JLG 110HX Operator Manual

Operators and Safety Manual

Model

100HX

100HX+10

110HX

ANSI

3120635

April 20, 2000

– JLG Lift –

FOREWORD

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR .

BECAUSE THE MANUFACTURER HAS NO DI RECT CONTROL OVER MA CHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER­ATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITI ONS, WITH NO DE VIA TION S FROM THE OR IGINAL DESIG N. ALT ERA TION AND /OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA RE GUL ATIONS AND APPLICABL E ANSI STANDARDS.

THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.

Safety of personnel and proper u se of the m achine are of primary concern, DANGER, WARNING, CAU­TION, IMPORTANT, INSTRUCTIONS and NOTE are i nserted throughout this manual to emphasize t hese

areas. They are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR
DEATH.]

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE
INJURY. IT MAY ALSO BE USED TO ALERT AGAINST UNSAFE
PRACTICES

JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHOR IZED JLG DISTR IBUTOR FOR INFORMATION CONCERNING SAF ETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM­PLETED ON THE AFFECTED JLG PRODUCT

WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
OR DEATH.

IMPORTANT OR INSTRUCTIONS INDICATES A PROCEDURES
ESSENTIAL FOR SAFE OPERATION AND WHICH, IF NOT FOL­LOWED, MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
MACHINE.

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.

3120635 – JLG Lift – a

FOREWORD

This page left blank intentionally.

b – JLG Lift – 3120635

FOREWORD

All procedures herein are based on the use of the
machine under proper operating conditions, with no
deviation s fr om or igin al desi gn i nte nt. .. as p er OSHA
regulations and applicable ANSI standards.

READ & HEED!

The ownership, use, service, and/or maintenance of
this machine is su bject to various governmental and
local laws and regu la tio ns. It is th e re sp ons ibil it y of
the owner/user to be knowledgeable of these laws
and regulations and to comply with them. Owner/
user/operator/lessor and lessee must be familiar
with Sections 6,7,8,9, and 10 of ANSI A92.5-1992.
These sections contain the responsibilities of the
owner, users, operators, lessors, and lessees con­cerning safety, training, inspection, maintenance,
application and operation. The most prevalent regu­lations of this type in the United States are the Fed­eral OSHA Safety Regulations*. Listed below, in
abbreviated form are some of the requirements of
Federal OSHA regulations in effect as of the date of
publication of this handbook.

The listing of these requirements shall not relieve
the owner/user of the responsibility and obligation
to determine all applicable laws and regulations and
their exact wording and re quirements, and t o com­ply with the requirements. Nor shall the listing of
these requirements constitute an assumption of
responsibility of liability on the part of JLG Indus­tries, Inc.

1. Only trained and authoriz ed operat ors shall be
permitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until
repaired.

3. The controls shall be plainly marked as to their
function.

4. The controls shall be tested each day prior to
use to determ in e that they are in safe ope ra t in g
condition.

5. All personnel in the platform shall, at all times,
wear approved fall protection devices and
other safety gear as required.

6. Load limits specified by the manufacturer shall
not be exceeded.

7. Instruction and warning placards mu st be legi­ble.

8. Aerial lifts may be field modified for us es other
than those in te nd ed by the manufacturer only if
certified in writ ing by the m anufactur er to be in
conformity to JLG requirements and to be at
least as safe as it was prior to modification.

9. Aerial lifts shall not be used near electric power
lines unless the lines have been de energized
or adequate clearance is maintained (See
OSHA 29 CFR 1910.67 and 1926.453).

10. Employees using aeri al lifts shall be instructed
on how to rec ognize and avoid un safe condi­tions and hazards.

11. Ground controls shall not be operated unless
permission has be en obtained fro m personnel
in the platform, except in case of an emer­gency.

12. Regular inspection of the job site and aerial lift
shall be perfor med by competent persons.

13. Person n el s hall always stand on the floor of the
platform, not on boxes, p lanks, railing or other
devices, for a work position.

*Applicable Federal OSHA regulations for the
United States, as of the date of publicat ion of this
manual, include, but are not limited to, 29 CFR

1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR

1926.28, and 29 CFR 1926.453. Consult the current

regulations for the exact wording and full text of the
requirement and contact the closest Federal OSHA
office for specific interpretations.

3120635 – JLG Lift – c

FOREWORD

REVISON LOG

September, 1988 - Original Issue
August, 1989 - Revised
August, 1997 - Revised
January, 1999 - Revised
Prop65 page added - Updated 4-20-00
4-1 - Updated 4-20-00

d – JLG Lift – 3120635

TABLE OF CONTENTS

TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - FOREWORD

SECTION 1 - SAFETY PRECAUTIONS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Electrocut ion Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.4 Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8

SECTION 2 - PREPARATION AND INSPECTION

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery and Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.5 Daily Func t ional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2.6 Torque Req uirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2.7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

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

3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Operati ng Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 Contro ls and Ind icators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3.5 Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-14

SECTION 4 - MACHINE OPERATION

4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Engine Op e r at ion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Traveling (Driving). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5 Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.6 Parking and St owing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.7 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.8 Axles, Extending and Retracting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.9 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.10 Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4.11 Tie Down and Lift ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4.12 Steer/tow Selector (If Equipped). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4.13 Towing (If Equip pe d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

SECTION 5 - OPTIONAL EQUIPMENT

5.1 Rotator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Dual Fuel System (Gas Engine Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 Tow Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.4 Travel Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.5 Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.6 Electric Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.7 Foam Filled Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.8 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.9 Cylinder Bellows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.10 Boom Wipers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.11 Hostile Environment Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

3120635 – JLG Lift – i

TABLE OF CONTENTS

(Continued)

TABLE OF CONTEN TS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

5.12 Motion Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.13 Desert Environment Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.14 110 Volt/ 60Hz Ge nerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.15 220 Volt Re ceptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.16 Spark A rr e st or Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.17 110 Volt Re ceptacle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION 6 - EMERGENCY PROCEDURES

6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Emergency Con t r ol s and Their Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 Emergency Ope ra t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

SECTION 7 - INSPECTION AND RE PAI R LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Machine Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Daily Walk-Around Inspection Points - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-4. Daily Walk-Around Inspection Points - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-5. Lubrication Point Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2-6. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

3-1. Positi on of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Position of Least Backward Stabi l ity - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Position of Least Backward Stability - 100HX +10 and 110HXER . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Ground Control Station Dual Capacity Only - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-5. Ground Control Station - Single Capacity Only - 100HX+10 and 110HXER. . . . . . . . . . . . . . . . .3-8

3-6. Platform Station - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11

3-7. Platform Station - 100HX+10 and 110HXER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-8. Caution, Danger, Warning Decal Location - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

3-9. Caution, Danger, Warning Decal Location - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-10. Common Symbols - Sheet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-19

3-11. Common Symbols - Sheet 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-12. Common Symbols - Sheet 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

3-13. Common Symbols - Sheet 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-22

4-1. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4-2. Lifting t h e Axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-3. Lifting Chart - 100HX and 110HX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4-4. Lifting Chart - 110HXER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-5. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -11

4-6. Drive Disconnect Hug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 M ini mum Safe Approach Distances (M.S.A.D.) to energi ze d (exposed or insulated)

power lines and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

2-1 Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1 0

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

ii – JLG Lift – 3120635

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section prescribes the proper and sa fe practices for
major areas of machine usage. In order to prom ote prop er
usage of the machine, it is mandatory that a daily routine
be established based on instructions given in this section.
A maintenance pr ogram must be also be esta bl ished by a
qualified person and must be follow ed to ensure t hat the
machine is safe to operate.

The owner/user/operator of the machine should not
accept operating responsibility until this manual has been
read and understood, and operation of the machine,
under the supervision of an exper ienced and qu alified per ­son, has been completed. Owner/user/operator must be
familiar with Sections 6, 7, 8, 9, and 10 of ANSI A92.5-

1992. These sections contain the responsibilities of the
owner, users, operator s, lessors and lessees concerning
safety, training, inspection, maintenance, application and
operation. If there is a question on application and or
operation, JLG Industr ies Inc., should be consulted.

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

1.2 DRIVING/TOW ING

Before driving the machine, the user must be familiar with
the drive, steer and stopping characteristics. This is espe­cially important when driving in close quarters.

The user should be familiar with the driving surface before
driving. The surface s hould be firm and level an d grades
should not exceed the allowable grade for the machine.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

The machine is not equipped with provisions for towing.
Refer to Section 6 for emergency towing procedures.

SPECIAL NOTE:

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION AND ON THE MACHINE COULD RESULT IN
MACHINE DAMAGE, PERSONNEL INJURY OR DEATH, AND IS A
SAFETY VIOLATION.

3120635 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

Table 1-1. Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V 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)

DANGER: DO NOT maneuver machine or personnel inside PROHIBITED ZONE. ASSUME all electrical parts and wiring
are ENERGIZED unless known otherwise.

