Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Model(s)
1932RS/6RS
3248RS/10RS
ANSI
P/N - 3121272
April 8, 2013
NOTES:
SECTION 1 - FOREWORD
SECTION 1. 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.
3121272 – JLG Lift – A
SECTION 2 - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
NOTICE
SECTION 2. 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 POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED,
COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN
ORANGE BACKGROUND.
B – JLG Lift – 3121272
INDICATES A POTENTIALITY 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.
SECTION 2 - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
NOTICE
NOTICE
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 Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Product Modifications
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
3121272 – JLG Lift – C
SECTION 3 - REVISION LOG
SECTION 3. REVISION LOG
Original Issue of Manual. . . . . . . . . . . . . . . . . . . . . January 10, 2012
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . January 4, 2013
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . April 8, 2013
D – JLG Lift – 3121272
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . B
Contact: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Outside USA:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Operator Training and Knowledge. . . . . . . . . . . . . . . . . . . . . .1-2
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Crushing and Collision Hazards. . . . . . . . . . . . . . . . . . . . . . . . .1-9
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . .2-2
2.3 PRE-START INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . . . . . .2-6
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 OPERATING CHARACTERISTICS/LIMITATIONS . . . . . . . . . . . . .3-2
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.4 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.5 MACHINE CONTROL LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3.6 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Ground Emergency Stop Switch . . . . . . . . . . . . . . . . . . . . . . . .3-6
Key Selector Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Platform Lift/Lower Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3121221 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
MDI-Indicator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
Overload Indicator (If Equipped) . . . . . . . . . . . . . . . . . . . . . . .3-7
3.7 PLATFORM CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
Platform Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . .3-10
Lift/Drive Select. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
Forward/Reverse/Lift/Lower Direction Decal. . . . . . . . . . .3-10
Drive/Lift/Steer Joystick Control . . . . . . . . . . . . . . . . . . . . . . .3-11
Steering And Traveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
Traveling Forward and Reverse. . . . . . . . . . . . . . . . . . . . . . . .3-12
Raising And Lowering Platform. . . . . . . . . . . . . . . . . . . . . . . .3-14
Arm Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14
Overload Indicator (If Equipped) . . . . . . . . . . . . . . . . . . . . . .3-14
Tilt Indicator Warning Light and Alarm . . . . . . . . . . . . . . . .3-15
Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Low Battery Charge and System Fault Indicator . . . . . . . .3-15
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3.8 PLATFORM EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3.9 PLATFORM RAILS - FOLD-DOWN PROCEDURE - (3248RS/10RS
AND 6RS-CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3.10 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . . . .3-21
3.11 DC TO AC INVERTER OPERATION (OPTION) . . . . . . . . . . . . . .3-22
3.12 PARKING AND STOWING MACHINE. . . . . . . . . . . . . . . . . . . . . .3-23
3.13 SCISSOR ARM - SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
3.14 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . .3-26
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3.15 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-29
Mechanical Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . . . . . . . . . . .4-1
Platform Caught Overhead. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Righting of Tipped Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 PLATFORM MANUAL DESCENT. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Other Publications Available:. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Machine Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
ii – JLG Lift – 3121221
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5.3 CRITICAL STABILITY WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Lubrication Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5.6 BATTERY MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
Battery Maintenance and Safety Practices. . . . . . . . . . . . . . .5-9
Battery Quick-Disconnect - (If Equipped) . . . . . . . . . . . . . . . .5-9
5.7 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5.9 DECAL INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.10 DIAGNOSTIC TROUBLE CODES (DTC). . . . . . . . . . . . . . . . . . . . 5-17
5.11 DTC CHECK TABLE INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5.12 DIAGNOSTIC TROUBLE CODES (DTC)
CHECK TABLES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
0-0 Help Comments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . 5-22
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . 5-22
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
6-6 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
8-2 LSS - Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . 5-27
8-4 Elevation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
SECTION - 6 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around Inspection - All Machines . . . . . . . . . .2-7
2-2. Machine Limit Switch Location . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1. 1932RS/6RS - Location of Machine Controls.. . . . . . . . . . . 3-3
3-2. 3248RS/10RS - Location of Machine Controls. . . . . . . . . .3-4
3-3. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3-4. MDI Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5. Location of Manual Descent Control . . . . . . . . . . . . . . . . . .3-8
3-6. Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3121221 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3-7. Platform Control Components. . . . . . . . . . . . . . . . . . . . . . .3-11
3-8. Grade and Sideslope Definition . . . . . . . . . . . . . . . . . . . . . .3-13
3-9. Platform Deck Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-10. Platform Rails - Fold Down Sequence -
3248RS/10RS Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-11. Platform Rails - Fold Down Sequence -
6RS (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
3-12. Charger Decal LED Indicators . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-13. Location of AC Inverter ON/OFF - Toggle Switch. . . . . .3-22
3-14. Securing Control Station to Platform. . . . . . . . . . . . . . . . .3-23
3-15. 1932RS/6RS - Scissor Arm - Safety Prop . . . . . . . . . . . . . .3-25
3-16. 3248RS/10RS - Scissor Arm - Safety Prop . . . . . . . . . . . . .3-25
3-17. Fork Lift Pockets - Location . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
3-18. Lifting Using Spreader Bar and
Lift Lug Locations - All Machines . . . . . . . . . . . . . . . . . . . . .3-27
3-19. Tie Down and Lift Lug Locations - All Machines. . . . . . .3-28
3-20. Electric Brake Release - Location - All Machines. . . . . . .3-29
3-21. Brake - Manual Disengage. . . . . . . . . . . . . . . . . . . . . . . . . . .3-30
4-1. Location of Manual Descent Control . . . . . . . . . . . . . . . . . . 4-2
5-1. Hydraulic Oil Check Procedure - All Machines . . . . . . . . . 5-8
5-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
5-3. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . .5-11
5-4. Machine Decal Installation - All Machines . . . . . . . . . . . .5-12
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . . . 1-8
2-1 Inspection and Maintenance Table. . . . . . . . . . . . . . . . . . . .2-3
2-2 High Drive Cutout Height. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
2-3 Tilt Activation Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
3-1 Battery Charger Fault (LED Flash) . . . . . . . . . . . . . . . . . . . .3-21
5-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3
5-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4
5-4 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-6 Electrical System Specifications . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-7 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-8 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-10 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
5-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-12 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5-13 Machine Decal Installation Chart. . . . . . . . . . . . . . . . . . . . .5-13
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
iv – JLG Lift – 3121221
SECTION 1. SAFETY PRECAUTIONS
SECTION 1 - SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper and
safe machine usage and maintenance. In order to promote
proper machine usage, it is mandatory that a daily routine is
established based on the content of this manual. 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.
These sections contain 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.
3121272 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operation and Safety Manual must be read and understood
in its entirety before operating the machine. For clarification,
questions, or additional information regarding any portions of
this manual, contact JLG Industries, Inc.
• 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 floor 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.
1-2 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
• This machine can be operated in nominal ambient temperatures
of 0o F to 104o F (-20o C to 40o C). Consult JLG to optimize operation outside of this temperature range.
Machine Inspection
• Do not operate this machine until the inspections and functional
checks have been performed as specified in Section 2 of this
manual.
• 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 deck. Keep mud, oil,
grease, and other slippery substances from footwear and platform deck.
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 oppo-
site direction. Always return switch to neutral and stop before
moving the switch to the next function. Operate controls with
slow and even pressure.
3121272 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Do not allow personnel to tamper with or operate the machine
from the ground with personnel in the platform, except in an
emergency.
• 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.
• 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.
• The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/EC
and is only applicable to CE machines.
For electric powered machines, the equivalent continuous AWeighted sound pressure level at the work platform is less than
70dB(A).
For combustion engine powered machines, guaranteed Sound
Power Level (LWA) per European Directive 2000/ 14/EC (Noise
Emission in the Environment by Equipment for Use Outdoors)
based on test methods in accordance with Annex III, Part B,
Method 1 and 0 of the directive, is 109 dB.
The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s2. The highest root mean square
value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s2.
1-4 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
Trip and Fall Hazards
• Prior to operation, ensure all gates and rails are fastened and
secured in their proper position.
• JLG Industries, Inc. recommends that all persons in the platform
wear a full body harness with a lanyard attached to an authorized
lanyard anchorage point while operating this machine. For further information regarding fall protection requirements on JLG
products, contact JLG Industries, Inc.
• Identify the designated lanyard anchorage point(s) at the platform and securely attach the lanyard. 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.
.
• 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.
• Never use the scissor arm assembly to gain access to or leave the
platform.
• Keep oil, mud, and slippery substances cleaned from footwear
and the platform floor.
3121272 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
• 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.
• 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.
• 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.
1-6 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Approach Distances (M.A.D.)
VOLTAGE RANGE
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
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 govern-
mental regulations are more stringent.
Tipping Hazards
• 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.
• The user must be familiar with the driving 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.
• 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 operate the machine when wind conditions exceed specifications shown in Section 5, Table 5-2 or as shown on the capacity placard on the platform billboard.
3121272 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 5, TABLE 5-2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLATFORM BILLBOARD.
Table 1-2. Beaufort Scale (For Reference Only)
BEAUFORT
NUMBER
0
1
2
3
4
5
6
7
8
9
WIND SPEED
DESCRIPTION LAND CONDITIONS
mph m/s
0 0-0.2 Calm Calm. Smoke rises vertically.
1-3 0.3-1.5 Light air Wind motion visible in smoke.
4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle.
8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion.
13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
19-24 8.0-10.7 Fresh breeze Smaller trees sway.
25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use
becomes difficult.
32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
47-54 20.8-24.4 Strong Gale Light structure damage.
1-8 – JLG Lift – 3121272
SECTION 1 - SAFETY PRECAUTIONS
• 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 cover the platform sides or carry large surface-area items
in the platform when operating outdoors. The addition of such
items increases the exposed wind area of the machine.
• Do not increase the platform size with unauthorized deck extensions or attachments.
• If the scissor arm assembly or platform is caught so that one or
more wheels are off the ground, all persons must be removed
before attempting to free the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine and remove
personnel.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and ground
personnel.
• Keep hands and limbs out of the scissor arm assembly during
operation and when elevated without safety prop engaged.
• Watch for obstructions around machine and overhead when driving. Check clearances above, on sides, and bottom of platform
when lifting or lowering platform.
• During operation, keep all body parts inside platform railing.
3121272 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
• 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 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.
• 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.
• Ensure that operators of other overhead and floor level machines
are aware of the aerial work platform’s presence. Disconnect
power to overhead cranes. Barricade floor area if necessary.
• Do not operate over ground personnel. Warn personnel not to
work, stand, or walk under a raised platform. Position barricades
on floor as necessary.
1-10 – JLG Lift – 3121272
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
emergency towing procedures.
• Ensure platform is fully retracted and completely empty of tools
prior to towing, lifting or hauling.
• When lifting machine with a forklift, position forks only at designated areas of the machine. Lift with a forklift of adequate capacity.
• Refer to Section 3 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.
• 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.
3121272 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS
• 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.
• Reference 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.
Battery Hazards
• 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 bat-
teries only after the batteries are fully charged.
