JLG 1100SB Operator Manual

Operation and Safety Manual

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

Boom Lift Models
1100SB

ANSI

3121264

July 7, 2010

FOREWORD

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.

3121264 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

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

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

b – JLG Lift – 3121264

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

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

FOREWORD

• Standards and Regulations
Compliance Information

• Questions Regarding Spe­cial Product Applications

• Questions Regarding Prod­uct Modifications

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.

Contact:

Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742

or Your Local JLG Office
(See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

3121264 – JLG Lift – c

Phone: [phone]
Fax: [phone]
E-mail: [e-mail]

FOREWORD

Original Issue - July 7, 2010

REVISION LOG

d – JLG Lift – 3121264

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

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

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

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

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

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

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

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

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA­RATION, AND INSPECTION

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

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

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

Boom Control System Check Procedure . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

Ground Control Indicator Panel . . . . . . . . . . . . . 3-5

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Platform Control Indicator Panel . . . . . . . . . . . . 3-13

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

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

3121264 – JLG Lift – i

TABLE OF CONTENTS

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

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

4.4 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-6

Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . 4-6

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-7

4.5 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-7

Traveling Forward and Reverse. . . . . . . . . . . . . 4-8

4.6 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.7 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . 4-8

4.8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Platform Level Adjustment . . . . . . . . . . . . . . . . 4-10

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-11

Raising and Lowering the Boom . . . . . . . . . . . 4-11

Telescoping the Boom. . . . . . . . . . . . . . . . . . . 4-11

Swinging the Jib. . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . 4-11

4.11 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . 4-12

4.12 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-13

4.13 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-13

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.14 STOWING THE JIB FOR TRANSPORT . . . . . . . . .4-14

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1

Operator Unable to Control Machine . . . . . . . . . 5-1

Platform or Boom Caught Overhead . . . . . . . . . 5-2

Boom Movement Prevented By Boom

Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Major Component Weights. . . . . . . . . . . . . . . . . 6-7

ii – JLG Lift – 3121264

TABLE OF CONTENTS

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-11

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-18

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-19

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-20

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-9

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10

3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Ground Control Indicator Panel. . . . . . . . . . . . . . . .3-5

3-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-8

3-4. Platform Control Indicator Panel . . . . . . . . . . . . . .3-14

4-1. Dual Capacity Decal. . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2. Position of Least Forward Stability . . . . . . . . . . . . .4-5

4-3. Position of Least Backward Stability . . . . . . . . . . . .4-6

4-4. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-9

4-5. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . .4-12

4-6. Lifting and Tie Down Chart - Sheet 1 of 2. . . . . . . 4-15

4-7. Lifting and Tie Down Chart - Sheet 2 of 2. . . . . . . 4-16

4-8. Decal Location Sheet 1 of 5 . . . . . . . . . . . . . . . . . 4-17

4-9. Decal Location Sheet 2 of 5 . . . . . . . . . . . . . . . . . 4-18

4-10. Decal Location Sheet 3 of 5 . . . . . . . . . . . . . . . . . 4-19

4-11. Decal Location Sheet 4 of 5 . . . . . . . . . . . . . . . . . 4-20

4-12. Decal Location Sheet 5 of 5 . . . . . . . . . . . . . . . . . 4-21

6-1. Engine Operating Temperature Specifications - Deutz

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-2. Engine Operating Temperature Specifications - Deutz

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-3. Lubrication and Maintenance Point Location. . . . 6-10

3121264 – JLG Lift – iii

TABLE OF CONTENTS

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

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

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

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Chassis Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-6 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . 6-3

6-7 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . 6-4

6-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . .6-4

6-9 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-10 UCon Hydrolube HP-5046. . . . . . . . . . . . . . . . . . . . 6-5

6-11 Mobil EAL H 46 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-6

6-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . 6-6

6-13 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-14 Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-11

6-15 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . 6-20

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . .7-1

iv – JLG Lift – 3121264

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
machine use, 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 followed to ensure the
machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine
should not operate the machine 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.

If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).

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

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the
machine.

• Do not operate this machine until complete training is per­formed by authorized persons.

• Only authorized and qualified personnel can operate the
machine.

3121264 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

• Use the machine in a manner which is within the scope of
its intended application set 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
operation of the machine.

Workplace Inspection

• The operator is to take safety measures to avoid all haz­ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail­ers, railway cars, floating vessels, scaffolds or other equip­ment unless approved in writing by JLG.

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

• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.

o

• This machine can be operated in temperatures of 0

o

F (-20o C to 40o C). Consult JLG for operation out-

104
side this range.

F to

Machine Inspection

• Before machine operation, perform inspections and func­tional checks. Refer to Section 2 of this manual for
detailed instructions.

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

• Be sure the footswitch and all other 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 WRITTEN PERMISSION FROM THE MANU­FACTURER

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

• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from foot­wear and platform floor.

1-2 – JLG Lift – 3121264

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

• Do not use the machine for any purpose other than posi­tioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If a
malfunctions occurs, shut down the machine.

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

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

• Do not carry materials directly on platform railing. Contact
JLG for approved material handling accessories.

• 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.

• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.

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

• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.

• Do not place boom or platform against any structure to
steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lan­yard anchorage point. Attach only one (1) lanyard per lan­yard anchorage point.

3121264 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

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

• Never use the boom assembly to enter or leave the plat­form.

• Use extreme caution when entering or leaving platform.
Be sure that the boom is fully lowered. It may be neces­sary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.

Electrocution Hazards

• This machine is not insulated and does not provide pro­tection from contact or proximity to electrical current.

1-4 – JLG Lift – 3121264

SECTION 1 - SAFETY PRECAUTIONS

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

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

1.

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations
are more stringent.

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

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3121264 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

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

Tipping Hazards

• The user must be familiar with the surface before driving.
Do not exceed the allowable sideslope and grade while
driving.

