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Oshkosh Corporation JLG 340AJ, Operation And Safety Manual

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Oshkosh Corporation JLG 340AJ Operation And Safety Manual Download Page 7

TABLE OF CONTENTS

ii

– JLG Lift –

3121258

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - PARAGRAPH, SUBJECT

PAGE

4.4 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 PLATFORM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Platform Level Adjustment . . . . . . . . . . . . . . . . .   4-8
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . .   4-8

4.6 BOOM  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . .   4-9
Raising and Lowering the Tower Boom  . . . . .   4-10
Raising and Lowering the Main Boom  . . . . . .   4-10
Telescoping the Main Boom . . . . . . . . . . . . . .   4-10

4.7 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . 4-10
4.8 DUAL FUEL SYSTEM (GAS ENGINE ONLY)  . . . . 4-10

Changing From Gasoline to LP Gas . . . . . . . .   4-10
Changing From LP Gas to Gasoline . . . . . . . .   4-11

4.9 SHUT DOWN AND PARK  . . . . . . . . . . . . . . . . . . . 4-11

Shut Down and Park  . . . . . . . . . . . . . . . . . . . .   4-11
Storage Position. . . . . . . . . . . . . . . . . . . . . . . .   4-14

4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-14

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-14
Tie Down  . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   4-14

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine  . . . . . . . .   5-1

Platform or Boom Caught Overhead . . . . . . . . .  5-2

5.4 AUXILIARY DESCENT SYSTEM. . . . . . . . . . . . . . . .5-2
5.5 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . .5-2
5.6 EMERGENCY TOWING PROCEDURES  . . . . . . . . .5-4

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR 

MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS AND PERFORMANCE 

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

Operating Specifications  . . . . . . . . . . . . . . . . . .  6-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . .  6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-2
Tires  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-3
Engine Data  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . .  6-4
Major Component Weights. . . . . . . . . . . . . . . . .  6-9

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-13
6.4 TIRES & WHEELS  . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . .  6-18
Wheel and Tire Replacement . . . . . . . . . . . . . .  6-19
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . .  6-19

Summary of Contents for JLG 340AJ

Page 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Boom Lift Models 340AJ 3121258 January 2 2013 ...

Page 2: ...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 3: ...VE 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 IMPORTANT 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 ...

Page 4: ...JLG PRODUCTS 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 ...

Page 5: ...FOREWORD d JLG Lift 3121258 REVISION LOG Original Issue June 17 2010 Revised December 20 2010 Revised March 17 2011 Revised May 16 2012 Revised January 2 2013 ...

Page 6: ...tor Training 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 9 2 3 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 2 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control Station 3 2 Ground Control Indicator Panel 3 6 Platform Station 3 8 Pla...

Page 7: ...osition 4 14 4 10 LIFTING AND TIE DOWN 4 14 Lifting 4 14 Tie Down 4 14 SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL 5 1 5 2 INCIDENT NOTIFICATION 5 1 5 3 EMERGENCY OPERATION 5 1 Operator Unable to Control Machine 5 1 Platform or Boom Caught Overhead 5 2 5 4 AUXILIARY DESCENT SYSTEM 5 2 5 5 MANUAL SWING OVERRIDE 5 2 5 6 EMERGENCY TOWING PROCEDURES 5 4 SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTEN...

Page 8: ...de and Side Slopes 4 7 4 4 Stowed Position 4 12 4 5 Storage Position 4 13 4 6 Lifting and Tie Down Chart 4 15 4 7 Decal Location Sheet 1 of 10 4 16 4 8 Decal Location Sheet 2 of 10 4 17 4 9 Decal Location Sheet 3 of 10 4 18 4 10 Decal Location Sheet 4 of 10 4 19 4 11 Decal Location Sheet 5 of 10 4 20 4 12 Decal Location Sheet 6 of 10 4 21 4 13 Decal Location Sheet 7 of 10 4 22 4 14 Decal Location ...