1-12 – JLG Lift – 3121272
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.
Operator Training
Operator training must cover:
• Use and limitations of the controls in the platform and at the
ground, emergency controls and safety features.
• Control labels, instructions, and warnings on the machine.
• Rules of the employer and government regulations.
• Use of approved fall protection equipment.
• Enough knowledge of the mechanical operation of the machine to
recognize a malfunction or potential malfunction.
• The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes,
and drop-offs exist.
• Means to avoid the hazards of unprotected electrical conductors.
• Specific job requirements or machine application.
• Reading and understanding the Operation and Safety Manual.
3121272 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
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.
NOTE: The Manufacturer or Distributor will provide qualified people for
training assistance with the first unit(s) delivered and from that
time forward as requested by the user or his/her personnel.
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
Table 2-1 explains the periodic machine inspections and maintenance
recommended 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.
2-2 – JLG Lift – 3121272
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE
Table 2-1. Inspection and Maintenance Table
TYPE FREQUENCY
Pre-Start Inspec tion Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection
(see note below)
Frequent Inspection In service for 3 months or 150 hours, whichever comes
Annual Machine
Inspection
(see note below)
Preventative Maintenance At intervals as specified in the Service and Mainte-
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
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.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG
first; or Out of service for a period of more than 3
months; or Purchased used.
Annually, no later than 13 months from the date of
prior inspection.
nance Manual.
2.3 PRE-START INSPECTION
PRIMARY
RESPONSIBILITY
User or Operator User or Operator Operation and Sa fety Manual
Owner, Dealer, or User Qualified JLG
Owner, Dealer, or User Factory Trained Ser-
Owner, Dealer, or User Qualified JLG
The Pre-Start Inspection should include each of the following:
SERVICE
QUALIFICATION
Mechanic
Mechanic
vice Technician
(Recommended)
Mechanic
REFERENCE
Service and Maintenance Manual and
applicable JLG inspection form
Service and Maintenance Manual and
applicable JLG inspection form
Service and Maintenance Manual and
applicable JLG inspection form
Service and Maintenance Manual
3121272 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
1. Cleanliness – Check all surfaces for leakage (oil or battery
fluid) or foreign objects. Report this to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.
Report this to the proper maintenance personnel.
.
Parent Metal Crack Weld Crack
3. Decals and Placards – Check all for cleanliness and legibility. Ensure none of the decals and placards are missing.
Ensure all illegible decals and placards are cleaned or
replaced. (See Section 5.8, DECAL INSTALLATION)
4. Operation and Safety Manuals - Ensure that 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 2-1. on page 3-
7.
6. Battery – Charge as required.
7. Hydraulic Oil Level - Check the hydraulic oil level in the
pump reservoir, add as required. (See Section 5.5)
8. Accessories/Attachments - Reference the Operation and
Safety Manual of each attachment or accessory installed
upon the machine for specific inspection, operation, and
maintenance instructions.
9. 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 3 for more specific instructions on the operation of
each function.
2-4 – JLG Lift – 3121272
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
1
1
1
10. Platform Gate - Keep gate and surrounding area clean and
unobstructed. Check that gate closes properly and is not
bent or damaged. During operation keep gate closed.
Chain Gate
Self-Closing Swing Gate
11. Lanyard Anchorage Points - JLG Industries, Inc. recommends personnel in the platform wear a full body harness
with a lanyard attached to an authorized lanyard anchorage
point (1).
3121272 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE
2.4 DAILY WALK-AROUND INSPECTION
Begin the “Walk-Around Inspection” at item 1, see Figure 2-1. on
page 3-7. 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 UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING
THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE
EXTENSIVE MACHINE DAMAGE.
INSPECTION NOTE: On all components, make sure there are no loose or
missing parts, that they are securely fastened, and that no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.
1. Frame/Chassis - See Inspection Note. Ensure that passive pot-
hole components on frame are in place, undamaged, not
bent or worn.
2. Ground Controls - Placard secure and legible, control
switches return to neutral position, emergency stop switch
functions properly. Control markings legible.
3. Hydraulic Pump/Motor, Control Valve Installation - No
unsupported wires or hoses; no damaged or broken wires -
See Inspection Note.
4. Front Wheels - Steer linkage, and Steer Cylinder - See Inspec-
tion Note.
5. Battery Compartment - See Inspection Note.
6. Rear Wheels, Tires and Drive Motors - Properly secured, no
missing lug nuts. Refer to Section 5.7, TIRES AND WHEELS.
Inspect wheels for damage and corrosion - See Inspection
Note.
7. Manual Descent Control - See Inspection Note.
8. Beacon (if equipped) - See Inspection Note.
9. Scissor Arms, Pivot Pins and Sliding Wear Pads, Lift Cylinder -
See Inspection Note.
10. Platform/Handrail/Gate Installation - Deck extension slides
in and out and locks in place properly. Gate closes properly.
All fold-down rail pins in place and secure (3248RS/10RS and
6RS CE ONLY) - See Inspection Note.
11. Platform Control Console - Ensure that the control console is
firmly secured in the proper location. Placards secure and
legible, control lever and switches return to neutral, and
emergency stop switch function properly, required manuals
in storage box.
2-6 – JLG Lift – 3121272
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
1
2
3
5
7
6
8
9
10
11
4
8
1
1
1
3121272 – JLG Lift – 2-7
Figure 2-1. Daily Walk-Around Inspection (Side Covers Removed) - All Machines
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.5 FUNCTION CHECK
Perform the Function Check as follows:
1. From the Ground Control Panel with no load in the platform:
a. Ensure that the key selector switch and the platform lift
switch operates properly.
b. Ensure that all machine functions are disabled when
the Emergency Stop Button is depressed.
c. With platform raised a few feet (1m), ensure that the
manual descent control (located at the right rear of the
machine), lowers the platform properly.
2. From the Platform Control Console:
a. Ensure that the control console is firmly secured in the
proper location.
b. Ensure that all guards protecting switches are in place.
c. Operate all functions, drive/lift mode select switch, and
horn button.
d. Operate all platform joystick functions to ensure proper
operation of drive, lift, steer, and enable trigger switch
operation.
e. With the platform elevated on a smooth, firm, level sur-
face with no overhead obstructions, drive the machine
to check if the high drive cutout speed-limit is engaged
at the height indicated in Table 2-2. Ensure drive speed
is reduced from a top speed to a slower speed. Limit
switch locations shown in Figure 2-2. on page 3-9.
Table 2-2. High Drive Cutout Height
MODEL
1932RS/6RS 68.9 in. (1.75m)
3248RS/10RS 88.5 in. (2.25 m)
f. Ensure that all machine functions are disabled when
3. With the platform in the transport (stowed) position.
a. Drive the machine on a grade, not to exceed the rated
b. Check the tilt indicator light/alarm to ensure proper
NOTE: When the tilt indicator warning is activated the following func-
tions are affected; drive and lift up functions are disabled, platform must be fully lowered (stowed) to drive out of tilt condition.
HIGH DRIVE SPEED
CUTOUT HEIGHT
DRIVE SPEED REDUCTION
2.5 mph (4 kph) to
0.3 mph (0.5 kph)
the platform Emergency Stop Button is depressed.
gradeability, and stop to ensure the drive motor brakes
hold.
operation. The light/alarm should be activated, and lift
up disabled when tilted at or beyond the values in
Table 2-3.
2-8 – JLG Lift – 3121272
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
1
1
Table 2-3. Tilt Activation Setting
MODEL
TILT SETTING
(front to back)
TILT SETTING
(side to side)
1932RS/6RS - ALL 3° 1.5°
3248RS/10RS - ANSI/CSA/JPN 3° 2°
3248RS/10RS - CE 3° 1.5°
1932RS/6RS
3248RS/10RS
Figure 2-2. Machine Limit Switch Location
1. Elevation Switch
3121272 – JLG Lift – 2-9
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTES:
2-10 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
NOTICE
SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION
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
controls and their functions.
DO NOT RAISE PLATFORM EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE
FREE OF OBSTRUCTIONS AND HOLES.
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.
3.2 DESCRIPTION
This machine is a self-propelled aerial work platform on top of an elevating scissor arm mechanism. The Lift’s intended purpose is to position personnel with their tools and supplies at positions above ground
level. The machine can be used to reach work areas located above
machinery or equipment positioned at ground level.
This JLG Lift has a primary operator control station in the platform.
From this control station, the operator can drive and steer the machine
in both forward and reverse directions, raise and lower the platform.
The machine can be driven on a smooth, firm, and level surface from an
elevated platform position - Reference “Steering And Traveling” on
page 3-12. of this manual for specific requirements.
The machine also has a ground control station which can override the
platform control station. Ground controls operate lift up and down.
Ground controls are to be used only in an emergency to lower the platform to the ground should the operator in the platform be unable to do
so.
IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS
RELEASED, USE THE EMERGENCY STOP SWITCH TO STOP THE MACHINE.
3121272 – JLG Lift – 3-1
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.3 OPERATING CHARACTERISTICS AND LIMITATIONS
General
A thorough knowledge of the operating characteristics and limitations
of the machine is always the first requirement for any user, regardless of
user’s experience with similar types of equipment.
Placards
Important points to remember during operation are provided at the
control stations by DANGER, WARNING, CAUTION, NOTICE, and
INSTRUCTION placards. This information is placed at various locations
for the express purpose of alerting personnel of potential hazards constituted by the operating characteristics and limitations of the
machine. See foreword for definitions of placard safety signal words.
3.4 PLATFORM LOADING
The platform maximum rated load capacity is shown on a placard
located on the platform billboard and ground control station and is
based upon the machine positioned on a smooth, firm, and level surface. Refer to Section 5, Table 5-2, for the maximum platform capacity.
The platform is entered through an entry gate at the rear of the platform. Keep entry gate closed during machine operation.
NOTE: It is important to remember that the load should be evenly dis-
tributed on the platform. The load should be placed near the
center of the platform when possible.
3-2 – JLG Lift – 3121272
3.5 MACHINE CONTROL LOCATIONS
1
2
3
3
4
5
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1. Ground Control Station
2. Platform Control Station
3. Platform Manual Descent Control
4. AC Plug - To Platform AC Receptacle Outlet Box
5. AC Plug - Battery Charger Input Plug
3121272 – JLG Lift – 3-3
Figure 3-1. 1932RS/6RS - Location of Machine Controls.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
4
5
2
3
3
1. Ground Control Station
2. Platform Control Station
3. Platform Manual Descent Control
4. AC Plug - To Platform AC Receptacle Outlet Box
5. AC Plug - Battery Charger Input Plug
Figure 3-2. 3248RS/10RS - Location of Machine Controls.
3-4 – JLG Lift – 3121272
3.6 GROUND CONTROL STATION
1001132360A
1
2
3
4
5
1001146979A
DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN
THE PLATFORM EXCEPT IN AN EMERGENCY.
PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM
THE GROUND CONTROL STATION AS POSSIBLE.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1. Platform Lift/Lower Switch
2. Key Selector Switch
Figure 3-3. Ground Control Station
4. MDI - Indicator
5. Overload Indicator (If Equipped)
3. Ground Emergency Stop Button
3121272 – JLG Lift – 3-5
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
3
Ground Emergency Stop Switch - (Item 3 - Figure 3-3.)
