Oshkosh JLG 520AJ Operation And Safety Manual Download

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Operation and Safety Manual

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

AS/NZS

Boom Lift Models
520AJ

3121664

November 1, 2017

Summary of Contents for JLG 520AJ

Page 1: ...Operation and Safety Manual Original Instructions Keep this manual with the machine at all times AS NZS Boom Lift Models 520AJ 3121664 November 1 2017 ...

Page 2: ......

Page 3: ...e owners users operators lessors and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information ...

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

Page 5: ... WHERE JLG PRODUCTS 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 rear cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outsi...

Page 6: ...FOREWORD d JLG Lift 3121664 REVISION LOG Original Issue July 10 2015 Revised November 17 2016 Revised November 1 2017 ...

Page 7: ... 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 SkyGuard Function Test 2 7 General 2 10 2 3 OSCILLATING AXLE LOCKOUT TEST 2 12 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control Console 3 2 Ground Control Indicator Panel 3 8 Ground Control Conso...

Page 8: ... 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 MANUAL SWING OVERRIDE 5 2 5 5 EMERGENCY TOWING PROCEDURES 5 2 5 6 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY 5 3 SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTE NANCE 6 1 INTRODUCTION 6 1 6 2 OPE...

Page 9: ... 11 3 7 Platform Control Console 3 13 3 8 Platform Control Indicator Panel 3 18 4 1 Position of Least Forward Stability 4 6 4 2 Position of Least Backward Stability 4 7 4 3 Grade and Side Slopes 4 8 4 4 Lifting and Tie Down Chart 4 13 4 5 Decal Location Sheet 1 of 6 4 14 4 6 Decal Location Sheet 2 of 6 4 15 4 7 Decal Location Sheet 3 of 6 4 16 4 8 Decal Location Sheet 4 of 6 4 17 4 9 Decal Locatio...

Page 10: ...iv JLG Lift 3121664 LIST OF FIGURES FIGURE NUMBER TITLE PAGE FIGURE NUMBER TITLE PAGE Thispageleftblankintentionally ...

Page 11: ...Table 2 3 4 1 SkyGuard Function Table 4 13 6 1 Operating Specifications 6 1 6 2 Dimensional Data 6 2 6 3 Capacities 6 2 6 4 Tires 6 3 6 5 Deutz D2011L03 6 3 6 6 Hydraulic Oil 6 4 6 7 Mobilfluid 424 Specs 6 4 6 8 DTE 10 Excel 32 Specs 6 5 6 9 Quintolubric 888 46 6 5 6 10 Mobil EAL 224H Specs 6 6 6 11 Critical Stability Weights 6 6 6 12 Lubrication Specifications 6 10 6 13 Wheel Torque Chart 6 18 ...

Page 12: ...vi JLG Lift 3121664 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE Thispageleftblankintentionally ...

Page 13: ...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 14: ...overnmental regulations as they pertain to your utilization and application of the machine Workplace Inspection 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 15: ...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 16: ...ing machine Remove all rings watches and jewelry when operating machine Do not wear loose fitting clothing or long hair unre strained which may become caught or entangled in equip ment Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Trip and Fall Hazards During operation occupants in the platform mus...

Page 17: ... 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 Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current ...

Page 18: ...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 19: ... 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 20: ...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 21: ...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 22: ...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 23: ...ring 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 mac...

Page 24: ...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 25: ...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 26: ...SECTION 1 SAFETY PRECAUTIONS 1 14 JLG Lift 3121664 NOTES ...

Page 27: ...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 28: ...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 29: ...quentInspection SeeNote Inservicefor3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended ServiceandM...

Page 30: ...l illegible decals and placards are cleaned or replaced 4 Operation and Safety Manuals Make sure a copy of the Operator and Safety Manual 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 Supply Ensure the engine oil level is at the ...

Page 31: ... 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 plat form 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 p...

Page 32: ...ons are disabled when the Emergency Stop Button is pushed in e Ensure that all machine functions stop when the foot switch 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 tire...

