Oshkosh Corporation JLG H800AJ Operation And Safety Manual Download

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SECTION 8 - INSPECTION AND REPAIR LOG

3121769

– JLG Lift –

8-1

SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 8-1.

Inspection and Repair Log

Date

Comments

Summary of Contents for JLG H800AJ

Page 1: ...Operation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times AS NZS Boom Lift Models H800AJ S N 0300000100 to 0300270863 3121769 August 26 2020 Rev D ...

Page 2: ...hich 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 your vehicle or equipment in a well ventilated area and wear gloves or wash your hands frequently when servicing For more information go to www P65Warnings ca gov ...

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 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 ...

Page 5: ...CTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 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 U...

Page 6: ...FOREWORD d JLG Lift 3121769 REVISION LOG Original Issue Revised Revised Revised A February 12 2018 B June 29 2018 C December 14 2018 D August 26 2020 ...

Page 7: ...rvision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 5 Walk Around Inspection 2 7 2 3 FUNCTION CHECK 2 10 From the Ground Control Console with No Load in the Platform 2 10 From the Platform Control Console 2 14 SkyGuard Function Test 2 16 2 4 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 2 17 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL...

Page 8: ...GING 4 16 4 9 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY 4 17 4 10 SKYGUARD OPERATION 4 17 4 11 LIFTING AND TIE DOWN 4 18 Lifting 4 18 Tie Down 4 18 4 8 TOWING 4 20 4 9 TOW BAR IF EQUIPPED 4 20 4 10 RE SYNCHRONIZE UPRIGHT 4 22 Releveling Valve 4 22 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 Platfo...

Page 9: ...utions 6 10 Preparation and Inspection 6 11 Operation 6 11 6 6 SOFT TOUCH 6 11 SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 1 INTRODUCTION 7 1 7 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA 7 1 Operating Specifications 7 1 Tires 7 2 Batteries 7 2 Capacities 7 3 Engine Data 7 3 Hydraulic Oil 7 4 Critical Stability Weights 7 7 7 3 MAINTENANCE AND LUBRICATION 7 12 7 4 TIRES WHEELS 7 18 ...

Page 10: ...iv JLG Lift 3121769 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE ThisPageLeftBlankIntentionally ...

Page 11: ...fting Chart 4 19 4 7 Tow Bar 4 21 4 8 Releveling Valve 4 23 4 9 Decal Installation Sheet 1 of 19 4 24 4 10 Decal Installation Sheet 2 of 19 4 25 4 11 Decal Installation Sheet 3 of 19 4 26 4 12 Decal Installation Sheet 4 of 19 4 27 4 13 Decal Installation Sheet 5 of 19 4 28 4 14 Decal Installation Sheet 6 of 19 4 29 4 15 Decal Installation Sheet 7 of 19 4 30 4 16 Decal Installation Sheet 8 of 19 4 ...

Page 12: ...vi JLG Lift 3121769 LIST OF FIGURES FIGURE NUMBER TITLE PAGE FIGURE NUMBER TITLE PAGE ThisPageLeftBlankIntentionally ...

Page 13: ... 2 Options Accessories Relationship Table 6 2 7 1 Operating Specifications 7 1 7 2 Tire Specifications 7 2 7 3 Battery Specifications 7 2 7 4 Capacities 7 3 7 5 Kubota D1305 7 3 7 6 Hydraulic Oil 7 4 7 7 Mobilfluid 424 Specs 7 4 7 8 Mobil DTE 10 Excel 32 Specs 7 5 7 9 UCon Hydrolube HP 5046 7 5 7 10 Mobil EAL 224H Specs 7 6 7 11 Exxon Univis HVI 26 Specs 7 6 7 12 Critical Stability Weights 7 7 7 1...

Page 14: ...viii JLG Lift 3121769 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE ThisPageLeftBlankIntentionally ...

Page 15: ...aining 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 ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any ques tions with regard to safety training inspection maintenance application and op...

Page 16: ...overnmental regulations as they pertain to your utilization and application of the machine WorkplaceInspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equip ment unless the application is approved in ...

Page 17: ...m floor Keep 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 device i e cell phones two way radios etc that will distract your attention from safely operating the machine Do not use the machine for any purpose other than position ing personnel their ...

Page 18: ...equip ment Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Hydraulic cylinders are subject to thermal expansion and con traction This may result in changes to the boom and or plat form position while the machine is stationary Factors affecting thermal movement can include the length of time the machi...

Page 19: ... 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 slippery substances cleaned from footwear and the platform floor ElectrocutionHazards This machine is not insulated and does not provide protection from contact or proximity to electrical current ...

Page 20: ...nd its 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 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 Over500KV...

Page 21: ... or governmental require ments 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 OTH ERWISE Tipping Hazards The user must be familiar with the surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform e...

Page 22: ...before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions including gusts may exceed 28 mph 12 5 m s Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Refer to Table 1 2 Beaufort scale For Reference Only or use other me...

Page 23: ...e Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effo...

Page 24: ...operator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driv ing in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters o...

Page 25: ...uring 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 to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the ma...

Page 26: ...he machine Do not use machine as a ground for welding When performing welding or metal cutting operations pre cautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine with the engine running Use only approved non flammable cleaning solvents Do not replace items critical to stability such as batteries or solid tires with items of...

Page 27: ...cts across the battery terminals Always wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfillin...

Page 28: ...SECTION 1 SAFETY PRECAUTIONS 1 14 JLG Lift 3121769 NOTES ...