Page 9: ...ufort Scale For Reference Only 1 10 2 1 Inspection and Maintenance Table 2 3 6 1 Operating Specifications 6 1 6 2 Dimensional Data 6 2 6 3 Capacities 6 2 6 4 Tires 6 3 6 5 Kubota D1105 E3 6 3 6 6 GM 0 97L 6 4 6 7 Hydraulic Oil 6 4 6 8 Critical Stability Weights 6 9 6 9 Lubrication Specifications 6 13 6 10 Wheel Torque Chart 6 20 7 1 Inspection and Repair Log 7 1 ...

Page 10: ...he machine shall 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 experienced 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 11: ...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 12: ...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 13: ...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 14: ...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 Over50KVto 200KV 15 5 Over 200 KVto 350 KV 20 6 Over 350 KVto 500 KV 25 8 Over 500...

Page 15: ...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 16: ...ne Do not tie off machine to any adjacent structure Do not elevate 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 17: ... 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 18: ...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 19: ...feltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentle breeze Leavesandsmaller twigsin constantmotion 4 13 18 5 5 7 9 Moderate breeze Dustand loose paper raised Small branchesbegin to move 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 NearGale ModerateGale Wholetreesinmot...

Page 20: ...e 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 or drop offs exist 7 Means to avoid the hazards of unprotected electrical condu...

Page 21: ...ions 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 TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE J...

Page 22: ...spection SeeNote Inservicefor3monthsor150hours whichever comes first or Outofserviceforaperiodofmorethan3months or Purchased used Owner Dealer or User Qualified JLG Mechanic ServiceandMaintenance Manual and applicable JLG inspectionform Annual MachineInspec tion SeeNote Annually nolaterthan13monthsfromthedateof priorinspection Owner Dealer or User Factory Trained ServiceTechnician Recommended Serv...

Page 23: ... replaced 4 Operation and Safety Manuals Make sure a copy of the Operator and Safety Manual AEM Safety Manual ANSI markets only and ANSI Manual of Responsibili ties ANSI markets only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 2 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine Oil ...

Page 24: ... REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION Function Check Perform the Function Check as follows 1 From the ground control console with no load in the platform a Check that all guards protecting the switches or locks are in place b Operate all functions and ensure proper operation c Check auxiliary descent and ensure pr...

Page 25: ...ons are disabled when the Emergency Stop Button is pushed in e Ensure that all machine functions stop when the footswitch is released 3 With the platform in the stowed position a Drive the machine on a grade not to exceed the rated gradeability and stop to ensure the brakes hold b Check that the tilt indicator is illuminated to ensure proper operation 4 Swing the boom over either of the rear tires...

Page 26: ... 5 6 7 8 10 11 9 15 14 13 12 Figure 2 1 Basic Nomenclature 1 Platform 2 PlatformConsole 3 Jib 4 FlyBoomSection 5 BaseBoomSection 6 MainLiftCylinder 7 MasterCylinder 8 UpperUpright 9 LowerUpright 10 TowerLiftCylinder 11 TowerBoom 12 FrontDrive SteerWheels 13 RearDrive Wheels 14 Frame 15 Turntable ...

Page 27: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 8 JLG Lift 3121258 1 2 15 8 8 8 3 5 6 7 9 8 13 6 5 2 8 12 10 5 6 4 7 6 5 11 14 Figure 2 2 Daily Walk Around Inspection Sheet 1 of 3 ...

Page 28: ...or blocked Latch and hinges in working condition 2 Platform Ground Control Consoles Switches and levers return to neutral decals placards secure and legible control markings legible 3 Boom Sections Uprights Turntable See Inspection Note 4 Swing Motor and Worm Gear No evidence of dam age 5 Wheel Tire Assemblies Properly secured no miss ing lug nuts Inspect for worn tread cuts tears or other discrep...

Page 29: ...11 Hydraulic Pump See Inspection Note 12 Fuel Tank See Inspection Note 13 Hydraulic Reservoir See Inspection Note 14 Battery Batteries have proper electrolyte level cables tight see Inspection Note 15 Platform Rotator See Inspection Note Figure 2 4 Daily Walk Around Inspection Sheet 3 of 3 ...

Page 30: ...control lever and position boom over right side of machine 5 With boom over right side of machine place Drive con trol lever to Reverse and drive machine off of block and ramp 6 Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground 7 Carefully activate Swing control lever and return boom to stowed position centered between rear wheels When bo...