Power is turned on by pulling the switch out, and is turned off by
depressing switch. A two-position, red, mushroom-shaped emergency
stop switch, when positioned to ON with the key selector switch positioned to ground, furnishes operating power to the ground control station key switch. In addition, the switch can be used to turn off power to
the function controls in the event of an emergency.
Key Selector Switch - (Item 2 - Figure 3-3.)
The key selector switch on the
Ground Control Station functions
to direct electrical power to the
desired control station. With the
switch turned to the ground posi-
tion (1), power is supplied to the
controls at the ground control station. When the switch is turned to
the platform position (2), power
is supplied to the controls at the
platform control station. The
switch should be set to the OFF position (3) when parking the
machine overnight.
Platform Lift/Lower Switch - (Item 1 - Figure 3-3.)
A three position, momentary contact lift control switch provides raising
and lowering of the platform from the Ground Control Station.
When operating platform from the ground controls -
Toggle the lift/lower switch to up position and hold to raise platform, or
down position and hold to lower an elevated platform. Release to center position to stop all movement.
MDI-Indicator - (Item 4 - Figure 3-3.)
(Also see Figure 3-4.)
The MDI indicator or Multifunction Digital Indicator displays a Battery
Discharge Indicator (BDI), an LCD display which shows the current
hour-meter reading or Diagnostic Trouble Code(s) (DTC) when a functional problem occurs with the machine, and a system distress LED.
When a problem occurs (DTC Code displayed):
• A wrench Icon (item 1) will display on the Diagnostic Trouble
Code LCD display (item 2).
• A three to five digit DTC code will display on the Diagnostic
Trouble Code LCD display (item 2), below the wrench icon.
• The system distress LED indicator (RED) (item 3) lights up solid
on the MDI when a DTC Code is displayed on the LCD display.
NOTE: When more than one DTC exists, each DTC will be displayed on
the LCD for 3 seconds before changing to the next DTC. Once the
last active DTC is displayed, the display will recycle indefinitely
until the DTC’s are corrected.
For DTC’s and descriptions, refer to Section 5.9.
3-6 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
3
7
6
5
4
Also located on the MDI are Battery Discharge Indicators (BDI)
(items 4 thru 7). (4) GREEN LEDs indicate the level of charge (voltage) remaining in the batteries.
NOTE: When the battery voltage is low and will need a charge soon, the
LED (item 4) in the 0-25% range "red area" will flash.
Under normal operating conditions the BDI’s and hour-meter will be
displayed. When a DTC exists (other than 00x
hour-meter will not be displayed.
DTC’s) the BDI LEDs and
Overload Indicator (If Equipped) - (Item 5 - Figure 3-3.)
Overload Indicator - Indicates the platform has been overloaded. An
audible alarm will also signal when the platform is overloaded.
NOTE: If the Overload Indicator is illuminated, all functions will be pre-
vented from the platform and ground controls. Reduce the
weight in the platform to not exceed the rated workload indicated on the capacity decal.
1. Wrench Icon Indicator
2. Hour-meter/DTC Code Display
3. System Fault LED Indicator (RED
LED)
4. 0-25% Charge Indicator
(RED AREA)
Figure 3-4. MDI Indicator
5. 50% Charge Indicator
(YELLOW AREA)
6. 75% Charge Indicator
(GREEN AREA)
7. 100% Charge Indicator
(GREEN AREA)
3121272 – JLG Lift – 3-7
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Platform Manual Descent Control
The platform manual descent control is used in the event of total
power failure to lower the platform using gravity. The manual descent
control T-handle is located on the right rear of the machine, just in front
of the drive wheel.
The lowering procedure is as follows:
1. Locate the manual descent control T-handle.
(See Figure 3-5.)
KEEP HANDS AND ARMS OUT OF THE PATH OF THE SCISSOR ARMS AND PLAT-
1932RS/6RS
FORM WHILE LOWERING.
2. Grasp the T-handle and slowly pull out to lower the scissor
arms/platform, when the platform is lowered to desired
level, allow the T-handle to return to it’s closed position.
3248RS/10RS
Figure 3-5. Location of Manual Descent Control
(Right Rear of Machine)
3-8 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1001132362 B
1
3
4
8
9
10
2
5
1
2
6
7
11
3.7 PLATFORM CONTROL STATION
1. Steer Control Switch
2. Drive and Lift Joystick Control
3. Trigger Switch
4. Forward/Reverse/Lift/Lower Direction Decal
5. Alarm
6. Overload Indicator (If Equipped)
7. Machine Tilt Indicator
8. Emergency Stop Switch
9. Horn Button
10. Drive and Lift Select Switch
11. Low Battery Charge and
System Fault Indicator
Figure 3-6. Platform Control Station.
3121272 – JLG Lift – 3-9
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1001132362 B
Platform Emergency Stop Switch - (Item 8 - Figure 3-6.)
NOTE: Both the ground and platform emergency stop buttons must be
set to ON in order to operate the machine.
When power is directed to the platform from the ground control station, the platform emergency stop switch is turned on by pulling the
switch out (on), and is turned off by pushing the switch in (off ). The
two-position, red, mushroom-shaped emergency stop switch functions
to provide power to the platform control station and also to turn off
power to machine functions in the event of an emergency.
Lift/Drive Select - (Item 10 - Figure 3-6.)
NOTE: When selecting between the Lift and Drive functions the joystick
control must be returned to the neutral position for approximately 1/2 second before the function change is operable.
This toggle switch is used to select operation of either the drive or lift
function. After selecting a function, the joystick controller must be
moved in the proper direction in order to activate that function. Only
change the function selected, with the joystick in the neutral position.
Otherwise, the function selected will not change until the joystick is
returned to the neutral position.
Forward/Reverse/Lift/Lower Direction Decal - (Item 4 - Figure 3-6.)
This decal indicates the proper direction to mount
the platform control box, the black arrow must
point to the front of the machine. The black/white
arrow also indicates the direction to move the joystick control per the lift/drive selector switch decal
for the lift and drive select functions.
3-10 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
2
3
1
Drive/Lift/Steer Joystick Control
Figure 3-7. Platform Control Components
1. Trigger Switch
2. Steer Switch
3. Joystick Controller
1. Trigger Switch - This switch is located on the front of the
joystick controller. The trigger switch acts as an enable and
must be depressed before operating the drive, steer and lift
functions. When released, the function being operated will
stop.
NOTE: Once the trigger switch is pressed, the operator has (5) seconds
to begin operating a function, after 5 seconds you must release
the trigger switch and press it again to operate a joystick function.
The speed on all selected functions is proportionally controlled
by the distance from the neutral (center) position of the joystick
controller.
NOTE: If the machine is equipped with a footswitch (Japanese Specifi-
cation Only), the footswitch must be depressed in conjunction
with the red trigger switch, located on the controller. Power is
removed from the platform controls when the footswitch is
released.
2. Steer Switch - The steer switch is a thumb operated switch
located at the top of the control handle. Depressing the
switch to the right will steer the wheels to the right. Depressing the switch to the left will steer the wheels to the left.
3. Joystick Controller - The control handle controls three functions: drive, lift, and steer.
3121272 – JLG Lift – 3-11
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Steering And Traveling
DO NOT DRIVE WITH PLATFORM RAISED EXCEPT ON A SMOOTH, FIRM AND
LEVEL SURFACE FREE OF OBSTRUCTIONS AND HOLES.
TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES,
DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE
SPECIFIED IN TABLE 5-1 ON PAGE 3-2.
BEFORE DRIVING, LOCATE THE DECALS WITH THE BLACK/WHITE ORIENTATION ARROWS ON THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE
JOYSTICK IN THE DIRECTION OF THE BLACK OR WHITE ARROW THAT
MATCHES THE COLOR OF THE ARROW ON THE CHASSIS FOR THE INTENDED
DIRECTION OF TRAVEL.
IF THE TILT INDICATOR WARNING LIGHT/ALARM IS ACTIVATED WHILE DRIVING WITH PLATFORM RAISED, LOWER PLATFORM COMPLETELY AND DRIVE
TO A FIRM LEVEL SURFACE.
1. Place key selector switch at the ground control station to
platform operation.
2. Position emergency stop switches, one at the platform and
one at the ground control station to the ON position.
Steering
(Item 2 - Figure 3-7.)
On the platform control station, position the lift/
drive select switch to the drive position.
To steer the machine, press the thumb operated
steer rocker-switch on the joystick handle to the
right for steering right, or to the left for steering
left. When released, the switch will return to the center-off position and
the wheels will remain in the previously selected position. To return the
wheels to the center position, the switch must be activated in the
opposite direction until the wheels are centered.
Traveling Forward and Reverse
(Item 1 and 3 - Figure 3-7.)
Position the platform lift/drive select
switch to drive/steer position.
Squeeze the trigger switch on front
of the joystick, and move the joystick forward to drive forward or
backward to drive in reverse. The
drive system is proportional, for additional drive speed push the joystick further from the neutral position in the direction of travel. Releasing the trigger switch or returning the joystick to center will stop
machine movement.
3-12 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
HORIZONTAL (LEVEL)
GRADE
SIDESLOPE
Figure 3-8. Grade and Sideslope Definition
3121272 – JLG Lift – 3-13
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Raising And Lowering Platform
1. If the machine was shut down, place the key selector switch
to the desired position (platform or ground).
2. Position emergency stop switches, one at the platform and
one at the ground control station to the ON position.
3. Position the lift/drive
select switch to lift. (Item
10 - Figure 3-6.)
4. Squeeze and hold the trig-
ger switch, and move the
joystick back (platform up white arrow direction) or move the joystick forward (platform down - black arrow direction) and hold until desired
elevation is reached. Releasing the trigger switch or moving
the joystick back to it’s center position will stop the function
being operated. (Item 1 and 3 - Figure 3-7.)
NOTE: To ensure proper operation of the desired platform function,
move the joystick in the direction of the black or white arrow
that matches the color of the arrow on the chassis for the
intended direction of travel.
Arm Guards
If the machine is equipped with arm guards, the platform will stop lowering and an alarm will sound once it has reached a preset height. At
this point, the joystick must be returned to the neutral position and the
trigger switch released before the lowering function can begin again.
Overload Indicator (If Equipped) -
(Item 6 - Figure 3-6.)
Indicates the platform has been overloaded.
An audible alarm will also signal when the
platform is overloaded.
NOTE: If the Overload Indicator is illuminated, all functions will be pre-
vented from the platform and ground controls. Reduce the
weight in the platform to not exceed the rated workload indicated on the capacity decal.
3-14 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Tilt Indicator Warning Light and Alarm -
(Item 7 - Figure 3-6.)
A red warning light on the control panel illuminates and an audible alarm sounds when the
chassis is at or beyond the tilt cutout settings.
IF THE TILT INDICATOR WARNING LIGHT/ALARM IS ACTIVATED WHEN PLATFORM IS RAISED LOWER PLATFORM AND DRIVE TO A SMOOTH FIRM LEVEL
SURFACE.