Page 33: ...nction will operate for a short duration and the horn will sound until the SkyGuard sensor and footswitch are disengaged NOTE If equipped ensure the SkyGuard beacon illuminates when Sky Guard is activated Disengage the SkyGuard sensor release controls recycle the foot switch make sure normal operation is available If SkyGuard remains activated after function reversal or cutout depress and hold the...

Page 34: ...sic Nomenclature 1 Platform 2 SkyGuard IfEquipped 3 CrossRail IfEquipped 4 PlatformConsole 5 Jib 6 FlyBoomSection 7 BaseBoomSection 8 MainLiftCylinder 9 MasterCylinder 10 UpperUpright 11 LowerUpright 12 TowerLiftCylinder 13 TowerBoom 14 FrontDrive SteerWheels 15 RearDriveWheels 16 Frame 17 Turntable OR ...

Page 35: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121664 JLG Lift 2 9 Figure 2 2 Daily Walk Around Inspection Sheet 1 of 3 ...

Page 36: ...ed 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 damage 5 Wheel Tire Assemblies Properly secured no missing lug nuts Inspect for worn tread cuts tears or other discre...

Page 37: ...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 16 SkyGuard If Equipped See Inspection Note Figure 2 4 Daily Walk Around Inspection Sheet 3 of 3 ...

Page 38: ...se the main boom enough to get it out of the transport position 5 Place Drive control 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 return boom to stowed position centered between rear wheels if swung or fully lowered if raised When boom reaches stowed position loc...

Page 39: ...r by the ground controls for these symbols and the correspond ing 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 In...

Page 40: ...ion NOTE The Function Enable switch must be held down in order to operate Main Boom Telescope Tower Lift Swing Main Lift Jib Lift Platform Level Override and Platform Rotate functions 2 Display Gauge Registers the amount of time the machine has been in use with engine running The hourmeter registers up to 16 500 hours and cannot be reset WHEN THE MACHINE IS SHUT DOWN THE POWER EMERGENCY STOP SWITC...

Page 41: ...t 3 3 Figure 3 1 Ground Control Console 1 IndicatorPanel 2 DisplayGauge 3 Power EmergencyStop 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 JibLift 8 Telescope 9 MainBoomLift 10 TowerBoomLift 11 Swing 12 EngineStart AuxiliaryPower FunctionEnable ...

Page 42: ...splayGauge 3 Power EmergencyStop 4 Platform GroundSelect 5 PlatformLevel 6 PlatformRotate 7 JibLift 8 Telescope 9 MainBoomLift 10 TowerBoomLift 11 Swing 12 EngineStart AuxiliaryPower FunctionEnable 13 MachineSafetySystemOverride MSSO Figure 3 2 Ground Control Console with MSSO CE Only ...

Page 43: ...n positioned to PLATFORM With the switch key turned to the GROUND position only ground controls are operable 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 5 Platform Leveling Override A three position switch allows the operator to adjust the ...

Page 44: ...ring of the jib 8 Telescope Control Provides extension and retraction of the boom 9 Main Boom Lift Provides raising lowering of the main boom when positioning up or down 10 Tower Boom Lift Provides raising and lowering of the tower boom 11 Swing Provides 355 degrees non continuous turntable rotation ...

Page 45: ...e held UP until the engine starts To use auxiliary power the switch must be held DOWN for duration of function use When the engine is running the switch must be held DOWN to enable all boom controls 13 Machine Safety System Override MSSO Provides override of function controls that are locked out such as in the event of Load Sense System activation ...

Page 46: ...normally high and service is required 5 System Distress Indicator The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval The system distress indicator light will illuminate for 2 3 sec onds when the key is p...

Page 47: ...664 JLG Lift 3 9 1 BatteryMalfunction 2 LowEngineOilPressure 3 HighEngineCoolantTemperature 4 EngineOilTemperature 5 SystemDistress 6 LowFuel 7 GlowPlug 8 PlatformOverload 9 DriveandSteerDisable IfEquipped Figure 3 3 Ground Control Indicator Panel ...