1-6 – JLG Lift – 3121264

SECTION 1 - SAFETY PRECAUTIONS

• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.

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

• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi­tion unless the machine is on firm, level (up to the rated 3
degrees) and smooth surfaces.

• Keep the chassis of the machine at least 2 ft. (0.6m) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.

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

• Never attempt to use the machine as a crane. Do not tie­off machine to any adjacent structure.

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

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

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

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

Crushing and Collision Hazards

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

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

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

3121264 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

• Limit travel speed according to conditions of ground sur­face, congestion, visibility, slope, location of personnel,
and other factors which may cause collision or injury to
personnel.

• Be aware of stopping distances in all drive speeds. When
driving in high speed, switch to low speed before stop­ping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quarters
or when driving in reverse.

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

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

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

1.4 TOWING, LIFTING, AND HAULING

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

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

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

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

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

1-8 – JLG Lift – 3121264

SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.

• Charge batteries only in a well ventilated area.

3121264 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

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

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

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically

1 1-3 0.3-1.5 Light air Wind motion visible in smoke

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves ru stle

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.

8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.

9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.

Operator Training

Operator training must cover:

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

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

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential mal­function.

6. The safest means to operate the machine where over­head obstructions, other moving equipment, and obsta­cles, depressions, holes, drop-offs, etc. exist.

7. Means to avoid the hazards of unprotected electrical
conductors.

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121264 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

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

2-2 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection
(See Note)

Frequent Inspection
(See Note)

Annual Machine Inspec­tion
(See Note)

Preventative Maintenance At intervals as specified in the Ser vice and Main-

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

Before each sale, lease, or rental deliver y. Owner, Dealer, or User Qualified JLG

In service for 3 months or 150 hours, whichever
comes first;
o r
Out of service for a period of more than 3 months;
o r
Purchased used.

Annually, no later than 13 months from the date of
prior inspection.

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Mechanic

Service 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

3121264 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pare nt Metal C rack Weld Cr ack

Pre-Start Inspection

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

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

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

3. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible decals and placards are
cleaned or replaced.

4. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, AEM Safety Manual
(ANSI markets only), and ANSI Manual of Responsibili-

ties (ANSI markets only) is enclosed in the weather
resistant storage container.

5. “Walk-Around” Inspection – Refer to Figure 2-2. and
Figure 2-3.

6. Battery – Charge as required.

7. Fuel (Combustion Engine Powered Machines) – Add the

proper fuel as necessary.

8. Engine Oil Supply - Ensure the engine oil level is at the
Full mark on the dipstick and the filler cap is secure.

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

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

11. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems in
an area free of overhead and ground level obstructions.
Refer to Section 4 for more specific operating instruc­tions.

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

2-4 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

Function Check

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or

locks are in place;

b. Operate all functions and check all limiting and cut-

out switches;

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

2. Check the Boom Control System. Refer to Boom Control
System Check Procedure below.

3. From the platform control console:

a. Ensure that the control console is firmly secured in

the proper location;

b. Check that all guards protecting the switches or

locks are in place;

c. Operate all functions and check all limiting and cut-

out switches;

d. Check that drive is disabled when the boom is ele-

vated more than 15 degrees above horizontal or
telescoped out beyond transport mode;

e. Ensure that all machine functions are disabled

when the Emergency Stop Button is pushed in.

4. With the platform in the (stowed) position:

a. Drive the machine on a grade, not to exceed the

rated gradeability, and stop to ensure the brakes
hold;

b. Check the tilt sensor alarm to ensure proper opera-

tion.

c. Check that the boom telescope (beyond transport

mode) and lift up (more than 15° above horizontal)
functions are disabled with the axles retracted.

5. Swing the boom over either of the rear tires and ensure
that the Drive Orientation indicator illuminates and that
the Drive Orientation Override switch must be used for
the drive function to operate.

3121264 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Boom Control System Check Procedure

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

1. Extend all axles fully.

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

boom rest to horizontal.

3. Position the jib horizontal, jib straight, and platform level.

4. Extend the boom until it stops.

5. Boom must stop on colored stripe matching the capac-

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

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

2-6 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1 . F r on t St e e r W h ee l s

2. Rear Drive Wheels

3 . L i f t C y l in d er

4. Ground Control Console

5 . B a s e B o om S ec t io n

6 . I n n er M id B oo m Se c t io n

7 . O u te r M id B oo m Se c t io n

8 . F l y B o om S ec t io n

9 . B oo m As se m bl y

10. Power Track

11. Jib

12. Platform

13. Platform Control Console

3121264 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1

2

13

14

3

9

4

7

7

5

5

55

6

6

6

6

9

9

9

9

8

2

11

11

12

11

11

10

9

Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 3

2-8 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on
the diagram. Continue to the right (counterclockwise viewed
from top) checking each item in sequence for the conditions
listed in the following checklist.

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN
CORRECTED.

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

1. Platform Assembly and Gate - Footswitch works prop­erly, not modified, disabled or blocked. Latch, stop, and
hinges in working condition.

2. Platform & Ground Control Consoles - Switches and
levers return to neutral, decals/placards secure and
legible, control markings legible.

3. Boom Sections/Uprights/Turntable - See Inspection
Note.

4. Swing Drive - No evidence of damage.

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

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

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

7. Hood Assemblies - See Inspection Note.

8. Auxiliary Hydraulic Pump - See Inspection Note.

9. All Hydraulic Cylinders - No visible damage; pivot

pins and hydraulic hoses undamaged, not leaking.

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

11. Steering Spindles and Sensors - See Inspection
Note.

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

3121264 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Main Hydraulic Pump - See Inspection Note.

13. Platform Rotator - See Inspection Note.

14. Jib Rotator - See Description.

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

2-10 – JLG Lift – 3121264

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

The front axles will oscillate when the boom is in the transport
position (i.e. when the boom is less than 15° above horizontal
and not extended beyond 12" (30.4 cm).