1.3 ELECTROCUTION HAZARD

MINIMUM SAFE APPROACH DIST ANCE

in Feet (Meters)

FROM CONTACT WITH OR PROXIMITY TO AN ELEC­TRICALLY CHARGED CONDUCTOR.

• MAINTAIN A CLEARANCE OF AT LEAST 10 FEET (3
M) BETWEEN ANY PART OF THE MACHINE OR ITS
LOAD AND ANY ELECTRICAL LI NE OR APPARATUS
CARRYING UP TO 50,000 VOLTS. ONE FOOT ADDI­TIONAL CLEARANCE IS REQUIRED FOR EVERY
ADDITIONAL 30,000 VOLTS OR LES S.

1.4 PRE-OPERATIONAL

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

• MAINTAIN SAFE CLEARANCE FROM ELECTRICAL
LINES AND APPARATUS. ALLOW FOR BOOM SWAY,
ROCK OR SAG AND ELECTRICAL LINE SWAYING.
THE MACHINE DOES NOT PROVIDE PROTECTION

• ALLOW ONLY AUTHORIZED AND QUALIFIED PER­SONNEL TO OPERATE MACHINE W HO HAVE DEM­ONSTRATED THAT THEY UNDERSTAND SAFE AND
PROPER OPERATION AND MAINTENANCE OF THE
UNIT.

1-2 – JLG Lift – 3120635

SECTION 1 - SAFETY PRECAUTIONS

• AN OPERATOR MUST NOT ACCEPT OPERATING
RESPONSIBILITIES UNTIL ADEQUATE TRA INING HAS
BEEN GIVEN BY COMPETENT AND AUTHORIZED
PERSONS.

• BEFORE OPERATION, CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES, MAC HINE TRAFFIC
SUCH AS BRIDGE CRANES, H IGHW AY, RAILWAY AND
CONSTRUCTION EQUIPMENT.

• NEVER DISABLE OR MODIFY THE FOOTSWITCH OR
ANY OTHER SAFETY DEVICE. ANY UNAUTHORIZED
MODIFICATION OF THE MA CHINE IS A SAFETY VIO­LATION AND IS A VIOLATION OF OSHA REGULA­TIONS AND ANSI STANDARDS.

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN
THE WORK AREA MUST BE TAKEN BY THE OPERA­TOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS
BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.

• ENSURE DAILY INSPECTION AND FUNCTION CHECK
IS PERFORMED PRIOR TO PLACING MACHINE INTO
OPERATION.

• DO NOT OPERATE MACHINE WHEN WIND CONDI­TIONS EXCEED 30 MPH (48 KMH).

• NEVER OPERATE BOOM FUNCTIONS (TELE, SWING,
LIFT) WHEN MACHINE IS ON A TRUCK, OTHER VEHI­CLE, OR ABOVE GROUND STRUCTURE.

• THIS MACHINE CAN BE OPERATED IN NOMINAL
AMBIENT TEMPERATURES OF 0° F TO 104° F (-20°C
TO 40°C). CONSULT FACTORY TO OPTIMIZE OPER­ATION OUTSIDE THIS RANGE.

• APPROVED HEAD GEAR MUST BE WORN BY ALL
OPERATING AND GROUND PERSONNEL.

3120635 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

.

• READ AND OBEY ALL DANGERS, WARNINGS, CAU­TIONS AND OPERATING INSTRUCTIONS ON
MACHINE AND IN THIS MANUAL.

• BE FAMILIAR WITH LOCATI ON AND OPERATION OF
GROUND STAT ION CONTROLS.

• ALWAYS POSITION BOOM OVER REAR (DRIVE) AXLE
IN LINE WITH DIRECTION OF TRAVEL. REMEMBER,
IF BOOM IS OVER FRONT (STEER) AXLE, DIRECTION
OF STEER AND DRIVE MOVEMENT WILL BE OPPO­SITE FROM NORMAL OPERATION.

• ALWAYS USE THREE POINT CONTACT WHEN
ENTERING OR EXITING THE MACHINE. FACE THE
MACHINE WHEN YOU ENTER OR LEAVE. THREE
POINT CONTACT MEANS THAT TWO HANDS AND
ONE FOOT OR O NE HAND AN D TWO F EET ARE IN
CONTACT WITH THE MACHINE AT ALL TIMES DUR­ING MOUNT AND DISMOUNT.

1.5 DRIVING

• WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN DRIVING.

• DO NOT USE DRIVE FUNCTION TO POSITION PLAT­FORM CLOSE TO OB STACLES. USE BOOM FUNC­TION INSTEAD.

• WHEN DRIVING IN HIGH SPEED, SWITCH TO LOW
SPEED BEFORE STOPPING. TRAVEL GRADES IN
LOW DRIVE, HIGH ENGINE ONLY.

• DO NOT USE HIGH SPEED DRIVE WHEN IN
RESTRICTED OR CLOSE QUARTERS, OR WHEN
DRIVING IN REVERSE.

• BE AWARE OF STOPPING DI STANCES WHEN TRAV­ELING IN HIGH AND LOW SPEEDS.

• ALWAYS POST A LOOKOUT AND SOUND HORN
WHEN DRIVING IN AREAS WHERE VISION IS
OBSTRUCTED.

• KEEP NON-OPERATING PERSONNEL AT LEAST 6
FEET (2 M) AWAY FROM MACHINE DURING DRIVING
OPERATIONS.

1-4 – JLG Lift – 3120635

SECTION 1 - SAFETY PRECAUTIONS

1.6 OPERATION.

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

• CHECK TRAVEL PATH FOR PERSONS, HOLES,
BUMPS, DROP-OFFS, OBSTRUCTIONS, DEBRIS,
AND COVERINGS WHICH MAY CONCEAL HOLES
AND OTHER HAZARDS.

• TRAVEL IS PERMITTED ON GRADES AND SIDES­LOPES NO GREATER THAN THOSE INDICATED IN
WARNING PLACARD AT MACHINE PLATF ORM.

• OPERATION WITH BOOM RAISED IS RESTRICTED
TO FIRM, LEVEL AND UNIFORM SURFACE.

• DO NOT TRAVEL ON SOFT OR UNEVEN SURFACES,
AS TIPPING WILL OCCUR.

• ENSURE THAT GROUND CONDITIONS ARE ADE­QUATE TO SUPPORT THE MAXIMUM TIRE LOAD.

• DO NOT DRIVE MACHINE NEAR PITS, LOADING
DOCKS OR OTHER DROP-OFFS.

• PRIOR TO ENTERING AND EXITING PLATFORM AT
GROUND LEVEL, FULLY LOWER THE B OOM.
EXTEND BOOM UNTIL END OF FLY B OOM CON­TACTS GROUND. WITH BOOM LIFT IN THIS CONFIG­URATION, ENTER AND/OR EXIT PLATFORM
THROUGH GATE OPENING.

• OSHA REQUIRES ALL PERSONS IN THE PLATFORM
TO WEAR LANYARDS WITH AN APPROVED FALL
PROTECTION DEVICE. SECURE LANYARD TO DES­IGNATED LANYARD ATTACH POINT ON PLATFORM.
KEEP GATE CLOSED AT ALL TIMES.

• TO AVOID FALLING - USE EXTREME CAUTION WHEN
ENTERING OR LEAVING PLATFORM ABOVE
GROUND. ENTER OR EXIT THRU GATE ONLY. PLAT­FORM FLOOR MUST BE WITHIN 1 FOOT (30 CM) OF
ADJACENT - SA FE AND SECURE - S TRUCTURE.
ALLOW FOR PLATFORM VERTICAL MOVEMENT AS
WEIGHT IS TRANSFERRED TO OR FROM PLAT­FORM.

3120635 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• TRANSFERS BETWEEN A STRUCTURE AND THE
AERIAL PLATFORM EXPOSE O PERATORS TO FALL
HAZARDS. THIS PRACTICE SHOULD BE D ISCOUR­AGED WHEREVER POS SIBLE. WHERE TRAN SFER
MUST BE ACCOMPLISHED TO PERFORM THE JOB
TWO LANYARDS WITH AN APPROVED FALL PRO­TECTION DEVICE WILL BE USED. ONE LANYARD
SHOULD BE ATTACHED TO THE AERIAL PLATFORM.
THE OTHER TO TH E STRUCTURE . THE LANYARD
THAT IS ATTACHED TO THE AERIAL PLATFORM
SHOULD NOT BE DISCONNECTED UNTIL S UCH
TIME AS THE TRANSFER TO THE STRUCTURE IS
COMPLETE. OT HERWISE , DO N OT STEP OUTSIDE
OF PLATFORM.

• DO NOT ADD NOTICE BOARDS OR SIMILAR ITEMS
TO THE PLATFORM. ADDITION OF SUCH ITEMS
INCREASES THE EXPOSED WIND AREA OF THE
MACHINE.

• NEVER POSITION LADDERS, STEPS, OR SIMILAR
ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE.

• WHEN RIDING IN OR WORKING FROM PLATFORM,
BOTH FEET MUST BE FIRMLY POSITIONED ON THE
FLOOR.