Page 29: ...he 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 malfunc tion 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes or drop offs exist 7 Means to avoid the hazards of unprotected electrical con du...

Page 30: ...ions for further requirements for aerial work platforms The fre quency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environ ment if the machine is used with increased 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 ...

Page 31: ... Basic Nomenclature 1 Chassis 2 GroundConsole 3 TowerLiftCylinder 4 UprightLevelCylinder 5 Upright 6 MainBoomLiftCylinder 7 MasterCylinder 8 MainBoomBaseSection 9 MainBoomFlySection 10 Jib 11 Rotator 12 PlatformControlConsole 13 Footswitch 14 Platform 15 JibLiftCylinder 16 SlaveCylinder 17 TowerFlySection 18 TowerBaseSection 19 Turntable 20 SkyGuard ...

Page 32: ...equentInspection SeeNote Inservicefor3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended Serviceand...

Page 33: ...ned or replaced 4 Operation and Safety Manuals Make sure a copy of the Operation and Safety Manual AEM Safety Manual ANSI markets only and ANSI Manual of Responsibilities ANSI markets only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 4 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engin...

Page 34: ...rform a functional check of all systems in an area free of overhead and ground level obstructions Refer to Section 4 for more specific operating instructions IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDI ATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION ...

Page 35: ... Ground Control Consoles Switches and levers return to neutral decals placards secure and legible con trol markings legible 3 Rotator See Inspection Note 4 Jib See Inspection Note 5 Power Track See Inspection Note 6 All Hydraulic Cylinders See Inspection Note 7 Drive Motor Brake and Hub See Inspection Note 8 Wheel Tire Assemblies Properly secured no missing lug nuts Inspect for worn tread cuts tea...

Page 36: ...e chassis Refer to Figure 2 7 and Figure 2 8 If out of alignment do not use machine until the upright has been synchronized in accor dance with Section 4 16 18 Tower Boom No visible damage wear pads secure All cyl inders rod end pins and barrel end pins properly secured 19 Hydraulic Pumps See Inspection Note 20 Frame See Inspection Note 21 Main Boom Sections No visible damage wear pads secure All ...

Page 37: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121769 JLG Lift 2 9 ...

Page 38: ...AND INSPECTION 2 10 JLG Lift 3121769 6 6 8 7 2 12 15 13 10 11 9 7 8 5 4 3 2 1 22 6 6 21 20 8 7 19 17 18 13 7 8 14 6 16 Figure 2 4 Daily Walk Around Inspection Sheet 3 of 3 6 16 6 8 7 2 15 13 12 11 10 9 7 8 5 6 4 6 3 2 21 22 1 20 8 7 19 13 14 7 8 6 18 17 ...

Page 39: ... proper operation 3 Test the tower boom assembly sequencing as follows a Place machine on level ground with the tower boom assembly in the stowed position Identify the tower boom vertical limit switch adjacent to the tower lift cyl inder at the bottom end rear of the tower base boom Open the left side hood and perform a visual check that the plunger on the tower boom vertical limit switch is fully...

Page 40: ...er the tower boom back to the below horizontal position While raising and lowering the tower boom assembly observe the position of the upright Ensure that the upright remains vertical rela tive to the chassis Refer to Figure 2 7 and Figure 2 8 DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY d Raise the tower base boom to full height E...

Page 41: ...CTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121769 JLG Lift 2 13 90 90 Figure 2 7 Boom Upright Positioning Correct UPRIGHT MUST BE 90 VERTICAL RELATIVE TO THE CHASSIS CORRECT CORRECT ...

Page 42: ...ft 3121769 90 90 Figure 2 8 Boom Upright Positioning Incorrect TO AVOID TIPPING IF THIS OCCURS LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNCTIONS HAVE CONDITION CORRECTED BY A TRAINED JLG SER VICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE INCORRECT INCORRECT ...

Page 43: ...es or locks are in place b Ensure all function controls and switches return to the off or neutral position when released c Operate all functions and ensure proper operation d Ensure that all machine functions are disabled when the Emergency Stop Button is activated e Ensure all machine functions stop when the footswitch is released 2 Check the high drive cutout for the tower boom assembly as follo...

Page 44: ... extreme caution partially position the DRIVE control to FORWARD just enough to cause the machine to move The drive speed should be in slow or creep mode 4 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 5 Swing the boom over eith...

Page 45: ...t bracket c SkyGuard SkyEye Put arm or hard in path of sensor beam 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 SkyGuard beacon the beacon illumi nates 4 Disengage the SkyGuard sensor release controls then recy cle the footswitch Ensure normal operat...

Page 46: ...nsion ramp until left front wheel is on top of block 5 Carefully activate Swing control lever and position boom over Right side of machine 6 With boom over right side of machine place Drive control lever to Reverse and drive machine off of block and ramp 7 Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground 8 Carefully activate Swing contro...

Page 47: ...ssistant check to see that right front or left rear wheel remains elevated in position off of ground 14 Carefully activate SWING control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary to activate DRIVE to release cylinders 15 If lockout cylinders d...

Page 48: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 20 JLG Lift 3121769 ...

Page 49: ...r by the ground controls for these symbols 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 50: ...m Rotate functions 1 Battery Balance Indicator The Battery Balance Indicator displays the state of charge balance of the bat tery packs The lights will glow a steady green when the battery pack s charge is balanced or a steady red when the bat tery pack s charge is too far out of balance resulting in a sys tem shutdown condition For conditions in between the light will be green and blink orange at...