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

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

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

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

2. From platform control station, start engine.

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

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

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

5. With boom in this position, place Drive control lever to
Reverse and carefully drive machine off of block and
ramp.

6. Have an assistant check to see that left front or right rear
wheel remains elevated in position off of the ground.

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

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

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

3121264 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-12 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

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

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

3.2 CONTROLS AND INDICATORS

NOTE: This machine is equipped with control panels that use

symbols to indicate control functions. Refer to decal
located on the control box guard in front of the control
box or by the ground controls for these symbols and the
corresponding functions.

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

Ground Control Station

NOTE: The Function Enable switch must be held

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

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

1. Indicator Panel

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

2. Boom Control System Test Button

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

3. Tel es co p e C o n tr ol

Provides extension and retraction of the boom when
positioned to IN or OUT.

3121264 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706911 A

1

13

3

2

4

5

6

7

8

9

10

11

12

Figure 3-1. Ground Control Station

1. Indicator Panel

2. Boom Control System Test Button

3. Telescope

4. Swing

5. Lift

6. Platform/Ground Select Switch

7. Hourmeter

8. Power/Emergency Stop

9. Engine Start/Auxiliar y Power/Function Enable

10. Articulating Jib

11. Platform Leveling Override

12. Platform Rotate

13. Jib Swing

3-2 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. Swing Control

Provides 360 degrees continuous turntable rotation.

5. Lift Control

Provides raising and lowering of the main boom.

NOTE: With PLATFORM/GROUND SELECT switch in the center

position, power is shut off to controls at both operating
stations.

6. Platform/Ground Select Switch

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

7. Hourmeter

Registers the amount of time the machine has been in
use, with engine running. By connecting into the oil
pressure circuit of the engine, only engine run hours are
recorded. The hourmeter registers up to 9,999.9 hours
and cannot be reset.

NOTE: When Power/Emergency Stop switch is in the “ON” posi-

tion and engine is not running, an alarm will sound, indi­cating Ignition is “ON”.

WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP
SWITCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENT
DRAINING THE BATTERY.

8. Power/Emergency Stop Switch

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

3121264 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: Auxiliary power only works if there is no engine oil pres-

sure, and is disabled if engine is running.

Functions will operate at a slower than normal rate
because of the lesser flow of hydraulic fluid delivered.

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

9. Engine Start/ Auxiliary Power Switch /Function Enable

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

To use auxiliary power, the switch must be
held “DOWN” for duration of auxiliary pump
use. Aux power can only be used if the engine
is not running.

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

10. Articulating Jib

This switch provides raising and lowering of the jib.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.

11. Platform Leveling Override

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

12. Platform Rotate

This switch permits rotation of the platform.

13. Jib Swing

This switch allows the operator to swing the jib to the left
and right.

3-4 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. High Engine Oil Temp.

5. Axles Set

6. Platform Capacity

7. Platform Overload

8. Boom Control System Warning

9. Boom Control System Calibrated

Figure 3-2. Ground Control Indicator Panel

Ground Control Indicator Panel

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

1. Battery Charging Indicator

3121264 – JLG Lift – 3-5

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

2. Low Engine Oil Pressure Indicator

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

3. High Engine Temperature Indicator

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

4. Engine Oil Temperature Indicator

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

5. Axles Set Indicator

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

6. Platform Capacity Indicator

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

SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

8. Boom Control System Warning Indicator

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

9. Boom Control System Calibrated Indicator

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

Platform Station

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

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

1. Power/Emergency Stop

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

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

3-6 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Start/Auxiliary Power

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

When pushed back, it energizes the electrically oper­ated hydraulic pump. (Switch must be held ON for dura­tion of auxiliary pump use.)

The auxiliary pump functions to provide sufficient oil flow
to operate the basic machine functions should the main
pump or engine fail. The auxiliary pump will operate
platform rotate, jib lift, jib swing, platform level override,
main boom lift, main telescope and swing.

3. Capacity Select

This switch allows the operator to select between an
operating envelope with a 500 lb. (230 kg) capacity
restriction or a 1000 lb. (450 kg) capacity restriction.

4. Drive Orientation Override

When the boom is swung over the rear tires or further in
either direction, the Drive Orientation indicator will illumi­nate when the drive function is selected. Push and
release the switch, and within 3 seconds move the
Drive/Steer control to activate drive or steer. Before driv­ing, locate the black/white orientation arrows on both
the chassis and the platform controls and match the
control direction arrow to the intended chassis direction.

NOTE: To operate the Drive Joystick, pull up on the locking ring

below the handle.

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

matically return to neutral (OFF) position when released.

5. Drive/Steer

The DRIVE joystick provides for driving either forward or
backward. The controller is ‘ramped’ to allow variable
drive speed.

Steering is controlled by a thumb operated switch on
top of the joystick.

3121264 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Engine Start / Aux Power

3. Capacity Select

4. Drive Orientation Override

5. Drive/Steer

6. Telescope

7. Lights

8. Jib Lift

9. Soft Touch Override

10. Jib Swing

11. Axle Extend/Retract

12. Soft Touch Indicator

13. Platform Rotate

14. Jib Stow Override

15. Function Speed Control

16. Main Lift / Swing

17. Drive Speed / Torque Select

18. Steer Select

19. Platform Level Override

20. Horn

21. Indicator Panel

22. Boom Control Select

Figure 3-3. Platform Control Console

3-8 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Main Telescope

This control allows extension and retraction of the main
boom.

7. Lights (If Equipped)

This switch operates accessory light packages if the
machine is so equipped.

8. Jib Lift

Provides for raising or lowering of the jib by positioning
up/down.

9. Soft Touch Override Switch (If equipped)

This switch enables the functions that were cut out by
the Soft Touch system to operate again at creep speed,
allowing the operator to move the platform away from
the obstacle that caused the shutdown situation.

