JLG 1500SJ Operator Manual

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Operation and Safety Manual

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

Boom Lift Models 1500SJ

ANSI

3121261

September 4, 2014

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and 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.

3121261 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

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

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

b – JLG Lift – 3121261

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

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 USA:

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

3121261 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - April 25, 2011

Revised - May 23, 2011

Revised - November 10, 2011

Revised - September 10, 2012

Revised - September 4, 2014

d – JLG Lift – 3121261

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,

AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2

Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-15

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 BOOM OPERATING CHARACTERISTICS AND

4.3 CAPACITY SELECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.4 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Boom Control System Check Procedure . . . . . . . . . . . . 2-7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-7

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-17

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Controlled Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-3

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-9

4.5 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-12

4.6 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-13

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-14

Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Telescoping the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Stowing/Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.11 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.13 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.14 STOWING THE JIB FOR TRANSPORT . . . . . . . . . . . . . . . . . . 4-18

SECTION - 5 - LCD DISPLAY PANEL - GENERATION 1 & 2

5.1 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

5.2 LCD DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.3 GENERATION 1 LCD DISPLAY PANEL SCREENS . . . . . . . . 5-3

Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5

Conditional Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

CAN Communication Error Screen . . . . . . . . . . . . . . . . . 5-9

Serviceable Fault Indication Screen . . . . . . . . . . . . . . . 5-11

Keyswitch in Ground Control Mode Screen . . . . . . . . 5-13

Keyswitch in Ground Control Mode Screen with

Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15

Operational Fault - No Graphics Screen . . . . . . . . . . . 5-17

Operational Fault - With Graphics Screen. . . . . . . . . . 5-19

Operational Fault - Footswitch Open Screen. . . . . . . 5-21

Out of Transport - Axles Retracted . . . . . . . . . . . . . . . . 5-23

Operational Fault - Transport Swing Fault Screen . . 5-25

Envelope Speed Reduction Screen . . . . . . . . . . . . . . . . 5-27

Operational Fault - Envelope Violation

Fault Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29

Operational Fault - Over/Under Moment Fault

(DTC 0017/0018) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31

5.4 GENERATION 2 LCD DISPLAY PANEL SCREENS . . . . . . . 5-33

Boot up Splash Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

Machine Operating Screen . . . . . . . . . . . . . . . . . . . . . . . 5-35

KeySwitch In Ground Mode: . . . . . . . . . . . . . . . . . . . . . . 5-37

Function Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

CAN Bus Lost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

Take Foot Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Put Foot In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

BCS Lamp On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

Broken Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

Platform Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

Capacity Mode Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

Swing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48

Jib Unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

Jib Locked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

Chassis Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

Machine Tilted Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55

Envelope Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56

Machine Model Unknown. . . . . . . . . . . . . . . . . . . . . . . . 5-60

5.5 OPERATIONAL FAULT CODE LISTING. . . . . . . . . . . . . . . . . 5-61

SECTION - 6 - EMERGENCY PROCEDURES

6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Operator Unable to Control Machine . . . . . . . . . . . . . . . 6-1

Platform or Boom Caught Overhead. . . . . . . . . . . . . . . . 6-2

Boom Movement Prevented By Boom

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . 6-2

SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.2 OPERATING SPECIFICATIONS AND PERFORMANCE

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4

Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

7.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-25

SECTION - 8 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

This Page Left Blank Intentionally.

iv – JLG Lift – 3121261

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-8

2-2. Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . 2-9

2-3. Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . 2-10

2-4. Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . . . . .2-11

2-5. Daily Walk-Around Inspection - Sheet 2 of 4 . . . . . . . . .2-12

2-6. Daily Walk-Around Inspection - Sheet 3 of 4 . . . . . . . . .2-13

2-7. Daily Walk-Around Inspection - Sheet 4 of 4 . . . . . . . . .2-14

3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-8

3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11

3-4. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-18

3-5. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-5

4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16

4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-6. Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-7. Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-8. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-9. Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-10. Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-11. Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

5-1. Generation 1 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1

5-2. Generation 2 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1

5-3. LCD Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5-4. Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

5-5. Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

5-6. Conditional Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8

5-7. CAN Communication Error Screen . . . . . . . . . . . . . . . . . . . 5-10

5-8. Serviceable Fault Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12

5-9. Keyswitch in Ground Control Mode Screen . . . . . . . . . . 5-14

5-10. Keyswitch in Ground Control Mode with Operational

Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16

5-11. Operational Fault - No Graphics Screen . . . . . . . . . . . . . . 5-18

5-12. Operational Fault - With Graphics Screen . . . . . . . . . . . . 5-20

5-13. Operational Fault - Footswitch Open Screen . . . . . . . . . 5-22

5-14. Out of Transport - Axles Retracted Screen. . . . . . . . . . . . 5-24

5-15. Transport Swing Fault Screen . . . . . . . . . . . . . . . . . . . . . . . 5-26

5-16. Backward Envelope Speed Reduction Fault Screen. . . 5-28

5-17. Forward Envelope Violation Fault Screen . . . . . . . . . . . . 5-30

5-18. Over/Under Moment Fault Screen . . . . . . . . . . . . . . . . . . . 5-32

5-19. Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33

5-20. Manual Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-21. Lanyard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-22. Select Capacity Zone Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-34

5-23. Machine Operating Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35

5-24. Keyswitch In Ground Mode Screen . . . . . . . . . . . . . . . . . . 5-37

5-25. Function Speed Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

5-26. CAN Bus Lost Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39

5-27. Take Foot Out Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

5-28. Put Foot In Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41

3121261 – JLG Lift – v

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

5-29. BCS Lamp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43

5-30. Broken Cable Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44

5-31. Level System DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45

5-32. Overload DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46

5-33. Capacity Mode Error Screen . . . . . . . . . . . . . . . . . . . . . . . . . 5-47