Page 48: ...uge The Display Gauge shows engine hours fuel level if applicable and Diagnostic Trouble Codes 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 ...

Page 49: ...played to 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 Figure 3 5 Diagnostic Screen Figure 3 6 Engine Diagnostic Screen ...

Page 50: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 12 JLG Lift 3121664 Figure 3 7 Ground Control Console Display Gauge INDICATORLAMP ENGINEHOURS NAVIGATEFORWARDARROW NAVIGATIONBUTTONS NAVIGATEBACKARROW ...

Page 51: ...ugh ter rain and climbing grades The center position allows the machine to be driven as quietly as possible 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 to adjust the a...

Page 52: ...wer EmergencyStop 5 Start AuxiliaryPower 6 DriveOrientationOverride 7 Drive Steer 8 Telescope 9 Lights IfEquipped 10 JibLift 11 SoftTouch SkyGuardOverride IfEquipped 12 TowerBoomLift 13 SoftTouch SkyGuardIndicator IfEquipped 14 PlatformRotate 15 FunctionSpeedControl 16 MainLift SwingController Figure 3 8 Platform Control Console ...

Page 53: ... main boom lift main telescope and swing 6 Drive Orientation Override When the boom is swung over the rear tires or further in either direction the Drive Orien tation indicator will illuminate 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 driving locate the black white orientation arrows on both t...

Page 54: ...uch SkyGuard or both Soft Touch and Sky Guard If equipped with Soft Touch the switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shutdown situation If equipped with SkyGuard the switch enables functions cut out by the Sky guard system to be operated again allowing ...

Page 55: ...ll flash and the horn will sound continuously 14 Platform Rotate Provides rotation of the platform when posi tioned to the right or left 15 Function Speed 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 main lift and swing into creep mode NOTE To operate the Main Boom Lift Swing joystick pull up on...

Page 56: ...that the chassis is on a slope An alarm will also sound when the chassis is on an excessive slope and the boom is out of transport position If lit when boom is out of trans port position lower to below horizontal then reposition machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an a...

Page 57: ...ND INDICATORS 3121664 JLG Lift 3 19 1 ACGenerator IfEquipped 2 PlatformOverload 3 Tilt 4 GlowPlug WaittoStart 5 Enable Footswitch 6 FuelLevel 7 Creep 8 SystemDistress 9 DriveOrientation Figure 3 8 Platform Control Indicator Panel ...

Page 58: ...o enable the controls Releasing the footswitch removes power from all controls 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 BOTTOM 6 Fuel Level Indicator Indicates a low fuel condition in the tank 7 Creep ...

Page 59: ... Refer to the Service Manual for instructions concerning the trouble 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 dir...

Page 60: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 22 JLG Lift 3121664 NOTES ...

Page 61: ...ontrol console the operator can drive and steer the machine in both forward and reverse directions The operator can raise or lower the boom or swing the boom to the left or right Standard boom swing is 355 degree non continuous The machine has a Ground Control Console which will override the Platform Control Console Ground Controls operate all functions except drive and steer and are to be used in...

Page 62: ...in manufacturers rated design capacity 3 All machine systems are functioning properly 4 Machine is as originally equipped from JLG Stability Machine stability is based on two 2 conditions which are called FORWARD and BACKWARD stability The machine s position of least FORWARD stability is shown in Figure 4 1 and its position of least BACKWARD stability is shown in Figure 4 2 TO AVOID FORWARD OR BAC...

Page 63: ...TTEMPTS 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 engin...

Page 64: ...will operate If starter operates with footswitch in the depressed posi tion DO NOT OPERATE MACHINE Shutdown Procedure IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE 1 Remove all load and allow engine to operate at low speed for 3 5 minutes this allows further reduction of internal engine temperature 2 Push Power Emergency Sto...

Page 65: ...m plete the Low Fuel light will flash 10 times a second and the engine will react according to machine setup Setup options are as follows Engine One Restart When the engine shuts down the operator will be permitted to cycle power and restart the engine once with approximately 2 minutes of run time After the 2 minute run time is complete or if the engine is shut down by the operator prior to the co...