NOTE: The Jib Swing function is not operable when the Capacity

Select control is in the 1000 lb. (450 kg) position.

10. Jib Swing

This switch allows the operator to swing the jib to the left
or right.

11. Axle Extend/Retract

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

12. Soft Touch Indicator (If Equipped)

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

13. Platform Rotate

This switch allows the operator to rotate the basket to
the left or right.

3121264 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

14. Jib Stow Override

This switch allows the operator to rotate the jib to the
right past the electronic stop to stow the jib under the
boom for transport.

15. Function Speed Control

This control affects the speed of telescope, main lift and
jib lift. Turning the knob all the way counterclockwise
until it clicks puts drive, main lift and swing into creep
mode.

NOTE: To operate the Main Lift/Swing Joystick, pull up on the

locking ring below the handle.

NOTE: The MAIN LIFT/SWING control lever is spring-loaded and

will automatically return to neutral (OFF) position when
released.

16. Main Lift/Swing Controller

An infinitely proportional dual axis joystick is provided
for main lift and swing. Push forward to lift up, pull back­ward to lift down. Move right to swing right, move left to
swing left.

NOTE: When boom is positioned above transport position or tele-

scoped out and any of the following switches, DRIVE
SPEED/TORQUE SELECT or FUNCTION SPEED, are posi­tioned to HIGH, high function speeds are automatically
cut out and the machine continues to operate at a lower
speed.

DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT or
FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS MORE THAN
15° ABOVE HORIZONTAL.

17. Drive Speed/Torque Select

The forward position gives maximum drive speed by
shifting the drive motors to minimum displacement and
giving high engine when drive controller is moved. The
back position gives maximum torque for rough terrain
and climbing grades by shifting the wheel motors to
maximum displacement and giving high engine speed
when drive controller is moved. The center position
allows the machine to be driven as quietly as possible
by leaving the engine at mid speed and the drive motors
in maximum displacement.

3-10 – JLG Lift – 3121264

18. Steer Select

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

To re-synchronize the front and rear axles, position the
rear drive wheels to the forward drive position by select­ing either crab or compound steer, then select front
steer (center switch position) to operate the normal
steering function.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.

19. Platform Leveling Override

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

20. Horn

If pressed, this switch supplies power to the horn.

3121264 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

21. Indicator Panel

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

22. Boom Control Select

Automatic Mode:

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

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

out.

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

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

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

Manual Mode:

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

NOTE: When positioned to Manual, boom functions will be

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

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

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

3-12 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

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

NOTE: The platform control indicator panel uses different shaped

symbols to alert the operator to different types of opera­tional situations that could arise. The meaning of those
symbols are explained below.

Indicates a potentially hazardous situation, which if
not corrected, could result in serious injury or
death. This indicator will be red.

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

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

1. Level System Fault Indicator

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

transport mode (12 inches [30.5 cm]) or elevated more
than 15° above horizontal.

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

2. AC Generator

Indicates the generator is in operation.

3. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

4. Platform Capacity Indicator

Indicates the maximum platform capacity selected for
the platform.

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

3121264 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Level System

2. AC Generator

3. Platform Overload

4. Platform Capacity

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed

10. System Distress

11. Cable Service

12. Drive Orientation

13. Axles Set

14. Boom Control System Warning

Figure 3-4. Platform Control Indicator Panel

3-14 – JLG Lift – 3121264

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Tilt Alarm Warning Light and Alarm

Indicates that the chassis is on a slope. An alarm will
also sound when the chassis is on a slope and the
boom is above transport position. If lit when the boom is
raised or extended, retract and lower to below horizontal
then re-position machine so that it is level (within the
rated 3 degrees) before continuous operation. If the
boom is above transport position or telescoped, out and
the machine is on a slope, the tilt alarm warning light will
illuminate and an alarm will sound and CREEP is auto­matically activated.

IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND
LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT
IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM MORE
THAN 15 DEGREES ABOVE HORIZONTAL.

6. Glow Plug Indicator

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

7. Footswitch/Enable Indicator

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

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

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE
THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN
SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT­TOM.

3121264 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Fuel Level Indicator

Indicates the level of fuel in the fuel tank.

9. Creep Speed Indicator

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

10. System Distress Indicator

The light indicates that the JLG Control System has
detected an abnormal condition and a Diagnostic Trou­ble Code has been set in the system memory. Refer to
the Service Manual for instructions concerning the trou­ble codes and trouble code retrieval.

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

11. Cable Service Indicator

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

12. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or
further in either direction, the Drive Orientation indicator
will illuminate when the drive function is selected. This is
a signal for the operator to verify that the drive control is
being operated in the proper direction (i.e. controls
reversed situations).

13. Axles Set Indicator

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

3-16 – JLG Lift – 3121264

14. Boom Control System Warning Indicator

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

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121264 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-18 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

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

The primary operator control station is in the platform. From
this control station, the operator can drive and steer the
machine in both forward and reverse directions. The opera­tor can raise or lower the upper or lower boom or swing the
boom to the left or right. Standard boom swing is 360 degree
continuous left and right of the stowed position. The machine
has a Ground Control Station which will override the Platform
Control Station. Ground Controls operate Boom Lift and
Swing, and are to be used in an emergency to lower the plat­form to the ground should the operator in the platform be
unable to do so.

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

The boom can be raised more than 15° above horizontal with
or without any load in platform, if:

1. Machine is positioned on a smooth, firm and level (up to
the rated 3 degrees) surface.

2. Axles are extended.

3. Load is within manufacturer’s rated capacity.

4. All machine systems are functioning properly.

5. Proper tire pressure.

6. Machine is as originally equipped from JLG.

3121264 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Controlled Arc

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

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

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

4-2 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

BUFFER LINE

ENVELOPE

SLOWDOWN LINE

BUFFER
ZONE

SLOWDOWN
ZONE

Envelope Tracking

When the platform approaches the edges of the operating
envelope all machine functions are slowed down automati­cally by the boom control system to reduce machine
motions.