Page 31: ...d 12 Carefully activate Swing control lever and return boom to stowed position centered between rear wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary activate Drive to release cylinders 13 If lockout cylinders do not function properly have quali fied personnel correct the malfunction prior to any fur ther operati...

Page 32: ... by the ground controls for these sym bols and the corresponding functions NOTE The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise The meaning of those symbols are explained below Indicates a potentially hazardous situation which if not corrected could result in serious injury or death This indicator will be red Ind...

Page 33: ...e switch must be held down in order to operate Main Boom Tele scope Tower Lift Swing Main Lift Jib Lift Platform Level Override and Platform Rotate functions 2 Hourmeter Registers the amount of time the machine has been in use with engine running The hourmeter registers up to 9 999 9 hours and cannot be reset WHEN THE MACHINE IS SHUT DOWN THE POWER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE O...

Page 34: ...4 5 6 7 8 9 10 11 12 Figure 3 1 Ground Control Station 1 IndicatorPanel 2 Hourmeter 3 Power EmergencyStop 4 Platform Ground Select 5 Telescope 6 Main Boom Lift 7 Tower BoomLift 8 Swing 9 EngineStart AuxiliaryDescentEnable Function Enable 10 PlatformRotate 11 PlatformLevel 12 JibLift ...

Page 35: ... ground personnel in the event of an emergency 4 Platform Ground Select Switch The three position key operated switch supplies power to the platform control console when positioned to PLATFORM With the switch key turned to the GROUND position only ground controls are operable 5 Telescope Control Provides extension and retraction of the boom 6 Main Boom Lift Provides raising lowering of the main bo...

Page 36: ...le all boom controls 10 Platform Rotate Provides rotation of the platform 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 SERIOUS INJURY 11 Platform Leveling Override A three position switch allows the operator to adjust the automatic self leveling system Thi...

Page 37: ...ates the fuel level is low The Fuel Reserve Cut Out System will shut the engine down or allow it start and run for an additional minute depending upon machine setup before the fuel tank is emptied 6 Glow Plug Indicator Indicates the glow plugs are operating After turning on ignition wait until light goes out before cranking engine 7 System Distress Indicator The light indicates that the JLG Contro...

Page 38: ...ORS 3121258 JLG Lift 3 7 1 2 3 4 5 6 7 8 Figure 3 2 Ground Control Indicator Panel 1 DriveandSteerDisable 2 HighEngine Coolant Temperature 3 LowEngineOilPressure 4 BatteryMalfunction 5 LowFuel 6 GlowPlug 7 SystemDistress 8 PlatformOverload ...

Page 39: ...en the drive controller is moved The center position allows the machine to be driven as quietly as possible by leaving the engine at mid engine and the drive pump at a reduced displacement 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 SERIOUS INJURY 2 Platf...

Page 40: ... 11 12 13 14 15 1 DriveSpeed TorqueSelect 2 Platform Leveling Override 3 Horn 4 Power EmergencyStop 5 Start AuxiliaryDescentEnable 6 Fuel Select 7 Drive Orientation Override 8 Drive Steer 9 Telescope 10 Lights 11 JibLift 12 Tower Boom Lift 13 PlatformRotate 14 Function Speed Control 15 MainLift SwingController Figure 3 3 Platform Control Console ...

Page 41: ... boom is swung over the rear tires or further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driv ing locate the black white orientation arrows on both the chassis and the platform controls Move the drive controls in a direction m...

Page 42: ... Control This control affects the speed of telescope tower lift and jib lift Turning the knob all the way counterclockwise until it clicks puts drive tower lift and swing into creep mode NOTE To operate the Main Boom Lift Swing joystick pull up on the locking ring below the handle NOTE The Main Boom Lift Swing joystick is spring loaded and will automatically return to neutral off position when rel...

Page 43: ...es that the chassis is on a slope An alarm will also sound when the chassis is on a slope and the boom is out of transport position If lit when boom is out of transport position lower to below horizontal then reposition machine so that it is level before continuing operation If the boom is above hori zontal and the machine is on a slope the tilt alarm warn ing light will illuminate and an alarm wi...

