optional 31gallons 117liters 52 8gallons 200liters HydraulicSystem 66gallons 250liters Table 7 4 Tire Specifications Size 445 50D710 LoadRange J PlyRating 18 LoadRating 26...

Page 136: ...Filter TotalCapacity 5Quarts 4 5L 11Quarts 10 5L 16Quarts 15L AverageFuelConsumption 1 1gph 4 1lph IdleEngineRPM 1200 MidEngineRPM 1800 HighEngineRPM 2475 Table 7 6 Deutz TCD 2 9L4 Specifications Type...

Page 137: ...ecommendations 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 7 Caterpillar 3 4T Specificati...

Page 138: ...int Max 46 F 43 C Flash Point Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 7 10 Mobil DTE 10 Excel 32 Specs ISOViscosityGrade 32 SpecificGra...

Page 139: ...9 1 Viscosity at0 C 32 F 340cSt 1600SUS at40 C 104 F 46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 Table 7 12 Mobil EAL H 46 Specs Type Synthetic Biodegradable ISOViscosityGrade 46 Specifi...

Page 140: ...14 Component Weights Component Pounds Kilograms Tire Wheel FoamFilled 867 393 Tire Wheel Solid 990 449 DriveHub Motor 275 5 123 SwingDrive 290 132 EngineAssembly 1275 579 1350Boom Complete 11850 5375...

Page 141: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 31215054 7 9 Figure 7 1 Engine Operating Temperature Specifications...

Page 142: ...N JLG APPROVED HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE HYDRAULIC FLUID OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE HYDRAULIC...

Page 143: ...able Virtually Non toxic Fire Resistant 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...

Page 144: ...EMPERATURE WITH THE RECOMMENDED 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 W...

Page 145: ...T 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 HYDRAULI...

Page 146: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 14 31215054 4 4 4 17 4 5 14 12 18 7 8 1 10 11 9A 15 16 9B 2 3 6 13 Figure 7 6 Lubrication and Maintenance Point Location...

Page 147: ...ood practice to replace 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 15 Lubric...

Page 148: ...nt s Fill Plug Capacity 79 ounces 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 ounc...

Page 149: ...eration Comments Place Fill port at 12 o clock position and Check port at 8 o clock position Pour lubricant into fill port until it just starts to flow out of check port B Wheel Drive Hub Reggiana Rid...

Page 150: ...r as indicated by condition indicator 6 Hydraulic Charge Filter Lube Point s Replaceable Element Interval Change after first 50 hours and every 300 hours thereafter or as indicated by condition indica...

Page 151: ...ion Remove and clean at time of hydraulic oil change 9 A Oil Change w Filter Deutz 2011 Lube Point s Fill Cap Spin on Element Capacity 5 Quarts 4 5 L Cooling System 11 Quarts 10 5 L w Filter 16 Quarts...

Page 152: ...E 7 20 31215054 B Oil Change w 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 com...

Page 153: ...ANCE 31215054 7 21 Figure 7 7 Deutz 2011 Engine Dipstick MAXIMUMOIL LEVEL NOTE Hotoilchecksshouldbemadeaperiodof5minutesaftertheenginehasbeenshutdown MINIMUMLEVELOIL HOT MAXIMUMLEVELOIL HOT MINIMUMLEV...

Page 154: ...R MAINTENANCE 7 22 31215054 10 A 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 Inter...

Page 155: ...E 31215054 7 23 11 Fuel Strainer Deutz 2011 Lube Point s Replaceable Element Interval Every year or 600 hours of operation 12 Fuel Pre Filter TCD2 9 Lube Point s Replaceable Element Interval Drain wat...

Page 156: ...e Point s Fill Cap Spin on Element 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...

Page 157: ...l Filter China III Lube Point s Replaceable Element Interval Every year or 600 hours of operation 16 Radiator Coolant TCD2 9 Lube Point s Fill Cap Capacity 3 2Gallon 12 1 L Lube Anti Freeze Interval C...

Page 158: ...nt s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator B Air Filter Deutz TCD2 9 Lube Point s Replaceable Element Interval Every 6 months...

Page 159: ...Filter Lube Point s Replaceable Element Interval Change after first 50 hours and then every year or 600 hours of operation thereafter 19 Optional Fuel Filter Water Separator Lube Point s Replaceable...

Page 160: ...lowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts Manual for the part number of th...

Page 161: ...EROUS 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 w...

Page 162: ...The 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...

Page 163: ...hinery Directive 2014 30 EU EMC Directive 2014 53 EU RED Directive If fitted with optional equipment 2000 14 EC Outdoor Noise Directive NOTE This declaration conforms with the requirements of annex II...

Page 164: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 32 31215054...

Page 165: ...SECTION 8 INSPECTION AND REPAIR LOG 31215054 8 1 SECTION 8 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 8 1 Inspection and Repair Log Date Comments...

Page 166: ...SECTION 8 INSPECTION AND REPAIR LOG 8 2 31215054 Table 8 1 Inspection and Repair Log Date Comments...

Page 167: ......

Page 168: ...CorporateOffice JLGIndustries Inc 1JLGDrive McConnellsburg PA17233 9533USA 717 485 5161 Corporate 877 554 5438 CustomerSupport 717 485 6417 Visit our website for JLG Worldwide Locations www jlg com...

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