• KEEP OIL, MUD AND SLIPPERY SUBSTANCES
CLEANED FROM FOOT WEAR AND PLATFORM
FLOOR.

• NEVER "WALK" THE BOOM TO GAIN ACCESS TO OR
LEAVE PLATFORM.

• NEVER PLACE HANDS OR ARMS IN TOWER B OOM
OR UPRIGHT MECHANISM.

• KEEP ALL NON-OPERATING PERSONNEL AT LEAST
6 FEET (2 M) AWAY FROM THE MACHINE AT ALL
TIMES.

• IF PLATFORM OR BOOM IS CAUGHT SO THAT ONE
OR MORE WHEELS ARE OFF THE FLOOR, ALL PER­SONNEL MUST BE REMOVED FROM PLATFORM
BEFORE ATTEMPTING TO FREE MACHINE. USE
CRANES, FORKLIFT TRUCKS OR OTHER EQUIP­MENT TO REMOVE PERSONNEL AND STABILIZE
MACHINE MOTION, IF NECESSARY.

• THE OPERATOR IS RESPONSIBLE TO AVOID OPER­ATING MACHINE OVER GROUND PERSONNEL AND
TO WARN THEM NOT TO WORK, WALK OR STAND
UNDER A RAISED B OOM OR PL ATFORM. POSITI ON
BARRICADES ON FLOOR IF NECESSARY.

1-6 – JLG Lift – 3120635

SECTION 1 - SAFETY PRECAUTIONS

.

• ENSURE MACHINE IS POSITIONED ON A FIRM,
LEVEL AND UNIFORM SUPPORTING SURFACE
BEFORE RAISING OR EXTENDING BOOM.

• CHECK CLEARA NCES ABOVE, ON SI DES AND BOT­TOM OF PLATFORM WHEN RAISING, LOWERING,
SWINGING, AND TELESCOPING BOOM.

• EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER-

FERING WITH OPERATING CONTROLS AND PER­SONS IN PLATFORM.

• ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR MACHINES ARE AWARE OF THE AERIAL
PLATFORMS PRESENCE. DISCONNECT POWER TO
OVERHEAD CRANES. POSITION BARRICADES ON
FLOOR IF NECESSARY.

• NEVER "SLAM" A CONTROL SWITCH OR LEVER
THROUGH NEUTRAL TO THE OPPOSITE DIRECTION.
ALWAYS RETURN SWI TCH TO NEUTRAL AN D STOP;
THEN MOVE SWITCH TO THE DE SIRED POSI TION.
OPERATE LEVERS WITH SLOW, EVEN PRESSURE.

• DO NOT CARRY MATERIALS ON PLATFORM RAILING
UNLESS APPROVED BY JLG INDUSTRIES INC.

• NEVER PUSH OR PULL THE MACHINE OR OTHER
OBJECTS BY TELESCOPING THE BOOM.

• NEVER USE BOOM FOR ANY PURPOSE OTHER
THAN POSITIONING PERSONNEL, T HEIR TOOLS
AND EQUIPMENT.

• NEVER EXCEED MANUFACTURERS RATED PLAT­FORM CAPACITY - REFER TO CAPACITY DECAL ON
MACHINE. DISTRIBUTE LOADS EVENLY O N PLAT­FORM FLOOR.

• NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE, RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.

• DO NOT REMOVE, MODIFY, OR DISABLE FOOT­SWITCH BY BLOCKING OR ANY OTHER MEANS.

• DO NOT ASSIST A STUCK OR DISABLED MACHINE
BY PUSHING OR PULLIN G EXCEPT BY PULLING AT
CHASSIS TIE-DOWN LUGS.

• NEVER ATTEMPT USING BOOM AS A CRANE.
STRUCTURAL DAMAGE OR TIPPING MAY OCCUR.

• STOW BOOM AND SHUT OFF ALL POWER BEFORE
LEAVING MACHINE.

• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.

3120635 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• NEVER ATTEMPT TO FREE A MACHINE STUCK IN
SOFT GROUND OR AS SI ST A MA CHINE UP A ST EEP
HILL OR RAMP BY USING BOOM "LIFT", "TELE­SCOPE", OR "SWING" FUNC TI ON S.

• NEVER ATTACH WIRE, CABLE, OR ANY SIMILAR
ITEMS TO PLATFORM.

• DO NOT PLACE BOOM OR PLATFORM AGAINST ANY
STRUCTURE TO STEADY PLATFORM OR SUPPORT
STRUCTURES.

• DO NOT USE THE LIFT, SWING, OR TELESCOPE
FUNCTIONS FOR THE BOOM, TO MOVE EITHER THE
MACHINE OR OTHER OBJECTS.

• HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT
FULLY EXTENDED OR RETRACTED FOR ANY
LENGTH OF TIME. ALWAYS "BUMP" CONTROL IN
OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION
BEING USED REACHES END OF T RAVEL. THIS
APPLIES TO MACHINES IN OPERATION OR IN
STOWED MODE.

• DO NOT OPERATE ANY MACHINE ON WHICH DAN­GER, WARNING, CAUTION OR INSTRUCTION PLAC­ARDS OR DECALS ARE MISSING OR ILLEGIBLE.

• MACHINE MUST ALWAYS BE SHUT DOWN WHEN
REFUELING. NO SMOKING IS MANDATORY. NEVER
REFUEL DURING AN ELECTRICAL STORM. ENSURE
THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.

1.7 TOWING AND HAULING

• DO NOT TOW A MACHINE EXCEPT IN AN EMER­GENCY. SEE SECTION 6 FOR EMERGENCY TOWING
PROCEDURES.

• LOCK TURNTABLE BEFORE TRAVELING LONG DIS­TANCES OR BEFORE HAULING MACHINE ON A
TRUCK OR TRAILER.

1-8 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This section provides the necessary information needed
by those personnel that are responsible t o place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtainin g maxi­mum service life and safe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE F IELD INSPECTION AND MAINT ENANCE,
SAFETY IS THE RESPONSIBILITY OF THE OWNER/OPERATOR.

2.2 PREPARATION FOR USE

Before a new machine is put into operation it must be
carefully inspected fo r any evi dence of dam age resu lting
from shipment and inspecte d periodicall y therea fter, as
outlined in Delivery and Frequent Inspection ( Section 2.3,
Delivery and Frequent Inspection). During initial start-up
and run, the unit should be thoroughly checke d for
hydraulic leaks. A check of all compo nents should be
made to ensure their security.

All preparation necess ary to pl ace the machin e in opera­tion readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate prop­erly) coupled with a series of visual inspections. The man­datory requirements are given in the D aily Walk Around
Inspection (Section 2.4, Daily Walk-Aro und Inspection).

It should be assured that the items appearing in the Deliv­ery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.

NOTE: An annual inspection shall be performed on the

aerial platform no later than thirteen (13) months
from the date of the prior annual inspection. The
inspection shall be performed by person(s) qualified
as a mechanic on the specific make and model of
aerial platform.

The following checklist provides a systematic inspection
to assist in detecting de fective, damaged, or improperly
installed parts. The checklist denotes the items to be
inspected and conditio ns to ex am ine.

Frequent inspection shall be performed every 3 months or
150 hours whichever comes first, or more often when
required by environment, severity, and frequency of
usage.

This inspection checklist is also applicable and must be
followed for all machines that have been in storage or for
all machines that will be exposed to harsh or changing cli­mates.

These checks are also performed after maintenance has
been performed on the machine.

Chassis

1. Check front tire and wheel assemblies for loose or
worn spindles, components and hardware for secu­rity, tires for wear and damage.

2. Check steering assembly for loose or bent tie rod,
cylinder and hydraulic lines for leaks and security,
and hardware for proper installation.

3. Check rear tire and wheel assemblies for security,
tires for wear and damage.

4. Check drive hubs, hydraulic motors, brakes and
hydraulic lines for damage an d leaks .

5. Check oil level in drive hub by removing pipe plug
on side and feeling for oil level. (Contact Service
Personnel for assistance if needed).

2.3 DELIVERY AND FREQUENT INSPECTION

NOTE: Torque hubs should be one-half full of lubricant.

NOTE: This machine requires frequent safety and mainte-

nance inspections by an authorized JLG Dealer. A
decal located on the turntable provides a place to
record (stamp)Annual Inspection dates. Check decal
and notify dealer if inspection is overdue.

3120635 – JLG Lift – 2-1

6. Check 4WS steering assembly (if equipped) for
loose or bent tie rod, cylinder and hydraulic lines for
leaks and security, and hardware for proper installa­tion.

7. Check counterbalance, flow divider valves, h ydraulic
swivel assembly and lines for visible damage, evi­dence of leakage, and security and electrical con­nections for corrosion and tightness.

SECTION 2 - PREPARATION AND INSPECTION

8. Check extending axle assemblies for evidence of
leakage and security; pressure lines for abnormal
chafing drive hubs, hydraulic motors, brakes and
hydraulic lines for damage and leaks.

