JLG Commander CM1432 Setup guide

WORLD HEADQUAR'I'ERS
JLG INDUSTRIES, INC.
JLGDI'Ive
McConnellsbu4 M 17233·9502
USA
,...,.,.. [phone]
Fu [phone]
,I
,.
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MODELS
CM1432
CM1432 PLUS
CM1732
CM2033
CM2046
CM2546
CM2558
CHANGE 2 DECEMBER 1995
15 DECEMBER 1992
OPERATORS & SAFETY
SERVICE & MAINTENANCE
ILLUSTRATED PARTS MANUAL
PRINTED IN U.S.A.
3120587
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FOREWORD
The purpose of this manual is to provide the customer with the operating procedures essential for the
promotion of proper machine operation for its intended purpose.
It is important to over-stress proper usage.
All information in this manual should be READ and UNDERSTOOD before any attempt is made to operate
the machine.
YOUR OPERATING MANUAL IS YOUR MOST IMPORTANTTOOL- Keep itwith the machine.
SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, CONFORMANCE WITH GOOD SAFETY PRACTICE IN THIS AREA IS THE RESPON-
SIBILITY
OF THE USER AND HIS OPERATING PERSONNEL.
ALLPROCEDURES HEREIN ARE BASED
ON THE USE OF THE MACHINE UNDER PROPER OPERAT-
ING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGNAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINEISSTRICTLY FORBIDDEN WITHOUTWRITTEN APPROVAL FROM
JLG INDUSTRIES, INC.
A MOSTIMPORTANTFACT TO REMEMBER ISTHATANY EQUIPMENTISONLYASSAFEASTHOSE
WHO OPERATE IT.
DANGER, WARNING, CAUTION, IMPORTANT, INSTRUCTIONS AND NOTE DEFINITIONS
Since safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING,
CAUTION, IMPORTANT, INSTRUCTIONS and NOTES are inserted throughout this manual to emphasize
these areas. They
are defined as follows:
DANGER
IFNOT CORRECTLY FOLLOWED THERE IS A HIGH PROBABILITY OF SERIOUS INJURY OR DEATH
TO PERSONNEL.
WARNING or CAUTION
IF NOT CORRECTLY FOLLOWED THERE IS
SOME POSSIBILITY OF SERIOUS INJURY OR DEATH
TO PERSONNEL.
THE "SAFETY ALERT SYMBOL" IS
USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO DEATH OR SERIOUS INJURY IFIGNORED.
IMPORTANT
OR INSTRUCTIONS
DENOTES PROCEDURES ESSENTIAL
TO SAFE OPERATION AND PREVENTION OF DAMAGE TO
OR DESTRUCTION OF MACHINE.
Note
Provides information
of special interest to illustratethetext.
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JLGSizzor INTRODUCTION -OPERATION SAFETY PRECAUTIONS JLGSizzor
All procedures herein are based on the use of the
machine under proper operating conditions, with no
deviations from original design intent
•.. as per OSHA
regulations.
READ &HEED!
The ownership, use, service, and/or maintenance of this
machineis subjecttovarious federal, state and local laws
and regulations. It is the responsibility of the owner/user
to be knowledgeable of these laws and regulations and
to comply with them. The most prevalent regulations of
this type are the Federal OSHA Safety Regulations*.
Listed below, in abbreviatedform aresome oftherequire-
ments of Federal OSHA regulations
in effect as of the
date of publication of this handbook.
The listing of these requirements shall not relieve the
owner/user of the responsibility and obligation to deter-
mine all applicable laws and regulations and their exact
wording and requirements, and to comply with the re-
quirements. Nor shall the listing of these requirements
constitute an assumption of responsibility of liability
on
the part of JLG Industries, Inc.
1. Only trained and authorized operators shall be per-
mitted to operate the aerial lift.
2. A malfunctioning liftshall beshut down until repaired.
3. The controls shall be plainly marked as to their
function.
4. The controls shall be tested each day prior to use to
determine that they are
in safe operating condition.
5. When applicable to local regulations or job site/em-
ployersafety rules, all personnel in the platform shall
wear an approved safety belt with the lanyard at-
tached to the platform attachment point.
6. Load limits specified by the manufacturer shall not
be exceeded.
7. Instruction and warning placards must be legible.
8. Aerial lifts may be "field modified"foruses otherthan
those intended by the manufacturer only if certified
in writing bythe manufacturer or an equivalententity,
such as a nationally recognized testing lab, to be in
conformity to applicable OSHA safety regulations
and to be at least as safe as it was prior to modifica-
tion.
9. Aerial lifts shall notbe used nearelectric power lines
unless the lines have been deenergized or adequate
clearance is maintained (see OSHA 20 CFR 191 0.67
and 1926.400).
10. Employees using aerial lifts shall be instructed how
to recognize and avoid unsafe conditions and haz-
ards.
11. Ground controls shall notbe operated unlesspermis-
sion has been obtained from personnel in the plat-
form, except in case of an emergency.
12. Regular inspection ofthe job site and aerial lift shall
be performed by competent persons.
13. Personnel shall always stand
on the floor of the
platform, not on boxes, planks, railing or other de-
vices for a work position.