5-34. Swing DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49

5-35. Jib Unlocked Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50

5-36. Jib Locked Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51

5-37. Axles Retracted Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52

5-38. Axles Extended Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

5-39. Machine Tilted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-55

5-40. Unrestricted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57

5-41. Restricted Mode Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58

5-42. Machine Model Unknown Screen . . . . . . . . . . . . . . . . . . . 5-60

7-1. Oil Sampling Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

7-2. Engine Operating Temperature Specifications - Deutz -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

7-3. Engine Operating Temperature Specifications - Deutz -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

7-4. Operator Maintenance and Lubrication Diagram . . . . 7-12

vi – JLG Lift – 3121261

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6

1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3

4-1 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-26

5-1 Operational Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-61

7-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

7-5 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-6 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-4

7-7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-5

7-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

7-9 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

7-10 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

7-11 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-12 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7

7-13 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

7-14 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .7-13

7-15 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-25

8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

3121261 – JLG Lift – vii

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

viii – JLG Lift – 3121261

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

1.2 PRE-OPERATION

Operator Training and Knowledge

• The Operation and Safety Manual must be read and under-

stood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.

3121261 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.

• Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.

• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.

• Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG.

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

• Read, understand, and obey all applicable employer, local, and governmental 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 equipment unless the application is approved in writing by JLG.

• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential overhead obstructions.

• Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

• Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel. Do not travel on unsupported surfaces.

1-2 – JLG Lift – 3121261

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.

• Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual.

• Ensure all safety devices are operating properly. Modification of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instruction placards or decals are missing or illegible.

• Check the machine for modifications to original components. Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform 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 positioning personnel, their tools, and equipment.

• Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.

• Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove the unit from service and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

• Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency.

3121261 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless approved by JLG.

• When two or more persons are in the platform, the operator shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed.

• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leaving machine.

• Remove all rings, watches, and jewelry when operating machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.

• 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 must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point..

• Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.

1-4 – JLG Lift – 3121261

SECTION 1 - SAFETY PRECAUTIONS

• Before operating the machine, make sure all gates are closed and fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.

• Keep oil, mud, and 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.

3121261 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

Table 1-1. Minimum Approach Distances (M.A.D.)

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8) Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

1-6 – JLG Lift – 3121261

SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping 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 elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.

• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

3121261 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.

• Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

• Do not increase the platform size with unauthorized deck extensions or attachments.

• If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine.

1-8 – JLG Lift – 3121261

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ S).

Table 1-2. Beaufort Scale (For Reference Only)

SECTION 1 - SAFETY PRECAUTIONS

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically 1 1-3 0.3-1.5 Light air Wind motion visible in smoke 2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move. 5 19-24 8.0-10.7 Fresh breeze Smaller trees sway. 6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 8 39-46 17.2-20.7 Fresh Gale Twigs broken fro m trees. Cars veer on road. 9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

becomes difficult.

3121261 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personnel.

• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.

• During operation, keep all body parts inside platform railing.

• Use the boom functions, not the drive function, to position the platform close to obstacles.

• Always post a lookout when driving in areas where vision is obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations.

• Under all travel conditions, the 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 driving 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 or when driving in reverse.

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1-10 – JLG Lift – 3121261

SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting, or hauling.

• This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lifting information.

1.5 MAINTENANCE

This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service 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 machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.

• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.

• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.

3121261 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.

• Ensure replacement parts or components are identical or equivalent to original parts or components.

• Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate support is provided when raising components of the machine.

• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter.

• Do not refuel the machine with the engine running.

• Use only approved non-flammable cleaning solvents.

• Do not replace items critical to stability, such as batteries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.

• Refer to the Service and Maintenance Manual for the weights of critical stability items.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

1-12 – JLG Lift – 3121261

Battery Hazards

SECTION 1 - SAFETY PRECAUTIONS

• Always disconnect batteries when servicing electrical components or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery during charging or servicing.

• Do not contact tools or other metal objects 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 overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged.

3121261 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

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.

Operator Training

Operator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential malfunction.

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 conductors.

8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

3121261 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

2-2 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Type Frequ ency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection (See Note)

Frequent Inspection (See Note)

Annual Machine Inspection (See Note)

Preventative Maintenance At intervals as specified in the Service and Maintenance

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified J LG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of mo re than 3 months; or Purchase d used.

An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f p r i or inspection.

Manual.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Service

Qualification

Service Technician (Recommended)

Reference

and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

3121261 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.

3. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned 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. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.

9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

10. Accessories/Attachments - Reference the Operation and Safety Manual of each attachment or accessory installed upon the machine for specific inspection, operation, and maintenance instructions.

2-4 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

11. Function Check – Once the “Walk-Around” Inspection is complete, perform 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.

12. Boom Control System Check - Perform a check of the boom control system as specified in this section.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.

Function Check

Perform the Function Check as follows:

1. From the ground control console with no load in the platform:

a. Check that all guards protecting the switches or locks

are in place.

b. Operate all functions and ensure proper operation.

c. Check auxiliary power and ensure proper operation.

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure all boom functions stop when the function

enable switch is released.

2. Check the Boom Control System. Refer to Boom Control System Check Procedure later in this section.

3121261 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3. From the platform control console:

a. Ensure that the control console is firmly secured in the

proper location.

b. Check that all guards protecting the switches or locks

are in place.

c. Operate all functions and ensure proper operation.

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure that all machine functions stop when the foot-

switch is released.

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.

c. Check that the boom telescope (beyond transport

mode), lift up (more than 6° above horizontal), and swing (beyond 40° from center) functions are disabled with the axles retracted.

5. With the jib inline with the boom and locked, make sure the jib will not unlock unless:

a. The machine is in transport position (booms retracted;

main boom below elevation [5 degrees]; jib boom below 40 degrees; axles retracted).

b. The boom capacity select switch is in 500# mode.