9. Check extending axles for visible damage and loose
or missing parts.

10. Check oscillating axle (if equipped) for loose, miss­ing and worn parts, pivot pin and lockout cylinder
pins for security, lockout cylinders and hydraulic
hoses for damage and leaks.

Turntable

1. Check turntable and turntable lock for damage,
loose or missing parts, and security. Check swing
drive hub, hydraulic motor, and brake for damage,
loose or missing parts, hydraulic lines and compo­nent housings for evidence of leakage; pinion for
proper mesh with swing gear.

2. Check swing bearing for damage, wear, lubrication
and loose or miss ing bearing bolts.

3. Check solenoid valves and hydraulic lines for dam­age, leakage, security and electrical connections for
tightness and evidence of corrosion.

4. Check ground controls for damage, loose or miss­ing parts, security, electrical connections for evi­dence of corrosion and tightness and wiring for
insulation damage. Assure that all switches function
properly.

5. Check manual descent valves for visible damage,
evidence of leakage and security. Assure that valves
function properly.

6. Check battery for damage, loose or missing vent
caps, electrical connections for tightness, and evi­dence of corrosion, holddown brackets for tight­ness, and electrolyte for proper water level. Add only
clean distilled water to battery.

7. Check engine and accessories for damage, loose or
missing parts, leakage and security. Check throttle
solenoid and linkage for damage, electrical connec­tions for tightness, and evidence of corrosion and
wiring for insulation damage.

8. Check fuel lines for damage, leakage and security.

9. Check all access doors for damage, proper opera­tion of latches, props and security.

10. Check fuel tank for damage, leakage and filler cap
for security.

11. Check hydraulic reservoir and hydraulic lines for
damage, leakage and security.

every 300 hours thereafter, unless system indicator
require earlier replacement.

12. Check all cylinder pin and shaft retaining hardware
for security and wear.

13. Check all electrical cables for defects, damage,
loose or corroded connections.

Boom

1. Check all cylinder pin and shaft retaining hardware
for security and wear.

2. Check hydraulic lines, electrical cable and track
assemblies for damage, missing parts and security.

3. Check lift cylinder and cross pi ns and hyd raul ic lines
for damage, wear, leakage and security .

4. Check boom pivot pin s for dama ge, wear, and secu­rity.

5. Check hydraulic line and electrical cable track
assembly for visible damage, loose or missing parts,
and security.

6. Check boom for damage, missing parts and secu­rity.

7. Check boom wear pads for damage, wear and secu­rity.

8. Check boom telescope cylinder and cross pins and
hydraulic lines for damage, wear, leakage and secu­rity.

9. Check platform leveling cylinder and cross pins and
hydraulic lines for damage, wear, leakage and secu­rity.

10. Check boom/platform pivot pin for damage, wear
and security.

11. Check horizontal and capacity limit switches
mounted on turntable for security of mounting, dam­age to switch arms and rollers; and for debris.

12. Check boom tape for correct length, tearing, or
defacing at any point.

Extend-A-Reach (If Equipped)

1. Check the slave cylinder, weld link and cross pins,
and lines for visible damage, wear, lubrication, evi­dence of leakage, and security.

2. Check extend-a-reach for visible damage, loose or
missing parts, and securit y.

NOTE: JLG recommends replacing the hydraulic filter ele-

ment after the first 50 hours of operation and then

3. Check hydraulic lines and electrical cable for dam­age, missing parts and security.

2-2 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Machine Nomenclature

3120635 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

Platform

1. Check platform and control console for damage,
loose or missing parts , an d security.

2. \Check control switches and levers for damage,
loose or missing parts and security. Assure that all
levers function properly.

3. Check control switches, levers and electrical con­nections for tightness and evidence of corrosion,
and wiring for defects and chafing damage. Assure
that all switches function properly.

4. Check access gate hinges and latch for proper
operation, damage and security.

5. Check platform rotator mechanism for proper opera­tion, damage, security. Check hydraulic lines for
leakage, damage and securi ty.

NOTE: Check all DANGER, WARNING, CAUTION and

INSTRUCTION placards for legibility and security on
the entire machine.

Torque Requirements

The Torque Chart (See Figure 2-6.) consists of standard
torque values based on bolt diameter and grade, also
specifying dry and we t torq ue va lues in accor dance with
recommended shop pr actices. This chart i s provide d as
an aid to the operator in the event he/she notices a condi­tion that requires prompt attention during the walk-around
inspection or during operation, until the proper service
personnel can be not ified. The Service a nd Mainte nance
manual provides specific t orque values and periodi c
maintenance procedure s with a listi ng of ind ividual com­ponents. Utilizing this Torque Chart in conjunction with the
preventive maintenance section in the Se rvice and Main te­nance manual will enhance safety, reliability, and perfor­mance of the machine.

2.4 DAILY WALK-AROUND INSPECTION

It is the operator’s responsibility to inspect the machine
before the start of each workday. It is recommended that
each operator inspect the machine before op eration, even
if the machine has already been put into service under
another operator. This Daily Walk - Aro und Inspection is the
preferred method of inspection. (See Figure 2-2.)

2. Placards.
Keep all information and operating placards clean

and unobstructed. Cover when spray painting or
shot blasting to protect legibility.

3. Operator’s and Safety Manual.
Ensure a copy of this manual and the ANSI A92.5-

1992 Responsibilities, are enclosed in the manual
storage box.

4. Machine Log.
Ensure a machine operating record or log is kept,

check to see that it is current and that no entries
have been left uncleared, leaving machine in an
unsafe condition for operatio n.

5. Start each day with a full fuel tank.

TO AVO ID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAV E BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS
“OFF” DURING WALK-AROUND INSPECTION.

NOTE: Check boom horizontal limit switch for proper opera-

tion and security, both visually and manually. Switch
must shut down high engine and high drive speed
when boom is raised above horizontal:

6. Check platform footswitch for proper operation.
Switch must be released to start engine and
depressed to operate machine.

7. Check that drive brakes hold when machine is
driven up a grade and stopped.

NOTE: On new machines, those recently overhauled, or

after changing hydraulic oil, operate all systems a
minimum of two complete cycles and recheck oil
level in reservoir.

8. Assure that all items requiring lubrication are ser­viced. Refer to Figure 2-5., Lubrication Point Loca­tion, for specific requirements.

In addition to the Daily Walk-Around Inspection, be sure to
include the f ollowing as part of th e d aily inspection:

1. Overall cleanliness.
Check all standing surfaces for oil, fuel and hydrau-

lic oil spillage and foreign objects. Ensure overall
cleanliness.

2-4 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-2. Daily Walk-Around Inspection Diagram

3120635 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

GENERAL

Begin the “Walk-Around Inspection” at Item 1, as noted
on the diagram. Continue to the ri ght (coun terclockwis e
viewed from top) checking each item in sequence for the
conditions listed in the “Walk-Around Inspection Check­list”.

TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MAL­FUNCTIONING MACHINE IS A SAFETY VIOLATION. TO AVOID
POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF” DUR­ING WALK-AROUND INSPECTION.

NOTE: Do not overlook visual inspection of chassis under-

side. Checking this area often results in discovery of
conditions which could cause extensive machine
damage.

1. Platform Assembly - No loos e or missing parts, no
visible damage. Lock bolts in place. Footswitch in
good working order, not modified, disabled or
blocked. Check area of fly boom nose section
above and under platform slave level cylinder for
accumulation of foreign m aterial. Remove any for­eign material present.

2. Platform Control Console - Switches and levers
return to neutral and are properly secured, no loose
or missing parts, no visible damage, decals/plac­ards secure and legible, control m arking legible.

3. Slave Leveling Cylinder, Extend-A-Reach - Properly
secured, no visible damage, no evidence of leak­age. (If equipped on Extend-A-Reach)

4. Extend-A-Reach Lift Cylinder - Properly secured, no
visible damage, or signs of leakage, evidence of
proper lubrication. (If equipped on Extend-A­Reach)

5. Extend-A-Reach Pivot - No loose, damaged, or
missing parts, evidence of proper lubrication. (If
equipped on Extend-A-Reach)

6. Hose and Cable Guards/Clamps - Properly
secured, no visible dama ge.

7. Power Track - No loose, damaged or missing parts,
no visible damage.

8. Drive Motor and Brake, Right Rear - No visible dam­age, no evidence of leakage.

9. Drive Hub, Right Rear - No visible damage, no evi­dence of leakage.

10. Wheel/Tire Assembly, Right Rear - Properly
secured, no loose or missing lug nuts, no visible
damage.

11. Extendable Axle - Lock pins in place, properly
secured. Check both sides.

12. Swing Drive Motor and Brake - No visible damage,
no evidence of leakage.

13. Fuel Supply - Fuel filler cap secure. Tank - no visible
damage; no evidence of leaks.

14. Cowling and Latches - All cowling and latches in
working condition, properly secured, no loose or
missing part.

15. Control Valve Compartment - No loose or missing
parts; evidence of leakage; unsupported wires or
hoses; damaged or broken wires .