*Applicable Federal OSHA regulations, as of the date of
publication of this manual include, but are not limited to,
29 CFR 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29
CFR 1926.28, 29 CFR 1926.400 and 29 CFR 1926.556.
Consultthe current regulations for the exactwording and
full text of the requirements and contact the closest
Federal OSHA office for specific interpretations.
-JLGSizzor -a
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JLGSizzor INTRODUCTION -MAINTENANCE SAFETY PRECAUTIONS JLGSizzor
A. GENERAL.
1. This section contains the general safety
precautions which must be observed during
maintenance of the aerial platform. It is of ut-
most importance that maintenance personnel
pay strict attention to these warnings and
precautions to avoid possible injuryto themsel-
ves or others or damage to the equipment. A
maintenance program must be established by
a qualified person and must
be followed to
ensure that the machine is safe to operate.
WARNING
MODIFICATION OF THE MACHINE WITHOUT
CERTIFICATION BY A RESPONSIBLE
AUTHORITY THAT THE MACHINE IS
AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS
A SAFETY VIOLATION.
2. The specific precautions to be observed during
machine maintenance are inserted at the ap-
propriate point in the manual. These precau-
tions are, for the most part, those that apply
when servicing hydraulic and larger machine
component parts. ·
3. Your saf~ty. and that of others, is the first con-
sideration when engaging in the mainenance of
equipment. Always be conscious of weight.
Never attempt to move heavy parts without the
aid of a mechanical device.
Do notallow heavy
objects to rest in
an unstable position. When
raising a portion of the equipment, ensure that
adequate support is provided.
WARNING
SINCETHE MACHINEMANUFACTURERHASNO
DIRECT CONTROL OVER THE FIELD INSPEC-
TION AND MAINTENANCE, SAFETY IN THIS
AREA IS THE RESPONSIBILITY OF THE
OWNER/OPERATOR.
B. HYDRAULIC SYSTEM SAFETY.
1. It should be particularly noted that the
machines hydraulic systems operate at ex-
tremely high and potentially dangerous pres-
sures. Every effort should be made to relieve
any system pressure prior to disconnecting or
removing any portion ofthe system.
2. Relieve system pressure by cycling the ap-
plicable control several times with the engine
stopped and ignition
on, to direct any line pres-
sure back into the return line to the reservoir.
Pressure feed lines to system components can
then be disconnected with minimal fluid loss.
C. MAINTENANCE.
WARNING
FAILURE TO COMPLY WITH SAFETY PRECAU-
TIONS LISTEDINTHISSECTION MAYRESULT IN
MACHINE DAMAGE, PERSONNEL INJURY OR
DEATH AND IS A SAFETY VIOLATION.
REMOVE ALL RINGS, WATCHES, AND JEWEL-
RY WHEN PERFORMING ANY MAINTENANCE.
DO NOT WEAR LONG HAIR UNRESTRAINED,
OR LOOSE FITTING CLOTHING AND NECKTIES
WHICH
ARE APT TOBECOME CAUGHT ON OR
ENTANGLED IN EQUIPMENT.
OBSERVE AND OBEY ALL WARNINGS AND
CAUTIONS ON MACHINE AND IN SERVICE
MANUAL.
KEEP OIL, GREASE, WATER, ETC. WIPED
FROM STANDING SURFACES AND HAND
HOLDS.
NEVER WORK UNDER AN ELEVATED PLAT-
FORM UNTIL SAFETY PROPS HAVE BEEN
ENGAGED
OR PLATFORM HAS BEEN SAFELY
RESTRAINED FROM ANY MOVEMENT BY
BLOCKING OR OVERHEAD SLING.
BEFORE MAKING ADJUSTMENTS, LUBRICAT-
. lNG OR PERFORMING ANY OTHER MAIN-
TENANCE, SHUT OFF ALL POWER CONTROLS.
BATTERY SHOULD ALWAYS BE DISCON-
NECTED DURING REPLACEMENTOF ELECTRI-
CAL COMPONENTS.
KEEP ALL SUPPORT EQUIPMENT AND AT-
TACHMENTS STOWED IN THEIR PROPER
PLACE.
USE ONLY APPROVED, ·NONFLAMMABLE
CLEANING SOLVENTS.