6. With the jib in the stowed position, make sure the jib will not

swing unless:

a. The jib is fully retracted.

b. The machine is in transport position (booms retracted;

main boom below elevation [4 degrees]; jib boom below 40 degrees; axles retracted).

c. The boom capacity select switch is in 500# mode.

7. Extend the axles and swing the boom over either of the rear

tires and ensure that the Drive Orientation indicator illuminates and that the Drive Orientation Override switch must be used for the drive function to operate.

2-6 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Boom Control System Check Procedure

Perform the following check with no load (personnel or material) in the platform from the ground control station.

1. Extend all axles fully.

2. With the boom fully retracted, raise the boom off the boom

rest to horizontal.

3. Position the jib horizontal and fully retracted, jib straight and locked, and platform level.

4. Extend the boom until it stops.

5. Boom must stop on colored stripe matching the capacity

indicator. If the boom does not stop on the correct stripe, the system must be repaired by JLG authorized Service Personnel before the machine can be used.

6. Push and hold the gray Boom Control System Test Button on the ground control panel. The lighting of the green Boom Control System Calibrated indicator indicates the system is functioning properly. No indicator light or the lighting of the red Boom Control System Warning indicator indicates the system must be repaired by JLG authorized Service Personnel before the machine can be used.

3121261 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature - Sheet 1 of 3

1. Platform

2. Jib

3. Fly Boom Section

4. Outer Mid Boom Section

5. Inner Mid Boom Section

6. Base Boom Section

7. Boom Assembly

8. Lift Cylinder

9. Turntable

10. Chassis

2-8 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Basic Nomenclature - Sheet 2 of 3

11. Platform

12. Platform Control Console

13. Platform Level Cylinder

14. Platform Rotator

15. Jib Fly Boom

16. Jib Base Boom

17. Jib Lock Cylinder

18. Jib Rotator

3121261 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-3. Basic Nomenclature - Sheet 3 of 3

19. Turntable

20. Drive Hub

21. Rear Drive Wheels

22. Frame

23. Front Drive/Steer Wheels

24. Gro und Contro l Consol e

2-10 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

555

Figure 2-4. Daily Walk-Around Inspection - Sheet 1 of 4

3121261 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-5. Daily Walk-Around Inspection - Sheet 2 of 4

2-12 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.

1. Platform Assembly and Gate - Footswitch works properly, not modified, disabled or blocked. Gate 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/Turntable - See Inspection Note.

4. Swing Drive - No evidence of damage.

5. Wheel/Tire Assemblies - Properly secured, no missing lug

nuts. Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

6. Drive Motor, Brake, and Hub - No evidence of leakage.

7. Hood Assemblies - See Inspection Note.

8. Auxiliary Hydraulic Pump - See Inspection Note.

9. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

10. Turntable Bearing - Evidence of proper lubrication. No evidence of loose bolts or looseness between bearing and machine.

11. Steering Spindles and Sensors - See Inspection Note.

Figure 2-6. Daily Walk-Around Inspection - Sheet 3 of 4

3121261 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Hydraulic Pump - See Inspection Note.

13. Platform Rotator - See Inspection Note.

14. Jib Rotator and Jib Lock Cylinder - See Inspection Note.

Figure 2-7. Daily Walk-Around Inspection - Sheet 4 of 4

2-14 – JLG Lift – 3121261

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

The front axles will oscillate when the boom is in the transport position (i.e. when the boom is less than 6° above horizontal and not extended beyond 12" [30.4 cm]) and drive is selected.

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure the axles are extended and the boom is fully retracted,

lowered, and centered between the rear wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control station, start engine.

3. Place the Drive control lever to the forward position and

carefully drive machine up ascension ramp until left front wheel is on top of block.

4. Carefully extend the boom just enough to get it out of the transport position.

5. With boom in this position, place Drive control lever to Reverse and carefully 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 the ground.

7. Carefully return the boom to the transport position. When boom reaches the transport position, carefully activate Drive to release cylinders. The lockout cylinders should release and allow the wheel to rest on ground.

8. Repeat the procedure for the right oscillation cylinder checking to see that the right front or left rear wheel remains elevated in position off of the ground.

9. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3121261 – JLG Lift – 2-15

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-16 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control panels that use symbols

to indicate control functions. On ANSI machines refer to decal located on the control box guard in front of the control box or 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.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

3121261 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Jib Telescope Control

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.

Ground Control Station

(See Figure 3-1., Ground Control Station)

NOTE: The Function Enable switch must be held down in

order to operate Main Boom Telescope, Swing, Main Lift, Jib Lift, Platform Level Override, Platform Rotate, and Jib Telescope functions.

1. Indicator Panel

The Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation.

Provides extension and retraction of the jib.

3. Platform Rotate

Provides rotation of the platform.

3-2 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001120323 B

Figure 3-1. Ground Control Station

1. Indicator Panel

2. Jib Telescope Control

3. Platform Rotate

4. Platform Leveling Override

5. Jib Lift

6. Engine Star t/Auxiliary Power Switch/Function Enable

7. Power/Emergency Stop

8. Hourmeter

9. Platform/Ground Select

10. Lift

11. Swing

12. Telescope

13. Boom Control System Test

3121261 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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.

4. Platform Leveling Override

NOTE: Auxiliary power only works if there is no engine oil pressure, and

is disabled if engine is running.

Functions will operate at a slower than normal rate because of the reduced hydraulic flow.

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/ descending a grade.

5. Jib Lift

Provides raising and lowering of the jib.

WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.

6. Engine Start/ Auxiliary Power Switch /Function Enable

To start the engine, the switch must be held "UP" until the engine starts.

To use auxiliary power, the switch must be held “DOWN” for duration of auxiliary pump use.

When the engine is running, the switch must be held "DOWN" to enable all boom controls.