Page 44: ...S 3121258 JLG Lift 3 13 1001107853 C 1 2 3 4 6 5 7 8 9 1 ACGenerator 2 PlatformOverload 3 Tilt 4 Glow Plug Wait to Start 5 Enable Footswitch 6 FuelLevel 7 Creep 8 SystemDistress 9 Drive Orientation Figure 3 4 Platform Control Indicator Panel ...

Page 45: ...ll go out and the footswitch must be released and depressed again to enable the controls Releasing the footswitch removes power from all con trols and applies the drive brakes TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOT TOM 6 Fue...

Page 46: ... Refer to the Service Manual for instructions concerning the trou ble codes and trouble code retrieval 9 Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to verify that the drive control is being operated in the proper di...

Page 47: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 16 JLG Lift 3121258 NOTES ...

Page 48: ... control station the operator can drive and steer the machine in both forward and reverse directions The opera tor can raise or lower the boom or swing the boom to the left or right Standard boom swing is 355 degree non continu ous The machine has a Ground Control Station which will override the Platform Control Station Ground Controls oper ate Boom Lift and Swing and are to be used in an emer gen...

Page 49: ...stability is shown in Fig ure 4 2 TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT OF LEVEL SURFACE 4 3 ENGINE OPERATION NOTE Initial starting should always be performed from the Ground Control station Starting Procedure IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED TIME SHOULD ENGINE FAIL TO START AGAIN ALLOW STARTER TO COOL OFF FOR 2 ...

Page 50: ...ngine to operate at low speed for 3 5 minutes this allows further reduction of internal engine temperature 2 Push POWER EMERGENCY STOP switch in 3 Turn Platform Ground Select switch to Off Refer to Engine Manufacturer s manual for detailed informa tion Fuel Reserve Shut Off System Gas or Diesel Engines Only The Fuel Shutoff System senses when the fuel level is getting low and automatically shuts t...

Page 51: ...ION 4 4 JLG Lift 3121258 Figure 4 1 Position of Least Forward Stability LOWERBOOM FULLYELEVATED MAINBOOM HORIZONTAL MAIN BOOM FULLYEXTENDED MACHINEWILL TIPOVER INTHIS DIRECTIONIFOVERLOADED OR OPERATED ONAN OUT OF LEVEL SURFACE ...

Page 52: ...JLG Lift 4 5 Figure 4 2 Position of Least Backward Stability LOWERBOOM FULLYELEVATED MAINBOOM FULLYELEVATED ANDFULLYRETRACTED MACHINEWILL TIPOVER INTHIS DIRECTIONIFOVERLOADED OR OPERATED ONAN OUT OF LEVEL SURFACE PLATFORMROTATED 90DEGREES ...

Page 53: ...n climb 2 Sideslope which is the angle of the slope the machine can be driven across DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN THE OPERAT ING SPECIFICATIONS SECTION OF THIS MANUAL DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION W...

Page 54: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 7 GRADE LEVEL SIDE SLOPE Figure 4 3 Grade and Side Slopes ...

Page 55: ...nd release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direction of machine travel The indicator light will flash during the 3 second interval until the drive function is selected 4 5 STEERING Position thumb switch on Drive Steer controller to RIGHT for steering right or to LEFT for steering left 4 6 PLATFORM ONLY USE ...

Page 56: ...VOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED ABOVE HORIZONTAL LOWER PLATFORM TO GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICA TIONS SECTION OF THIS MANUAL TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR T...

Page 57: ... tower boom lift and jib lift Turning the knob all the way counterclockwise until it clicks puts drive main lift platform rotate and swing into creep mode 4 9 DUAL FUEL SYSTEM GAS ENGINE ONLY The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST B...

Page 58: ...OWN AND PARK Shut Down and Park See Figure 4 4 The procedures to shut down and park the machine are as follows 1 Drive machine to a reasonably well protected area 2 Ensure boom is lowered over rear drive axle 3 Shut down Emergency Stop at Platform Controls 4 Shut down Emergency Stop at Ground Controls Posi tion Platform Ground Select switch to center OFF 5 If necessary cover Platform Controls to p...

Page 59: ...SECTION 4 MACHINE OPERATION 4 12 JLG Lift 3121258 Figure 4 4 Stowed Position ...