NOTE: Boom Control System in Automatic Mode: When the

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

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

Controlled Angle

The control system automatically maintains a constant ele­vated boom angle when swinging the turntable. If the boom
angle is at 30 degrees, swing engaged by itself shall add lift
to maintain the relative boom angle at 30 degrees.

Swing Speed Proportioning

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

3121264 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-1. Dual Capacity Decal

Stability

Machine stability is based on two (2) conditions which are
called FORWARD and BACKWARD stability. The machine’s
position of least FORWARD stability is shown in (See Figure
4-2.), and its position of least BACKWARD stability is shown
in (See Figure 4-3.)

TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD
MACHINE OR OPERATE THE MACHINE ON A SURFACE OUT-OF-LEVEL
MORE THAN THE RATED 3 DEGEES.

4.3 CAPACITY SELECT

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

NOTE: Operation in the 1000 pound (450 kg) envelope requires

the jib to be fixed in the centered position.

4-4 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Forward Stability

3121264 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-3. Position of Least Backward Stability

.

4.4 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure

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

NOTE: Diesel engines only: After turning on ignition, operator

must wait until glow plug indicator light goes out before
cranking engine.

1. Turn key of SELECT switch to GROUND. Position
POWER/EMERGENCY STOP switch to ON, then push
the ENGINE START switch until engine starts.

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED
BEFORE APPLYING ANY LOAD.

2. After engine has had sufficient time to warm up, shut
engine off.

4-6 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

3. Turn SELECT switch to PLATFORM.

4. From Platform, pull POWER/EMERGENCY STOP switch

out, then push the ENGINE START switch until engine
starts.

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

starter will operate. If starter operates with footswitch in
the depressed position, DO NOT OPERATE MACHINE.

Shutdown Procedure

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUT­DOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTART­ING THE ENGINE.

1. Remove all load and allow engine to operate at low
speed for 3-5 minutes; this allows further reduction of
internal engine temperature.

2. Push POWER/EMERGENCY STOP switch in.

3. Turn MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed informa­tion.

4.5 TRAVELING (DRIVING)

NOTE: When the boom is raised approximately 15 degrees

above horizontal, all drive functions will be disabled.

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A
SMOOTH, FIRM AND LEVEL (UP TO THE RATED 3 DEGREES) SURFACE.

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

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

3121264 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

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

Traveling Forward and Reverse

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

2. Position Drive controller to FORWARD or REVERSE as
desired.

This machine is equipped with a Drive Orientation Indicator.
The yellow light on the platform control console indicates
that the boom is swung beyond the rear drive tires and the
machine may Drive/Steer in the opposite direction from the
movement of the controls. If the indicator is illuminated,
operate the Drive function in the following manner:

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

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

4.6 STEERING

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

4.7 EXTENDING THE AXLES

NOTE: The operator must be driving the machine (forward or

reverse) in order to extend the axles.

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

4-8 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

G

R

A

D

E

LEVEL

S

I

D

E

S

L

O

P

E

Figure 4-4. Grade and Side Slopes

3121264 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.8 PLATFORM

Platform Level Adjustment

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.

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

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

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

Platform Rotation

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

4.9 BOOM

DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN
MACHINE IS OUT OF LEVEL MORE THAN THE RATED 3 DEGREES.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE
CHASSIS.

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN
DRIVE MACHINE TO A LEVEL SURFACE (WITHIN THE RATED 3
DEGREES) BEFORE RAISING BOOM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON­TROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE­MENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN
RELEASED.

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

4-10 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Swinging the Boom

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

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

Raising and Lowering the Boom

NOTE: The lift function is not operable above 15 degrees above

horizontal if the axles are not fully extended.

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

Telescoping the Boom

NOTE: The telescope function is not operable beyond the trans-

port position if the axles are not fully extended.

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

Swinging the Jib

NOTE: For 1000 lb. (450 kg) mode operation, the jib must be

centered and the Jib Swing function is not operable. If the
jib is out of the centered position when in this mode, the
jib swing function will allow the operator to center the jib
again.

To swing the jib, use the Jib Swing control to select Right or
Left direction.

4.10 FUNCTION SPEED CONTROL

This control affects the speed of telescope, main lift and jib
lift. Turning the knob all the way counterclockwise until it
clicks puts drive, main lift and swing into creep mode.

3121264 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Figure 4-5. Drive Disconnect Hub

4.11 EMERGENCY TOWING

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING
BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT
ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL­LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)

MAXIMUM TOWING GRADE 25%.

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

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

2. Disconnect drive hubs by inverting disconnect cap.

3. Reconnect the drive hubs by inverting the disconnect

cap when towing is complete.

4-12 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

4.12 SHUT DOWN AND PARK

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

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Posi-

tion Platform/Ground Select switch to center OFF.

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

4.13 LIFTING AND TIE DOWN

See Figure 4-6. and Figure 4-7.

Lifting

1. Refer to the Serial Number Plate, Specifications section
of this manual, or weigh the individual unit to find out the
Gross Vehicle Weight.

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

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the desig-

nated lifting points.

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

3121264 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Tie Down

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

NOTE: When loading the machine onto a trailer, it will be neces-

sary to rotate the turntable 180 degrees to provide better
weight distribution.

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

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or

chains of adequate strength and attached to the desig­nated tie down points.

4.14 STOWING THE JIB FOR TRANSPORT

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

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

NOTE: The Jib Swing function is not operable when the Capacity

Select control is in the 1000 lb. (450 kg) position.

NOTE: Automatic platform leveling is disabled when stowing the

jib.

