Oshkosh JLG 1500SJ Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
AS/NZS
Boom Lift Models
1500SJ
PVC 2001
31215063
November 22, 2019 - Rev A
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
31215063 a
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var-
ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
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.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related documentation.
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FOREWORD
b31215063
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-
GROUND.
INDICATES A POTENTIALLY HA ZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death
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FOREWORD
31215063 c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-
TION 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 OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-
ERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
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 Prod-
uct Modifications
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FOREWORD
d31215063
REVISION LOG
Original Issue A - November 22, 2019
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31215063 i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Machine Familiarization. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Boom Control System Check Procedure . . . . . . . . . . 2-16
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-8
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-18
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Controlled Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Envelope Tracking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-3
Platform Load Sensing System (LSS). . . . . . . . . . . . . . . . 4-4
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
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ii 31215063
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.3 CAPACITY SELECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Shutoff Valve (ASOV) (If Equipped). . . . . . . . . . . . . . 4-9
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . 4-10
4.5 SELECTIVE CATALYTIC REDUCTION (SCR) -
MACHINES USING DIESEL EXHAUST
FLUID (DEF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Maintenance Standstill Cleaning
Initiation Methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Cancelling Maintenance Standstill . . . . . . . . . . . . . . . . 4-13
Unsuccessful Cleaning Event. . . . . . . . . . . . . . . . . . . . . . 4-14
4.1 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-19
Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.2 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.3 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.4 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-21
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.5 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-22
Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Telescoping the Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Stowing/Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.6 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.7 MACHINE SAFETY SYSTEM OVERRIDE . . . . . . . . . . . . . . . . . . . .
(MSSO)(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.8 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.13 EMERGENCY TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.14 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
4.15 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.16 STOWING THE JIB FOR TRANSPORT. . . . . . . . . . . . . . . . . . 4-28
SECTION - 5 - LCD DISPLAY PANEL - GENERATION 1 & 2
5.1 IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 LCD DISPLAY PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 GENERATION 1 LCD DISPLAY PANEL SCREENS . . . . . . . . 5-3
Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Conditional Icons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
CAN Communication Error Screen . . . . . . . . . . . . . . . . . 5-9
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31215063 iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
Serviceable Fault Indication Screen. . . . . . . . . . . . . . . 5-11
Keyswitch in Ground Control Mode Screen . . . . . . . 5-13
Keyswitch in Ground Control Mode Screen
with Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
Operational Fault - No Graphics Screen. . . . . . . . . . . 5-17
Operational Fault - With Graphics Screen . . . . . . . . . 5-19
Operational Fault - Footswitch Open Screen . . . . . . 5-21
Out of Transport - Axles Retracted. . . . . . . . . . . . . . . . 5-23
Operational Fault - Transport Swing Fault Screen . 5-25
Envelope Speed Reduction Screen . . . . . . . . . . . . . . . 5-27
Operational Fault - Envelope Violation
Fault Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
Operational Fault - Over/Under
Moment Fault (DTC 0017/0018) . . . . . . . . . . . . . . . . . 5-31
5.4 GENERATION 2 LCD DISPLAY PANEL SCREENS. . . . . . . . 5-33
Boot up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
Machine Operating Screen. . . . . . . . . . . . . . . . . . . . . . . 5-35
KeySwitch In Ground Mode:. . . . . . . . . . . . . . . . . . . . . . 5-37
Function Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
CAN Bus Lost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Take Foot Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Put Foot In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
BCS Lamp On. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
Broken Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
Platform Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
Platform Overload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
Capacity Mode Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-47
Swing DTCs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-48
Jib Unlocked . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
Jib Locked. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
Chassis Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Machine Tilted Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-55
Envelope Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-56
Machine Model Unknown. . . . . . . . . . . . . . . . . . . . . . . . 5-60
5.5 OPERATIONAL FAULT CODE LISTING. . . . . . . . . . . . . . . . . 5-61
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine. . . . . . . . . . . . . . . 6-1
Platform or Boom Caught Overhead or
Boom Movement Prevented by Boom
Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . 6-2
6.5 MACHINE SAFETY SYSTEM OVERRIDE
(MSSO)(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SECTION - 7 - ACCESSORIES
7.1 FALL ARREST PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
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iv 31215063
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
7.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Capacity Specifications (Australia Only) . . . . . . . . . . . . 7-4
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7.3 SKYCUTTER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7.4 SKYGLAZIER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.5 SKYPOWER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . 7-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7.6 SKYWELDER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Welding Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . 7-12
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.7 SOFT TOUCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
7.8 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 7-13
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
SECTION - 8 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
8.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 OPERATING SPECIFICATIONS AND
PERFORMANCE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-24
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-25
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31215063 v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
8.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 8-26
SECTION - 9 - INSPECTION AND REPAIR LOG
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vi 31215063
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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31215063 v
LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
2-1. Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-4
2-2. Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . 2-5
2-3. Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . 2-6
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Ground Control Station with Machine Safety System
Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-5
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6
4-3. ASOV Reset (Open to Closed Position) . . . . . . . . . . . . . . . . 4-9
4-4. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-5. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-6. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4-7. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-8. Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-30