Page 60: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 13 7 09 ft 2 15 m Figure 4 5 Storage Position BLOCKING SUPPORT TIEDOWNSTRAP ...

Page 61: ...Y TIE DOWN EQUIPMENT 3 Place blocking under the platform support lower the platform support down onto the blocking and tie it down as shown in Figure 4 5 4 11 LIFTING AND TIE DOWN See Figure 4 6 Lifting 1 Refer to the Serial Number Plate refer to the Specifica tions section of this manual or weigh the individual unit to find out the Gross Vehicle Weight 2 Place the boom in the stowed position 3 Re...

Page 62: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 15 A 43 4 1 10m B 41 4 1 05m 340AJ 1001119576 B C L Figure 4 6 Lifting and Tie Down Chart ...

Page 63: ...SECTION 4 MACHINE OPERATION 4 16 JLG Lift 3121258 18 6 6 14 14 21 Figure 4 7 Decal Location Sheet 1 of 10 ...

Page 64: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 17 18 8 14 34 35 35 13 14 31 36 7 7 30 39 24 26 12 Figure 4 8 Decal Location Sheet 2 of 10 ...

Page 65: ...SECTION 4 MACHINE OPERATION 4 18 JLG Lift 3121258 CE ANSI AUS 8 24 42 11 8 24 43 12 8 24 11 Figure 4 9 Decal Location Sheet 3 of 10 ...

Page 66: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 19 32 32 6 10 6 14 14 43 19 26 28 JAPAN KOREA CHINESE PORTUGUESE SPANISH 11 11 26 26 Figure 4 10 Decal Location Sheet 4 of 10 ...

Page 67: ...SECTION 4 MACHINE OPERATION 4 20 JLG Lift 3121258 26 CE 32 32 6 10 6 14 14 27 19 32 32 6 10 6 14 14 27 26 19 AUSTRALIA Figure 4 11 Decal Location Sheet 5 of 10 ...

Page 68: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 21 41 26 19 32 32 6 10 6 14 14 43 28 ANSI FRENCH 32 32 6 10 6 14 14 28 36 41 26 19 Figure 4 12 Decal Location Sheet 6 of 10 ...

Page 69: ...SECTION 4 MACHINE OPERATION 4 22 JLG Lift 3121258 47 47 Figure 4 13 Decal Location Sheet 7 of 10 ...

Page 70: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 23 32 32 4 32 32 32 11 11 37 27 1 16 17 20 19 20 38 23 25 27 37 45 44 3 2 Figure 4 14 Decal Location Sheet 8 of 10 ...

Page 71: ...SECTION 4 MACHINE OPERATION 4 24 JLG Lift 3121258 ANSI SPANISH FRENCH KOREAN CHINESE PORTUGUESE JAPANESE 4 5 9 15 33 34 35 35 13 14 14 26 7 12 46 7 29 Figure 4 15 Decal Location Sheet 9 of 10 ...

Page 72: ...SECTION 4 MACHINE OPERATION 3121258 JLG Lift 4 25 CE AUSTRALIA 4 5 9 15 22 29 33 34 26 35 35 13 14 14 7 46 7 11 Figure 4 16 Decal Location Sheet 10 of 10 ...

Page 73: ...499 1701499 1701499 1701499 8 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 9 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 10 1702391 1701517 1701517 1001113166 1001113509 1001113169 1001113168 1001113170 1001113171 11 1703804 1701518 1701518 1703950 1703951 1703948 1703949 1703952 1703947 12 1703953 1703944 1703945 1703942 1703943 1705903 17039...

Page 74: ... 1705978 1707059 1707058 1707055 1707060 1707134 1707056 28 1707054 1707042 1707047 1707044 1707133 1707049 29 30 31 32 33 1001119576 1001119576 1001119576 1001119576 1001119576 1001119576 1001119576 1001119576 1001119576 34 1001119578 1001119578 1001119578 1001119578 1001119578 1001119578 1001119578 1001119578 1001119578 35 1001119580 1001119580 1001119580 1001119580 1001119580 1001119580 1001119...