Page 51: ... platform TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 4 Platform Leveling O...

Page 52: ...d Control Console 1 BatteryBalanceIndicator 2 ChargerStatus 3 PlatformRotate 4 PlatformLevelingOverride 5 Jib 6 EngineStart FunctionEnable ElectricMode 7 Power EmergencyStop 8 DisplayGauge 9 Platform GroundSelect 10 MachineSafetySystemOverride MSSO CEOnly 11 Swing 12 TowerLift 13 TowerTelescope 14 MainBoomLift 15 MainBoomTelescope ...

Page 53: ...must be held Up until the engine starts When the engine is running the switch must be held Down to enable all boom controls Hold Down for electric mode WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY 7 Power Emergency Stop Switch A two position red mushroom shaped switch supplies power to Platform Ground Select s...

Page 54: ...ey turned to the Ground position only ground controls are operable 10 Machine Safety System Override MSSO CE Only Provides emergency override of function controls that are locked out in the event of Load Sense System activation NOTE Main Lift Tower Lift Swing Platform Level Main Telescope Tower Telescope and Platform Rotate control switches are spring loaded and will automatically return to neutra...

Page 55: ... MACHINE IF TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM 14 Main Boom Lift Control Provides raising and lowering of the main boom 15 Main Telescope Control Provides extension and retraction of the main boom ...

Page 56: ...ht will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test 3 Low Fuel Level Indicator Indicates the fuel level is low The Fuel Reserve Cut Out System will shut the engine down or allow it start and run for an addi tional minute depending upon machine setup before the fuel tank is emptied 4 Glow Plug Indicator Indicates the glow plugs are operating After...

Page 57: ...CATORS 3121769 JLG Lift 3 9 1 2 3 4 5 6 7 1 EngineMalfunction CheckEngine 2 SystemDistressIndicator 3 LowFuelLevelIndicator 4 GlowPlug 5 BoomMalfunction 6 PlatformOverload 7 DriveandSteerDisable Figure 3 2 Ground Control Indicator Panel ...

Page 58: ...ntor themonitoringsystem is inneedofcalibration DISCONTINUE OPERATION IF THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY IF THE UPRIGHT IS OUT OF ALIGNMENT WITH THE PLATFORM RAISED LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION REPORT THE PROB LEM TO THE PROPER SERVICE PERSONNEL DO NOT OPERATE THE MACHINE UN...

Page 59: ... DTCs from both the JLG Control System and the engine control system During machine start up with no active DTCs in the control system the splash screen will show for 3 seconds and then switch to main screen If there is an active DTC while powering up the machine the splash screen will show for 3 seconds and then launch the Diagnostics Screen The indicator lamp will light when there is an active D...

Page 60: ...o show active faults The Engine Diagnostics Screen will show SPN Suspect Parameter Number FMI Failure Mode Identifier and Occurrence count information Engine SPN text is not scrollable If there is more than one engine trouble code the operator must exit from the Engine DTC Screen to see other SPN and FMI information DIAGNOSTIC CODES Figure 3 4 Diagnostic Screen Figure 3 5 Engine Diagnostic Screen ...

Page 61: ...ION 3 MACHINE CONTROLS AND INDICATORS 3121769 JLG Lift 3 13 h Figure 3 6 Ground Control Console Display Gauge INDICATORLAMP ENGINEHOURS BATTERYLEVEL NAVIGATEFORWARDARROW NAVIGATIONBUTTONS NAVIGATEBACKARROW ...

Page 62: ...he forward position gives maximum drive speed The back position gives maximum torque for rough terrain and climbing grades 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 Platform Leveling Override A three position switch allows the operator ...

Page 63: ... 8 1 DriveSpeed TorqueSelect 2 PlatformLevelOverride 3 Horn 4 Power EmergencyStop 5 EngineStart ModeSelect 6 DriveOrientationOverride 7 Drive Steer 8 Telescope 9 Lights 10 Jib 11 SoftTouch SkyGuardOverride 12 TowerTelescope 13 TowerLift 14 SoftTouch SkyGuardIndicator 15 PlatformRotate 16 FunctionSpeedControl 17 MainLift Swing Figure 3 7 Platform Control Console ...

Page 64: ...de the machine will run on a combina tion of electric and engine power depending upon machine operation The bottom posi tion selects Electric Only Mode In this mode the machine operates only on electric power 6 Drive Orientation Override When the boom is swung over the rear tires or further in either direction the Drive Orienta tion indicator will illuminate when the drive function is selected Pus...

Page 65: ...automatically return to neutral off position when released 7 Drive Steer Push forward to drive forward pull back to drive in reverse Steering is accomplished via a thumb activated rocker switch on the end of the steer handle 8 Main Boom Telescope Provides extension and retraction of the main boom 9 Lights If Equipped This switch operates control console panel lights and head lights if the machine ...

Page 66: ...hine functions If equipped with both Soft Touch and SkyGuard the switch operates like described above and allows the opera tor to override the system that has experienced a cutout situation 12 Tower Telescope This switch provides for extending and retract ing of the tower boom when positioned to in or out Tower Telescope must be fully retracted before operating Tower Lift Tower Telescope should no...

Page 67: ...lescope and platform rotate Turning the knob all the way counterclockwise until it clicks puts drive main 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 released 17 Main Lift Swing Controller Provides main ...

Page 68: ...sound and CREEP is automatically activated IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL NOTE In certain markets when the tilt sensor alarm is activated the Drive function will be disabled if the boom is elevated above hor izontal 4 Glow Pl...