b -JLGSizzor -
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December 1992 -Original Issue
March 1993 -Revised
July 1994 -Revised
January 1995 -Change 1
Pages Affected:
Cover
CM1432-2558
3120587 PARTS MANUAL
REVISION LOG
Table of Contents -Page iii and Page iv
Section 1
0 - Pages 1 0-1 and 10-2
Section 11 -Table of Contents -Page 11-0-1
Section
11-1 -Pages 11-1-4, 11-1-5, 11-1-12 and 11-1-13
Section 11-2 -Pages 11-2-1, 11-2-4, 11-2-9, 11-2-19 to 11-2-23
Section
11-4- Pages 11-4-7,11-4-12,11-4-13,11-4-15,11-4-19,11-4-21 to 11-4-23
Section 11-6 -Pages 11-6-3, 11-6-5, 11-6-7 and 11-6-8
Section
11-7- Pages 11-7-1, 11-7-58, 11-7-10, 11-7-11
Section 11-8 -Pages 11-8-4 and 11-8-5
Section 12 -Page 12-1
Section 13- Table of Contents- Page 13-0-1
Section 13-1 -Pages 13-1-13, 13-1-19 to 13-1-15
Section 13-2 -Pages 13-2-7, 13-2-11
Section 13-3 -Page 13-3-5
Section 13-4 -Pages 13-4-3 to 13-4-5, 13-4-7, 13-4-11, 13-4-13 to 13-4-15
Section 13-6 -Pages 13-6-3, 13-6-4
Section 13-7- Pages 13-7-1,13-7-5,13-7-10, 13-7-11
Section 13-8 -Page 13-8-5
December 1995 -Change 2
Pages Affected:
Cover
Revision Log -Page c/d
Section 11-1 -Pages 11-1-3 to 11-1-5, 11-1-9 and 11-1-11 to 11-1-12
Section 11-2- Pages 11-2-4to 11-2-7, 11-2-11 and 11-2-15
Section 11-3 -Pages 11-3-3, 11-3-5, 11-3-7 and 11-3-8
Section 11-4 -Pages 11-4-5, 11-4-7, 11-4-13, 11-4-15 and 11-4-21 to 11-4-23
Section 11-5 -Page 11 -5-9
Section 11-6 -Pages
11 -6-5 and 11-6-8
Section
11-7- Pages 11-7-2to 11-7-9
Section 11-8 -Pages 11-8-2 to 11-8-4
Section 13-1 -Pages 13-1-3, 13-1-7 and 13-1-10
Section 13-2- Pages 13-2-2, 13-2-5, 13-2-7 and 13-2-12
Section 13-3 -Pages 13-3-2, 13-3-3 and 13-3-5
Section 13-4- Pages 13-4-3, 13-4-4, 13-4-7, 13-4-13 and 13-4-14
Section 13-5 -Page 13-5-9
Section 13-7 -Pages 13-7-2 to 13-7-9
Section 13-8 -Pages 13-8-2, 13-8-3 and 13-8-5
Change 1 c/d Blank
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JLGSizzor TABLE OF
CONTENTS JLGSizzor
TABLE OF CONTENTS
SUBJECT- SECTION, PARAGRAPH PAGE NO.
INTRODUCTION- OPERATION SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . a
I~TRODUCTION -MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . b
TABI_E OF CONTENTS ...................... ; .......................... .
LIST OF ILLUSTRATIONS ......................... , ..................... :. iii
LIST OFTABLES ...... ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iv
SECTION 1 -SAFETY PRECAUTIONS
1-1. General............................................................... 1-1
1-2. Drivingffowing/Carrying.................................................. 1-1
1-3. Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-4. Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1-5. Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . • . . 1-4
1-6. Operation . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . 1-5
1-7. Towing and Hauling .............................. , . . . . . .. . . . . . . . . . . . . . . . . 1-9
1-8. Maintnenace ... : ......................... ~............................. 1-10
SECTION 2- PREPARATION AND INSPECTION
2-1. General . . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . 2-1
2-2. Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3. Delivery and Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-4. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-5. Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2-6. Torque Requirements.................................................... 2-3
2-7. Battery Charging . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . .. . . . . . . 2-3
SECTION 3- USER RESPONSIBILITIES AND MACHINE CONTROL
3-1. General ........................... ·. . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . 3-1
3-2. Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3. Operating Characteristics and Limitations . . . .. . . . . . . . . . . . .. . . . . . . . . . . . . . . .. . . 3-1
3-4. Controls and Indicators . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
SECTION 4- MACHINE OPERATION
4-1. Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-2. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3. MotorOperation ......................................... , . . . . . . . . . . . . . . 4-1
4-4. Raising and Lowering (Lifting) . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . . .. . . . . . . . . . . . . 4-2
4-5. Platform Extension (If Equipped) . . .. . . . . . . . . . . . . . .. . . . . . . . . . . . .. . . . . . . . . . . . 4-2
4-6. Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-7. Traveling (Driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4-8. Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-9. Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-1 0. Safety Prop ......................... ·. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-11. Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-12. Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
SECTION 5- OPTIONAL EQUIPMENT
5-1. PQ Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2. Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . 5-1
5-3. Travel Alarm ........... :. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-4. Motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . 5-1
5-5. Descent Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
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JLGSizzor
TABLE OF CONTENTS
TABLE OF CONTENTS (cont.)
SUBJECT-SECTION, PARAGRAPH
SECTION 5- OPTIONAL EQUIPMENT (cont.)
5-6.
5-7.
5-8.
5-9.
5-10.
5-11.
5-12.
5-13.
5-14.
5-15.
Platform Receptacle ......................................... , ........ .
Platform Work Lights ....•.............................................
Non-Marking Tires ................................................... .
Rotating Beacon
.................................................... .
High Output Batteries (CM2046, CM2546 and CM2558 Only)
................. .
Battery Condition Indicator . ,
.. ~ ....................................... .
Fold-Down Hand Rails ................................................ .
Control Box Cover ................................................... .
Platform Access Door ................................................ .
Lifting Lugs
.......................................................... .
SECTION 6- EMERGENCY PROCEDURES
6-1.
6-2.
6-3.
6-4.
6-5.
General ........................................................... .
Emergency Towing Procedures
......................................... .
Emergency Controls and Their Locations
................................. .