Page 75: ...45 1001120002 1001120003 1001120279 1001120280 1001120004 1001120281 1001120282 1001120283 46 1001119981 1001119981 1001119981 1001119981 1001119981 1001119981 1001119981 1001119981 1001119981 47 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 Item ANSI 1001119732 C CE 1001115783 C Australia 1001119733 C Japan 1001119734 C Korea 1001119735 C French 1001119736 C Chinese 1001...

Page 76: ...8 hours of such an occur rence may void any warranty consideration on that particular machine FOLLOWING ANY INCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 5 3 EMERGENCY OPERATION Ope...

Page 77: ... the Ground position 2 Pull out the Power Emergency Stop control 3 Hold down the Auxiliary Descent Enable Switch and the control switch for the desired function If it is necessary to raise the jib in order to properly perform the auxiliary descent procedure use the following proce dure 1 From the ground control console place the Platform Ground Select switch in the Ground position 2 Pull out the P...

Page 78: ...SECTION 5 EMERGENCY PROCEDURES 3121258 JLG Lift 5 3 1001127549 A 1 2 3 1 2 3 HAND PUMP PUMP HANDLE 4 4 5 Figure 5 1 Auxiliary Descent Decal and Hand Pump ...

Page 79: ...ALLOWABLE TOWING DISTANCE IS 0 6 MILES 1 KM 1 Chock wheels securely 2 Engage the mechanical release on both drive hubs by loosening completely reversing and tightening the two bolts on each hub 3 Connect suitable equipment remove chocks and move machine After moving machine complete the following procedure 1 Position machine on a firm level surface 2 Chock wheels securely 3 Disengage the mechanica...

Page 80: ...e thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 3121259 Illustrated Parts Manual 3121260 6 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA Operating Specifications Table 6 1 Operating Specifications Capacity Unrestricted ANSI CE Australia 500lbs 227kg 500lbs 230kg MaximumTravelGrade...

Page 81: ... 52m TurningRadius Outside 13 3 96m MachineHeight stowed 6 7 2m MachineHeight storage 7 1 2 17m MachineLength stowed 18 2 5 52m MachineLength storage 13 1 3 98m Table 6 1 Operating Specifications UpandOverPlatformHeight 17 0 5 17m Horizontal Reach 19 11 6 06m MachineWidth 6 4 1 93m WheelBase 6 2 1 87 cm PlatformHeight ANSI CE Australia 33 9 10 29m 33 10 5 10 33m GroundClearance 10 1 23 7cm Table 6...

Page 82: ...re Load 4800lbs 2177kg Type Air Foam Filled Size 18 x 7 MaximumTire Load 4800lbs 2177kg Type Solid Table 6 5 Kubota D1105 E3 Type LiquidCooled Number ofCylinders 3 Bore 3 07in 78mm Stroke 3 09 in 78 4mm Total Displacement 68 5cu in 1123cm CompressionRatio 24 1 Firing Order 1 2 3 Output 24 8hp 18 5kW LowIdle RPM 1200 50 HighIdleRPM 3000 50 ...

Page 83: ...he same anti wear and rust protection characteristics as mineral oils but will not adversely affect the ground water or the environment when spilled or leaked in small amounts Table 6 6 GM 0 97L Type LiquidCooled Number ofCylinders 4 Bore 2 58in 65 5mm Stroke 2 84 in 72 0mm Total Displacement 59cu in 967cm CompressionRatio 8 8 1 Firing Order 1 3 4 2 Output 28 6hp 21 3kW LowIdle RPM 1200 50 HighIdl...

Page 84: ...ot con tain the same required additives or be of comparable vis cosities If use of hydraulic oil other than Mobil 424 is desired contact JLG Industries for proper recommenda tions OIL SAMPLING See Figure 6 1 Oil Sampling Port This machine is equipped with an oil sampling valve to allow for verification of hydraulic oil condition Refer to the Service Manual for Oil Sampling procedures ...

Page 85: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 6 JLG Lift 3121258 Figure 6 1 Oil Sampling Port ...

Page 86: ...USING NON 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 SYSTEM HYDRAULIC FLUID OPERATION CHART Figure 6 2 Hydraulic Oil Operation Chart Sheet 1 of 2 ...