3-4 – JLG Lift – 3121261

WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: With PLATFORM/GROUND SELECT switch in the center position,

power is shut off to controls at both operating stations.

9. Platform/Ground Select Switch

7. Power/Emergency Stop Switch

A two-position red mushroom shaped switch supplies power to PLATFORM/GROUND SELECT switch when pulled out (on). When pushed in (off ), power is shut off to the PLATFORM/GROUND SELECT switch.

8. Hourmeter

Registers the amount of time the machine has been in use, with engine running. In the event of a fault, the hourmeter also displays the three digit fault code. Refer to the Service Manual for a listing of fault codes. Additionally, there is a small, red indicator light that will blink when there is a fault on the machine to draw operator attention to the display.

A three position, key operated switch supplies power to the platform control console when positioned to Platform. With the switch key positioned in the Ground position, power is shut off to platform and only ground controls are operable.

3121261 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Lift Control

Provides raising and lowering of the main boom.

11. Swing Control

Provides 360 degrees continuous turntable rotation.

12. Main Telescope Control

Provides extension and retraction of the main boom.

13. Boom Control System Test Button

The push button is used to test the boom control system and confirm that it is working properly.

3-6 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel

(See Figure 3-2., Ground Control Indicator Panel)

1. No Alternator Output Indicator

Indicates a problem in the charging circuit, and service is required.

2. Low Engine Oil Pressure Indicator

Indicates that engine oil pressure is below normal and service is required.

3. High Engine Temperature Indicator

Indicates that engine coolant temperature is abnormally high and service is required.

4. Engine Oil Temperature Indicator

Indicates the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. Glow Plug Indicator

Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine.

6. Axles Set Indicator

Indicates that the axles are fully extended. The indicator will flash as the axles are extending or retracting and be on solid when fully extended. The light will go out when the axles are fully retracted.

7. Platform Capacity Indicator

Indicates which capacity range is selected. This capacity can only be selected at the platform control console.

3121261 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. No Alternator Output

2. Low Engine Oil Pressure

3. High Engine Coolant Temperature

4. Engine Oil Temperature

5. Glow Plug Indicator

6. Axles Set

7. Platform Capacity

8. Platform Overload

9. Boom Control System Warning

10. Boom Control System Calibrated

Figure 3-2. Ground Control Indicator Panel

3-8 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

9. Boom Control System Warning Indicator

Indicates the platform is outside the operating area and operation of certain boom functions may be disabled (i.e. lift, telescope). Attempts to use the disabled functions cause the indicator to flash and an alarm to sound. Immediately return the platform to the ground. If the indicator remains lit, a boom control system fault or failure has been detected. If a failure is discovered, the system must be repaired by JLG authorized service personnel before the machine can be used.

10. Boom Control System Calibrated Indicator

When the Boom Control System Test Button is pushed, illuminates to indicate that the Boom Control System is calibrated properly.

3121261 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Station

(See Figure 3-3., Platform Control Console)

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

1. Drive Speed/Torque Select

The forward position gives maximum drive speed. The back position gives maximum torque for rough terrain and climbing grades. The center position allows the machine to be driven as quietly as possible.

2. Steer Select

The action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is for normal driving at maximum speeds. The forward position is for “crab” steering. When in this mode both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This can be used for positioning the machine in aisle ways or close to buildings. The back switch position is for “coordinated” steering. In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas.

3-10 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001125195 B

1702566 B

1702565 B

1705170 A

1705744 A

1706741

1001125194 A

1702938

811109

161820

1. Drive Speed/Torque Select

2. Steer Select

3. Platform Leveling Override

4. Axle Extend/Retract

5. Horn

6. Indicator Panel

7. Boom Control Select

8. Power/Emergency Stop

9. Start/Au xiliary Power

10. Capacity Select

11. Drive Orientation Override

12. Drive/Steer

13. Main Telescope

14. Lights

15. Jib Lift

16. Soft Touch Override

17. Jib Stow

18. Jib Telescope

19. Soft Touch Indicator

20. Platform Rotate

21. Lock Pin Indicator

22. Function Speed Control

23. Main Lift/Swing

Figure 3-3. Platform Control Console

3121261 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Indicator Panel

3. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/descending a grade.

4. Axle Extend/Retract

Allows the operator to extend or retract the axles. The axles can only be extended or retracted while the machine is being driven forward or reverse.

5. Horn

A push-type HORN switch supplies electrical power to an audible warning device when pressed.

The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation.

Within about 2 seconds of pulling the Power/Emergency Stop switch out, the machine will perform a diagnostic check of the various electrical circuits, and if everything is OK, the platform alarm will beep once. During this time the lights on the indicator panel will also blink once as a bulb check.

7. Boom Control Select

Automatic Mode:

When the Boom Control is positioned to Automatic, lift and telescope movements are coordinated by the JLG control system and the automatic platform leveling feature is active during lift, telescope, swing, and drive movements.

NOTE: • While operating lift up, the boom may also telescope out.

• While operating lift down, the boom may also telescope in.

• While operating swing or drive, the boom may lift up or lift down.

• While operating telescope in, the boom may lift down when at high boom angles and the creep light is flashing.

3-12 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Manual Mode:

When the boom control is positioned to Manual, lift and telescope movements are controlled separately by the operator and the automatic platform leveling feature is active only during lift functions.

NOTE: When positioned to Manual, boom functions will be stopped

when the envelope limits are reached. When this occurs, operate a different function or select the automatic position.

NOTE: Depending upon the angle of the chassis and the angle of the

boom, swing left or swing right may be disallowed while in the Manual mode. The BCS light will illuminate and further attempts to swing in the disallowed direction will cause the BCS to flash. When this occurs the only choices are to swing in the opposite direction or switch to automatic mode.

8. Power/Emergency Stop

A two-position red mushroom shaped switch supplies power to Platform Controls when pulled out (on). When pushed in (off), power is shut off to the platform controls.