Horn - (Item 9 - Figure 3-6.)
This push-button switch, when pressed, permits
the operator to warn job site personnel when the
machine is operating in the area.
Low Battery Charge and System Fault Indicator - (Item 11 - Figure 3-6.)
This indicator light comes on and stays lit when
the battery charge level is very low, indicating
the batteries will need recharging soon.
When indicator light is flashing a system fault
has occurred, possibly stopping machine operation. Check the MDI indicator on the Ground Control Station to see if a
(DTC) Diagnostic Trouble Code(s) is displayed. An explanation of DTC
codes is shown in Section 5.9.
If the code cannot be cleared by the operator, the machine will require
service by a qualified JLG mechanic.
Alarm - (Item 5 - Figure 3-6.)
This alarm mounted on the front of the platform control station will
sound for various machine conditions or warnings such as, system
ready chirp or if the machine tilt warning is activated.
3121272 – JLG Lift – 3-15
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
3.8 PLATFORM EXTENSION
(See Figure 3-9.)
This machine is equipped with an extension deck, giving the operator
better access to certain work areas. The deck extension adds length to
the front of the platform.
FOR MAXIMUM CAPACITY OF THE DECK EXTENSION SEE SECTION 5, Table 5-2
OR REFER TO THE CAPACITY PLACARD ON THE PLATFORM BILLBOARD.
DO NOT “LOWER” WITHOUT COMPLETELY RETRACTING THE PLATFORM
EXTENSION.
To extend the deck:
1. Pull up on the locking pin (1) on left side mid-rail near the
front of the machine. Rotate pin 90° to hold in up position.
2. Grasp the top handrails (2) of the extendible deck and push
the extension out until it hits the stops.
3. Re-engage the locking pin (1) and move platform extension in or out until the locking pin engages.
To retract the deck:
1. Pull up on the mid-rail locking pin (1) and turn the pin 90°
to hold in up position.
2. Pull the extension deck all the way back into the main deck
using the top handrail (2).
3. Re-engage the mid-rail locking pin (1) back to the locked
position and engage the hole in the mid-rail.
Figure 3-9. Platform Deck Extension
3-16 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.9 PLATFORM RAILS - FOLD-DOWN PROCEDURE (3248RS/10RS and 6RS-CE Only)
(See Figure 3-10. and Figure 3-11.)
DO NOT RAISE PLATFORM WITH RAILS FOLDED DOWN. THE RAILS MUST BE
IN THE UPRIGHT POSITION AND PROPERLY PINNED WHEN RAISING THE
PLATFORM.
NOTE: The rails must only be folded down when the machine is in the
stowed (platform fully lowered) position.
The platform control box should be removed from mount before
the side rails are folded down.
The platform rails fold down from the mid rail only, except for the rear
gate rail.
NOTE: If equipped with the optional self-closing gate, the gate must be
held open while lowering the rear and side rails.
The platform rails fold down in the following sequence;
(See Figure 3-10. and Figure 3-11.)
• First - pull pins, fold down rear gate rail (1).
NOTE: Front deck extension top rail pins must be removed and deck
extension top side rails slid towards rear of machine before low-
ering side rails. Place pins back in the extension side top rails
before folding main platform side rails down.
• Second - pull pins, fold down both side rails (2 & 3).
• Last - pull pins, fold down front platform extension rail (4).
1. To fold down each of the rails, remove the bail pins for that
rail.
2. Taking a firm hold on the top rail, carefully lower until the
top rail is fully folded in the down position.
3. To raise the rails back to the upright position, unfold the rails
in the reverse sequence they were folded. Firmly pull the
rails back up into position and replace the bail pins into the
rails.
4. Retract the extension deck and set it’s lock pin.
AFTER THE RAILS HAVE BEEN FOLDED DOWN, USE EXTREME CAUTION WHEN
EXITING AND ENTERING THE PLATFORM. ENTER AND EXIT PLATFORM ONLY
AT THE GATE AREA AND LADDER PROVIDED.
IF OPERATING (DRIVING) MACHINE WITH PLATFORM CONTROL STATION
FROM GROUND, WITH RAILS FOLDED, KEEP AT LEAST 3 FT. (1 M) DISTANCE
FROM MACHINE.
3121272 – JLG Lift – 3-17
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
1
3
3
2
2
4
4
3-18 – JLG Lift – 3121272
Figure 3-10. Platform Rails - Fold Down Sequence - 3248RS/10RS Only
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
1
3
3
2b
2a
2
4
4
Figure 3-11. Platform Rails - Fold Down Sequence - 6RS (CE Only)
3121272 – JLG Lift – 3-19
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
GREEN (ON) Battery Fully Charged
AMBER (ON) Battery Charging
AMBER (FLASHING) Battery/System
Problem
RED (FLASHING) Charger Problem
GREEN
AMBER
RED
LEDS
3.10 BATTERY CHARGING
NOTE: Be sure that machine is parked in a well ventilated area before
charging begins.
NOTE: If the charger is left plugged in, the charger will automatically
ONLY PLUG THE CHARGER INTO A PROPERLY INSTALLED AND GROUNDED
OUTLET. DO NOT USE GROUND ADAPTORS OR MODIFY PLUG. DO NOT TOUCH
These LED indicators can be viewed through the opening on
the rear panel where the charger AC cord is accessed.
4. The batteries are fully charged when the green light on the
battery charger status panel is illuminated.
restart a complete charge cycle if the batteries voltage drops
below a minimum voltage or 30 days has elapsed.
NON-INSULATED PORTION OF OUTPUT CONNECTOR OR NON-INSULATED
BATTERY TERMINAL.
DO NOT OPERATE CHARGER IF THE AC SUPPLY CORD IS DAMAGED OR IF THE
CHARGER HAS RECEIVED A SHARP BLOW, BEEN DROPPED, OR OTHERWISE
DAMAGED IN ANY WAY.
ALWAYS DISCONNECT THE CHARGER AC SUPPLY BEFORE MAKING OR BREAKING THE (POS/NEG) CONNECTIONS TO THE BATTERY.
DO NOT OPEN OR DISASSEMBLE CHARGER.
1. The battery charger AC input plug is located in an opening
on the panel at the lower rear of the machine.
2. Connect the charger AC input plug to a grounded outlet
using a 3 wire heavy duty extension cord. (See Table 5-6,
“Electrical System Specifications,” on page 3-6, for battery
charger AC input specifications.)
3. When powered up the charger will go through a short LED
indicator self-test. The battery charger LED indicators on the
charger (Figure 3-12.), will flash in sequence for two seconds.
3-20 – JLG Lift – 3121272
Figure 3-12. Charger Decal LED Indicators
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Battery Charger Fault (LED Flash)
If a fault has occurred during battery charging, the (AMBER or RED) LED
on the charger LED indicator (See Figure 3-12.) will flash corresponding
to the fault which occurred. Refer to Table 3-1 following for the charger
LED flash codes and their meaning.
Table 3-1. Battery Charger Fault (LED Flash)
FLASHING LED FAULT REMEDY
AMBER Battery High Voltage
AMBER Batte ry Low Voltage
AMBER Failed Trickle to min V
RED Charger Internal Fault Signals a hardware fault of the charger and shall indicate flashing red LED.
Upon battery voltage >2.5V per cell @ startup, charger shall flash amber LED and not
allow charging - Battery or System problem.
Upon battery voltage <0.17V per cell @ startup, charger shall flash amber LED and
not allow charging - Battery or System problem.
Should battery fail to reach 1.75V per cell charge shall flash an amber LED until charger is power cycled - Battery or System problem.
If required, further general and troubleshooting information about the
battery charger can be found in the charger manufacturers Owner’s
Guide.
3121272 – JLG Lift – 3-21
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
NOTICE
INVERTER
ON
OFF
1001143010A
1
2
3.11 DC TO AC INVERTER OPERATION (OPTION)
Figure 3-13. Location of AC Inverter ON/OFF - Toggle
Switch
1. Inverter ON/OFF Switch 2. Ground Control Panel
1. The AC inverter ON/OFF toggle switch (1) is located on the
machines’ ground control panel (2).
2. When the toggle switch is set to the ON position this will
allow AC current from the inverter to flow to the inverter AC
extension cable plug located at the right rear of the
machine.
The platform AC receptacle box extension cable plug, also
located at the rear of the machine can be plugged into the
inverter AC extension cable, or a device can be plugged
directly into the inverter AC cable at this point.
NOTE: Turn off any device before connecting to inverter AC circuit. Con-
nect devices one at a time to the AC receptacle box. Do not connect to many high-surge devices at once.
IF INVERTER SWITCH IS LEFT ON AND EMERGENCY STOP BUTTON IS NOT
PUSHED IN, POWER WILL DRAIN FROM THE BATTERIES.
3. To turn off the AC current to the platform AC receptacle box,
set the inverter toggle switch to the OFF position.
NOTE: The inverter audible alarm may make a momentary chirp when
the inverter is turned OFF. This same alarm may also sound
when the inverter is being connected to or disconnected from
the 24 volt battery bank.
NOTE: Further General and Troubleshooting information about the
Inverter can be found in the Service Manual for this machine.
3-22 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
NOTICE
1001132362 B
1
2
3.12 PARKING AND STOWING MACHINE
1. Drive the machine to a well-protected and well-ventilated
area.
2. Ensure the platform is fully lowered.
WHEN THE MACHINE IS SHUT DOWN FOR OVERNIGHT PARKING OR BATTERY
CHARGING, THE EMERGENCY STOP AND POWER SELECT SWITCHES MUST BE
POSITIONED TO OFF TO PREVENT DRAINING THE BATTERIES.
3. At the ground control station, turn the platform - ground
selector key switch to OFF and remove the key to disable the
machine and prevent unauthorized use.
NOTE: For added protection, the platform control station can be
secured to it’s mounting plate see Figure 3-14.
4. At the ground control station, depress emergency stop
switch to the off position.
5. If necessary, cover the platform control box, instruction plac-
6. Chock at least two wheels when parking the machine for an
ards, caution and warning decals so that they will be protected from hostile environment.
extended period of time.
To prevent unauthorized removal, the platform control station can
be secured to it’s mount by replacing the lock pin located on it’s
mounting tab with a keyed or combination lock.
Figure 3-14. Securing Control Station to Platform
3121272 – JLG Lift – 3-23
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.13 SCISSOR ARM - SAFETY PROP
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL IT HAS BEEN
RESTRAINED FROM MOVEMENT WITH THE SAFETY PROP, BLOCKING OR
OVERHEAD SLING.
The safety prop is located at the rear of the machine on the rod end of
the lift cylinder located between the scissor arms.
To engage the safety prop:
1. From the Ground Control Station, raise the platform far
enough to allow the safety prop to be engaged on the lift
cylinder rod.
2. Pull out/up on the stop handle to release the safety prop
locking pin.
3. Rotate the prop assembly until it rests on the lift cylinder
rod.
4. Lower the platform until the safety prop rests against the
head of the lift cylinder, stopping all downward movement
of the platform/scissor arm assembly.
To release the safety prop:
1. Raise the platform enough to release the safety prop off the
head of the cylinder.