Emergency Operation
................................................ .
Incident Notifications ................................................. .
SECTION 7- SPECIFICATIONS
7-1.
7-2.
7-3.
7-4.
7~5.
7-6.
7-7.
7-8.
7-9.
7-10.
Capacities
......................................................... .
Component Data
...•...................................................
Performance Data ................................................... .
Torque Requirements
................................................ .
Lubrication
................................................... · ...... .
CylinderSpecifications ............................................... .
Pressure Settings
.................................................... .
Serial Number Locations .............................................. .
Limit Switches
...................................................... .
Major Component Weights
............................................ .
SECTION 8- PROCEDURES
8-1.
8-2.
8-3.
8-4.
8-5.
8-6.
8-7.
8-8.
8-9.
8-10.
8-11.
8-12.
8-13.
8-14.
8-15.
General ........................................................... .
Servicing and Maintenance Guidelines
................................... .
Lubrication Information
............................................... .
Cylinders -Theory ofOperation ......................................... .
Valves -Theory of Operation ........................................... .
Component Functional Description
...................................... .
Wear Pads
........................•.................................
Cylinder Checking Procedures ......................................... .
Cylinder Removal and Installation ....................................... .
Cylinder Repair (Except Brake Cylinder) .................................. .
Brake Cylinder Repair
................................................ .
Tilt Alarm Switch .................................................... .
Limit Switch Adjustment
............................................... .
Pressure Setting Procedures
........................................... .
Preventive Maintenance and Inspection Schedule
.......................... .
SECTION 9- TROUBLESHOOTING
9-1.
9-2.
9-3.
General ........................................................... .
Troubleshooting Information
........................................... .
Hydraulic Circuit Checks .............................................. .
Updated 02/93
ii
- .JLGSizzor-
JLGSizzor
PAGE NO.
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
5-1
6-1
6-1
6~1
6-1
6-2
7-1
7-1
7-1
7-2
7-2
7-2
7-6
7-6
7-6
7-6
8-1
8-1
8-2
8-3
8-3
8-4
8-4
8-5
8-5
8-6
8-8
8-10
8-11
8-11
8-14
9-1
9-1
9-1
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JLGSizzor TABLE
OF CONTENTS JLGSizzor
TABLE OF CONTENTS (cont.)
SUBJECT-SECTION, PARAGRAPH PAGE NO.
SECTION 10- RECOMMENDED SPARE PARTS UST- CM2033/CM2046/CM20546/CM2558
Recommended Spare Parts Ust -CM2033/CM2046/CM2546/CM2558 . . . . . . . . . . 1 0-1
SECTION 11 -ILLUSTRATED PARTS LIST- CM2033/CM2046/CM2546/CM2558
Table ofContents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-0-1
SECTION 12- RECOMMENDED SPARE PARTS LIST- CM1432
Recommended Spare Parts Ust- CM1432................................. 12-1
SECTION 13 -ILLUSTRATED PARTS LIST- CM1432/CM1432 PLUS/CM1732
Table of Contents..................................................... 13-0-1
FIGURE NO.
LIST OF ILLUSTRATIONS
TITLE
2-1
2-2
3-1
3-2
3-2
3-3
3-4
3-5
4-1
7-1
7-2
7-3
7-4
7-5
8-1
8-2
8-3
8-4
8-5
11-1-1
11-1-2
11-1-3
11-1-4
11-2-1
11-2-2
11-2-3
11-2-4
11-2-5
11-2-6
11-3-1
11-3-2
11-4-1
Daily Walk-Around Inspection- CM1432 .................................. .
Daily Walk-Around Inspection- CM2033/CM2046/CM2546/CM2558 ........... .
Ground Control Station -CM1432
....................................... .
Ground Control Station- CM2033/CM2046/CM2546/CM2558 ................. .
Platform Control Station w/o PQ Controller -All Models
(Machines Built Before August 1992) .................................... .
Platform Control Station w/PQ Controller -All Models
(Machines Built Before August 1992) .................................... .
Platform Control Station w/o PQ Controller -All Models
(Machines Built After August 1992) ...................................... .
Platform Control Station w/PQ Controller -All Models
(Machines Built After August 1992) ...................................... .
Grade and Sideslope
................................................. .
Torque Chart
....................................................... .
Lubrication Chart- CM1432 ............................................ .
Lubrication Chart -CM2033/CM2046/CM2546/CM2558 ..................... .
Serial Number Locations- CM1432 ..................................... .
Serial Number Locations- CM2033/CM2046/CM2546/CM2558 ............... .
Poly-Pak Seal Installation ............................................. .
Brake Cylinder Assembly .............................................. .
Tilt Alarm Switch Leveling -Voltmeter Adjustment .......................... .
Pressure Adjustment Locations -Proportional Valve ........................ .
Pressure Adjustment Locations -Bang-Bang Valve ......................... .
Frame, Steering and Drive Installation
................................... .
Drive Motor Assemblies
............................................... .
Rear Axle and Brake Installations
....................................... .
Frame Mounted Components Installation ................................. .
Covers, Controls, Tank and Valves Installation
............................. .
Control Valve Assembly- Hydro-Air (Machines with Bang-Bang Drive) .......... .
Control Valve Assembly -Hydro-Air (Machines with Proportional Drive) ......... .