9. Start/Auxiliary Power

When pushed forward, the switch energizes the starter motor to start the engine.

When pushed back, it energizes the electrically operated hydraulic pump, when actuated. (Switch must be held on for duration of auxiliary pump use.)The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate platform rotate, jib lift, jib level, jib telescope, jib stow, platform level, main boom lift, main telescope and swing.

3121261 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Capacity Select

This switch allows the operator to select between an operating envelope with a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia markets) capacity restriction or a 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Australia markets) capacity restriction.

11. Drive Orientation Override

When the boom is swung over the rear tires or further in either direction, the Drive Orientation 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 the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows.

NOTE: To operate the Drive Joystick, pull up on the lock-

ing ring below the handle.

NOTE: The DRIVE control levers are spring-loaded and will automati-

cally return to neutral (OFF) position when released.

12. 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.

13. Main Telescope

Provides extension and retraction of the main boom.

3-14 – JLG Lift – 3121261

14. Lights (If Equipped)

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Operates accessory light packages if the machine is so equipped.

15. Jib Lift

Provides raising and lowering of the jib.

16. Soft Touch Override Switch (If equipped)

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.

UPON ACTIVATING THE JIB STOW CONTROL SWITCH, A SLIGHT DELAY WILL BE EXPERIENCED BEFORE THE JIB WILL BEGIN TO MOVE.

17. Jib Stow

Allows the jib to be returned to the stowed position for transport and also taken out of the transport position for machine usage. This control operates both jib swing and the jib lock pin in a coordinated manner.

NOTE: The Jib Telescope function only operates in the 500 lb. (227 kg for

ANSI markets and 230 kg for CE and Australia markets) capacity mode.

18. Jib Telescope

Provides extension and retraction of the jib.

3121261 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

19. Soft Touch Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode.

20. Platform Rotate

Allows the operator to rotate the platform to the left or right.

21. Lock Pin Indicator

When illuminated, indicates the jib is centered and the jib lock pin is engaged. When blinking, indicates the jib is in the process of being stowed or centered. The indicator is off when the lock pin is disengaged and the jib is stowed (machine in transport position).

22. Function Speed Control

This control affects the speed of main boom telescope, jib telescope, and jib lift. Turning the knob all the way counterclockwise until it clicks puts drive, main lift, platform rotate, 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.

23. Main Lift/Swing Controller

Provides main lift and swing. Push forward to lift up, pull backward to boom down. Move right to swing right, move left to swing left. Moving the joystick activates switches to provide the functions selected.

3-16 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

(See Figure 3-4., Platform Control Indicator Panel)

1. Level System Fault Indicator

Indicates a fault in the electronic leveling system. The fault indicator will flash and an alarm sound. All functions will default to creep if the boom is out of transport mode.

IF THE LEVEL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUT DOWN THE MACHINE, RESET THE EMERGENCY STOP, AND RESTART THE MACHINE. IF THE FAULT PERSISTS, RETURN THE PLATFORM TO THE STOWED POSITION, USING MANUAL LEVELING AS REQUIRED, AND HAVE LEVELING SYSTEM REPAIRED.

2. AC Generator (If Equipped)

Indicates the generator is in operation.

3. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

4. Platform Capacity Indicator

Indicates the maximum platform capacity selected for the platform.

One of the capacity lights should be on at all times. Both lights will flash and an alarm will sound if the platform is out of the operating envelope for the selected capacity.

3121261 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 456

789

1012 111314

1. Level System

2. AC Generator

3. Platform Overload

4. Platform Capacity

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed

10. System Distress

11. Cable Service

12. Drive Orientation

13. Axles Set

14. Boom Control System Warning

Figure 3-4. Platform Control Indicator Panel

3-18 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Tilt Alarm Warning Light

IF 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 FROM THE TRANSPORT POSITION.

Indicates that the chassis is on a slope. If the boom is out of transport position and the machine is on a slope, an alarm will sound and CREEP is automatically activated.

6. Glow Plug/Wait to Start Indicator

NOTE: If the engine fails to start due to cold temperatures or excessive

amounts of smoke are produced on startup, wait for the glow plug/wait to start indicator to go out before starting the engine.

Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before starting engine.

7. Footswitch/Enable Indicator

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.

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next function, the enable light will go out and the footswitch must be released and depressed again to enable the controls.

Releasing the footswitch removes power from all controls and applies the drive brakes.

3121261 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-5. Fuel Level Indicator

NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more

detailed information concerning the Low Fuel Indicator.

8. Fuel Level Indicator

Indicates the level of fuel in the fuel tank.

9. Creep Speed Indicator

When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. The light flashes if the control system puts the machine into creep speed and will be on continuously if the operator selects creep speed.

3-20 – JLG Lift – 3121261

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. 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 malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

11. Cable Service Indicator

When illuminated, the light indicates the boom cables are loose or broken and must be repaired or adjusted immediately.

12. 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 direc-

tion (i.e. controls reversed situations).

13. Axles Set Indicator

14. Boom Control System Warning Indicator

3121261 – JLG Lift – 3-21

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-22 – JLG Lift – 3121261

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. From this control station, 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 360 degree continuous rotation. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform 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 platform, is based on the following criteria:

1. Machine is positioned on a smooth, firm and level surface.

2. Axles are fully extended.

3. Jib is centered and lock pin is engaged.

4. Load is within manufacturer’s rated capacity.

5. All machine systems are functioning properly.

6. Proper tire pressure.

7. Machine is as originally equipped from JLG.

3121261 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Controlled Arc

When the Boom Control Select switch is in the automatic mode, the Boom Control System automatically controls lift and telescope when the lift function is selected to move the platform through a predetermined arc, equivalent to the percentage of extension. (i.e. If you start at 70% boom extension, you will end up at approximately 70% boom extension no matter where you stop in the arc). This means that when lifting down, telescope in

will function automatically, or when lifting up, telescope out will function automatically.