2. Pull the prop handle downward to restore the prop back to
its released position.
3. Ensure the locking pin to hold the safety prop in the released
position is engaged.
3-24 – JLG Lift – 3121272
Prop Engaged
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Prop Engaged
Prop Released and Locked
Figure 3-15. 1932RS/6RS - Scissor Arm - Safety Prop
Figure 3-16. 3248RS/10RS - Scissor Arm - Safety Prop
Prop Released and Locked
3121272 – JLG Lift – 3-25
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
1
3.14 MACHINE LIFTING AND TIE DOWN
Lifting
The machine may be lifted using a fork lift truck. Lift only from the rear
of the machine and only with the platform in the stowed position.
Adjust the width of the forklift truck, lifting tines (1) to properly fit
the machine, see Figure 3-17.
The machine can also be lifted using a spreader bar and four equal
length straps or chains capable of supporting the full gross weight of
the machine, see Figure 3-18. Lift only using the lifting lugs provided at
the four corners of the machine. (See Section 5 for machine gross weight).
Tie Down
When transporting the machine, the platform must be fully lowered in
the stowed position with the machine securely tied down to the truck
or trailer deck. There are two tie-down/lift lugs located at the front and
rear of the machine. (See Figure 3-19.)
1932RS/6RS
3248RS/10RS
Figure 3-17. Fork Lift Pockets - Location
3-26 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
1
Figure 3-18. Lifting Using Spreader Bar and Lift Lug Locations - All Machines
1. Four (4) equal length chains or lifting straps. 2. Spreader Bar Assembly.
3121272 – JLG Lift – 3-27
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Figure 3-19. Tie Down and Lift Lug Locations - All Machines
3-28 – JLG Lift – 3121272
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
2
1
3.15 TOWING
It is not recommended that this machine be towed, except in the event
of an emergency such as a machine malfunction or a total machine
power failure.
Electric Brake Release
(See Figure 3-20.)
NOTE: Electrical release of the brakes requires enough battery power to
hold the brakes in released mode until destination is reached.
1. Chock wheels or secure machine with tow vehicle.
2. Turn power on in ground mode on the ground control sta-
NOTE: Any action which causes a loss of power from the brakes such as,
tion (1).
3. The brake release switch (2) is located inside the hydraulic
components side cover, remove cover to access the switch.
4. Depress the brake release switch once to release brakes.
5. When finished towing depress brake release switch again or
turn power off at the ground control station to re-engage
the brakes.
depressing the ground control emergency stop switch, or switching the key switch to OFF or PLATFORM MODE will re-engage the
brakes.
Figure 3-20. Electric Brake Release - Location - All Machines
3121272 – JLG Lift – 3-29
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
4
3
Mechanical Brake Release
(See Figure 3-21.)
CHOCK WHEELS OR SECURE MACHINE WITH TOW VEHICLE.
1. At the ground control station turn power off by pressing the
Emergency Stop switch in.
2. Remove the two cover bolts (1), and the cover (2), from
the back of drive motor unit.
3. Insert the cover bolts (1) into the two disengage holes in
the brake housing (4), see Figure 3-21., Brake - Manual Dis-
engage.
4. Tighten down the cover bolts (3) in the disengage holes
and the brake on that drive motor will disengage.
5. Repeat this procedure on opposite wheel drive. With both
drive motor brakes now disengaged the machine can be
moved manually.
6. After towing is complete, chock wheels and remove cover
bolts from disengage holes.
7. Reinstall cover (2) - before installation check the cover gasket (3) for damage, replace if necessary.
AFTER THE MACHINE IS TOWED THE COVER BOLTS (1) MUST BE REMOVED
FROM THE BRAKE DISENGAGE HOLES (4). THE BRAKES CANNOT BE ENGAGED
IF THE DISENGAGE BOLTS ARE LEFT IN THE DISENGAGE HOLES. THIS WILL
CAUSE THE MACHINE TO ROLL WHEN PARKED ON AN INCLINE.
3-30 – JLG Lift – 3121272
Figure 3-21. Brake - Manual Disengage.
SECTION 4 - EMERGENCY PROCEDURES
SECTION 4. EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION
This section explains the steps to be taken in case of an emergency situation during operation.
4.2 EMERGENCY OPERATION
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS UNABLE TO OPERATE OR CONTROL THE
MACHINE:
1. Other personnel should operate the machine from ground
controls only as required.
2. Only qualified personnel in the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS
DO NOT FUNCTION PROPERLY.
3. Rescue equipment can be used to remove the platform
occupant(s). Cranes and forklifts can be used to stabilize
motion of the machine.
Platform Caught Overhead
If the platform becomes jammed or snagged in overhead structures or
equipment, rescue the platform occupant(s) prior to freeing the
machine.
Righting of Tipped Machine
A fork truck of suitable capacity or equivalent equipment should be
placed under the elevated side of the chassis, with a crane or other suitable lifting equipment used to lift the platform while the chassis is lowered by the forklift or other equipment.
4.3 PLATFORM MANUAL DESCENT
The platform manual descent control is used in the event of total
power failure to retract and lower the platform using gravity. The manual descent control T-handle is located on the right rear of the machine,
just in front of the drive wheel. Look for the instruction decal located
beside the release handle.
The lowering procedure is as follows:
1. Locate the manual descent control T-handle.
(See Figure 4-1.)
KEEP HANDS AND ARMS OUT OF THE PATH OF THE SCISSOR ARMS AND PLATFORM WHILE LOWERING.
3121272 – JLG Lift – 4-1
SECTION 4 - EMERGENCY PROCEDURES
NOTICE
2. Grasp the T-handle and slowly pull out to lower the scissor
arms/platform, when the platform is lowered to desired
level, allow the T-handle to return to it’s closed position.
Figure 4-1. Location of Manual Descent Control
(Right Rear of Machine - All Machines)
4.4 INCIDENT NOTIFICATION
JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, JLG
must be contacted by telephone and provided with all necessary
details.
USA: 877-JLG-SAFE (554-7233)
EUROPE: (44) 1 698 811005
AUSTRALIA: (61) 2 65 811111
E-mail: productsafety@jlg.com
Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.
FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE. DO NOT
ELEVATE PLATFORM UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN
REPAIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY. TEST ALL
FUNCTIONS FIRST FROM THE GROUND CONTROL STATION, THEN FROM THE
PLATFORM CONTROL CONSOLE.
4-2 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
SECTION 5. GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION
This section of the manual provides additional necessary information
to the operator for proper operation and maintenance of this machine.
The maintenance portion of this section is intended as information to
assist the machine operator to perform daily maintenance tasks only,
and does not replace the more thorough Preventive Maintenance and
Inspection Schedule included in the Service and Maintenance Manual.
3121272 – JLG Lift – 5-1
Other Publications Available Specific to this Machine:
Service and Maintenance Manual......................................3121273
Illustrated Parts Manual .........................................................3121274
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.2 OPERATING SPECIFICATIONS
Table 5-1. Operating Specifications
DESCRIPTION 1932RS/6RS 3248RS/10RS
PLATFORM
Maximum Platform Height 19 ft. (5.79 m) 32 ft. (9.75 m)
DRIVING
Ma x im u m D r iv e S p ee d Sto wed:
Elevated:
Maximum Stowed Travel Grade (Gradeability)
(Reference Figure 3-8. on page 3-13)
Inside Turning Radius 23.6 in. (0.6 m) 47.2 in. (1.2 m)
Outside Turning Radius 84.4 in. (2.22 m) 124.8 in. (3.17 m)
CHASSIS
Approximate Gross Machine Weight ANSI/CSA/JPN:
CE:
Maximum Tire Load (per wheel) ANSI/CSA/JPN:
CE:
5-2 – JLG Lift – 3121272
3,000 lb. (1,360 kg)
3,450 lb. (1,565 kg)
1,365 lb. (620 kg)
2.5 mph (4 kph)
0.3 mph (0.5 kph)
25% (14°)
5,070 lb. (2,300 kg)
6,050 lb. (2,744 kg)
1,835 lb. (832 kg)
2,070 lb. (940 kg)
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Table 5-1. Operating Specifications (Continued)
DESCRIPTION 1932RS/6RS 3248RS/10RS
CHASSIS (continued)
Ground Bearing Pressure ANSI/CSA/JPN:
CE:
130 PSI (9.18 kg/cm
2
)
Ground Clearance (Chassis Base Plate) 3 in. (76.2 mm) 4 in. (102 mm)
Maximum Hydraulic Pressure (Main Relief) 2300 psi (159 bar) 2500 psi (172 bar)
81 PSI (5.69 kg/cm
108 PSI (7.6 kg/cm
2
)
2
)
3121272 – JLG Lift – 5-3
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Platform Capacities
Table 5-2. Platform Capacities
SPECIFICATION MACHINE MODEL
MAXIMUM
PLATFORM
CAPACITY
MAXIMUM CAPACITY
(1)
ALLOWED ON
PLATFORM EXTENSION
MAXIMUM PERSONS
ALLOWED IN PLATFORM
MAX. SIDE FORCE
(Platform Fully Extended
@ Max. Capacity)
MAXIMUM
OPERATING
WIND SPEED
ANSI/CSA/JPN 1932 500 Lb. (227 Kg) 250 Lb. (113 Kg) 2 100 Lb. (445 N) 28 mph
3248 705 Lb. (320 Kg) 250 Lb. (113 Kg) 2 100 Lb. (445 N) 28 mph
ANSI EXPORT 1932 480 Lb. (218 Kg) 240 Lb. (109 Kg) 2 100 Lb. (445 N) 28 mph
3248 683 Lb. (310 Kg) 236 Lb. (107 Kg) 2 100 Lb. (445 N) 28 mph
CE 6RS 230 Kg 120 Kg Indoor - 2 Persons + 70 Kg 400 N 0 m/s
Outdoor - 1 Person + 150 Kg 200 N 12.5 m/s
10RS 320 Kg 120 Kg Indoor - 2 Persons + 160 Kg 400 N 0 m/s
Outdoor - 1 Person + 240 Kg 200 N 12.5 m/s
NOTE: (1) Maximum Platform Capacity includes platform and platform extension.
5-4 – JLG Lift – 3121272
Machine Dimensional Data
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Table 5-3. Dimensions
DESCRIPTION 1932RS/6RS 3248RS/10RS
Platform Height - Elevated
(Ground to Platform Floor)
Platform Height - Stowed
(Ground to Platform Floor)
Working Height 25 ft. (7.6 m) 38 ft. (11.5 m)
Rail Height
(Platform Floor to Top of Rail)
Rail Height - Folded
(Ground to Mid R ail)
Overall Machine Width 32 in. (81.28 cm) 48 in. (122 cm)
Overall Machine Length
Platform Size - Length 71.7 in. (1.82 m) 84.75 in. (2.15 m)
Platform Size - Width 26.9 in. (68.4 cm) 42.5 in. (1.07 m)
Wheelbase 55 in. (139.7 cm) 73 in. (185.4 cm)
3121272 – JLG Lift – 5-5
19 ft. (5.79 m) 32 ft. (9.75 m)
39.5 in. (100 cm) 54.75 in. (139 cm)
40 in. (101.6 cm)
69.3 in. (176 cm) - CE ONLY
81.4 in. (2.07 m)
41 in. (104.3 cm) - ANSI
43.6 in. (110.7 cm) - CE
78.3 in. (198.9 cm)- ANSI
77.6 in. (197.1 cm) - CE
90 in. (2.28 m) - ANSI
94.8 in. (240.7 cm) - CE
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Tires
Table 5-4. Tire Specifications
DESCRIPTION 1932RS/6RS 3248RS/10RS
Size 12.71 in. x 3.94 in.