Page 87: ...Virtually Non toxic Fire Resistant Mobilfluid 424 55 145 X Mobil DTE10Excel 32 32 164 X X UnivisHVI26 26 376 X Mobil EAL Hydraulic Oil 47 176 X X X MobilEALEnvirosynH46 49 145 X X X Quintolubric888 46 50 185 X X X X Readily biodegradable classification indicates oneofthefollowing CO2Conversion 60 per EPA560 6 82 003 CO2Conversion 80 per CEC L 33 A 93 VirtuallyNon toxicclassification indicatesanLC5...

Page 88: ...R SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES PLATFORM DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 6 8 Critical Stability Weights Components LBS KG Counterweight 1875 75 850 5 34 Tire andWheel 20x9Pneumatic 130 59 Tire and Wheel 20x9Foam Filled 220 99 8 Tire and Wheel 18x7 230 104 3 Platform Console 30x60 242 5 110 Platform Console 30x48 216 98 Battery 66 30 ...

Page 89: ...8 1001120074 A NOTICE MACHINE OPERATION USING NON JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE ENGINE OIL OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE Figure 6 4 Engine Oil Operation Chart GM ...

Page 90: ...1001120075 A NOTICE MACHINE OPERATION USING NON JLG APPROVED ENGINE OIL OR OPERATION OUTSIDE OF THE TEMPERATURE BOUNDARIES OUTLINED IN THE ENGINE OIL OPERATION CHART MAY RESULT IN PREMATURE WEAR OR DAMAGE TO COMPONENTS OF THE ENGINE Figure 6 5 Engine Oil Operation Chart Kubota ...

Page 91: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 12 JLG Lift 3121258 1 5 5 3 4 5 2 9 7 6 8 5 Figure 6 6 Operator Maintenance and Lubrication Diagram ...

Page 92: ...s of operation Comments Apply grease and rotate in 90 degree intervals until bearing is completely lubricated Table 6 9 Lubrication Specifications KEY SPECIFICATIONS BG BearingGrease JLGPartNo 3020029 Mobilith SHC460 HO HydraulicOil APIserviceclassificationGL 4 e g Mobilfluid 424 EPGL ExtremePressure GearLube oil meeting API ServiceClas sification GL 5orMil SpecMil L 2105 MPG Multipurpose Grease h...

Page 93: ...2 Swing Bearing Worm Gear Teeth Lube Point s Grease Fitting Capacity A R Lube Lubriplate 930 AAA Interval A R Lube Point s Grease Fitting Capacity A R Lube Mobil SHC 007 Interval A R DO NOT OVERGREASE BEARINGS OVERGREASING BEARINGS WILL RESULT IN DAMAGE TO OUTER SEAL IN HOUSING ...

Page 94: ...200 hours of operation 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 4 Hydraulic Tank Return Filter and Breather Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments For breather element twist top to replace Under certain conditions it may b...

Page 95: ...rval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation 6 Oil Change with Filter Kubota Lube Point s Fill Cap Spin on Element Capacity 5 4 Quarts 5 1 L w Filter Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on dipstick OIL LEVEL CHECK AND FILL ...

Page 96: ...Lube Point s Replaceable Element Interval Every year or 600 hours of operation 8 Oil Change with Filter GM Lube Point s Fill Cap Spin on Element Capacity 3 1 Quarts 3 L w Filter Lube EO Interval Check level daily change every 500 hours or six months whichever comes first Adjust final oil level by mark on dipstick ...

Page 97: ... approved replace ment tire we recommend that replacement tires have the follow ing characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically ...

Page 98: ...UTS 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 wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently def...

Page 99: ...r 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 the directive is 104 dB The vibration total value to which the hand arm system is subjected does not exceed 2 5 m s2 The highest root mean square value of w...

Page 100: ...ECTION 7 INSPECTION AND REPAIR LOG 3121258 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerial Number _______________________________________ Table 7 1 Inspection and Repair Log Date Comments ...

Page 101: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121258 Table 7 1 Inspection and Repair Log Date Comments ...

Page 102: ... NOTE Leased or rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Previous Owner ___________________________________________________________ Address _________________________________________________________________ _____________________________________...

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