4-9. Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4-10. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-11. Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-33
4-12. Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-34
4-13. Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
5-1. Generation 1 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1
5-2. Generation 2 Boot Up Splash Screen. . . . . . . . . . . . . . . . . . 5-1
5-3. LCD Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5-4. Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-5. Default Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-6. Conditional Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
5-7. CAN Communication Error Screen . . . . . . . . . . . . . . . . . . . 5-10
5-8. Serviceable Fault Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-9. Keyswitch in Ground Control Mode Screen . . . . . . . . . . 5-14
5-10. Keyswitch in Ground Control Mode with
Operational Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
5-11. Operational Fault - No Graphics Screen . . . . . . . . . . . . . . 5-18
5-12. Operational Fault - With Graphics Screen . . . . . . . . . . . . 5-20
5-13. Operational Fault - Footswitch Open Screen . . . . . . . . . 5-22
5-14. Out of Transport - Axles Retracted Screen. . . . . . . . . . . . 5-24
5-15. Transport Swing Fault Screen . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-16. Backward Envelope Speed Reduction Fault Screen. . . 5-28
5-17. Forward Envelope Violation Fault Screen . . . . . . . . . . . . 5-30
5-18. Over/Under Moment Fault Screen. . . . . . . . . . . . . . . . . . . 5-32
5-19. Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5-20. Manual Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-21. Lanyard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-22. Select Capacity Zone Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5-23. Machine Operating Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5-24. Keyswitch In Ground Mode Screen . . . . . . . . . . . . . . . . . . 5-37
5-25. Function Speed Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5-26. CAN Bus Lost Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5-27. Take Foot Out Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5-28. Put Foot In Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
5-29. BCS Lamp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-43
5-30. Broken Cable Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-44
5-31. Level System DTC Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-45
5-32. Overload DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-46
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vi 31215063
LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
5-33. Capacity Mode Error Screen. . . . . . . . . . . . . . . . . . . . . . . . . 5-47
5-34. Swing DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-49
5-35. Jib Unlocked Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-50
5-36. Jib Locked Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-51
5-37. Axles Retracted Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
5-38. Axles Extended Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
5-39. Machine Tilted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-55
5-40. Unrestricted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-57
5-41. Restricted Mode Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-58
5-42. Machine Model Unknown Screen . . . . . . . . . . . . . . . . . . . 5-60
7-1. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . 7-15
7-2. Bolt On Fall Arrest System. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
8-1. Oil Sampling Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
8-2. Engine Operating Temperature Specifications . . . . . . . 8-10
8-3. Hydraulic Oil Operation Chart . . . . . . . . . . . . . . . . . . . . . . . 8-11
8-4. Operator Maintenance and Lubrication Diagram . . . . 8-12
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31215063 vii
LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Maintenance Standstill Cleaning. . . . . . . . . . . . . . . . . . . . .4-15
4-2 Cleaning When Crystallization is Detected
During SCR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-3 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-36
5-1 Operational Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-61
7-1 Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Options/Accessories Relationship Table. . . . . . . . . . . . . . . 7-2
8-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
8-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8-5 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-6 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-9 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-10 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
8-11 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8-12 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
8-13 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
8-14 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .8-13
8-15 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-26
9-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
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viii 31215063
LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
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SECTION 1 - SAFETY PRECAUTIONS
31215063 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper and
safe machine usage and maintenance. It is mandatory that a daily
routine is established based on the content of this manual to pro-
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
nance 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 quali-
fied operator.
This section contains the responsibilities of the owner, user, oper-
ator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any ques-
tions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read, understand, and study the Operation and Safety Manual
in its entirety before operating the machine. For clarification,
questions, or additional information regarding any portions of
this manual, contact JLG Industries, Inc.
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SECTION 1 - SAFETY PRECAUTIONS
1-2 31215063
• Only personnel who have received proper training regarding
the inspection, application and operation of MEWPs (including
recognition and avoiding hazards associated with their opera-
tion) shall be authorized to operate a MEWP.
• Only properly trained personnel who have received unit-spe-
cific familiarization shall operate a MEWP. The user shall deter-
mine if personnel are qualified to operate the MEWP prior to
operation.
• Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, 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 have a thorough understanding
of the intended purpose and function of the MEWP controls,
including platform, ground and emergency descent controls.
• 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 equip-
ment unless the application is approved in writing by JLG.
• Before operation, check work area for overhead hazards such
as electric lines, bridge cranes, and other potential overhead
obstructions.
• Check operating surfaces for holes, bumps, drop-offs, obstruc-
tions, debris, concealed holes, and other potential hazards.
• Check the work area for hazardous locations. Do not operate
the machine in hazardous environments unless approved for
that purpose by JLG.
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
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SECTION 1 - SAFETY PRECAUTIONS
31215063 1-3
Machine Inspection
• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
been performed.
• Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the machine’s Service and Main-
tenance Manual.
• Ensure all safety devices are operating properly. Modification
of these devices is a safety violation.
MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT-
TEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which the safety or instruction
placards or decals are missing or illegible.
• Check the machine for modifications to original components.
Ensure that any modifications have been approved by JLG.
• Avoid accumulation of debris on platform floor. Keep mud, oil,
grease, and other slippery substances from footwear and plat-
form floor.
1.3 OPERATION
General
• Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell phones,
two-way radios, etc. that will distract your attention from
safely operating the machine.
• Do not use the machine for any purpose other than position-
ing personnel, their tools, and equipment.
• Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from service
and notify the proper authorities.
• Do not remove, modify, or disable any safety devices.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and stop
before moving the switch to the next function. Operate con-
trols with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
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