(323 mm x 100 mm)
Wheel Bolt Torque 120 ft lb. (163 Nm)
16 in. x 5 in.
(406 mm x 127 mm)
Batteries
Table 5-5. Battery Specifications
DESCRIPTION ALL MACHINES
Voltage (24V System - Series) 6 V per battery
Amp Hour (Standard Battery) 220 Amp Hour @ 20 HR. Rate
Reserve Capacity (Standard Battery) 447 Minutes
Electrical System
Table 5-6. Electrical System Specifications
DESCRIPTION ALL MACHINES
Electrical System Voltage (DC) 24V
Battery Charger: (1001129847)
In p ut : AC In p ut V ol t ag e:
Nominal AC Input Voltage:
Input Frequency:
Max. AC Input Current:
Ingress Protection:
Operatin g Temperature:
Output:
Nominal DC Output Voltage:
Max. DC Output Voltage:
Max DC Output Current:
Max. Interlock Current:
Protection:
Output Reverse Polarity:
Output Short Circuit:
AC Ove rloa d:
DC Overload:
DC t o A C I n ve r te r - O ut p ut R at in g :
(OPTION)
85-265V AC
120VAC / 230VAC RMS
45 - 65Hz
12A - RMS @ 108V AC
IP46 NEMA4 Type 4
-22°F (-30°C) to 122°F (+50°C)
24V
33.6V
25A
1A
Electronic Protection-Auto Reset
Electronic Protection-Auto Reset
Current Li mited
Current Li mited
120V-AC, 60Hz - 7.5 Amps - 900 Watts Mod. Sinewave
5-6 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.3 CRITICAL STABILITY WEIGHTS
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.
Table 5-7. Critical Stability Weights
COMPONENT 1932RS/6RS 3248RS/10RS
Wheel and Tire Assembly (each)
Front:
Wheel/Tire and Drive Assembly
(each)
Batteries (each) Standard:
Batteries (combined) Standard :
21.6 lb. (9.8 kg)
Rear:
21.6 lb. (9.8 kg)
113 lb. (51.3 kg) 134 lb. (60.8 kg)
62 lb. (28.1 kg)
AGM:
AGM:
65 lb. (29.5 kg)
248 lb. (111.1 kg)
260 lb. (118 kg)
43 lb. (19.5 kg)
40.5 lb. (18.4 kg)
5.4 LUBRICATION
Lubrication Capacities
Table 5-8. Capacities
COMPONENT 1932RS/6RS 3248RS/10RS
Hydraulic
Reservoir 1.32 Gal. (5 L) 2.38 Gal. (9 L)
Hydraulic System
(Including
Reservoir)
Hydraulic Oil
Table 5-9. Hydraulic Oil
HYDRAULIC SYSTEM OPERATING
TEMPERATURE RANGE
0° F to +23° F (-18° C to -5° C) 10W
0° F to 210° F (-18° C to + 99° C) 10W-20, 10W-30
50° F to 210° F (+10° C to +210° C) 2 0W-20
NOTE: Aside from JLG recommendations, it is not advisable to mix oils
of different brands or types, as they may not contain the same
required additives or be of comparable viscosities.
1.85 Gal. (7 L) 3.96 G al. (15 L)
SAE VISCOSITY GRADE
3121272 – JLG Lift – 5-7
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Lubrication Specifications
Table 5-10. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F. Excel-
lent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)
EPGL Ex treme Pressure Gear Lube (oil) meeting API service classification GL-5 or
MI L-S pe c M IL- L-2 10 5.
HO JLG Recommends -Mobil DTE 10 EXCEL 15
ATF - Automatic Transmission Fluid
Mobil EAL ENVIRONSYN H 32
Mobil EAL HYDRAULIC OIL 32
Table 5-11. Hydraulic Oil Specifications
SPECIFICATION
MOBIL
DTE 10
EXCEL 15
MOBIL EAL
ENVIRONSYN
H 32
MOBIL EAL
HYDRAULIC OIL 32
ISO Viscosity Grade #15 #32 #32
Spec Gravity API 31.9 0.950 —
Pour Point, M ax
-40° F
(-40° C)
-59° F
(-51° C)
-38.2° F
(-39° C)
Flash Point, Min. 330° F (166° C) 514.4° F (268° C) 478° F (248° C)
VISCOSITY SPECIFICATIONS
at 40° C 15 cSt
at 100° C 4.1 cSt
at 100° F 80 SUS
at 210° F 43 SUS
cp at -30° F 3.2
33.1 cSt 32 cSt
6.36 cSt 7 cSt
——
——
——
Viscosity Index 140 147 189
Operating Temp — -20° F (29° C) - 200° F (392° C)
1001102685_3
5-8 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
1
2
3
4
5.5 MAINTENANCE
Hydraulic Oil Check Procedure
Lube Point(s) - Hydraulic Reservoir
Reservoir Capacity - See Table 5-8.
Lube - Hydraulic Oil
Interval - Check Daily
NOTE: Check the hydraulic oil level with the platform in the stowed
position ONLY. Be certain the hydraulic oil has warmed to operating temperature before checking the oil level in the reservoir.
1. On the left side of the machine, remove the side access
door on the base frame. Locate the hydraulic oil reservoir
(1) on the pump unit (2). Check the oil level in the hydraulic
reservoir by looking at the markings on the side. The reservoir is marked with a MAX (maximum) marking (3). The oil
level must be kept at or within one (1) inch of this marking to
operate properly.
2. If additional oil is required, wipe all dirt and debris from the
filler/breather cap (4) area, add proper grade of oil. Fill until
oil level is close to the MAX marking (3), but not over the
MAX marking.
NOTE: Care should be taken not to introduce any impurities (dirt, water,
etc.) while cap is removed.
Figure 5-1. Hydraulic Oil Check Procedure - All Machines
NOTE: Recommended lubricating intervals are based on machine oper-
ations under normal conditions. For machines used in multi-shift
operations and/or exposed to hostile environments or conditions, lubrication frequencies must be increased accordingly.
3121272 – JLG Lift – 5-9
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
1/8 "
BATTERY
FILLER CAP
FLUID LEVEL OF FULLY
CHARGED BATTERY
VENT TUBE
PLATES
1706740A
5.6 BATTERY MAINTENANCE
Battery Maintenance and Safety Practices
NOTE: These instructions are for unsealed (wet) batteries only.
if machine is equipped with sealed batteries, no maintenance
other than cleaning corroded battery terminals is required.
ENSURE THAT BATTERY ACID DOES NOT COME INTO CONTACT WITH SKIN OR
CLOTHING. WEAR PROTECTIVE CLOTHING AND EYEWEAR WHEN WORKING
WITH BATTERIES. NEUTRALIZE ANY BATTERY ACID SPILLS WITH BAKING
SODA AND WATER.
BATTERY ACID RELEASES AN EXPLOSIVE GAS WHILE CHARGING, ALLOW NO
OPEN FLAMES, SPARKS OR LIGHTED TOBACCO PRODUCTS IN THE AREA
WHILE CHARGING BATTERIES. CHARGE BATTERIES ONLY IN A WELL VENTILATED AREA.
ADD ONLY DISTILLED WATER TO BATTERIES. WHEN ADDING DISTILLED
WATER TO THE BATTERIES, A NON-METALLIC CONTAINER AND/OR FUNNEL
MUST BE USED.
Check the electrolyte level of the batteries often, adding only distilled
water when required. When fully charged, battery fluid level should be
1/8" below vent tubes. (See Figure 5-2.).
• DO NOT fill to bottom of vent tubes.
• DO NOT allow fluid level to go below the top of the plates when
charging or operating.
Figure 5-2. Battery Fluid Level.
Battery Quick-Disconnect (If Equipped)
Machines equipped with the battery quickdisconnect allow all machine power to be easily disconnected at the batteries without
removing battery cables from the battery
posts. To disconnect power, locate the RED quick-disconnect connector
on top of the batteries inside the battery compartment and pull halves
apart.
5-10 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.7 TIRES AND WHEELS
Tire Wear and Damage
The tire and rim assemblies installed on RS machines have been
approved by the tire manufacturer for applications in which those
products are intended to be used. The tire and rims installed on each
product model have been designed for stability requirements, which
consist of track width, tire compound, and load capacity. Tire changes
such as rim width, centerpiece location, larger or smaller diameter, tire
compound, etc., without written manufacturers approval, could result
in an unsafe condition regarding stability.
The tires and rims installed on RS machines are to be inspected daily as
part of the daily walk-around inspection. JLG requires that the daily
walk-around inspection be performed at each operator change during
a shift and at each shift change.
Wheel and Tire Replacement
JLG recommends that any replacement tire be the same size and
brand as originally installed on the machine or offered by JLG as an
approved replacement. Please refer to the JLG Parts Manual for the
part number of the approved tires for a particular machine model.
If any of the following is discovered during tire inspection, measures
must be taken to remove the JLG product from service immediately.
Arrangements must be made for replacement of the tire(s) or tire
assembly(s). Both tires/wheels on the same axle must be replaced:
• If the overall diameter of the tire is less than one of the following:
100 x 323 Tire – 12.25 in. (311mm) minimum
127 x 406 Tire – 15.50 in. (394mm) minimum
• If any uneven wear is discovered.
A tire with significant damage in the tread area or sidewall
requires immediate evaluation before placing the machine into
service. If a cut, tear, chunk, or other discrepancy exceeds any one
or more of the following dimensions, the tire must be replaced:
3.0 in. (76 mm) long
0.75 in. (19 mm) wide
0.75 in. (19 mm) deep
• If the metal wheel is visible at any point through the tread area of
the tire.
• If more than one discrepancy exists in any quadrant of the wheel
(within 90 degrees of one another).
3121272 – JLG Lift – 5-11
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
1
2
3
4
5
2
3
4
6
5
1
Wheel Installation
It is extremely important to apply and maintain proper wheel
mounting torque.
WHEEL LUG NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
TORQUE TO PREVENT LOOSE WHEELS, BROKEN LUG NUTS, AND POSSIBLE
SEPARATION OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE LUG
NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels from coming loose. Use a torque wrench to tighten the fasteners. Over-tightening will result in breaking the lug nuts or permanently deforming the
mounting holes in the wheel. The proper procedure for attaching
wheels is as follows:
1. Start all lug nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
2. Tighten lug nuts in the following sequence. (See Figure 5-3.)
3. The tightening of the lug nuts should be done in stages. Fol-
lowing the recommended sequence, tighten lug nuts per
wheel torque.
4. Wheel lug nuts should be torqued after the first 50 hours of
operation and after each wheel removal. Check torque every
3 months or 150 hours of operation.