16. Extendable Axle - Lock pins in place, properly
secured. Check both sides.

17. Hydraulic Oil Supply - Recommended oil level in
sight gauge. (Check level with cold oil, systems
shut down, machine in stowed position) Cap in
place and secure.

18. Hydraulic Oil Filter Housing - Housing secure; no
visible damage or signs of leakage.

19. Hydraulic Oil Breather - Element in place, not
clogged, no signs of overflow.

20. Wheel/Tire Assembly, Right Front - Properly
secured, no loose or missing lug nuts, no visible
damage.

21. Tu rntable Springs - Properly secured, no loose or
missing nuts or bolt s .

22. Ground Controls - Switches operable, no visible
damage, decals secure and leg ible.

23. Engine Air Filter - No loose or missing parts, no vis­ible damage, element clean.

24. Tie Rod and Steering Linkage - No loose or missing
parts, no visible damage. Tie rod end studs locked.

25. Wheel/Tire Assembly, Left Front - Properly s ecured,
no loose or missing lug nuts, no visible damage.

26. Engine Oil Supply - Full mark on dipstick; filler cap
secure.

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

2-6 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

27. Muffler and Exhaust System - Properly secured, no
evidence of leakage

28. Cowling and Latches, Right Side - All cowling and
latches in working condition, properly secured, no
loose or missing part.

29. Turntable Bearing and Pinion - No loose or missing
hardware; no visible damage, evidence of proper
lubrication. No evidence of loose bolts or looseness
between bearing and structure.

30. Battery - Proper electrolyte levels; cables tight, no
visible dama ge or corrosion.

31. Frame - No visible damage, no loose or missing
hardware (top and underside).

Figure 2-4. Daily Walk-Around Inspection Points - Sheet 2

32. Drive Hub, Lef t Rear - No visible damage, no evi­dence of leakage.

33. Wheel/Tire Assembly, Left Rear - Properly secured,
no loose or missing lug nuts, no visible damage.

34. Drive Motor and Brake, Left Rear - No visible dam­age, no evidence of leakage.

35. Boom Sections - No visible damage; wear pads
secure. All cylinders - rod en d shafts and barrel- end
shafts properly secured.

36. Rotator and Motor - Properly secured, no visible
damage, no evidence of leakage.

37. Platform Pivot and Slave Cylinder Attach Pins ­Properly secured; evidence of proper lubrication
where applicable.

3120635 – JLG Lift – 2-7

SECTION 2 - PREPARATION AND INSPECTION

2.5 DAILY FUNCTIONAL CHECK

THE LOAD MANAGE MENT SYSTEM A ND THE AXLES ( PROPER
EXTENSION AND RETRACTION) MUST BE CHECKED PRIOR TO
ANY OTHER SYSTEMS AND/OR FUNCTIONS.

A functional check of all systems sh ould be performed,
once the walk-around inspection is complete, in an area
free of overhead and ground level obstructions. First,
using the ground control s, check all fu nctions control led
by the ground controls. Next, using the platform controls,
check all functions controlled by the platform con tr ols.

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

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

NOTE: Perform checks from ground controls first, where

applicable, then from platform controls.

1. Axles, Extending and Retracting.
a. From the ground control, activate the machine

hydraulic system and raise the boom. Extend
the boom no more than 8 feet (2.4 m).

b. Position STEER/AXLES valve, located at the

front of the frame to AXLES.

c. Position boom over drive wheel end of machine.

Remove axle lock pins.

e. With the aid of an assistant, position EXTEND-

ABLE AXLE/STEER switch located on platform
control console to EXTEND until axles are fully
extended and the AXLES SET light is on . Install
axle lock pins.

f. Position LIFT control to UP to lower the

machine; elevate the boom sufficien tly and rep o­sition the boom over the steer whee l end of the
machine.

g. Rem ove the tie rod lock pins, steer cylinder lock

pin, and axle lock pins.

h. P osition LIFT control to DOW N and hold un til the

steer wheels rise from the ground; it may be
necessary to feather the LIFT control to maintain
wheel elevation.

i. With the aid of an assistant, position EXTEND-

ABLE AXLE/STEER switch on platform console
to EXTEND until axles are fully extended.

j. Align steer wheels and insert tie rod lock pin,

axle lock pins, and steer cylinder lock pins .

k. Position LIFT control to UP to lower the machine

steer wheels; position STEER/AXLES valve to
STEER.

l. Cycle the steer system in both directions to

ensure the tie rods are properly locked.

m. Remove any one of the axle lock pins. From the

ground control, monitor the AXLES SET indica­tor and attempt to lift and telescope the boom.
With an axle lock pin removed, you wil l not be
able to lift the boom above horizontal or tele­scope out beyond 11.5 feet (3.5 m). At these
positions, the AXLES SET indicator will not light,
indicating the axles are n ot extended and
locked. If the light does not ill uminate when t he
axles are extended and set and the pins
installed, contact a qualified service technician
before continuing operation.

DO NOT USE EXTEND-A-REACH (IF EQUIPPED) TO LIFT
MACHINE WHEN EXTENDING AND RETRACTING AXLES.

d. Position LIFT control to DOWN and hold until

drive wheels rise from the ground; it may be n ec­essary to feather the lift control to maintain drive
wheel elevation.

2-8 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-5. Lubrication Point Location

3120635 – JLG Lift – 2-9

SECTION 2 - PREPARATION AND INSPECTION

Table 2-1. Lubrication Chart

Components

Master Cylin der - Barrel End

1

Master Cylinder - Rod End

2

Boom Pivot Bushings

3

Lift Cylinder - Rod End

4

Lift Cylinder - Barrel End

5

Slave Cylinder - Rod End

6

Slave Cylinder - Shaft End

7

Extend-A-Reach Cylinder - Rod End

8

Extend-A-R each Cylind er - Attach Pin

9

Platform Door Hinges

10

Platform Door Latch

11

Rotary Platform Control Stand

12

Platform Attach Pin and Rotary Worm

13

Gear

Drive Hubs

14

Swing Bearing Gear

15

Swing Bearing

16

Steer Spindles

17

Steer Cylinder - Rod End

18

Steer Cylinder - Barrel End

19

Tie Rod Ends

20

Extending Axle Beams

21

Wheel Bearings

22

Engine Crankcase

23

Engine Oil Filter

24

Door and Access Panel Hinges

25

Hydraulic Fluid

26

Hyd. Filter Element (Tank)

27

Hyd. Filter Element (Inline)

28

T elescope Cylinder Sheave

29

Extend Chain Sheave

30

Retract Chain Sheave

31

Number/Type

Lube Points

Lube & Method

Interval

Hours

Comments

1 Grease Fitting MPG - Pressure Gun 150 Remote Access
1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150
1 Grease Fitting MPG - Pressure Gun 150 Remote Access
1 Grease Fitting MPG - Pressure Gun 150
1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG- Pressure Gun 150
2 Grease Fittings MPG - Pressure Gun 150
2 Grease Fittings MPG - Pressure Gun 150

N/A SAE10 - Oil Ca n 150

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fittin g Each MP G - Pressure Gun 150

Fill Plug EPGL - SAE90 150/1200 Check every 150 hrs. / Change every 120 0 hrs.

N/A MPG - Brush 150

1 Grease Fitting MPG - Pressure Gun 150
2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150
2 Grease Fittings MPG - Pressure Gun 150

N/A MPG - Brush 150
N/A MPG - Repack 1200

Fill Cap EO-SAE30 10/300 Check daily/Chang e every 300 hrs.

N/A Replaceable Cartridge 300
N/A SAE10 - Oil Ca n 150

Fill Cap HO 10/1200 Check daily/Chang e every 1200 hrs.

N/A N/A 50/300 Rep lace filter af ter first 50 hr s. of operation,

then every 300 hrs. thereafter

N/A N/A 50/300 Rep lace filter af ter first 50 hr s. of operation,

then every 300 hrs. thereafter
1 Grease Fitting MPG - Pressure Gun 150
1 Grease Fitting MPG - Pressure Gun 150
1 Grease Fitting MPG - Pressure Gun 150

2-10 – JLG Lift – 3120635

SECTION 2 - PREPARATION AND INSPECTION

Table 2-1. Lubrication Chart

Components

Boom Chains

32

Turntable Pivot Pin

33

Extend-A-Reach Link Attach Pin

34

Extend-A-Reach Pivot Pin

35

NOTES:

Number/Type

Lube Points

N/A Chai n Lube/Hot Oil D ip 1200 Includes extend an d retract cha ins

2 Grease Fittings MPG - Pressure Gun 150

1 Grease Fitting MPG - Pressure Gun 150

2 Grease Fittings MPG - Pressure Gun 150

Lube & Method

2. Load Management System.
110HX.

NOTE: The blue light should illuminate when the ignition is

turned on.

a. Activate the hydraulic system from the ground

controls. The blue light should illuminate when
the SELECT SWITCH is in the ground position
and the EMERGENCY STOP switch is in the ON
position.

b. Extend the boom at horizontal until the yellow

band on the inner mid section is exposed from
the base. The yellow light should illuminate at
this point.

c. Continue extending the boom until the red mark-

ing band on the inner mid section is exposed
from the base section. The red light should illu­minate at this point.

d. Continue extending the boom until the white

marking band on the inner mid section i s
exposed from the base section. The red light
should blink and an audible alarm sound. Also
the telescope out and lift down will not function
in this mode.