Page 69: ...LG Lift 3 21 1 1 2 3 4 5 6 7 8 9 10 11 1 ACGenerator 2 Overload 3 Tilt 4 GlowPlug WaittoStart 5 Footswitch Enable 6 BatteryCharge 7 Creep 8 SystemDistress 9 BoomMalfunctgion 10 DriveOrientation 11 LowFuelLevel Figure 3 8 Platform Console Indicator Panel ...

Page 70: ... 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 BOTTOM 6 Battery Charge Indicator This indicator lights to show the state of charge of the battery packs 7 Creep Speed Indicator When the Function Speed Control is turned to t...

Page 71: ...THE PLATFORM RAISED LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION REPORT THE PROB LEM TO THE PROPER SERVICE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL THE CONDITION IS CORRECTED 10 Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation...

Page 72: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 24 JLG Lift 3121769 NOTES ...

Page 73: ...rive and steer and are to be used in an emergency to lower the plat form to the ground should the operator in the platform be unable to do so 4 2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities Raising boom above horizontal with or without any load in plat form is based on the following criteria 1 Machine is positioned on a smooth firm and level surface 2 Load is within manufacturer s ra...

Page 74: ...SECTION 4 MACHINE OPERATION 4 2 JLG Lift 3121769 BOOM FULLY EXTENDED AT HORIZONTAL 0 DEGREES TOWER BOOM AT MAX ANGLE AND FULLY RETRACTED Figure 4 1 Position of Least Forward Stability ...

Page 75: ...ift 4 3 MAIN BOOM FULLY RETRACTED AND FULLY ELEVATED TOWER BOOM FULLY RETRACTED AND LOWERED LEVEL SURFACE MACHINE WILL UPSET IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE Figure 4 2 Positions of Least Backward Stability Sheet 1 of 2 ...

Page 76: ...ft 3121769 MAIN BOOM FULLY ELEVATED AND RETRACTED TOWER BOOM FULLY EXTENDED AND ELEVATED MACHINE WILL UPSET IN THIS DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE LEVEL SURFACE Figure 4 3 Positions of Least Backward Stability Sheet 2 of 2 ...

Page 77: ...TS REFER TO ENGINE MAINTENANCE MANUAL NOTE After turning on ignition operator must wait until glow plug indicator light goes out before cranking engine 1 Turn key of Platform Ground Select switch to Ground 2 Pull the Power Emergency Stop switch to On 3 Push the Engine Start switch until engine starts ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 4 After engine has...

Page 78: ...itch in 3 Turn Platform Ground Select switch to Off Refer to Engine Manufacturer s manual for detailed information Engine Warmup When it is below 32 F 0 C the clutch is disengaged from the engine when started When engine operating temperature reaches 86 F 30 C the Integrated Motor Generator IMG will spin at 1800 rpm for 10 seconds After the 10 second period the clutch also spinning at 1800 rpm wil...

Page 79: ...wn or the mode selection switch is flipped to ELECTRIC Mode position The clutch is engaged under this mode so engine clutch IMG hydraulic pump turn at the same RPM The engine drives the IMG to generate electricity to charge the battery pack and also drive the hydraulic pumps to provide energy needed to operate boom functions and drive functions Some functions need additional power provided by the ...

Page 80: ...ng indicators are illumi nated and the machine is stored the Low Battery warning indica tor will resume flashing after the Emergency Stop is reset Switching BetweenModes If the selection switch is changed from HYBRID Mode to ELECTRIC Mode position while the engine is running the clutch will disen gage and the engine will stop automatically The operator can continue operation under ELECTRIC Mode af...

Page 81: ...an climb 2 Sideslope which is the angle of the slope the machine can be driven across DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL 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 ON THE SERIAL NUMBER PLATE BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED TRAVELING DO NOT DRIVE ON SIDESLOPES WHICH EXC...

Page 82: ...SECTION 4 MACHINE OPERATION 4 10 JLG Lift 3121769 LEVEL GRADE SIDE SLOPE Figure 4 4 Grade and Sideslopes ...

Page 83: ...and the machine may Drive Steer in the opposite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both platform con trol panel and the chas sis to determine the direction the machine will travel 2 Push and release the Drive Orientation Over ride switch Within 3 seconds slowl...

Page 84: ... OF THE CONTROLS 4 4 STEERING Position thumb switch on Drive Steer controller to Right for steering right or to Left for steering left 4 5 PLATFORM Platform LevelAdjustment 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 To Level Up or Down Pos...

Page 85: ...IN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SEC TION OF THIS MANUAL TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWIT...

Page 86: ...ele vated up position a Operate Tower Telescope in until Tower Boom is fully retracted Tower must not lift down until boom is telescoped in or up fully b The Tower lift down will only operate when the Tower Boom is fully retracted TO AVOID TILTING MACHINE IF TOWER BOOM SWITCHING MALFUNCTIONS LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNC TIONS HAVE CONDITION CORRECTED BY A QUALIF...

Page 87: ...7 SHUT DOWN AND PARK 1 Drive machine to a protected area 2 Assure boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured 3 Remove all load and allow engine to operate 3 5 minutes at idle to permit reduction of engine internal temperatures 4 At Ground Controls turn Key Select switch to center Off Position Power Emergency Stop switch down to Off Remov...