Page 66: ...SECTION 4 MACHINE OPERATION 4 6 JLG Lift 3121664 Figure 4 1 Position of Least Forward Stability ...

Page 67: ...pe ratings All ratings for Gradeability and Sideslope are based upon the machine s boom being in the stowed position fully lowered and retracted Traveling is limited by two factors 1 Gradeability which is the percent of grade of the incline the machine can climb 2 Sideslope which is the angle of the slope the machine can be driven across Figure 4 2 Position of Least Backward Stability ...

Page 68: ...SECTION 4 MACHINE OPERATION 4 8 JLG Lift 3121664 Figure 4 3 Grade and Side Slopes ...

Page 69: ...s pull out Emergency Stop switch start the engine and activate foot switch 2 Position Drive controller to Forward or Reverse as desired This machine is equipped with a Drive Orientation Indicator The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer in the opposite direction from the movement of the controls If...

Page 70: ... OF THE CONTROLS 4 5 STEERING Position thumb switch on Drive Steer controller to Right for steering right or to Left for steering left 4 6 PLATFORM Platform Level Adjustment 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 Po...

Page 71: ...IZONTAL 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 SPECIFICATIONS SECTION OF THIS MANUAL TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEUT...

Page 72: ... OUT move ment 4 8 FUNCTION SPEED CONTROL This control affects the speed of telescope 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 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY The Machine Safety System Override MSSO is used to override function controls for Emergency Platform Retrieval o...

Page 73: ...outlines these functions Table 4 1 SkyGuard Function Table Main Lift Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lift Up Tower Lift Down Platform Level Platform Rotate Jib Lift DOS Enabled DOS Not Enabled R C R R R C R R R C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated Disregardwhenboomisinlineanddrivingforwardwithorwithoutsteeringandnootherfunctionsacti...

Page 74: ...trols from hostile envi ronment 4 12 LIFTING AND TIE DOWN See Figure 4 5 Lifting 1 Refer to the Serial Number Plate refer to the Specifications 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 Remove all loose items from the machine 4 Properly adjust the rigging to prevent damage to the machine and so the machine rem...

Page 75: ...SECTION 4 MACHINE OPERATION 3121664 JLG Lift 4 15 Figure 4 5 Lifting and Tie Down Chart ...

Page 76: ...SECTION 4 MACHINE OPERATION 4 16 JLG Lift 3121664 Figure 4 6 Decal Location Sheet 1 of 6 ...

Page 77: ...SECTION 4 MACHINE OPERATION 3121664 JLG Lift 4 17 Figure 4 7 Decal Location Sheet 2 of 6 ...

Page 78: ...SECTION 4 MACHINE OPERATION 4 18 JLG Lift 3121664 Figure 4 8 Decal Location Sheet 3 of 6 ...

Page 79: ...SECTION 4 MACHINE OPERATION 3121664 JLG Lift 4 19 Figure 4 9 Decal Location Sheet 4 of 6 ...

Page 80: ...SECTION 4 MACHINE OPERATION 4 20 JLG Lift 3121664 Figure 4 10 Decal Location Sheet 5 of 6 ...

Page 81: ...SECTION 4 MACHINE OPERATION 3121664 JLG Lift 4 21 Figure 4 11 Decal Location Sheet 6 of 6 ...

Page 82: ...04 1703950 1703951 1703848 1703949 1703952 1703947 5 1001173262 1001173262 1001173262 6 1706941 1706941 1706941 7 8 9 10 1702868 1705969 1704000 1705968 1704002 1704001 11 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 12 1001162416 1001190913 1001162418 1001162420 1001162422 1001162416 1001162426 1001190913 1001162415 13 14 1703953 1701518 1703944 1703945 1703942 1703953 ...

Page 83: ...7 28 1703980 1703981 1703984 1703982 1703985 1705828 1703983 29 30 1705514 1705514 31 32 33 34 35 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 36 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 37 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 38 39 Item ANSI 1001162521 E Australia 1001162522 D Japan 100...