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

4-14 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Figure 4-6. Lifting and Tie Down Chart - Sheet 1 of 2

3121264 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

38’11”/11.86 m

11’2”/3.40 m

27’9"/8.46 m

R

Figure 4-7. Lifting and Tie Down Chart - Sheet 2 of 2

4-16 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Location Sheet 1 of 5

3121264 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Location Sheet 2 of 5

4-18 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location Sheet 3 of 5

3121264 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Location Sheet 4 of 5

4-20 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Location Sheet 5 of 5

3121264 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001120455-1

1- -

2 1701499

3- -

4- -

5 1701509

6 1701529

7 1703811

8 1703814

9 1704277

10 1704412

11 - -

12 - -

13 3251243

14 - -

15 1705337

16 - -

17 - -

18 1703953

Item # ANSI

1001120455-1

19 1702868

20 1703797

21 1001120457

22 1703804

23 1703805

24 - -

25 3251813

26 1705492

27 1702631

28 1705168

29 1705181

30 1700584

31 1706751

32 1705868

33 1705351

34 1701505

35 1704972

36 1705511

37 1701501

38 - -

4-22 – JLG Lift – 3121264

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001120455-1

39 - -

40 - -

41 - -

42 - -

43 - -

44 - -

45 - -

46 - -

47 - -

48 - -

49 - -

50 - -

51 - -

52 - -

53 - -

54 - -

55 - -

56 - -

57 - -

58 - -

Item # ANSI

1001120455-1

59 - -

60 - -

3121264 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

NOTES:

4-24 – JLG Lift – 3121264

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

This section explains the steps to be taken in case of an
emergency situation while operating.

5.2 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, the factory should be contacted by tele­phone and provided with all necessary details.

In USA:
JLG Phone: 877-JLG-SAFE (554-7233)

Outside USA:
240-420-2661

E-mail:

[e-mail]

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 ACCIDENT, THOROUGHLY INSPECT THE MACHINE
AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS,
THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10
FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF
REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:

1. Other personnel should operate the machine from
ground controls only as required.

2. Other qualified personnel on the platform may use the
platform controls. DO NOT CONTINUE OPERATION IF
CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to
remove platform occupants and stabilize motion of the
machine.

3121264 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in
overhead structures or equipment, rescue platform occu­pants prior to freeing the machine.

Boom Movement Prevented By Boom Control System

Lowering the boom onto an object or structure, with the
boom at high angles, may cause the boom control system to
prevent movement of the machine. This can include move­ment necessary to lift the boom off the object. Movement of
the boom can be regained by observing the following:

1. Shut off the engine.

2. Rescue platform occupants prior to freeing machine.

3. Use cranes, forklifts or other equipment to stabilize

motion of the machine as required.

4. From the ground control position, use the Auxiliary
Power System to carefully raise the boom off the object.

5. Once clear, restart the engine and return the platform to
the ground.

6. Inspect the machine for damage before continued use
of the machine.

5.4 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly equipped.
However, provisions for moving the machine have been
incorporated. For specific procedures, refer to Section 4.

5-2 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 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.

Other Publications Available:

Service and Maintenance Manual ............................ 3121265

Illustrated Parts Manual ............................................ 3121266

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications

Maximum Work Load (Capacity)
Unrestricted
R es t ri c te d

Max.Vertical Platform Height (Unrestricted) 110 f t. (33.5 m)

Max.Vertical Platform Height (Restricted) 110 ft. (33.5 m)

Max.Horizontal Platform Reach (Unrestricted) 76 f t. (23.1 m)

Max.Horizontal Platform Reach (Restricted) 68 f t. (20.7 m)

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 100 lb (450 N)

JibPLUS
L en g t h
H or i z on t al M ot i on
Ve r t i ca l M ot i on

500 lb (230 kg)
1000 lb. (450 kg)

8ft. (2.44m)
180° working, 244° stowed
130° (+75/-55)

3121264 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Dimensional Data Chassis

Table 6-2. Dimensional Data

Overall Width
Axles Retracted
A xl e s Ex t en d ed

Stowed Height 10ft. (3.04 m)

Stowed Length (Transpor t Mode) 38f t. 11in. (11.86 m)

Stowed Length (Working Mode) 48ft. 11in. (14.91 m)

Wheelbase 12ft. 6in. (3.81 m)

Tailswing 5ft. 6 in. (1.6 m)

Ground Clearance (Axle) 12 in. (30.4 cm)

Ground Clearance (Chassis) 25.5 in. (64.7 cm)

8ft. 2in. (2.49 m)
12ft. 6in. (3.8 m)

Table 6-3. Chassis Specifications

Maximum Travel Grade With boom in
stowed position (Gradeability)

Maximum Travel Grade With boom in
stowed position (Side Slope)

Maximum Elevated Operating Slope 3°

Turning Radius (Axles Retracted)
O ut s i de
I ns i d e

Turning Radius (Axles Extended)
I ns i d e
O ut s i de

Max Tire Load 26,250 lbs. (11,907 kg)

Max Ground Bearing Pressure

Maximum Drive Speed 3.25 mph (5.2 kph)

Max. Hydraulic System Pressure 4600 psi (317 Bar)

Electrical System Voltage 12 Volts

Gross Machine Weight (Platform Empty) 44,750 lb. (20,298 kg)

22 ft. 6 in. (6.8 m)
14 ft. 5 in. (4.4 m)

19 ft. 4 in. (5.9 m)

105 psi (7.38 kg/cm

45%

5°

8 ft. (2.4 m)

2

)

6-2 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-4. Capacities

Hydraulic Tank 55 gallons (208 liters)

Fuel Tank 31 gallons (117 liters)

Hydraulic System 66 gallons (250 liters)

Table 6-5. Tire Specifications

Size 445/50D710

Load Range J

Ply Rating 18

Load Rating 26,500 lbs. @ 100 psi (12020 kg

@ 6.9 Bar)

Foam Fill Poly urethane HD (55 Durometer)