Page 88: ...R IF USING 220V TO CHARGE A STANDARD 220V 15A CIRCUIT MAY BE USED NOTE When the battery chargers are plugged in no machine functions can be performed DTCs will be set if a function is attempted when the chargers are plugged in NOTE Be sure that machine is parked in a well ventilated area before charging begins ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED OUTLET DO NOT USE GROUND AD...

Page 89: ...s on these functions During activation the horn will sound and if equipped with a SkyGuard beacon the beacon will illuminate until 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 intil the sensor is disengaged Consult the following illustrations to determine which...

Page 90: ... SkyGuard Function Table Drive Fwd Drive Rev Steer Swing Tower Lift Up Tower Tele Out Tower Lift Down Tower Tele In Boom Lift Up Boom Lift Down Boom Tele Out Boom Tele In Jib Lift Basket Level Basket Rotate R C R C R R C C C R R R C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated IfSkyGuardhasbeenactivatedbeforeSoftTouchthefunctionwillreverse ifSoftTouchhasbeenactivatedbeforeSkyG...

Page 91: ...nated lifting points 5 Properly adjust the rigging to prevent damage to the machine and so the machine remains level Tie Down WHEN TRANSPORTING THE MACHINE THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST NOTE Putting the platform in certain positions for transporting may cause an LSS activation that restricts normal boom functions Use of the MSSO will result in a MSSO fault 1 Place the boom in t...

Page 92: ...SECTION 4 MACHINE OPERATION 4 20 JLG Lift 3121769 1001233452A 81 05 2059mm 58 14 1477mm Figure 4 6 Lifting Chart ...

Page 93: ... TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 5 M P H 8 K M H MAXIMUM TOWING GRADE 25 Prior to towing the machine complete the following DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower and position boom in travel position lock turntable 2 Lower tow bar and conne...

Page 94: ...SECTION 4 MACHINE OPERATION 4 22 JLG Lift 3121769 Figure 4 7 Tow Bar ...

Page 95: ...tion as shown in Figure 4 7 The machine is now in the driving mode 4 10 RE SYNCHRONIZE UPRIGHT Releveling Valve A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90 vertical relative to the chassis Refer to Figure 2 9 and Figure 2 10 This valve is located in the tank compartment area Perform the following steps with the aid of an assistant 1 T...

Page 96: ...t 3121769 6 Lower the tower boom fully and con tinue to hold down the switch to Tower Down for an additional 20 sec onds 7 Repeat steps 3 thru 6 as necessary until the upright is 90 vertical relative to the chassis Figure 4 8 Releveling Valve ...

Page 97: ...HINE OPERATION 3121769 JLG Lift 4 25 SEE DETAIL A ENGINE SIDE VIEW FRONT OF MACHINE 3 2 14 13 14 34 TANK SIDE VIEW FRONT OF MACHINE 3 2 14 13 14 36 DETAIL A 8 24 27 42 51 Figure 4 9 Decal Installation Sheet 1 of 19 ...

Page 98: ...SECTION 4 MACHINE OPERATION 4 26 JLG Lift 3121769 FRONT VIEW 13 13 14 14 17 17 REAR VIEW 17 17 Figure 4 10 Decal Installation Sheet 2 of 19 ...

Page 99: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 27 TOP VIEW 3 3 FRONT OF MACHINE Figure 4 11 Decal Installation Sheet 3 of 19 ...

Page 100: ...SECTION 4 MACHINE OPERATION 4 28 JLG Lift 3121769 ENGINE SIDE VIEW 52 TANK SIDE VIEW 4 6 54 INSIDE ACCESS DOOR 43 Figure 4 12 Decal Installation Sheet 4 of 19 ...

Page 101: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 29 ENGINE SIDE VIEW 41 35 15 12 TANK SIDE VIEW 22 32 41 35 15 12 INSIDE ACCESS DOOR 38 Figure 4 13 Decal Installation Sheet 5 of 19 ...

Page 102: ...TION 4 MACHINE OPERATION 4 30 JLG Lift 3121769 INSIDE ACCESS DOOR 38 50 HOOD DECALS CE MARKET ONLY ENGINE SIDE VIEW 41 35 44 46 TANK SIDE VIEW 22 47 41 35 44 46 Figure 4 14 Decal Installation Sheet 6 of 19 ...

Page 103: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 31 HOOD DECALS AUS MARKET ONLY ENGINE SIDE VIEW 41 35 44 46 TANK SIDE VIEW 22 50 47 41 35 44 46 Figure 4 15 Decal Installation Sheet 7 of 19 ...

Page 104: ...SECTION 4 MACHINE OPERATION 4 32 JLG Lift 3121769 HOOD DECALS FRONT VIEW ANSI ANSI EXPORT CSA JAPAN CHINA 12 15 REAR VIEW 11 11 12 12 Figure 4 16 Decal Installation Sheet 8 of 19 ...

Page 105: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 33 HOOD DECALS FRONT VIEW CE ONLY 46 53 44 REAR VIEW 44 44 46 46 Figure 4 17 Decal Installation Sheet 9 of 19 ...

Page 106: ...SECTION 4 MACHINE OPERATION 4 34 JLG Lift 3121769 HOOD DECALS FRONT VIEW AUS ONLY 46 53 44 REAR VIEW 46 46 44 44 Figure 4 18 Decal Installation Sheet 10 of 19 ...

Page 107: ...ECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 35 BOOM UPRIGHT TYPICAL BOTH SIDES ANSI ANSI EXPORT CSA JAPAN CHINA 16 15 TYPICAL BOTH SIDES CE AUS ONLY 16 44 Figure 4 19 Decal Installation Sheet 11 of 19 ...