Page 84: ...1701499 1701499 43 3251813 3251813 3251813 1001204510 3251813 44 45 1704008 1704007 46 1001112551 1001189882 47 48 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 Item ANSI 1001162521 E Australia 1001162522 D Japan 1001162523 B Korea 1001162524 B French 1001162525 B Chinese 1001162526 C Portuguese 1001162527 C CE 1001162528 F Spanish 1001162529 C ...

Page 85: ... hours of such an occurrence 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 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 EMERGENCY OPERATION Ope...

Page 86: ...ion desired 5 5 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited However provisions for moving the machine have been incorporated The following procedures are to be used ONLY for emergency movement to a suitable mainte nance area THE ALLOWABLE TOWING SPEED IS 1 9 MPH 3 KPH THE MAXIMUM ALLOWABLE TOWING DISTANCE IS 0 6 MILES 1 KM 1 Chock wheels securely 2 Engage the mechanical release o...

Page 87: ... functionality is used the fault indicator will flash and a fault code is set in the JLG Control System which must be reset by a qualified JLG Service Technician NOTE No functional checks of the MSSO system are necessary The JLG Control system will set a Diagnostic Trouble Code if the control switch is faulty To operate the MSSO 1 From the ground control console place the Platform Ground Select sw...

Page 88: ...SECTION 5 EMERGENCY PROCEDURES 5 4 JLG Lift 3121664 NOTES ...

Page 89: ...nance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 3121665 Illustrated Parts Manual 3121666 6 2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA Operating Specifications Table 6 1 Operating Specifications Capacity Unrestricted 550lbs 250kg MaximumTravelGrade stowed Position Gradeability 45 MaximumTravelGrade stowed ...

Page 90: ... Outside 15 8 4 78m MachineHeight stowed 89 3 2269mmm MachineLength stowed 305 8 7768mm UpandOverPlatformHeight 24 7 3m HorizontalReach 32 8 10m MachineWidth 92 6 2353m WheelBase 93 0 2362mm PlatformHeight 52 6 16m GroundClearance 16 5 419mm Table 6 3 Capacities HydraulicSystem 38gal 143 8L HydraulicOilTank toFullLevel 31 7Gal 119 9L DriveHub 24oz 0 7L DriveBrake 27oz 0 8L ...

Page 91: ...Pneumatic 40psi 3Bar 155lbs 70kg 315 55D20 Foam Filled N A 286lbs 130kg Solid N A 286lbs 130kg 33x12 20 Solid N A 285lbs 129kg Table 6 5 Deutz D2011L03 Fuel Diesel No ofCylinders 3 Bore 3 7in 94mm Stroke 4 4in 112mm Displacement 142cu in 2331cm3 OilCapacity crankcase cooler totalcapacity 6 3qt 6L 3 7qt 3 5L 10qt 9 5L LowRPM 1200 MidRPM TowerLift UpperLift Tele Swing BasketLevel Basket Rotate JibLi...

Page 92: ...hen spilled or leaked in small amounts NOTE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobil 424 is desired contact JLG Indus tries for proper recommendations Table 6 6 Hydraulic Oil Hydraulic System Operating Temperature Range S A ...

Page 93: ...t40 C 32 7cSt at100 C 6 63cSt at100 F 32 7cSt at212 F 6 63cSt ViscosityIndex 164 Density Kg L at15 0 8468 Density lb in3 at60 F 0 0305 Table 6 9 Quintolubric 888 46 Density 0 91 15 C 59 F PourPoint 20 C 4 F FlashPoint 275 C 527 F FirePoint 325 C 617 F AutoignitionTemperature 450 C 842 F Viscosity at0 C 32 F 360cSt at20 C 68 F 102cSt at40 C 104 F 46cSt at100 C 212 F 10cSt ViscosityIndex 220 ...

Page 94: ...sityGrade 32 46 SpecificGravity 922 PourPoint Max 25 F 32 C FlashPoint Min 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 6 11 Critical Stability Weights Components LBS KG UpperCounterweight 5353 107 2428 48 6 LowerCounterweight 617 18 5 280 8 4 TireandWheel 20x9Pneum...