Foam

Max Tire Load 26,250 lbs. (11,907 kg)

Table 6-6. Deutz TD2011L4 Specifications

Type Liquid Cooled

Number of Cylinders 4

Bore 3.7 in. (94 mm)

Stroke 4.4 in. (112 mm)

Total Displacement 190 cu. in. (3108 cm³)

Compression Ratio 17.5

Firing Order 1-3-4-2

Output 75hp (56 kW)

Oil Capacity
Cooling System
w /F i l te r
Total Capacity

5 Quar ts (4.5 L)
11 Quarts (10.5 L)
16 Quar ts (15 L)

Average Fuel Consumption 1.1 gph (4.1 lph)

Idle Engine RPM 1200

Mid Engine RPM 1800

High Engine RPM 2475

Capacities

Tires

3121264 – JLG Lift – 6-3

Engine Data

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-7. Hydraulic Oil Specifications

Hydraulic System Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F

(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Hydraulic Oil

Density, Lb/Gal. 60°F 7.35

Brookfield, cP at -18°C 2700

NOTE: Hydraulic oils must have anti-wear qualities at least to API

Service Classification GL-3, and sufficient chemical stabil­ity for mobile hydraulic system service. JLG Industries
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity index of 152.

NOTE: When temperatures remain consistently below 20

degrees F. (-7 degrees C.), JLG Industries recommends

6-4 – JLG Lift – 3121264

the use of Mobil DTE13.

Aside from JLG recommendations, it is not advisable to mix oils
of different brands or types, as they may not contain the same
required additives or be of comparable viscosities. If use of
hydraulic oil other than Mobilfluid 424 is desired, contact JLG
Industries for proper recommendations.

Table 6-8. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-9. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max

-40°F (-40°C)

Flash Point, Min.

330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

Table 6-10. UCon Hydrolube HP-5046

Typ e Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -5 8°F (- 50°C)

pH 9.1

Viscosity

at 0° C (32° F) 340 cSt (1600SUS)

at 40° C (104° F) 46 cSt (215SUS)

at 65° C (150° F) 22 cSt (106SUS)

Viscosity Index 170

3121264 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-11. Mobil EAL H 46 Specs

Typ e Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44 °F (-4 2°C)

Flash Point 500°F (260°C)

Operating Temp. 0 to 180°F (-17 to 162°C)

Weight 7.64 lb. per gal.

(0.9 kg per liter)

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

Table 6-12. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be checked

on a yearly basis for viscosity.

6-6 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Major Component Weights

Table 6-13. Component Weights

Component Pounds Kilograms

Tire & Wheel 867 393

Drive Hub & Motor 275.5 123

Swing Drive 290 132

Engine Assembly 1275 579

Boom (Complete) 11850 5375

Lift Cylinder 787 357

Te le C yl in d er 1322 600

Jib Cylinder 69 31

Axle Oscillation Cylinder 74 34

Axle Extend Cylinder 92 42

Level Cylinder 89 40

Platform 36 x 96 24 5 111

Platform 36 x 72 195 89

Counterweight 8500 3856

T/T Assy. (less Cwt) 9450 4286

3121264 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

-40° F(-40° C)

-30° F(-34° C)

-20° F(-29° C)

-10° F(-23° C)

0° F(-18° C)

10° F(-12° C)

20° F(-7° C)

30° F(-1° C)

40° F(4° C)

50° F(10° C)

60° F(16° C)

70° F(21° C)

80° F(27° C)

90° F(32° C)

100° F(38° C)

110° F(43° C)

120° F(49° C)

ENGINE

SPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATURE

WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER

PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR

GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

SUMMER

GRADE

FUEL

WINTER

GRADE

FUEL

WINTER

GRADE

FUEL
WITH

KEROSENE

ADDED

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

Figure 6-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2

6-8 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS

EXIST JLG HIGHLY RECOMMENDS

THE ADDITION OF A HYDRAULIC

OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

PROLONGED OPERATION IN
AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE.

EXTENDED DRIVING WITH
HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82°C) OR ABOVE.

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

M

O

B

I

L

4

2

4

1

0

W

-

3

0

HYDRAULIC
SPECIFICATIONS

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE

E

X

X

O

N

U

N

I

V

I

S

H

V

I

2

6

M

O

B

I

L

D

T

E

1

3

NOT E:

1) RECOMME NDAT IONS ARE FOR AMBIE NT TEMPERATURES
CO NS ISTANTLY WIT HIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED T O BE AT SEA LEVE L.

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 102030405060

% OF ADDED KE ROSENE

A

M

B

I

E

N

T

T

E

M

P

E

R

A

T

U

R

E

SUMMER-GRADE
FUEL

WINTER-GRADE
FUEL

Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2

4150548-D

3121264 – JLG Lift – 6-9

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-3. Lubrication and Maintenance Point Location

6-10 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-

3., Lubrication and Maintenance Point Location.

Table 6-14. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 35 0° F

(177° C). Excellent water resistance and adhesive qualities, and
being of extreme pressure type.
(Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API service classifica-

tion GL-5 or MIL-Spec MIL-L-2105

HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION
UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT
OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON­DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD­INGLY.

NOTE: It is recommended as a good practice to replace all filters

at the same time.

1. Swing Bearing - Remote Lube

Lube Point(s) - 2 Grease Fitting
Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hours of operation

3121264 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Swing Gearbox

Lube Point(s) - Fill Plug
Capacity - 79 ounces (2.3 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.

3. Swing Brake

Lube Point(s) - Fill Plug
Capacity - 2.7 ounces (80 ml)
Lube - DTE24
Interval - Check level every 150 hrs/Change every 1200
hours of operation.

6-12 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Wheel Drive Hub - Bonfiglioli

Lube Point(s) - Level/Fill Plug
Capacity - 2.1 quarts (2 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every 1200

hours of operation

Comments - Place Fill port at 12 o’clock position and

Check port at 8 o’clock position. Pour lubricant into fill
port until it just starts to flow out of check port.