Page 108: ...SECTION 4 MACHINE OPERATION 4 36 JLG Lift 3121769 PLATFORM DECALS FRONT ANSI ANSI EXPORT CSA JAPAN CHINA 11 11 CE AUS MARKETS 44 44 Figure 4 20 Decal Installation Sheet 12 of 19 ...

Page 109: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 37 PLATFORM DECALS ANSI ANSI EXPORT CSA JAPAN CHINA 31 CE AUS ONLY 47 Figure 4 21 Decal Installation Sheet 13 of 19 ...

Page 110: ... MACHINE OPERATION 4 38 JLG Lift 3121769 ANSI ANSI EXPORT CSA JAPAN CHINA DECAL PANEL 10 31 CE AUS ONLY 10 47 ANSI ANSI EXPORT CSA JAPAN CHINA PLATFORM CONSOLE 37 23 Figure 4 22 Decal Installation Sheet 14 of 19 ...

Page 111: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 39 29 9 18 18 18 25 5 9 PLATFORM DECALS Figure 4 23 Decal Installation Sheet 15 of 19 ...

Page 112: ...SECTION 4 MACHINE OPERATION 4 40 JLG Lift 3121769 ENGINE RADIATOR SUPPORT 21 FUEL TANK DECALS ALL MARKETS 4 Figure 4 24 Decal Installation Sheet 16 of 19 ...

Page 113: ...ATION 3121769 JLG Lift 4 41 HYDRAULIC TANK DECALS ANSI ONLY 20 30 HYDRAULIC TANK DECALS ANSI EXPORT CSA CE AUS JAPAN CHINA 20 30 12 VOLT ELECTRICAL BOX 33 IMG CONTROL BOX 33 40 7 Figure 4 25 Decal Installation Sheet 17 of 19 ...

Page 114: ...SECTION 4 MACHINE OPERATION 4 42 JLG Lift 3121769 B B FRONT VIEW 33 33 39 39 UNDER HOOD DECALS BATTERY BOXES CHARGERS 33 40 40 40 33 40 40 40 Figure 4 26 Decal Installation Sheet 18 of 19 ...

Page 115: ...SECTION 4 MACHINE OPERATION 3121769 JLG Lift 4 43 B B FRONT VIEW 33 33 39 39 UNDER HOOD DECALS BATTERY BOXES CHARGERS 33 40 40 40 33 40 40 40 Figure 4 27 Decal Installation Sheet 19 of 19 ...

Page 116: ... 1001233785 1001233785 1001233785 1001233785 1001233785 1001233785 1001233785 1001233785 7 1702155 1702155 1702155 1702155 1702155 1702155 1702155 1702155 1702155 8 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 9 1702868 1705969 1001116846 1704001 1705967 1704000 10 1703797 1703727 1703925 1703923 1705895 1703924 1705921 1703926 1705921 11 1703804 1703951 1703949 1703947 ...

Page 117: ...1706948 1706948 1706948 1706948 1706948 1001187083 1706948 1001249852 25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980 1705828 26 27 28 29 30 1001096141 1705977 1705977 1705977 1705977 1705977 1705977 1705977 1705977 31 1001121801 1001121918 1001121810 1001121805 1001121656 1001121803 1001121808 32 1001121814 1001121921 1001121823 1001121818 1001121655 1001121816 1001121821 33 10...

Page 118: ...6 1001223063 1001223060 1001223068 1001223560 40 1001223556 1001233009 1001233010 1001233012 1001233011 1001233008 1001223561 1001233013 1001223561 41 1001223558 1001223558 1001223558 1001223558 1001223558 1001223558 1001223558 1001223558 1001223558 42 1001228370 1001228370 43 1001228411 1001228411 1001228411 1001228411 1001228411 1001228411 1001228411 1001228411 1001228411 44 1701518 1701518 45 4...

Page 119: ...33452 1001233452 53 1001204510 1001204510 54 1001117307 1001117307 1001117307 1001117307 1001117307 1001117307 1001117307 1001117307 1001117307 Table 4 2 Decal Legend Item ANSI 1001223542 D Korean 1001223546 B Chinese 1001223548 B Spanish 1001223549 B Portuguese 1001223550 B French 1001223547 B CE 1001223544 D Japanese 1001223545 B Aus 1001223543 D ...

Page 120: ...SECTION 4 MACHINE OPERATION 4 48 JLG Lift 3121769 ...

Page 121: ...f such 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 PLATFORM CON TROLS 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 COR RECTLY 5 3 EMERGENCYOPERATION Operator Una...

Page 122: ... proper maintenance per sonnel Do not operate the machine until it is declared safe for operation 5 4 EMERGENCYTOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine have been incorpo rated For specific procedures refer to Section 4 5 5 MACHINE SAFETYSYSTEM OVERRIDE MSSO CE ONLY The Machine Safety System Override MSSO is only to be us...

Page 123: ...SECTION 5 EMERGENCY PROCEDURES 3121769 JLG Lift 5 3 2 Pull out the Power Emergency Stop control 3 Start the engine 4 Press and hold the MSSO switch and the control switch for the desired function ...

Page 124: ...SECTION 5 EMERGENCY PROCEDURES 5 4 JLG Lift 3121769 ...

Page 125: ...9 JLG Lift 6 1 SECTION 6 ACCESSORIES Table 6 1 Available Accessories Accessory Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x96 FallArrestPlatform 36 x72 PipeRacks SkyGlazier SkyPower SkyWelder SoftTouch ...