Batteries and Chargers Installation ...................................... .
Battery Charger Assembly (Prior to September 1994)
....................... .
Battery Charger Assembly (September 1994to Present) ..................... .
Sizzor Arms Installation- CM2033 and CM2046 ........................... .
Sizzor Arms Installation- CM2546 and CM2558 ........................... .
Standard Handrails and and Accessories Installation
........................ .
-JLGSizzor -
PAGE NO.
2-4
2-6
3-4
3-4
3-5
3-5
3-6
3-6
4-3
7-3
7-4
7-5
7-7
7-8
8-7
8-9
8-11
8-12
8-13
11-1-2
11-1-6
11-1-8
11-1-10
11-2-2
11-2-8
11-2-12
11-2-16
11-2-20
11-2-22
11-3-2
11-3-4
11-4-2
Change 1
iii
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JLGSizzor TABLE
OF CONTENTS
FIGURE NO.
LIST OF ILLUSTRATIONS (cont.)
TITLE
11-4-2
11-4-3
11-4-4
11-4-5
11-4-6
11-5-1
11-5-2
11-5-3
11-6-1
11-6-2
11-7-2
11-7-3
11-7-4
11-7-5
11-7-6
11-8-1
13-1-1
13-1-2
13-1-3
13-1-4
13-1-5
13-1-6
13-2-1
13-2-2
13-2-3
13-3-1
13-3-2
13-4-1
13-4-2
13-4-3
13-4-4
13-5-1
13-5-2
13-5-3
13-6-1
13-7-2
13-7-3
13-7-4
13-7-5
13-8-1
13-8-2
TABLE NO.
3-1
7-1
7-2
8-1
8-2
9-1
9-2
9-3
9-4
11-7-1
13-7-1
Change 1
iv
Optional Fold-Down Handrail Installation
................................. .
Optional Extendable Deck Installation with Standard Handrails
................ .
Optional Extendable Deck Installation with Fold-Down Handrails
.............. .
Steel Platform Console Box Assembly ................................... .
Molded Platform Console Box Assembly ................................. .
Brake Cylinder Assembly
.............................................. .
Lift Cylinder Sub-Assembly
............................................ .
Steer Cylinder Assembly
.............................................. .
Hydraulic Diagram -Bang-Bang Drive ................................... .
Hydraulic Diagram -Proportional Drive ................................... .
Electrical Diagram -Toggle Switch Drive ................................. .
Electrical Diagram -PQ Controller Bang-Bang Drive ........................ .
Electrical Diagram -PQ Controller Proportional Drive ....................... .
Electrical Diagram -Circuit Cards ....................................... .
Main Electrical Connector and Tools
..................................... .
Decal Installation .................................................... .
Frame, Steering and Drive Installation
................................... .
Drive Motor Assemblies
............................................... .
Rear Axle and Brake Installations
....................................... .
Frame Mounted Components Installation
................................. .
Battery Charger Assembly (Prior
to September 1994) ....................... .
Battery Charger Assembly (September 1994
to Present) ..................... .
Electrical Components Installation ...................................... .
Hydraulic Components and Covers Installation ............................ .
Control Valve Assembly- Hydro-Air ..................................... .
Sizzor Arms Installation- CM1432 and CM1432 Plus
....................... .
Sizzor Arms Installation- CM1732
...................................... .
Platform and Handrail Installation ....................................... .
Optional Platform Extension Installation .................................. .
Steel Platform Console Box Assembly ................................... .
Molded Platform Console Box Assembly ................................. .
Brake Cylinder Assembly
.............................................. .
Lift Cylinder Sub-Assembly
............................................ .
Steer Cylinder Assembly
.............................................. .
Hydraulic Diagram -Standard .......................................... .
Electrical Diagram -Toggle Switch Drive ................................. .
Electrical Diagram -PQ Controller Bang-Bang Drive ........................ .
Electrical Diagram -Circuit Cards ....................................... .
Main Electrical Connector and Tools
..................................... .
Decals Installation- CM1432 and CM1432 Plus ............................ .
Decals Installation- CM1732 ........................................... .
LIST OFTABLES
TITLE
Control Panel Symbols ............................................... .
Hydraulic Oil. ....................................................... .
Lubrication Specifications
............................................. .
Cylinder Piston Nut Torque Specifications ................................ .
Preventive Maintenance and Inspection
.................................. .
Elevation System Troubleshooting ...................................... .
Chassis Troubleshooting
.............................................. .
Hydraulic System Troubleshooting ...................................... .
Electrical System Troubleshooting ...................................... .
Electrical Diagrams and Components Chart -CM2033/CM2046/CM2546/CM2558 .
Electrical Diagrams and Components Chart- CM1432/CM1432 Plus/CM1732 .....
-JLGSizzor -
JLGSizzor
PAGE NO.
11-4-8
11-4-12
11-4-14
11-4-16
11-4-20
11-5-2
11-5-4
11-5-8
11-6-2
11-6-6
11-7-6
11-7-7
11-7-8
11-7-9
11-7-10
11-8-2
13-1-2
13-1-4
13-1-6
13-1-8
13-1-12
13-1-14
13-2-2
13-2-6
13-2-10
13-3-2
13-3-4
13-4-2
13-4-6
13-4-8
13-4-12
13-5-2
13-5-4
13-5-8
13-6-2
13-7-6
13-7-7
13-7-8
13-7-10
13-8-2
13-8-6
PAGE NO.