Page 95: ... RECOMMENDED FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY AMBIENT AIR TEMPERATURE SUMMER GRADE FUEL WINTER GRADE FUEL WINTER GRADE FUEL WITH KEROSENE ADDED NO OPERATION BELOW THIS AMBIENT TEMPERATU...

Page 96: ...PERATURE MOBIL 424 10W 30 HYDRAULIC SPECIFICATIONS NO OPERATION ABOVE THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE EXXON UNIVIS HVI 26 MOBIL DTE 13 N O T E 1 R E COM M E N D A T ION SA R EF ORA M B IE N TT...

Page 97: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121664 JLG Lift 6 9 Figure 6 3 Operator Maintenance and Lubrication Diagram ...

Page 98: ... operation Comments Apply grease and rotate in 90 degree intervals until bearing is completely lubricated Table 6 12 Lubrication Specifications KEY SPECIFICATIONS BG BearingGrease JLGPartNo 3020029 MobilithSHC460 HO HydraulicOil APIserviceclassificationGL 4 e g Mobilfluid424 EPGL ExtremePressureGearLube oil meetingAPIServiceClassificationGL 5or Mil SpecMil L 2105 MPG MultipurposeGreasehavingaminim...

Page 99: ... 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 DAM AGE TO OUTER SEAL IN HOUSING ...

Page 100: ...evel Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation Comments On new machines those recently overhauled or after changing hydraulic oil operate all systems a minimum of two complete cycles and recheck oil level in reservoir 4 Hydraulic Return Filter Lube Point s Replaceable Element Interval Change after first 50 hours and every 6 months or 300 hours thereafter ...

Page 101: ... hrs thereafter Comments Remove wing nut and cover to replace Under cer tain conditions it may be necessary to replace on a more frequent basis 6 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 24 oz 0 8 L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation OIL LEVEL CHECK AND FILL ...

Page 102: ...ug Capacity 27 oz 0 8 L Lube DTE 13M Interval Change as necessary 8 Oil Change with Filter Deutz 2 3 L3 Lube Point s Fill Cap Spin on Element Capacity 10 Quarts 9 5 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 103: ...r Water Separator Deutz 2 3 L3 Lube Point s Replaceable Element Interval Every year or 500 hours of operation 10 Charge Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter Comments Remove the engine tray retaining bolt and pull out engine tray to gain access ...

Page 104: ...FICATIONS OPERATOR MAINTENANCE 6 16 JLG Lift 3121664 11 Air Filter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator Comments Check Dust Valve daily ...

Page 105: ...etween tire brands both tires on the same axle should be the same Wheel and Tire Replacement The rims installed on each product model have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommen dations may result in an unsafe condition ...

Page 106: ...nce 3 The tightening of the nuts should be done in stages Follow ing the recommended sequence tighten nuts per wheel torque 4 Wheel nuts should be torqued after first 50 hours of opera tion and after each wheel removal Check and torque every 3 months or 150 hours of operation 1 2 3 4 5 6 7 8 9 Table 6 13 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2ndStage 3rdStage 40ftlbs 55Nm 95ftlbs 130Nm 170ft...

Page 107: ...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 104 dB The vibration total value to which the hand arm system is sub jected does no...

Page 108: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 20 JLG Lift 3121664 NOTES ...

Page 109: ... form Mfg Model ______________________________________________________________________ Serial Number ____________________________________________________________________ Previous Owner __________________________________________________________________ Address _________________________________________________________________________ __________________________________________________________________...

Page 110: ......

Page 111: ......

Page 112: ...Ritterhude Ihlpohl Germany 49 0 421 69350 0 49 0 421 69350 45 Email german parts jlg com JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia S R L Via Po 22 20010 Pregnana Milanese MI Italy 39 0 2 9359 5210 39 0 2 9359 5211 Email ricambi jlg com JLG EMEA B V Polaris Avenue 63 2132 JH Hoofdorf The Netherlan...

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