When the Boom Control Switch is in the manual mode, lift and telescope functions are independent functions controlled by the operator.

4-2 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

BUFFER LINE

ENVELOPE

SLOWDOWN LINE

BUFFER ZONE

SLOWDOWN ZONE

Envelope Tracking

When the platform approaches the edges of the operating envelope all machine functions are slowed down except jib and platform functions, telescope in or out at the rearward edge and telescope in or out on the forward edge are slowed down automatically by the boom control system to reduce machine motions.

NOTE: Boom Control System in Automatic Mode: When the boom is

completely elevated along the edge of the backward stability region and the telescope in function is activated, lift down will automatically function until the boom is away from the edge of the backward stability region.

Boom Control System in Manual Mode: The boom will stop when the end of the envelope is reached and the operator must activate lift and/or telescope in the proper direction to bring the boom back into the envelope.

Controlled Angle

The control system automatically maintains a constant elevated boom angle when swinging the turntable. If the boom angle is at 30 degrees and swing only is activated the control system shall add lift to maintain the relative boom angle at 30 degrees.

Swing Speed Proportioning

The Boom Control System sensors sense the distance the platform is extended from the turntable, allowing higher swing speeds with the boom retracted and gradually slower swing speeds as the boom is extended.

3121261 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

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 BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

4.3 CAPACITY SELECT

The Boom Control System allows the operator to select operation in a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia markets) capacity restriction envelope or a 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Australia markets) capacity restriction envelope. The operator selects the desired capacity restriction by positioning the Capacity Select switch on the platform console. The Capacity Indicator shows the capacity selected, and both capacity lights will flash and an alarm sound if the platform is out of the selected capacity range.

NOTE: Operation in the 1000 lb. (454 kg for ANSI markets and 450 kg for

CE and Australia markets) envelope requires the jib to be fully retracted.

4-4 – JLG Lift – 3121261

Figure 4-1. Position of Least Forward Stability

MAIN BOOM

ELEVATED 20 DEGREES

JIB HORIZONTAL &

FULLY EXTENDED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

MAIN BOOM

FULLY EXTENDED

SECTION 4 - MACHINE OPERATION

3121261 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability

MAIN BOOM FULLY RETRACTED,

ELEVATED 68 DEGREES

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

JIB FULLY

EXTENDED

PLATFORM

ROTATED

90 DEGREES

4-6 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

4.4 ENGINE OPERATION

NOTE: Initial starting should always be per-

formed from the Ground Control station.

Starting Procedure

IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, 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 the Ground position.

2. Pull the Power/Emergency Stop switch out.

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 had sufficient time to warm up, shut engine off.

5. Turn Platform/Ground Select switch to the Platform position.

3121261 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

6. From the Platform, pull the Power/Emergency Stop switch out.

7. Push the Engine Start switch until engine starts.

NOTE: Footswitch must be in released (up) position before starter will

operate. If starter operates with footswitch in the depressed position, 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 Stop switch in.

3. Turn key of Platform/Ground Select switch to

the Off position.

Refer to Engine Manufacturer’s manual for detailed information.

4-8 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

Fuel Reserve / Shut-Off System

NOTE: Reference the Service and Maintenance Manual along with a

qualified JLG Mechanic to verify your machine setup.

The Fuel Shutoff System monitors the fuel in the tank and senses when the fuel level is getting low. The JLG Control System automatically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

If fuel level reaches the Low Fuel range the ¼ tank indicator will flash once a second and there will be approximately 5 minutes of engine run time left. If the system is in this condition and automatically shuts down the engine, or the engine is manually shut down before the 5 minute run time is complete, the ¼ tank indicator 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 completion of the 2 minute run time, it cannot be restarted until fuel is added to the tank.

• Engine Restart - When the engine shuts down, the operator will be permitted to cycle power and restart the engine for approximately 2 minutes of run time. After the 2 minutes of run time is complete, the operator may cycle power and restart the engine for an additional 2 minutes of run time. The operator can repeat this process until there is no more fuel available.

CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE.

• Engine Stop - The engine will shut down. No restarts will be permitted until fuel is added to the tank.

3121261 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.5 TRAVELING (DRIVING)

See Figure 4-3., Grade and Side Slopes

NOTE: When the main boom is raised approximately 6 degrees above

horizontal, the high drive function will automatically be in low drive.

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS.

4-10 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

LEVEL

1500S

Figure 4-3. Grade and Side Slopes

3121261 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

1. At Platform Controls, pull out Emergency Stop switch, start engine, and activate footswitch.

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 the indicator is illuminated, operate the Drive function in the following manner:

1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

4.6 STEERING

Position thumb switch on Drive/Steer controller to Right for steering right, or to Left for steering left.

4.7 EXTENDING THE AXLES

NOTE: The boom must be oriented between the rear wheels to extend

or retract the axles.

The operator must be driving the machine (forward or reverse) in order to extend the axles.

Position the Axle Extend switch to extend the axles or to retract to retract the axles.

4-12 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

4.8 PLATFORM

Platform Level Adjustment

NOTE: When the Boom Control Select Switch is in the Manual mode,

Platform leveling only functions during Main Lift operation. When the Boom Control Select Switch is in the Automatic mode, Platform Leveling is active during all functions except during telescope operation. Also, when in the Manual mode, the Controlled Arc and Controlled Angle systems are not active.

During normal operation of the machine, the platform will automatically maintain it’s position. To manually Level Up or Down - Position the Platform/ Level control switch Up or Down and hold until the desired platform position is obtained.

Platform Rotation

To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached.