IF BOOM CONTINUES TO TELESCOPE BEYOND THE THIRD
MARKING BAND, RETRACT THE BOOM, IMMEDIATELY SHUT
DOWN MACHINE AND CONTACT A QUALIFIED SERVICE PER­SON.

100HX +10.

NOTE: The blue light should illuminate when the ignition is

turned on.

Interval

Hours

Key to Lubricants:

EO
EPGL
HO
MPG t

Engine Oil
Extreme Pressure Ge ar Lube
Hydraulic Fluid (Mobil #424 or e quivalent)
Multi-Purpose Grease

Comments

a. Activate the hydraulic system from the ground

controls. The blue light should illuminate when
the SELECT SWITCH is in the ground position
and the EMERGENCY STOP switch is in the ON
position.

b. Extend the boom until the red marking band on

the inner mid section is exposed from the base
section. The red light should illuminate at this
point.

c. Continue extending the boom until the white

marking band on the inner mid section is
exposed from the base section. The re d light
should blink and an audible alarm sound. Also
the telescope out and l ift down wi ll not f unction
in this mode.

IF BOOM CONTINUES TO TELESCOPE BEYOND SECOND MARK­ING BAND, RETRACT THE BOOM, IMMEDIATELY SHUT DOWN
MACHINE AND CONTACT A QUALIFIED SERVICE PERSON.

110HX/100HX+10.

a. With the boom fully retracted, raise the boom to

horizontal.

b. Position the toggle switch located on the right

side of the ground control box to the P position
and hold.

c. Extend the boom until it stops. The boom must

stop on the white band on the mid boom sec­tion. Release the toggle switch.

d. Ret ract the boom until tele out will function. The

system is no w reset.

e. Position the toggle switch to the M position and

hold.

3120635 – JLG Lift – 2-11

SECTION 2 - PREPARATION AND INSPECTION

f. Extend the boom until it stops. The boom must

stop on the white band on the mid boom sec­tion.

IF BOOM CONTINUES TO TELESCOPE BEYOND SECOND MARK­ING BAND, RETRACT THE BOOM, IMMEDIATELY SHUT DOWN
MACHINE AND CONTACT A QUALIFIED SERVICE PERSON.

3. Drive forward and reverse; check for proper opera­tion.

4. Steer left and right; check for proper operation.

5. If equipped with 4 wheel steer, check rear steer left
and right for proper operat ion.

6. If equipped, check platform rotator for smooth oper­ation and assure platform will rotate 90 degrees in
both directions from centerline of boom.

7. Raise, lo wer, and swing boom to LEFT and RIGHT a
minimum of 45 degrees (Cycle function several
times.) Check for smooth elevation and swing
motion.

8. If equipped with Extend-A-Reach, raise and lower
and swing Extend-A-Reach (Cycle functi ons several
times). check for smooth elevation and swing
motion.

14. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL
OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF
TRAVEL. IF SWITCH OPERATES W ITHIN LAST 1/4" OF TRAVEL,
TOP OR BOTTOM, IT SHOULD BE ADJUS TED.

a. Activate hydraulic system. By depressing foot-

switch. Operate TELESCOPE and hold control.
Remove foot from footswitch, motion should
stop. If it does not, shut down machine and con­tact a certifie d JL G s e r v ice technician.

b. With footswitch depressed, operate LIFT and

hold control. Remove foot from footswi tch,
motion should stop. If it does not, shut down
machine and contact a certified JLG service
technician.

c. With engi ne po wer shu t do wn, dep res s th e fo o t-

switch. Attempt to start e ngine. Engine should
not attempt to start when footsw itch is
depressed. If starter engages or engine turns
over, shut down machine and contact a certified
JLG service technician.

15. Auxiliary Power.

9. Telescope boom in and out several cycles at various
degrees of elevation lengths. Check for smooth tele­scope operation.

10. Check that platform automatic self-leveling system
functions properly during raisi ng and lowering of the
boom.

11. Check platform level adjustment system for proper
operation.

NOTE: Turntable lock is on turntable facing platform. To dis-

engage lock, pull snap pin from lock pin, lift lock pin
up to unlock turntable. Return snap pin to lock pin to
hold lock pin in the disengaged position. Reverse
procedure to engage turntable lock.

12. Swing turntable to LEFT and RIGHT a minimum of
45 degrees. Check for smooth motion.

13. With the aid of an assistant to monitor the CHASSIS
OUT OF LEVEL indicator light on the platform con­trol console, manually activate the indicat or light by
compressing any one of the three tilt indicator
mounting springs. If the light does not illuminate,
shut down machine and contact a qualified service
technician before continuing operation.

Operate each function control switch (e.g. TELE,
LIFT and SWING) to assure that they function in
both directions using auxiliary power instead of
engine power.

16. Ground Controls.

Place GROUND/PLATFORM SELECT switch to
GROUND. Start engine. Platform controls should not
operate.

2.6 TORQUE REQUIREMENTS

The Torque Chart (See Figure 2-6.) consists of standard
torque values based on bolt diameter and grade, also
specifying dry and wet torque values in accordance with
recommended shop pra ctices. This chart is pro vided as
an aid to the operator in the event a condition is noticed
that requires prompt at tention during t he walk-around
inspection or during operatio n unti l the pro per service per­sonnel can be notified. The Service and Maintenance
manual provides specific t orque values and periodi c
maintenance procedures wi th a l isting of ind ividual com­ponents. Utilizing this Torque Chart in conjunction with the
preventive maintenance section in the Ser vice an d Ma inte­nance manual, will enhance safety, reliability and perfor­mance of the machine.

2-12 – JLG Lift – 3120635

2.7 BATTERY MAINTENANCE

TO AVOID INJURY FROM AN EXPLOSION, DO NOT SMOKE OR
ALLOW SPARKS OR A FLAME NEAR BATTERY DURING SERVIC­ING.

ALWAYS WEAR EYE PROTECTION WHEN SERVICING BATTER­IES.

Battery Maintenance

1. The battery is maintenance free except for occa­sional battery terminal cleaning, as noted in the fol­lowing.

2. Remove battery cables from each battery post one
at a time, negative first. Clean cables with acid neu­tralizing solution (e.g. baking soda and water or
ammonia) and wire brush. Replace cables and/or
cable clamp bolts as re quired.

3. Clean battery post with wire brush then re-connect
cable to post. Coat non-contact surfaces with min­eral grease or petroleum jelly (Vaseline).

SECTION 2 - PREPARATION AND INSPECTION

4. When all cables and terminal posts have been
cleaned, ensure all cables are properly positioned
and are not pinched. Close battery compartment
cover.

3120635 – JLG Lift – 2-13

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-6. Torque Chart

2-14 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

SECTION 3. USER RESPONSIBILITIES AND MACHINE CONTROL

3.1 GENERAL

SINCE THE MANUFACTURER HAS NO DIRECT CONTROL OVER
MACHINE APPLICATION AND OPERATION, CONFORMANCE WITH
GOOD SAFETY PRACTICES IN THESE AREAS IS THE RESPONSI­BILITY OF THE USER AND HIS/HER OPERATING PERSONNEL.

This section provides the necessary information needed
to understand control functions. Included in this section
are the operating characteris tic s and limitations, and func­tions and purposes of controls and indicators. It is impor­tant that the operator read an d understand the proper
procedures before operating the machine. These proce­dures will aid in obtain ing optimum lift serv ice and safe
operation.

3.2 PERSONNEL TRAINING

The aerial platform is a personnel handling device; there­fore it is essential that it be operated and maintained only
by authorized and qualifi ed personn el w ho have de mon­strated that they understand the proper use and mainte­nance of the machine. It is important that all personnel
who are assigned to and responsible for the operation
and maintenance of the machine u ndergo a thorough
training program and check out perio d in or der to bec ome
familiar with the characteristics prior to operating the
machine.

In addition, personnel operating the machine should be
familiar with ANSI standard A92.5-1992 Responsibilities
Section. This outlines the responsibilities of the owners,
users, operators, lessors and lessees concerning safety,
training, inspection, maintenance, application and opera­tion.

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

Operator Training

Operator training must include instruction in the following
areas:

3. Knowledge and understanding of all safety work
rules of the employer and of Fede ral, State and local
statutes, including training in the recognition and
avoidance of potential hazards in the work place;
with particular attention to the work to be performed.