Page 126: ... SkyGlazier SkyPower 4 Platform PipeRacks Platform MTR SoftTouch SkyCutter SkyWelder SkyPower SkyCutter SkyGlazier SkyWelder SkyWelder SkyPower SkyCutter 4 Platform PipeRacks Platform MTR SoftTouch SkyGlazier SoftTouch PipeRacks SkyCutter SkyGlazier SkyWelder Note1 Anynon Sky accessorynotlistedunder INCOMPATIBLEWITH isassumedtobecompatible Note2 Canbeusedonsameunitbutnotsimultaneously PlatformMTR ...

Page 127: ...protection at all times A full body harness is required with lanyard not to exceed 6 ft 1 8 m in length that limits the maximum arrest force to 900 lbs 408 kg for the trans fastener type and 1350 lbs 612 kg for the shuttle type fall arrest system Safety Precautions DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM USE CAUTION WHEN ENTERING EXITING THE PLATFORM AT ELEVATION 6 2 PIPERA...

Page 128: ...dels Preparationand 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 from stowed to working position then secure with locking pins 2 Loosen and remove tie down straps Place material on racks with weight evenly distributed between both racks 3 Route the tie down s...

Page 129: ...zier includes a strap to secure the panel to the platform rail Capacity Specifications Capacity Zone Max Tray Capacity Max Platform Capacity With Max Weight in Tray 500lbs 227kg 150lbs 68kg 250lbs 113kg 550lbs 250kg 150lbs 68kg 250lbs 113kg 600lbs 272kg 150lbs 68kg 250lbs 113kg 750lbs 340kg 150lbs 68kg 440lbs 200kg 1000lbs 454kg 250lbs 113kg 500lbs 227kg Refertothecapacitydecalsinstalledonthemachi...

Page 130: ... LOCATED 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 rails Remove tray when not in use Use this option only on approved models Preparationand Inspection Check for cracked welds and damage to tray Ensure tray is properly secured to platform Ensure ...

Page 131: ...cable to the generator The generator supplies power when running at the specified speed with the power switch on switch is located on platform A three pole 30 Amp circuit breaker protects the generator from overload Generator Output ANSI Specifications 3 phase 240 V 60 Hz 7 5 kW 1 phase 240 V 120 V 60 Hz 6 kW CE Specifications 3 phase 240 V 7 5 kW 18 3 A 1 0 pf 1 phase 240 V 6 0 kW 26 A 1 0 pf 1 p...

Page 132: ...ly on specified models Keep lanyard attached at all times Do not use electrical tools in water Use correct voltage for tool being used Do not overload circuit Preparationand Inspection Ensure generator is secure Check condition of belt and wiring Operation Start the engine then turn on the generator See the Miller Generator Technical Manual PN 3121677 for more information ...

Page 133: ...uty 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 120 V 60 Hz 6 kW CE Specifications 3 phase 400 V 50 Hz 7 5 kW 1 phase 220 V 50 Hz 6 kW Welding Accessories 12 ft welding leads with clamp and stinger stored in the platform Fire extinguisher ...

Page 134: ...platform over rails or stand on rails Use this option only on approved models Keep lanyard attached at all times Ensure correct polarity of leads Wear proper welding apparel Welding Mode Input Power Rated Output Welding Amperage Range 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...

Page 135: ...t ground clamp to metal being welded Ensure there is a good ground connection and observe proper polarity Operation Start the engine turn on the generator then turn on the welder See the Miller Welder Owner s Manual PN 3128957 for more information 6 6 SOFT TOUCH A padding kit is mounted to the platform rails and to a frame sus pended below the platform Limit switches deactivate platform functions ...

Page 136: ...ERRIDE SWITCH OVERRIDE INDICATOR LIGHT RAIL BUMPER LIMIT SWITCH SOFT TOUCH RAIL BUMPER SOFT TOUCH FRAME LIMIT SWITCH Figure 6 1 Soft Touch OVERRIDESWITCH LIMITSWITCH SOFTTOUCHRAIL BUMPER SOFTTOUCHFRAME LIMITSWITCH RAILBUMPER OVERRIDEINDICATORLIGHT ...

Page 137: ...ce the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 3121770 Illustrated Parts Manual 3121771 7 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA Operating Specifications Table 7 1 Operating Specifications RatedCapacity 500lbs 230kg Max ManualForce ANSI 100lb 445N AUS 90lb 400N T...

Page 138: ...MachineHeightStowed 9ft 9 5in 2 98m MachineLength Stowed 36ft 6in 11 13m Wheelbase 10ft 0in 3 05m BoomElevation 800AJ AboveGrade BelowGrade 80ft 24 38m 13ft 1in 3 99m Max GroundBearingPressure 76psi 5 3kg cm2 Max TireLoad 17 755lbs 8054kg MachineWeightapproximately 35 500lbs 16 103kg Certainoptionsorcountrystandardscanincreaseweight Table 7 2 Tire Specifications Size Type Ply Rating Load Range Pre...

Page 139: ...draulicSystem IncludingTank 65Gal 246L DriveHub 44ounces 1 3L DriveBrake 2 7ounces 80ml Table 7 5 Kubota D1305 Fuel Diesel No ofCylinders 3 MaxRatedGrossOutput 24 8hp 18 5kW 2600rpm HighRPM 2600 LowRPM 1800 OilCapacityw filter 6qts 5 7L CoolantCapacity EngineOnly 0 45gal 1 7L EngineDryWeight 247lbs 112kg AcceptableFuelGrades LowSulfur 500ppm orUltraLowSulfur 15ppm stronglyrecommended Upto5 BioDies...