4.9 BOOM

A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (4 DEGREE OR GREATER ON CE & AUSTRALIA SPEC MACHINES, 5 DEGREE OR GREATER ON ANSI, CSA, & JAPAN SPEC MACHINES). CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL OR DRIVING WITH THE BOOM ELEVATED.

TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM.

3121261 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Swinging the 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 NEUTRAL POSITION WHEN RELEASED.

TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE.

NOTE: The axles must be fully extended to swing beyond the rear

wheels (40 degrees).

To swing boom, use Swing control to select Right or Left direction.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

Raising and Lowering the Boom

NOTE: The lift function is not operable above 6 degrees above horizon-

tal if the axles are not fully extended.

To raise or lower the Boom, use Boom Lift control to select Up or Down movement.

4-14 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

Telescoping the Boom

NOTE: The telescope function is not operable beyond the transport

position if the axles are not fully extended.

To extend or retract the main boom, use the Telescope Control Switch to select In or Out movement.

Telescoping the Jib

To extend or retract the jib, use the Jib Telescope Control Switch to select In or Out movement.

Stowing/Swinging the Jib

To swing the jib for stowage or machine usage, use the Jib Stow control to select Right or Left direction. The jib lock pin will also operate automatically while using the Jib Stow switch.

4.10 FUNCTION SPEED CONTROL

3121261 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

Figure 4-4. Drive Disconnect Hub

4.11 EMERGENCY TOWING

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE 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%.

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

1. Retract, lower and position boom in travel position; lock turntable.

2. Disconnect drive hubs by inverting disconnect cap.

3. Reconnect the drive hubs by inverting the disconnect cap

when towing is complete.

4-16 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

4.12 SHUT DOWN AND PARK

To shut down and park the machine, the procedures are as follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Position

Platform/Ground Select switch to the center Off position.

5. If necessary, cover Platform Controls to protect instruction placards, warning decals and operating controls from hostile environment.

4.13 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 with the turntable locked.

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the designated

lifting points.

5. Properly adjust the rigging to prevent damage to the machine and so the machine remains level.

3121261 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Tie Down

WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST.

1. Place the boom in the stowed position with the turntable locked.

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or chains of

adequate strength and attached to the designated tie down points.

4.14 STOWING THE JIB FOR TRANSPORT

1. Place the boom in the stowed position with the axles retracted.

2. Hold the Jib Swing control switch to the right until the platform will no longer swing.

NOTE: Automatic platform leveling is disabled when stowing the jib.

3. Push and hold the platform rotate switch until the jib and platform are in the stowed position under the boom.

4-18 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

1001125274 B

17’3”/5.26 m

6’10”/2.08 m

10’5”/3.18 m

43’0”/13.11 m

11’7”/3.53 m31’5”/9.58 m

Figure 4-5. Lifting and Tie Down Chart

3121261 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

ANSI & DUAL LANGUAGE

CE ONLY

1701518

1500SJ

Figure 4-6. Decal Location Sheet 1 of 6

4-20 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

DECAL LOCATIONS FOR ANSI AND CE

BOTH SIDES

BOTH

SIDES

ANSI, DUAL LANGUAGE ONLY

DECAL LOCATIONS FOR DUAL LANGUAGE

Figure 4-7. Decal Location Sheet 2 of 6

3121261 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Location Sheet 3 of 6

4-22 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

ANSI & DUAL LANGUAGE

ONLY!

DUAL LANGUAGE ONLY!

ANSI & CE ONLY!

AUS

878

www.jlg.com

Figure 4-9. Decal Location Sheet 4 of 6

3121261 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location Sheet 5 of 6

4-24 – JLG Lift – 3121261

SECTION 4 - MACHINE OPERATION

ANSI & DUAL LANGUAGE

1500SJ

ANSI, DUAL LANGUAGE ONLY

Figure 4-11. Decal Location Sheet 6 of 6

3121261 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

1001125140-B

1- -- -- -- -- -- -- -- -- 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3- -- -- -- -- -- -- -- -- 4- -- -- -- -- -- -- -- -- 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 - - 1701529 1701529 1701529 1701529 1701529 - - 1701529 - 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 - - - - - - - - - - - - 17055980 - - 17055980 12 - - - - - - - - - - 1705514 - - - - - 13 3251243 3251243 3251243 3251243 3251243 3251243 - - 3251243 - 14- -- -- -- -- -- -- -- -- 15 1705337 1705337 1001117034 1705904 1705337 1705341 - - 1705338 - 16 - - - - 1001117035 1705906 1705916 1705505 - - 1705493 - -

Korean

0274723-B

Chinese

0274724-B

Port uguese

0274725-B

English/ Spanish

0274726-B

French/English

0274727-BCE1001125143-B

Japan

0274729-B

Australia

1001125141-B

4-26 – JLG Lift – 3121261

Table 4-1. Decal Legend

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001125140-B

17 - - 1702153 - - - - - - - - - - - - - 18 1703953 1703953 1703943 1705903 1703941 1703942 - - 1703944 - 19 1702868 1702868 1001116846 1705967 1704001 1704000 - - - - - 20 1703797 1703797 1703925 1705895 1703923 1703924 1705921 1703926 1705921 21 1705336 1705336 1001116849 1705896 1705917 1705347 1705822 1705344 1705822 22 1703804 1703804 1703949 1705898 1703947 1703948 1701518 1703950 1701518 23 1703805 1703805 1001116851 1705897 1703935 1703936 1705961 1703938 1705961 24 3252347 - - 1703982 1705902 1703983 1703984 1705828 1703980 1705828 25 - - 3251813 3251813 3251813 - - 3251813 - - - - - 26 1705492 1705492 1705508 1705907 1705915 1705506 - - 1705494 - 27 1702631 1702631 1702631 1702631 1702631 1702631 - - 1702631 1702631 28 1001125175 1001122370 1001122371 1001122372 1001122373 1001122374 1001125177 1001122375 1001125177 29 1001125176 1001122377 1001122378 1001122379 1001122380 1001122381 1001125178 1001122382 1001125178 30 1001131269 - - - - - - - - 1700584 1700584 1700584 - 31 1001130584 1706751 1706751 1706751 1706751 1706751 - - 1706751 - 32 1705868 1705868 1705868 1705868 1705868 1705868 - - 1705868 - 33 1705351 1705351 1705430 1705905 1705910 1705429 - - 1705426 - 34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505