5-12 – JLG Lift – 3121272
1st Stage 2nd Stage 3rd Stage
20-30 ft. lb.
(28 - 42 Nm)
5 LUG WHEEL 6 LUG WHEEL
Figure 5-3. Wheel Lug Nut Tightening Sequence
Table 5-12. Wheel Torque Chart
TORQUE SEQUENCE
65-80 ft. lb.
(91 - 112 Nm)
105 -120 ft. lb.
(142 - 163 Nm)
5.8 DECAL INSTALLATION
3
1
2
5
6
7
9
10
11
12
13
14
16
17
19
21
20
22
24
25
(1932/6RS)
25
(3248/10RS)
8
15
4
13
14
26
18
18
23
(3248/10RS)
4
(1932/6RS)
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
3121272 – JLG Lift – 5-13
Figure 5-4. Machine Decal Installation - All Machines
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
ANSI
(FRE)
ANSI
(CHI)
ANSI
(KOR)
CE/JPN
(ALL)
ITEM
ANSI/
CSA
Table 5-13. Machine Decal Installation Chart (See Figure 5-4.)
ANSI
(LAT)
ANSI
(BRZ)
1 1001131270 — 1001131270 1001131270 — — —
2 1701504 1701504 1701504 1701504 1701504 1701504 1701504
3 1701509 1701509 1701509 1701509 1701509 1701509 1701509
4 1001136794 1001136794 1001136794 1001136794 1001136794 1001136794 1001146795
5 1703819 1703819 1703819 1703819 1703819 1703819 1703819
6 1703822 1703822 1703822 1703822 1703822 1703822 1703822
7 1704016 1704016 1704016 1704016 1704016 1704016 1704016
8 1704277 1704277 1704277 1704277 1704277 1704277 1704277
9 1704412 1704412 1704412 1704412 1704412 1704412 1704412
1001147258 -
3248RS/10RS
1001147259 -
1932RS/6RS
10
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
1706311 -
3248RS/10RS
1704134 -
1932RS/6RS
11 1705679 1705679 1705727 1705679 1705679 1705679 —
12 1705686 17 05720 1705726 1705723 (CAN) 1705946 1706057 1001092497
5-14 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Table 5-13. Machine Decal Installation Chart (See Figure 5-4.)
ITEM
13 1705694
14 1705695
15 1001115695 1001115695 1001115695 1001115695 1001115695 1001115695
16 4110226 4110226 4110226 4110226 4110226 4110226 4110226
17 1001132359 1001132359 1001132359 1001132359 1001132359 1001132359 1001132359
18
19 1001132376 1001132376 1001132396 1001132376 1001132376 1001132376 —
20
21 1001134280 1001134280 1001134280 1001134280 1001134280 1001134280 1001134280
ANSI/
CSA
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
ANSI
(LAT)
1705694
1705725 (SPA)
1705695
1705724 (SPA)
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
ANSI
(BRZ)
1705722
1705725 (POR)
1703834
1702724 (POR)
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
ANSI
(FRE)
1705694
1705717 (CAN)
1705695
1705718 (CAN)
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
ANSI
(CHI)
1705694
1705943 (CHI)
1705695
1705944 (CHI)
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
ANSI
(KOR)
1705694
1706052 (KOR)
1705695
1706056 (KOR)
1001132364 -
3248RS/10RS
1705699 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
CE/JPN
(ALL)
1705673
1705671
1001115696 - CE
1001115697- JPN
1001146903 -
3248RS/10RS
1001146902 -
1932RS/6RS
1001133159 -
3248RS/10RS
1001137394 -
1932RS/6RS
3121272 – JLG Lift – 5-15
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
Table 5-13. Machine Decal Installation Chart (See Figure 5-4.)
ITEM
ANSI/
CSA
ANSI
(LAT)
ANSI
(BRZ)
ANSI
(FRE)
ANSI
(CHI)
ANSI
(KOR)
CE/JPN
(ALL)
22 1706350 1706350 1706350 1706350 1706350 1706350 170635014
23 1703072 1703072 1703072 1703072 1703072 1703072 1703072
24 — 1705719 (SPA) 1705719 (POR) 3253098 (CAN) 1705945 (CHI) 1706053 (KOR) —
25 1703464 1703464 1703464 1703464 1703464 1703464 3252507
26 1705303 (CSA) ————— —
NOTE: Reference applicable Illustrated Parts Manual for decal description.
5-16 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
NOTICE
5.9 DIAGNOSTIC TROUBLE CODES (DTC)
The DTC tables following are sorted in groups by the first two digits,
these digits represent the number of flashes the system distress indicator lamp will flash on the platform indicator panel when a fault occurs.
For example: a “2-1 Power-Up” on page 19 would be indicated by 2
flashes, a pause, then 1 flash, a pause, then would keep repeating until
the fault is cleared.
The more detailed three digit code numbers in the DTC column of the
following tables are only indicated on a JLG handheld diagnostic analyzer.
To troubleshoot multiple DTCs, start with the DTC with the higher first
two digits. If a correction is made during a check, conclude the
check by cycling the machine power off then back on, using the
emergency stop switch.
SHOULD A FAULT OCCUR WHICH CANNOT BE CORRECTED BY THE OPERATOR,
THE PROBLEM MUST BE REFERRED TO A MECHANIC QUALIFIED TO REPAIR
THIS MODEL OF JLG LIFT.
5.10 DTC CHECK TABLE INDEX
DTC TABLE PAGE
0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
2-2 Platform Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
2-5 Function Prevented . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-1 Line Contactor Open Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-2 Line Contactor Short Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-24
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-25
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-26
8-2 LSS - Load Sensing System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-27
8-4 Elevation Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
9-9 Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-28
3121272 – JLG Lift – 5-17
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.11 DIAGNOSTIC TROUBLE CODES (DTC) CHECK TABLES
0-0 Help Comments
DTC FAULT MESSAGE DESCRIPTION CHECK
001 EVERYTHING OK The normal help message in platform mode.
Displays on the analyzer only.
002 GROUND MODE OK The normal help message in ground mode.
Displays on the analyzer only.
004 DRIVING AT CUTBACK - ABOVE ELEVA-
TION
005 DRIVE & LIFT UP PREVENTED - TILTED &
ELEVATED
008 FUNCTIONS LOCKED OUT - SYSTEM
POWERED DOWN
The platform is elevated and the machine is in
the driving in creep speed.
Driving is not possible since the platform is
elevated and the chassis is not level.
After 2 hours without activity, the control system enters a low-power st ate to preser ve battery c harge.
• Fully stow the platform.
• Check that the elevation sensor is securely mounted.
Refer problem to a qualified JLG mechanic.
• Check that the machine is tilted. If so, lower the platform and reposition the
machine to a level surface.
• Fully stow the platform.
• Check that the tilt sensor is securely mounted.
• Check that the elevation sensor is securely mounted.
Refer problem to a qualified JLG mechanic.
• Normal operation should resume after power is cycled off then back on.
• Check batteries charge, condition, etc.
Refer problem to a qualified JLG mechanic.
5-18 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
2-1 Power-Up
DTC FAULT MESSAGE DESCRIPTION CHECK
211 POWER CYCLE This help message is issued at each power
cycle. Displays on the analyzer only.
Normal operation. No check necessary.
2-2 Platform Controls
DTC FAULT MESSAGE DESCRIPTION CHECK
221 FUNCTION PROBLEM - HORN PERMA-
NENTLY SELECTED
223 FUNCTION PROBLEM - DRIVE & LIFT
ACTIVE TOGETHER
224 FUNCTION PROBLEM - STEER LEFT PER-
MANENTLY SELECTED
225 FUNCTION PROBLEM - STEER RIGHT
PERMANENTLY SELECTED
226 ACCELERATOR FAULTY - WIPER OUT OF
RANGE
227 STEER SWITCHES FAULTY The steer left and steer right inputs were
3121272 – JLG Lift – 5-19
The horn switch was closed during power-up
in platform mode.
The drive and lift inputs are closed simultaneously in platform mode.
The steer left switch was closed during powerup in platform mode.
The steer right switch was closed during
power-up in platform mode.
There is a problem with the joystick. • Center joystick and check to see if a power cycle will clear DTC.
closed simultaneously.
• Check if the horn switch is damaged, obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check drive/lift switch for visible damage.
Refer problem to a qualified JLG mechanic.
• Check if the steer left switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check if the steer right switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
• Check if the steer switches are damaged, obstructed or jammed.
Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
2-2 Platform Controls
DTC FAULT MESSAGE DESCRIPTION CHECK
228 FUNCTION LOCKED OUT - ACCELERATOR
NOT CENTERED
229 FUNCTION PROBLEM - TRIGGER PER-
MANENTLY CLOSED
2210 TRIGGER CLOSED TOO LONG WHILE IN
NEUTRAL
2232 FUNC TION PROBLEM - DRIVE & LIFT
BOTH OPEN
The joystick was not centered at power-up. • Release joystick and allow to center.
• Check if the joystick is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
The trigger switch was closed during powerup in platform mode.
The trigger switch was closed for more than
five seconds while the joystick was centered.
The drive and lift inputs are both de-energized
in platform mode.
• Check if the trigger switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check if the trigger switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check if either function is active, if Yes;
Refer problem to a qualified JLG mechanic.
2-3 Ground Controls
DTC FAULT MESSAGE DESCRIPTION CHECK
231 FUNCTION PROBLEM - LIFT PERMA-
NENTLY SELECTED
232 GROUND LIFT UP / DOWN ACTIVE
TOGETHER
233 FUNCTION PROBLEM - BRAK E RELEASE
PERMANENTLY SELECTED
5-20 – JLG Lift – 3121272
The ground control box lift switch was closed
up or down, during power-up in ground mode.
The lift up / down inputs are closed simultaneously.
The electric brake release switch was closed
during power-up.
• Check if the lift switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check if the lift switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Check if the brake release switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
2-5 Function Prevented
DTC FAULT MESSAGE DESCRIPTION CHECK
253 DRIVE PREVENTED - CHARGER CON-
NECTED
254 DRIVE & LIFT UP PREVENTED - CHAR-
GER CONNECTED
255 PLATFORM OVERLOAD The Load Sensing System (LSS) measured
258 DRIVE & LIFT PREVENTED - BRAKES
ELECTRICALLY RELEASED FOR TOWING
259 MODEL CHANGED - HYDRAULICS SUS-
PENDED - CYCLE EMS
2510 DRIVE PREV ENTED - BRAKES NOT
RELEASING
Driving is not possible while the vehicle is
charging.
Drive or lift is not possible while the vehicle is
charging AND is configured to prevent all
motion.
platform load is excessive.
Electric brake release mode is activated with
the switch in the battery box near the ground
control box. Drive or lift is not possible.
The model selection has been changed. Refer problem to a qualified JLG mechanic.
There is a problem with the drive or brake system.
• Check if the charger is connected to off board power source and disconnect if
desired.
Refer problem to a qualified JLG mechanic.
• Check if the charger is connected to off board power source and disconnect if
desired.
Refer problem to a qualified JLG mechanic.