Page 140: ...recommendations it is not advisable to mix oils of differ ent brands or types as they may not contain the same required addi tives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contactJLG Industries for proper recommenda tions Table 7 6 Hydraulic Oil Hydraulic System Operating TemperatureRange S A E Viscosity Grade 0 to 180 F 18 to 83 C 10W 0 to 210 F...

Page 141: ...t Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at100 C 6 6cSt at100 F 169SUS at210 F 48SUS cpat 20 F 6 200 ViscosityIndex 140 Table 7 9 UCon Hydrolube HP 5046 Type SyntheticBiodegradable SpecificGravity 1 082 PourPoint Max 58 F 50 C pH 9 1 Viscosity at0 C 32 F 340cSt 1600SUS at40 C 104 F 46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 ...

Page 142: ... 428 F 220 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 37cSt at100 C 8 4cSt ViscosityIndex 213 NOTE Must be stored above 32 F 14 C Table 7 11 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly b...

Page 143: ...ECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES COUNTER WEIGHT ENGINE AND PLATFORM DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY Table 7 12 Critical Stability Weights COMPONENTS LBS KG Tire WheelSize FoamFilledOnly 15 625 544 247 18 625 601 273 Engine Noaddedcomponents 247 112 Counterweight Turntable 1700 68 771 5 31 WheelHubs 218 99 Platform 6FT 1 83M 205 93 8FT 2 44M 230 105 ...

Page 144: ...001222023 B 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 7 1 Engine Oil Operating Specifications ...

Page 145: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121769 JLG Lift 7 9 1001228397 B Figure 7 2 Hydraulic Oil Operating Temperature Specifications Sheet 1 of 2 ...

Page 146: ... X Readilybiodegradableclassificationindicates oneofthefollowing CO2Conversion 60 perEPA560 6 82 003 CO2Conversion 80 perCEC L 33 A 93 Virtually Non toxic classificationindicates anLC50 5000ppmperOECD203 FireResistantclassificationindicates FactoryMutualResearchCorp FMRC Approval NOTICE MACHINE OPERATIONUSINGNON JLGAPPROVED HYDRAULICFLUIDS OROPERATIONOUTSIDE OF THE TEMPERATURE BOUNDARIESOUTLINEDIN...

Page 147: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121769 JLG Lift 7 11 2 3 7 4 10 1 5 3 3 6 8 9 10 11 13 12 Figure 7 4 Maintenance and Lubrication Diagram ...

Page 148: ... to replace all filters at the same time 1 Swing Bearing Internal Ball Bearing Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access Table 7 13 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excel lentwaterresistanceandadhesivequalities andbeingofextremepressuretype T...

Page 149: ...n change every 2 years or 1200 hours of operation Comments Place Fill port at 12 o clock position and Check port at 3 o clock position Pour lubricant into fill port until it just starts to flow out of check port 3 Oil Change w Filter Lube Point s Fill Cap Spin on Element Capacity 6 qt 5 7 L w filter Lube EO Interval Change in accordance with engine manual Comments Check level daily Adjust full lev...

Page 150: ... 14 JLG Lift 3121769 4 Fuel Filter Water Separator Lube Point s Replaceable Element Interval Drain water daily Change every year or 600 hours of operation 5 Fuel Strainer Lube Point s Replaceable Element Interval Change every year or 600 hours of operation ...

Page 151: ...s Fill Cap Lube Anti Freeze Coolant Refer to Engine Manual for com patible coolants Capacity 6 qt 5 7 L 7 Swing Drive Hub Lube Point s Level Fill Plug Capacity 43 oz 1 3 L Lube 90w80 Gear Oil Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation ...

Page 152: ...Hydraulic Return Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator 9 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator ...

Page 153: ...25 gallons 94 5 L total capacity 21 gallons 79 5 L to Full Mark on Sight Gauge 59 gallons 223 L System Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 11 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indi cated by the condition indicator ...

Page 154: ... 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 originally installed on the machine Please refer...

Page 155: ...ND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSIBLE 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 wrench tighten the fasteners with a lug wrench then ...

Page 156: ...e done in stages Follow ing the recommended sequence tighten nuts per wheel torque chart 4 Wheel nuts should be torqued after first 50 hours of opera tion and after each wheel removal Check torque every 3 months or 150 hours of operation Table 7 14 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2ndStage 3rdStage 70ft lbs 95Nm 170ft lbs 225Nm 300ft lbs 405Nm ...

Page 157: ...essure 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 the directive is 102 dB The vibration total value to which the hand arm system is sub jected does no...

Page 158: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 22 JLG Lift 3121769 NOTES ...

Page 159: ...SECTION 8 INSPECTION AND REPAIR LOG 3121769 JLG Lift 8 1 SECTION 8 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 8 1 Inspection and Repair Log Date Comments ...

Page 160: ...SECTION 8 INSPECTION AND REPAIR LOG 8 2 JLG Lift 3121769 Table 8 1 Inspection and Repair Log Date Comments ...

Page 161: ... form Mfg Model ______________________________________________________________________ Serial Number ____________________________________________________________________ Previous Owner __________________________________________________________________ Address _________________________________________________________________________ __________________________________________________________________...

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Page 164: ...rporateOffice 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 3121769 ...

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