4. Proper use of all required personnel safety equip­ment, in particular the wearin g of a s afety h arn es s or
other approved fall protection devices with a lan yard
attached to the platform at all times.

5. Sufficient 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, depre ssions , ho les, dro p-o ffs, etc. o n
the supporting surface exist.

7. Means to av oid the hazards of unprotect e d electrical
conductors.

8. Any other requirements of a specific job or machine
application.

Training Supervision

Training must be done under the supervision of a qualified
person in an open area free of obstru ctions until the
trainee has developed the ability to safely control a
machine in congested work locations.

Operator Responsibility

The operator must be instructed that he/she has the
responsibility and authori ty to shut down t he machine in
case of a malfunction or other unsafe condition of either
the machine or the job site and to request further informa­tion from his/her supervisor or an authorized JLG Distribu­tor before proceeding.

NOTE: Manufacturer or distributor will provide qualified per-

sons for training assistance with first unit(s) delivered
and thereafter as requested by the user or his/her
personnel.

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

2. Knowledge and un ders t anding of this manual and of
the control markings, instructions and warnings on
the machine itself.

3120635 – JLG Lift – 3-1

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

3.3 OPERATING CHARACTERIST ICS AND
LIMITATIONS

General

A thorough knowledge of the operating characteristics
and limitations of the machine is always the first require­ment for any operator, regardless of the user’s experience
with similar types of equipment.

Placards

Important points to remember during operation are pro­vided at the control stations by DANGER, WARNING,
CAUTION, IMPORTANT and INSTRUCTION placards. This
information is placed at various locations for the express
purpose of alerting personnel of potential hazards consti­tuted by the operating characteristics and load limitations
of the machine. See FOREWORD for definitions of the
above placards.

Capacities

Raising the boom above horizontal and/or the extension
of the boom beyond the retracted position with or without
any load in the platform, is based on the following criteria:

Stability

This machine as originally man ufactured by JLG Indus­tries Inc., when operated within its rated capacity on a
smooth, firm a nd lev el sup porti ng s urface, and i n acco r­dance with the instructions provided on the machine and
this manual, provides a stable machine for all platform
positions.

Machine stability is based on two positions which are
called FORWARD STABILITY and BACKWARD STABILITY.
The machines position of least forward stability is shown
in Figure 3-1. and its position of least backward stability is
shown in Figure 3-2.

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

2. Load is within manufacturer’s rated desig n capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure exists in the tires.

5. Machine is as originally equipped from JLG.

3-2 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-1. Position of Least Forward Stability

3120635 – JLG Lift – 3-3

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

Figure 3-2. Position of Least Backward Stability - 100HX and 110HX

3-4 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-3. Positio n of Least Backward Stability - 100HX+10

3120635 – JLG Lift – 3-5

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

3.4 CONTROLS AND INDICATORS
Precision Control Governor

This control allows the engine to remain at idle until any
function is activated, at which time the engine will acceler­ate to perform that function. Upon release of the function
the engine will accelerate back to idle. High engine can
only be obtained if the drive handle is placed in the
extreme drive position, if th e hi gh engine switch is ON and
the boom is horizontal or below .

Ground Controls

DO NOT OPERATE FROM THE GROUND STATION WITH PERSON­NEL IN THE PLATFORM E XCEPT IN AN EMERGENCY.

PERFORM PRE-OPERATIONAL CHECKS AND INSPECTIONS
FROM THE GROUND CONTROL STATION. WHEN PERSONNEL
ARE IN THE PLATFORM, OPER ATION OF THE BOOM FROM THE
GROUND CONTROL WILL ONLY BE PERFORMED WITH THE PER­MISSION OF THE PLATFORM OCCUPANT(S ).

3. Ignition Switch.
The machine is equipped with an on-off ignition

switch and a separate start push b utton switch on
the ground control panel which supplies electrical
power to the starter solenoid when the ignition
switch is placed in the ON position and the START
button is depressed.

NOTE: One of the capacity indicator lights should be illumi-

nated at all times during operation. If no capacity
lights are on, a bulb could be burned out. Operation
of the machine must be halted until the lights are
working properly.

Check the capacity decal in the platform and at the
ground station for the machines operating capac­ity(s).

4. Capacity Indicator.
The capacity indicator displays to the operator the

maximum rated platform capacity and the maximum
radius for that capacity using colored lights and a
reach diagram. The operator must not exceed the
rated capacity or the rated radius for the load (per­sonnel, tools, and supplies) shown on the indicator.

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

1. Master / Emergency Stop Switch.
A two-position key operated switch furnishes battery

power to the platform or ground control switches
when station power is selected from the ground con­trol panel and the master switch is turned “ON”.

2. Control Station Selector.
A three position, center off, key activated PLAT-

FORM/GROUND SELECT switch supplies po wer to
the platform control console when positioned to
PLATFORM. With the switch in the GROUND posi­tion, power is shut off to the platform station, and
only the controls on the ground control panel are
operable.

NOTE: With the Platform/Ground Select Switch in the center

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

A different color light for each different capacity is
used; blue indicates operating within maximum
capacity range, yellow indicates operating within
reduced capacity range. Models equipped with
Extend-A-Reach only have a blue and a red light.
When moving the platform from one capacity area to
another, one light will go out and another will come
on indicating the correct capacity for that area. A
steady red light indicates you have exceeded the
machines operating radius. You must immediately
stop all functions and then ’LIFT UP’’ or ‘’TELE IN’’
until the red light goes out. A blinking red light and a
buzzer sounding indicates you have exceeded the
platform load capacity (personnel, tools, and sup­plies) and or radius. You must immediately stop and
then ‘’LIFT UP’’ or ‘’TELE IN’’ until the red light goes
out and the buzzer stops. Check to make sure the
load in the platform does not exceed the rated
capacity.

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

3-6 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-4. Ground Control Station Dual Capacity Only - 100HX and 110HX

3120635 – JLG Lift – 3-7

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

Figure 3-5. Ground Control Station - Singl e Capacity Only - 100HX+1 0

3-8 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

NOTE: Lift, Swing, and Telescope control switches are

spring-loaded and will automatically return to neutral
(off) when released.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PER­SONNEL AROUND OR UNDER PLATFO RM.

5. Lift Control (M ain Boom).
The three-position LIFT control switch provides rais-

ing and lowering of the main boom when positioned
to UP or DOWN.

6. Lift Control (Extend-A-Reach, If Equipped).
A three-position EXTEND-A-REACH LIFT control

switch provides raising/lowering of the Extend-A­Reach when positioned to UP or DOWN.

7. Telescope Control.
The three-position TELESCOPE control switch pr o-

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

8. Swing Control.
The three-position SWING control switch provides

360 degrees continuous turntable rotation when
positioned to RIGHT or LEFT.

The push-button switch relays power to the glow
plugs used to warm the air intake on cold start oper­ations.

11. L.P. Gas/Gasoline Select Switch.
An optional two position contact toggle switch sup-

plies electrical power to open the gasoline shut-off
solenoid and closes the LP gas shut-off solenoid
when placed in the “GASOLINE” position. This
switch supplies electrical power to open the LP gas
shut-off solenoid and closes the gasoline shut-off
solenoid when positioned to the LP position.

12. Circuit Breaker.
The 3 amp circuit breaker return control power to the

High Engine circuit when depressed.

13. Hourmeter.
An hourmeter, installed in the ground control box,

registers the amount of time the machine has been
in use, with the engine running. The hourmeter reg­isters up to 9,999.9 hours and cannot be reset.

14. Voltmeter.
An voltmeter, installed in the ground control box,

indicates battery condition (i.e. charging or dis­charging).

15. Oil Pressure Gauge.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE
MORE THEN ONE FUNCTION AT THE SAME TIME. SI MULTA­NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
MOTOR.

9. Auxiliary Power Control.
A toggle type AUXILIARY POWER control switch

energizes the electrically operated auxiliary hydrau­lic pump, when actuated. The switch must be held in
the ON position for the duration of auxiliary pump
use.

The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine functions should
the main hydraulic pumps or engine fail. The auxil­iary pump enables the telescope, lift, and swing,
functions to be operated.

It should be noted that the functions will operate at a
slower than normal rate due to the lower amount of
hydraulic flow provided.

10. Glow Plug Switch (Diesel Engine Only).

An oil pressure gauge, installed in the ground con­trol box, provides an indication of the engine lubri­cating oil pressure. Normal operating pressure at
2000 rpm is 40 to 60 psi.

16. Engine Coolant Temperature Gauge (Gas Engines
Only).

An engine coolant temperature gauge installed in
the ground control box, provides a visual indication
of the temperature of the engine coolant.

17. Axle Set Indicator.
The AXLE SET INDICATOR provides a visual indica-

tion that the extendable axles are properly set. It
consists of a green indicator that lights up when the
axles are extended and the retaining pins are prop­erly installed.