• Remove excess weight from the platform.
• Check that platform is not caught on something, preventing up or down
movement.
Refer problem to a qualified JLG mechanic.
• Push manual brake release switch again or cycle power to clear manual brake
release mode.
• Check if the brake release switch is obstructed or jammed.
Refer problem to a qualified JLG mechanic.
• Ensure vehicle is not stuck on something preventing movement.
Refer problem to a qualified JLG mechanic.
3121272 – JLG Lift – 5-21
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
3-1 Line Contactor Open Circuit
DTC FAULT MESSAGE DESCRIPTION CHECK
311 OPEN CIRCUIT LINE CONTACTOR There is a problem with the line contactor. Refer problem to a qualified JLG mechanic.
314 AUXILIARY RELAY - OPEN CIRCUIT The auxiliary relay did not close when ener-
gized.
• Check the auxiliary relay coil and the as sociated wiring.
Refer problem to a qualified JLG mechanic.
3-2 Line Contactor Short Circuit
DTC FAULT MESSAGE DESCRIPTION CHECK
321 LINE CONTACTOR MISWIRED ON OR
WELDED
326 AUXILIARY RELAY - SHORT TO BATTERY There is a problem with the auxiliary relay con-
There is a problem with the line contactor. Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
tacts or wiring.
3-3 Ground Output Driver
DTC FAULT MESSAGE DESCRIPTION CHECK
333 LIFT UP SHORT TO BATTERY A problem has been detec ted in this function. Refer problem to a qualified JLG mechanic.
334 LIFT UP OPEN CIRCUIT A problem has been detected in this func tion. Refer problem to a qualified JLG mechanic.
335 LIFT DN SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
5-22 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
3-3 Ground Output Driver
DTC FAULT MESSAGE DESCRIPTION CHECK
336 LIFT DN OPEN CIRCUIT A problem has been detected in this func tion. Refer problem to a qualified JLG mechanic.
337 STEER LEFT SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
338 STEER LEFT OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
339 STEER RIGHT SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3310 STEER RIGHT OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3312 LEFT BRAK E SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3313 RIGHT BRAKE SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3314 LEFT BRAK E OPEN CIRCUIT A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3315 RIGHT BRAKE OPEN CIRCUIT A problem has been detected in this func tion. Refer problem to a qualified JLG mechanic.
3349 LINE CONTACTOR COIL - SHORT TO
GROUND
33297 LEFT BR AKE - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
33298 STEER LEFT VALVE - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
33299 LI NE CONTACTOR COIL - SHORT TO BAT-
TERY
33302 NEGATIVE SUPPLY - SHORT TO BATTERY A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
33303 NEGATIVE SUPPLY - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
3121272 – JLG Lift – 5-23
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
3-3 Ground Output Driver
DTC FAULT MESSAGE DESCRIPTION CHECK
33304 RIGHT BR AKE - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
33305 STEER RIGHT VALVE - SHORT TO
GROUND
33406 LI FT UP VALVE - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
33407 LI FT DN VALVE - SHORT TO GROUND A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
A problem has been detected in this function. Refer problem to a qualified JLG mechanic.
4-2 Thermal Limit (SOA)
DTC FAULT MESSAGE DESCRIPTION CHECK
421 POWER MODULE TOO HOT - PLEASE
WAI T
422 DRIVING AT CUTBACK - POWER MOD-
ULE CURRENT LIMIT
423 LIFT UP AT CUTBACK - POWER MODULE
CURRENT LIMIT
The power module has reached thermal cutout.
The drive portion of the power module has
reached thermal limit.
The lift up portion of the power module has
reached thermal limit.
• Power down and allow to cool.
• Do not operate in ambients over 140° F (60° C).
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
5-24 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
4-4 Battery Supply
DTC FAULT MESSAGE DESCRIPTION CHECK
441 BATTERY VOLTAGE TOO LOW - SYSTEM
SHUTDOWN
442 BATTERY VOLTAGE TOO HIGH - SYSTEM
SHUTDOWN
446
LOGIC SUPPLY VOLTAGE OUT OF RANGE The System Module logic supply voltage was
4421
4422
A problem has been detected with the batteries or power module.
A problem has been detected with the batteries or power module.
m e a s u r e d t o b e o u t o f n o r m a l o p e r a t i n g r a n g e .
• Recharge batteries or check for damaged batteries.
• Check battery charger function.
Refer problem to a qualified JLG mechanic.
• May be due to improper battery charging or incorrect voltage batteries being
used.
Refer problem to a qualified JLG mechanic.
• Check for severely discharged battery, loose cables or for damaged battery;
otherwise;
• Refer problem to a qualified JLG mechanic.
6-6 Communication
DTC FAULT MESSAGE DESCRIPTION CHECK
661 CANBUS FAILURE - POWER MODULE The control system failed to receive messages
from the power module.
6643 CANB US FAILURE - LSS ANGLE SENSOR The control system failed to receive messages
from the angle sensor.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
3121272 – JLG Lift – 5-25
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
7-7 Electric Motor
DTC FAULT MESSAGE DESCRIPTION CHECK
772 STALLED TRACTION MOTOR OR POWER
WIRING ERROR
773 CAPACITOR BANK FAULT - CHECK
POWER CIRCUITS
774 SHORT CIRCUIT FIELD WIRING The power module detected a problem in the
775 OPEN CIRCUIT FIELD WIRING The power module detected a problem in the
776 STALLED PUMP MOTOR OR POWER
WIRING ERROR
777 OPEN CIRCUIT PUMP MOTOR WIRING The power module detected a problem in the
778 TRACTION T HIGH - CHECK POWER CIR-
CUITS
779 TRACTION T LOW - CHECK POWER CIR-
CUITS
7710 PUMP P HIGH - CHECK POWER CIRCUITS The power module detected a problem in the
The power module detected a problem in the
drive motors' power circuit wiring.
The power module detected a problem in the
pump or drive motors' power circuit wiring.
drive motors' power circuit wiring.
drive motors' power circuit wiring.
The power module detected a problem in the
drive motors' power circuit wiring.
drive motors' power circuit wiring.
The power module detected a problem in the
drive motors' power circuit wiring.
The power module detected a problem in the
drive motors' power circuit wiring.
drive motors' power circuit wiring.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
5-26 – JLG Lift – 3121272
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
7-7 Electric Motor
DTC FAULT MESSAGE DESCRIPTION CHECK
7711 PUMP P LOW - CHECK POWER CIRCUITS The power module detected a problem in the
drive motors' power circuit wiring.
7741 ARMATURE BRAKING CURRENT TOO
HIGH
7742 FIELD VOLTAGE IMPROPER The power module detected a problem in the
The power module has detected excessive
braking current.
drive motors' power circuit wiring.
Refer problem to a qualified JLG mechanic.
Th i s c a n b e c a us e d b y t r an s po r ti n g a n ex ce s si ve l oa d o n a s t ee p g r ad e.
Recycle power on/off, if problem persists;
Refer problem to a qualified JLG mechanic.
8-2 LSS - Load Sensing System
DTC FAULT MESSAGE DESCRIPTION CHECK
8212 LSS PRESSURE SENSOR -
DISAGREEMENT
8213 LSS ANGLE SENSOR -
DISAGREEMENT
8214 LSS ANGLE SENSOR -
DIRECTION DISAGREEMENT
3121272 – JLG Lift – 5-27
Pressure Sensor 1 and Pressure Sensor 2 do not
agree. The system shall assume the machine is
overloaded until the sensors agree.
The angle sensor’s change in reading does not
agree with the direction of themachine
motion (lift up).
The angle sensor’s reading when the machine
is at maximum elevation does not fall within
the high end acceptable range.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
8-2 LSS - Load Sensing System
DTC FAULT MESSAGE DESCRIPTION CHECK
8215 LSS ANGLE SENSOR -
OUT OF RANGE LOW
8216 LSS ANGLE SENSOR HAS NOT BEEN CAL-
IBRATED
The angle sensor’s reading when the machine
is stowed does not fall within the low end
acceptable range.
The Angle Sensor has never been calibrated
and the control system assumes that the platform is overloaded.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
8-4 Elevation Switch
DTC FAULT MESSAGE DESCRIPTION CHECK
84109 ELE VATION SWITCH CONTACTS DIS-
AGREEMENT
The elevation switch is repeating an incorrect
value.
Refer problem to a qualified JLG mechanic.
9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
995 POWER MODULE FAILURE - PERSONAL-
ITY RANGE ERROR
996 POWER MODULE FAILURE - INTERNAL
ERROR
5-28 – JLG Lift – 3121272
A problem has been detected with the power
module.
A problem has been detected with the power
module.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
998 EEPROM FAILURE - CHECK ALL SET-
TINGS
999 FUNCTION LOCKED OUT - POWER MOD-
ULE SOFTWARE VERSION IMPROPER
The control system detected an EEPROM failure.
The power module software version i s not
compatible with the rest of the system.
Refer problem to a qualified JLG mechanic.
Refer problem to a qualified JLG mechanic.
3121272 – JLG Lift – 5-29
SECTION 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
9-9 Hardware
DTC FAULT MESSAGE DESCRIPTION CHECK
POWER MODULE FAILURE - INTERNAL
9950
9951
ERROR
9952
9953
9954
9955
9956
9957
9958
9960
9962
9963
9964
9969
9970
9971
99143
99144
99145
99146
99147
99148
99149
A problem has been detected with the power
module.
Cycle machine power on /off a few times if this doesn’t clear the DTC,
refer problem to a qualified JLG mechanic.
5-30 – JLG Lift – 3121272
SECTION 6. INSPECTION AND REPAIR LOG
Machine Serial Number _____________________________________ __
Table 6-1. Inspection and Repair Log
DATE COMMENTS
SECTION 6 - INSPECTION AND REPAIR LOG
3121272 – JLG Lift – 6-1
SECTION 6 - INSPECTION AND REPAIR LOG
DATE COMMENTS
Table 6-1. Inspection and Repair Log
6-2 – JLG Lift – 3121272
JLG Industries, Inc.
31212
7
2
1 JLG Drive
McConnellsburg PA. 172339533
USA
JLG Worldwide Locations
JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia
+61 2 65 811111
+61 2 65 813058
JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany
+49 (0)421 69 350 20
+49 (0)421 69 350 45
Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P. I. C as t el l bi s ba l Su r
08755 Castellbisbal, Barcelona
Spain
+34 93 772 4700
+34 93 771 1762
JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong
JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden
(717) 485-5161
(717) 485-6417
+55 19 3295 0407
+55 19 3295 1025
(852) 2639 5783
(852) 2639 5797
+46 (0)850 659 500
+46 (0)850 659 534
JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England
+44 (0)161 654 1000
+44 (0)161 654 1001
JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy
+39 029 359 5210
+39 029 359 5845
JLG France SAS
Z.I. de Fauillet
47400 Tonneins
Franc e
+33 (0)5 53 88 31 70
+33 (0)5 53 88 31 79
Oshkosh - JLG Singapore T. E. P. Ltd.
29 Tuas Ave 4
Jurong Industrial Estate
639379
Singapore
+65-6591-9030
+65-6591-9031
www.jlg.com
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