3-7
7-2
7-2
8-8
8-15
9-2
9-4
9-7
9-8
11-7-2
13-7-2
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSizzor
1-1. GENERAL.
a. This section prescribes the proper and safe
practices for major areas of machine usage
which have been divided into three basic
categories: Driving, Operation and Main-
tenance. In order to promote proper usage of
the machine, it
is mandatory that adaily routine
be established based
on instruction given in this
section. A maintenance program must also
be
established by a qualified person and must be
followed to ensure that the machine is safe to
operate.
b. The user/operator of the machine should not
acceptoperating responsibility until this manual
has been read and operation of the machine,
under the supervision of
an experienced and
qualified operator, has been completed. Ifthere
is a question on application and/or operation,
JLG Industries Product Safety and Reliability
should
be consulted.
WARNING
MODIFICATION OFTHE MACHINEWITHOUT AP-
PROVAL OF JLG INDUSTRIES, OR CERTIFICA-
TION BYA NATIONALLYRECOGNIZEDTESTING
LABTO BE IN CONFORMITY WITH APPLICABLE
OSHAREGULATIONS, ANDTO BE
AT LEASTAS
SAFE AS BEFORE MODIFICATION, IS
PROHIBITED AND IS A VIOLATION OF OSHA
RULES.
1-2. DRIVING/TOWING/CARRYING.
a. Before driving the machine the user must be
familiar with the drive, steer and stopping char-
acteristics. This is especially important when
driving
in close quarters.
b. The user should
be familiar with the driving
surface before driving. The surface should
be
firm and level and gradesshould notexceed the
allowable grade, as indicated
on the CAUTION
placard at the platform control station.
Note
Remember that the key
to safe and proper usage is
common sense and itscareful application.
c. Standard machine is not equipped with
provisions for towing. Refer to Section 6 for
emergency towing procedures.
SPECIAL NOTE:
CERTAIN 'CARTOONS' IN THIS PUBLICATION
SHOULD IN NO WAY BE CONSTRUED AS
SHOWING THE PROPER USE OF THE
MACHINES. THEY ARE INCLUDEDTO PROVIDE
VISUAL INDICATIONS OF INCORRECT EQUIP-
MENT OPERATION AND APPLICATION.
WARNING
FAILURE TO COMPLY WITH SAFETY PRECAU-
TIONS LISTED IN THIS SECTION AND ON
MACHINE MAY RESULT IN MACHINE DAMAGE,
PERSONNEL INJURY OR DEATH AND IS A
SAFETY VIOLATION.
d. Carrying or loading the unit should be ac-
complished using a forklift vehicle of suitable
capacity with the forks being positioned correct-
ly beneath the indicated areas on the lowerside
of the frame. ·
- JLG Sizzor - 1-1
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSizzor
1-3. ELECTROCUTION HAZARD.
DENOTES PROHIBITED ZONE M.S.A.D. =MINIMUM SAFE APPROACH DISTANCE
Table
(SEE TABLE BELOW)
MAINTAIN M.S.A.D. FROM ALL
OTHER CHARGED LINES AND PARTS
AS WELL AS THOSE SHOWN.
Minimumsafeapproach distances(M.S.A.D.) to energized (exposed or insulated)power lines and parts.
VOLTAGE RANGE MINIMUM SAFE APPROACH DISTANCE
(Phase to Phase) Feet (Meters)
0 to 300V AVOID CONTACT
Over 300V to 50KV 10 (3)
Over 50KV to 200KV 15 (5)
Over 200KV to 350KV 20 (6)
Over 350KV to 500KV
25 (8)
Over 500KV to 750KV 35 (11)
Over750KVto1000KV
45 (14)
DANGER:
DO NOT manuever machine or personnel inside PROHIBITED ZONE.
ASSUME all electrical parts and
wiring are ENERGIZED unless known otherwise.
1-2 -
JLG Sizzor -
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSizzor
MAINTAIN A SAFE DISTANCE FROM ELECTRICAL LINES
AND APPARATUS.
MAINTAIN SAFE CLEARANCE FROM ELECTRICAL
LINES AND APPARATUS. ALLOW FOR PLATFORM
SWAY, ROCK ORSAG AND ELECTRICAL LINE SWAY-
ING. THE MACHINE DOES NOT PROVIDE PROTEC-
TION FROM CONTACT WITH OR PROXIMITY TO
AN
ELECTRICALLYCHARGED CONDUCTOR.
MAINTAIN A CLEARANCEOFAT LEAST 10 FEET(3M)
BETWEEN ANY PARTOF THE MACHINE
OR ITS LOAD
AND ANY ELECTRICAL LINE OR APPARATUS CAR-
RYING UP TO 50,000 VOLTS. ONE FOOT (0.3 M) AD-
DITIONAL CLEARANCE IS REQUIRED FOR EVERY
ADDITIONAL 30,000 VOLTS OR LESS.
1-4. PRE-OPERATIONAL
READ YOUR MANUAL. UNDERSTAND WHAT YOU'VE
READ- THEN BEGIN OPERATIONS.