Wheel Drive Hub - Reggiana Riduttori

Lube Point(s) - Level/Fill Plug
Capacity - 0.5 quarts (0.5 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every 1200

hours of operation

Comments - Place Fill port at 12 o’clock position and

Check port at 3 o’clock position. Pour lubricant into fill
port until it just starts to flow out of check port.

3121264 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

FULL LEVEL (HOT OIL)

FULL LEVEL (COLD OIL)

5. Hydraulic Return Filter

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 300 hours
thereafter or as indicated by condition indicator

6. Hydraulic Charge Filter

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and every 300 hours
thereafter or as indicated by condition indicator.

7. Hydraulic Oil

Lube Point(s) - Fill Cap
Capacity - 55 gallons (208 liters) Tank
Lube - HO
Interval - Check level daily. Change every 2 years or 1200
hours of operation.

6-14 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. Suction Strainers (In Tank)

Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation.
Remove and clean at time of hydraulic oil change.

9. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element
Capacity ­ 5 Quarts (4.5 L) Cooling System
11 Quarts (10.5 L) w/Filter
16 Quarts (15 L) Total Capacity
Lube - EO
Interval - Check level daily; change every 500 hours or six

months, whichever comes first. Adjust final oil level by
mark on dipstick.

3121264 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

10. Fuel Filter - Deutz

Lube Point(s) - Replaceable Element
Interval - Every year or 600 hours of operation

11. Fuel Strainer

Lube Point(s) - Replaceable Element
Interval - Every year or 600 hours of operation

6-16 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

12. Air Filter - Deutz

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator

13. Platform Filter

Lube Point(s) - Replaceable Element
Interval - Change after first 50 hours and then every year

or 600 hours of operation thereafter

3121264 – JLG Lift – 6-17

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.4 TIRES & WHEELS

Tire Inflation

The air pressure for pneumatic tires must be equal to the air
pressure that is stenciled on the side of the JLG product or
rim decal for safe and proper operational characteristics.

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that when
any cut, rip, or tear is discovered that exposes sidewall or tread
area cords in the tire, measures must be taken to remove the
JLG product from service immediately. Arrangements must be
made for replacement of the tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recom­mends that when any of the following are discovered, measures
must be taken to remove the JLG product from service immedi­ately and arrangements must be made for replacement of the
tire or tire assembly.

• a smooth, even cut through the cord plies which

exceeds 3 inches (7.5 cm) in total length

•any tears or rips (ragged edges) in the cord plies

which exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, the tire
must be inspected on a daily basis to insure the damage has
not propagated beyond the allowable criteria.

Tire Replacement

JLG recommends a replacement tire be the same size, ply and
brand as originally installed on the machine. Please refer to the
JLG Parts Manual for the part number of the approved tires for a
particular machine model. If not using a JLG approved replace­ment tire, we recommend that replacement tires have the follow­ing characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to
the original

• Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneu­matic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to the pressure recommended

6-18 – JLG Lift – 3121264

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

by JLG. Due to size variations between tire brands, both tires
on the same axle should be the same.

Wheel Replacement

The rims installed on each product model have been designed
for stability requirements which consist of track width, tire pres­sure, and load capacity. Size changes such as rim width, center
piece location, larger or smaller diameter, etc., without written
factory recommendations, may result in an unsafe condition
regarding stability.

Wheel Installation

It is extremely important to apply and maintain proper wheel
mounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI­BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE
TO USE ONLY THE 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. If
you do not have a torque wrench, tighten the fasteners with a

lug wrench, then immediately have a service garage or dealer
tighten the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming the
mounting stud holes in the wheels. The proper procedure for
attaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.

2. Tighten nuts in the following sequence:

3121264 – JLG Lift – 6-19

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3. The tightening of the nuts should be done in stages. Fol­lowing the recommended sequence, tighten nuts per
wheel torque chart.

Table 6-15. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

45 ft. lbs.

(60 Nm)

4. Wheel nuts should be torqued before first road use and
after each wheel removal. Check and torque every 3
months or 150 hours of operation.

100 ft. lbs.

(140 Nm)

180 ft. lbs.

(252 Nm)

6.5 SUPPLEMENTAL INFORMATION

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 106 dB.

The vibration total value to which the hand-arm system is

subjected does not exceed 2,5 m/s
square value of weighted acceleration to which the whole

body is subjected does not exceed 0,5 m/s

2

. The highest root mean

2

.

6-20 – JLG Lift – 3121264

SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 7-1. Inspection and Repair Log

Date Comments

SECTION 7 - INSPECTION AND REPAIR LOG

3121264 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3121264

TRANSFER OF OWNERSHIP

To Product Owner:

If you now own but ARE NOT the original purchaser of the product covered by this

manual, we would like to know who you are. For the purpose of receiving safety-related

bulletins, it is very important to keep JLG Industries, Inc. updated with the current

ownership of all JLG products. JLG maintains owner information for each JLG product

and uses this information in cases where owner notification is necessary.

Please use this form to provide JLG with updated information with regard to the

current ownership of JLG products. Please return completed form to the JLG Product

Safety & Reliability Department via facsimile or mail to address as specified below.

Thank You,

Product Safety & Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

Telephone: [phone]

Fax: [phone]

NOTE: Leased or rented units should not be included on this form.

Mfg. Model: _____________

__________________________________________________

Serial Number: ____________________________________________________________

Previous Owner: ___________________________________________________________

Address: _________________________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______

) ____________________

Date of Transfer: _________________________________

Current Owner: ____________________________________________________________

Address: _______________

__________________________________________________

_________________________________________________________________________

Country: _________________________ Telephone: (_______

) ____________________

Who in your organization should we notify?

Name: ___________________________________________________________________

Title:____________________________________________________________________

An Oshkosh Corporation Company