Korean

0274723-B

Chinese

0274724-B

Port uguese

0274725-B

English/ Spanish

0274726-B

French/English

0274727-BCE1001125143-B

Japan

0274729-B

Australia

1001125141-B

3121261 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

1001125140-B

35 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972 1706098 36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511 37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 38- -- -- -- -- -- -- -- -- 39- -- -- -- -- -- -- -- -- 40- -- -- -- -- -- -- -- -- 41- -- -- -- -- -- -- -- -- 42- -- -- -- -- -- -- -- -- 43- -- -- -- -- -- -- -- -- 44- -- -- -- -- -- -- -- -- 45- -- -- -- -- -- -- -- -- 46- -- -- -- -- -- -- -- -- 47- -- -- -- -- -- -- -- -- 48- -- -- -- -- -- -- -- -- 49- -- -- -- -- -- -- -- -- 50- -- -- -- -- -- -- -- -- 51- -- -- -- -- -- -- -- -- 52- -- -- -- -- -- -- -- -- -

Korean

0274723-B

Chinese

0274724-B

Port uguese

0274725-B

English/ Spanish

0274726-B

French/English

0274727-BCE1001125143-B

Japan

0274729-B

Australia

1001125141-B

4-28 – JLG Lift – 3121261

Table 4-1. Decal Legend

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001125140-B

53- -- -- -- -- -- -- -- -- 54- -- -- -- -- -- -- -- -- 55- -- -- -- -- -- -- -- -- 56- -- -- -- -- -- -- -- -- 57- -- -- -- -- -- -- -- -- 58- -- -- -- -- -- -- -- -- 59- -- -- -- -- -- -- -- -- 60- -- -- -- -- -- -- -- -- 61- -- -- -- -- -- -- -- -- 62- -- -- -- -- -- -- -- -- 63- -- -- -- -- -- -- -- -- 64 - - - - - - - - - - - - - - - - 1001112551

Korean

0274723-B

Chinese

0274724-B

Port uguese

0274725-B

English/ Spanish

0274726-B

French/English

0274727-BCE1001125143-B

Japan

0274729-B

Australia

1001125141-B

3121261 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

NOTES:

4-30 – JLG Lift – 3121261

SECTION 5. LCD DISPLAY PANEL - GENERATION 1 & 2

Figure 5-1. Generation 1 Boot Up Splash Screen

Figure 5-2. Generation 2 Boot Up Splash Screen

5.1 IDENTIFICATION

The Operator can identify the Generation of the LCD Display Panel by the boot up splash screen that is displayed when the LCD screen is activated. Those screens are shown below.

SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2

3121261 – JLG Lift – 5-1

SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2

Figure 5-3. LCD Panel

5.2 LCD DISPLAY PANEL

Description

This machine utilizes an LCD display panel to assist the operator by supplying additional information during the operation of the machine. It is NOT a substitute for the Operation and Safety Manual, nor is it a replacement for thorough operational knowledge of the machine.

5-2 – JLG Lift – 3121261

5.3 GENERATION 1 LCD DISPLAY PANEL SCREENS

Boot Up Splash Screen

The Boot Up Splash Screen appears when the machine is first powered on. The screen contains several reminders for the operator prior to operation. There is a reminder for the operator to wear a full body harness with a lanyard attached to an authorized lanyard anchorage point, a reminder for the operator to read and understand the Operation and Safety Manual, and a reminder for the operator to select the desired capacity range of the machine. In addition, the display also uses a yellow circle and arrows to indicate the location of the Capacity Select switch and the available options for moving the switch.

SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2

3121261 – JLG Lift – 5-3

SECTION 5 - LCD DISPLAY PANEL - GENERATION 1 & 2

Figure 5-4. Boot Up Splash Screen

Attach Lanyard

Reminder

Capacit y Selec t

Reminder

Read Operation and

Safety Manual

Reminder

5-4 – JLG Lift – 3121261

JLG 1500SJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 GENERAL

SECTION 1. SAFETY PRECAUTIONS

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 MAINTENANCE

Maintenance Hazards

Battery Hazards

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

Function Check

Boom Control System Check Procedure

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Ground Control Indicator Panel

Platform Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Controlled Arc

Envelope Tracking

Controlled Angle

Swing Speed Proportioning

Stability

4.3 CAPACITY SELECT

4.4 ENGINE OPERATION

Starting Procedure

Shutdown Procedure

Fuel Reserve / Shut-Off System

4.5 TRAVELING (DRIVING)

Traveling Forward and Reverse

4.6 STEERING

4.7 EXTENDING THE AXLES

4.8 PLATFORM

Platform Level Adjustment

Platform Rotation

4.9 BOOM

Swinging the Boom

Raising and Lowering the Boom

Telescoping the Boom

Telescoping the Jib

Stowing/Swinging the Jib

4.10 FUNCTION SPEED CONTROL

4.11 EMERGENCY TOWING

4.12 SHUT DOWN AND PARK

4.13 LIFTING AND TIE DOWN

Lifting

Tie Down

4.14 STOWING THE JIB FOR TRANSPORT

SECTION 5. LCD DISPLAY PANEL - GENERATION 1 & 2

5.1 IDENTIFICATION

5.2 LCD DISPLAY PANEL

Description

5.3 GENERATION 1 LCD DISPLAY PANEL SCREENS

Boot Up Splash Screen