ALLOW ONLY THOSE AUTHORIZED AND QUALIFIED
PERSONNEL TO OPERATE MACHINE WHO HAVE
DEMONSTRATED THAT THEY UNDERSTAND SAFE
AND PROPER OPERATION AND MAINTENANCE OF
THE UNIT.
AN OPERATOR MUST NOT ACCEPT OPERATING
RESPONSIBILITIES UNTIL ADEQUATE TRAINING
HAS BEEN GIVEN BY COMPETENT AND
AUTHORIZED PERSONS.
BEFORE OPERATION CHECK WORK
AREA FOR
BAREOVERHEAD ELECTRIC LINES, MACHINETRAF- .
FIC SUCH AS BRIDGE CRANES, HIGHWAY, RAILWAY
AND CONSTRUCTION EQUIPMENT.
PRECAUTIONS TO AVOID ALL KNOWN HAZARDS
IN
THE WORK AREA MUST BE TAKEN BY THE
OPERATOR AND HIS SUPERVISOR BEFORE START-
ING THE WORK.
DO NOT OPERATE THIS MACHINE UNLESS IT HAS
BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.
ENSURE DAILY INSPECTION AND FUNCTION CHECK
IS PERFORMED PRIOR TO PLACING MACHINE INTO
OPERATION.
NEVER DISABLE OR MODIFY ANY SAFETY DEVICE.
ANY MODIFICATION OF THE MACHINE IS A SAFETY
VIOLATION AND
IS A VIOLATION OF OSHA RULES.
DO NOT OPERATE MACHINE WHEN WIND CONDI-
TIONS EXCEED 20 MPH.
NEVER OPERATE OR RAISE PLATFORM WHEN
MACHINE IS ON A TRUCK OR OTHER VEHICLE.
APPROVED HEAD GEAR MUST BE WORN WHEN RE-
QUIRED BY ALL OPERATING AND GROUND PER-
SONNEL
READ AND OBEY·ALL WARNINGS, CAUTIONS AND
OPERATING INSTRUCTIONS ON MACHINE AND IN
THIS MANUAL.
BE FAMILIAR WITH LOCATION AND OPERATION OF
GROUND STATION CONTROLS.
- JLG Sizzor -1-3
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JLGSizzor SECTION 1 ~ SAFETY PRECAUTIONS
JLGSizzor
1-5. DRIVING.
WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN DRIVING.
CHECK TRAVEL PATH FOR PERSONS, HOLES,
BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS,
AND COVERINGS WHICH MAY CONCEAL HOLES
AND OTHER HAZARDS.
WHEN DRIVING
IN HIGH SPEED, SWITCH TO LOW
BEFORE STOPPING. TRAVEL GRADES
IN LOW
DRIVE ONLY.
DO NOT DRIVE ON GRADES AND SIDESLOPES EX-
CEEDING THOSE INDICATED ON CAUTION
PLACARD AT MACHINE PLATFORM.
BEFORE DRIVING ON FLOORS, BRIDGES, TRUCKS
AND OTHER SURFACES, CHECK ALLOWABLE
CAPACITY OF SURFACES.
ALWAYS LOOK IN THE DIRECTION OFTRAVEL.
DO NOT TRAVEL ON SOFTOR UNEVEN SURFACES,
AS TIPPING WILL OCCUR.
DO NOT USE HIGH SPEED DRIVE IN RESTRICTED OR
CLOSE QUARTERS OR WHEN DRIVING IN REVERSE.
BE AWARE OF STOPPING DISTANCES WHEN
TRAVELING
IN HIGH AND LOW SPEEDS.
ALWAYS POST A LOOKOUT AND SOUND HORN
WHEN DRIVING IN AREAS WHERE VISION IS
OBSTRUCTED.
KEEP NON-OPERATING PERSONNEL AT LEAST 6
FEET (1.8
M) AWAY FROM MACHINE DURING DRIV-
ING OPERATIONS.
1-4 -
JLG Sizzor -
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSizzor
1-6. OPERATION.
READ YOUR MANUAL, UNDERSTAND WHAT YOU'VE
READ- THEN BEGIN OPERATIONS.
DO NOT OPERATE ANY MACHINE ON WHICH
DANGER, WARNING, CAUTION OR INSTRUCTION
PLACARDS OR DECALS ARE MISSING OR IL-
LEGIBLE.
MACHINE MUST ALWAYS BE SHUT DOWN WHEN
REFUELING. 'NOSMOKING' IS MANDATORY. NEVER
REFUEL DURING
AN ELECTRICAL STORM. ENSURE
THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.
NEVER EXCEED MANUFACTURERS RATED PLAT-
FORM CAPACITY- REFER TO CAPACITY DECAL ON
MACHINE. DISTRIBUTE LOAD EVENLY
ON PLAT-
FORM FLOOR.
ENSURE MACHINE IS POSITIONED ON A FIRM,
LEVEL AND UNIFORM SURFACE BEFORE RAISING
PLATFORM.
NEVER OPERATE ON SOFT OR UNEVEN SURFACES.
THOROUGHLY CHECK ALL CLEARANCES BEFORE
POSITIONING PLATFORM.
NEVER 'SLAM' A. CONTROL SWITCH OR LEVER
THROUGH NEUTRALTO OPPOSITE DIRECTION. AL-
WAYS RETURN SWITCH TO NEUTRAL AND STOP;
THEN MOVE SWITCH TO THE DESIRED POSITION.
OPERATE LEVERS WITH SLOW, EVEN PRESSURE.
NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE, RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.
CHECK CLEARANCES ABOVE, ON SIDES AND BOT-
TOM OF PLATFORM WHEN RAISING AND LOWERING
PLATFORM:
- JLG Sizzor -1-5
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSizzor
NEVER USE SIZZOR ARMS TO GAIN ACCESS TOOR
LEAVE PLATFORM.
DO NOT ATTACH OVERHANGING LOADS TO THE
PLATFORM OR INCREASE THE PLATFORM SIZE
WITH UNAUTHORIZED DECK EXTENSIONS OR AT-
TACHMENTS.
DO NOT ELEVATE PLATFORM WHILE DRIVING, OR
UNLESS MACHINE IS LEVEL.
DO NOT TIE OFF MACHINE TO ANY ADJACENT
STRUCTURE. NEVER ATTACH WIRE, CABLE OR ANY
SIMILAR ITEMS TO PLATFORM.
ALWAYS STAND ON PLATFORM FLOOR, NOT ON
BOXES, PLANKS OR RAILINGS.
DURING ENTRY OR EXIT ABOVE GROUND OSHA
REQUIRES THAT SAFETY BELT
BE ATTACHED TO
THE STRUCTURE BEING ENTERED.
TO AVOID FALLING- USE EXTREME CAUTION WHEN
ENTERING OR LEAVING PLATFORM ABOVE
GROUND. ENTER OR EXITTHRU GATE ONLY. PLAT-
FORM MUST BE WITHIN 1 FOOT (0.3 M) OF AD-
JACENT- SAFE AND SECURE -STRUCTURE.
NOSTUNT DRIVING OR HORSEPLAY IS PERMITTED.
DO NOT ALLOW PERSONNEL TO TAMPER WITH,
SERVICE, OR OPERATE THIS MACHINE FROM THE
GROUND WITH PERSONNEL
IN PLATFORM EXCEPT
IN AN EMERGENCY.
WHEN TWOOR MORE PERSONS ARE
IN PLATFORM,
THE OPERATOR SHALL BE RESPONSIBLE FOR ALL
MACHINE OPERATIONS.
DURING OPERATION KEEP ALL BODY PARTS INSIDE
PLATFORM RAILINGS.
1-6 -
JLG Sizzor -
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS
NEVER POSITION LADDERS, STEPS, OR SIMILAR
ITEMS
ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE.
WHEN RIDING IN OR WORKING FROM PLATFORM
BOTH FEET MUST
BE FIRMLY POSITIONED ON
DECK.
DO NOT EXTEND REACH LIMITS OF THIS MACHINE
WITH ADDITIONAL EQUIPMENT SUCH
AS PLANKS,
BOXES, ETC.
OBSERVE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER-
FERING WITH OPERATING CONTROLS AND PER-
SONS
IN THE PLATFORM.
JLGSizzor
KEEP EVERYONE CLEAR OF A WORKING PLATFORM.
- JLG Sizzor -1-7
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS
ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR LEVEL MACHINES ARE AWARE OF THE
AERIAL .PLATFORMS PRESENCE. DISCONNECT
POWER TO OVERHEAD CRANES. BARRICADE
FLOOR AREA IF NECESSARY.
DO NOT OPERATE WITHOUT HANDRAILS
IN PLACE
AND SECURED. IT IS A SAFETY VIOLATION.
DO NOT STEP OUTSIDE OF HANDRAILS.
ALWAYS ENSURE THAT POWER TOOLS ARE
PROPERLYSTOWEDAND NEVERLEFTHANGING BY
THEIR CORD FROM THE PLATFORM WORK AREA.
AVOID ACCUMULATION OF DEBRIS ON PLATFORM
WORK AREA. KEEP MUD, OIL, GREASE AND OTHER
SLIPPERY SUBSTANCES FROM FOOTWEAR AND
PLATFORM DECK.
JLGSizzor
PLATFORM RAILS ARE NOT FOR HANDLING MATERIAL.
1-8 -JLGSizzor -
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JLGSizzor SECTION 1 - SAFETY PRECAUTIONS JLGSiuor
1-7. TOWING AND HAULING.
NEVER ATTEMPT TO TOW OR PULL MACHINE. AL-
WAYS CARRY MACHINE WITH FORKLIFT OF
SUITABLE CAPACITY.
HAVE PLATFORM COMPLETELY EMPTY OF TOOLS
AND DEBRIS BEFORE CARRYING.
WHEN LIFTING MACHINE, POSITION FORKS ONLY
AT DESIGNATED AREA AT REAR OF MACHINE.
HAVE PLATFORM FULLY RETRACTED WHILE
MACHINE
IS BEING CARRIED.
·NEVER ALLOW PERSONNEL IN PLATFORM WHILE
CARRYING.
&. .
~-
LIFT MACHINE AT DESIGNATED AREA ONLY ••
- JLG Sizzor -1-9
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