18. Broken Fan Belt Indicator. (Diesel Engine Only).
The BROKEN FAN BELT indicator provides a visual

indication that the engine fan belt is broken and
must be replaced immediately. It consists of a red
indicator that lights up when the fan belt has broken.

3120635 – JLG Lift – 3-9

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

19. Start Button.
The START button is a momentary contact, push

button type switch that supplies electrical power to
the starter solenoid, when the key switch and igni­tion switch are in the ON position and the start but­ton is depressed.

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

20. Rotate (If equipped).
The three position PLATFORM ROTATE control

switch permits rotation of the platform when posi­tioned to LEFT or RIGHT.

21. Level.
The three position PLATFORM LEVEL control switch

allows the operator to compensate for any differ­ence in the automatic self leveling system by posi­tioning the control switch to UP or DOWN.

Platform Station

NOTE: For engine starting, the footswitch must be in the

released (up) position. Footswitch must be actuated
in order for controls to function.

to off while operating the machine will stop all func­tions and shut down the engine.

3. Start Button.
The START button is a momentary contact, push-

button switch. With the IGNITION /EMERGENCY
STOP switch positioned to ON and the START but­ton depressed, electrical power is supplied to the
start solenoid.

4. Warning Horn.
A push-type HORN switch, when pressed, supplies

electrical power to activate the horn.

5. Chassis Out of Level Warning Light.
This red indicator lights to indica te that the chassis is

on a slope (over 5 degrees). If illuminated when
boom is raised or extended, retract and lower to
below horizontal then reposition the machine so that
it is level before extending the boom or raising the
boom above horizontal.

IF THE CHASSIS OUT OF LEVEL WARN ING LIGHT IS ILLUMI­NATED WHEN THE BOOM IS RAISED OR EXTENDED, RETRACT
AND LOWER THE PLATFORM TO BELOW HORIZONTAL THEN
REPOSITION THE MACHINE SO IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING THE BOOM ABOVE HORIZ ONTAL.

1. Footswitch.
This feature makes it necessary to depress the foot-

switch to allow operation of the controls.

TO AV OID SERIOUS INJURY, DO N OT REMOVE, MODIFY OR DIS­ABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

THE FOOTSWITCH M UST BE ADJU STED SO THAT FUNCTIONS
WILL OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS
CENTER OF TRAVEL. IF THE SWITCH OPERATES WITHIN LAST
1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

2. Power/Emergency Stop.
An on-off IGNITION/EMERGENCY STOP switch and

a separate START push button on the platform con­sole supply electrical power to the starter solenoid,
when the power switch is positioned to “on” and the
START button is depressed. Positioning the switch

3-10 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-6. Platform Station - 100HX and 110HX

3120635 – JLG Lift – 3-11

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

Figure 3-7. Platform Station - 100HX+10

3-12 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

NOTE: LIFT, SWING, and DRIVE control levers or switches

are spring-loaded and will automatically return to the
neutral (OFF) position when released.

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

6. Lift.
The LIFT control lever provides raising and lowering

of the boom when positioned to UP or DOWN and
automatically returns to off when released.

7. Telescope.
The TELE control lever provides extension and

retraction or the boom when positioned to IN or
OUT, and automatically returns to off when released.

8. Steer/Axles.
When in the steering mode, positioning the STEER/

AXLES control switch right or left enables steering
the machine to the right or to the left. When in the
axles mode, positioning the switch to EXTEND to
extend the axles and RETRACT to retract the axles.

The function the switch con trols is depe ndent upon
the position of the STEER/AXLES selector valve.

9. Swing.
The SWING control lever provides 360 degrees con-

tinuous swing when positioned to left or right.

NOTE: When the boom is above horizontal and if either the

HIGH ENGINE, PUMP VOLUME, or WHEEL
SPEED are positioned to high, high speed functions
are automatically cut out and the machine continues
to operate at a lower speed.

DO NOT OPERATE MACHINE IF HIGH ENGINE SPEED, HIG H
WHEEL MOTOR SPEED, OR HIGH PUMP VOLUME OPERATE
WHEN BOOM IS ABOVE HORIZONTAL.

10. High Engine.

11. Wheel Motor Speed.
The two position WHEEL MOTOR SPEED control

switch allows the operator to select high wheel
motor speed when in the high position. When used
in conjunction with HIGH ENGINE speed, it gives the
machine a faster drive speed.

TO AVOID PERSONNEL INJURY OR MACHINE DAMAGE, USE
SLOW FUNCTION SPEED CONTROL WHEN POSITIONING THE
PLATFORM IN CLOSE QUARTERS.

12. Pump Volume.
The two-position PUMP VOLUME control switch

allows the operator to select high pump flow, provid­ing additional speed to all functions when in the high
position. When used in conjunction with HIGH
ENGINE and WHEEL MOTOR SPEED switches, it
gives the machine a faster drive speed range.

13. Creep.
The CREEP control switch allows the operator to

select a lower speed for DRIVE, LIFT, SWING and
TELESCOPE, when in the on position.

14. Drive.
The DRIVE controller provides driving either forward

or backward when positioned to forward or reverse.
The controller is ramped to allow infinitely variable
driving speed between fast and slow.

15. Platform Level.
The PLATFORM LEVEL control switch allows the

operator to compensate for any difference in the
automatic self-leveling system by positioning the
switch up or down .

16. Platform Rotate.
The platform ROTATE control switch allows operator

to rotate the basket to the left or right when posi­tioned to the desired direction.

17. Extend-A-Reach (If Equipped).
The EXTEND-A-REACH LIFT control switch allows

operator to raise or lower the extend-a-reach, as
required.

The two position HIGH ENGINE control switch
allows the operator to select higher function speeds
or higher drive speed when in the high posit ion.

18. Choke (If Equipped).
A push-button switch supplies power to the choke

solenoid for cold weather starting.

3120635 – JLG Lift – 3-13

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

19. Auxiliary Power.
The AUXILIARY POWER control switch ener gizes the

electrically operated hydraulic pump, when actu­ated. The 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 system should the
main pump or engine fail. The auxiliary pump will
operator boom lift, telescope and swing.

It should be noted that the functions will operate at a
slower th an normal rate beca use of l ower hyd raulic
flow.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE
MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTA­NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
MOTOR.

NOTE: The main function of the auxiliary power is to lower

the platform in the event of primary power failure.
Determine the reason for primary power failure and
have the problem corrected by a qualified service
technician.

NOTE: Auxiliary power is primarily intended for platform low-

ering in the event of primary power failure. However,
auxiliary power may be used for platform positioning
when operating in close quarters in the following
sequence:

a. Position PLATFORM/GROUND switch to PLAT-

FORM.

b. Position the POWER/EMERGENCY STOP switch

to the ON position.
c. Depress and hold footswitch.
d. Operate appropriate control switch or lever for

desired function an d hold.
e. Position AUXILIARY POWER switch on and hold.
f. Release AUXILIARY POWER switch, selected

control switch or lever, and footswitch.
g. Position the POWER/EMERGENCY STOP switch

to the OFF position.

20. Axles Set Indicator (If equipped).
The green AXLES SET indicator lights to inform the

operator that the axles are set and locked (pinned )
in position.

21. Lights Switch (If equipp ed).
The LIGHTS switch allows the operator to turn the

installed light options on or off.

NOTE: One of the capacity indicator lights should be illumi-

nated at all times during operation. If no capacity
lights are on, a bulb could be burned out. Operation
of the machine must be halted until the lights are
working properly.

Check the capacity decal in the platform and at the
ground control station for the machines operating
capacity(s).

22. Capacity Indicator.
The capacity indicator displays to the operator the

maximum rated platform capacity and the maximum
radius for that capacity using different colored lights
and a reach diagram. The operator must not exceed
the rated capacity or the maximum radius for the
load (personnel, tools, and supplies) shown on the
indicator.

A light for each different capacity is used; blue indi­cates operating within maximum capacity range, yel­low indicates operating within reduced capacity
range. Models equipped with Extend-A-Reach only
have a blue and a red light. When moving the plat­form from one capacity area to another, one light will
go out and another will come on indicating the cor­rect capacity for that area. A steady red light indi­cates you have exceeded the machines operating
radius. You must immediately stop and ‘’L I FT UP’’ or
‘’TELE IN’’ until the red light goes out. A blinking red
light and a buzzer sounding indicates you have
exceeded the platform load capacity (personnel,
tools, and supplies) and maximum radius. You must
immediately stop all functions and then ‘’LIFT UP’’ or
‘’TELE IN’’ until the red light goes out and the buzzer
stops. Check to make sure the load in the platform
does not exceed the rated capacity.

3.5 PLACARDS AND DECALS

Read and understand all placards an d decals. Do not
operate any machine on which DANGER, WARNING,
CAUTION, or INSTRUCTION PLACARDS OR DECALS
ARE MISSING OR ILLEGIBLE . Replace placards and
decals if damaged, missing, or illegible.

Decals are made o f Lexan Pr essure Sen sitive Adhesive
with a protective film on the front. Remove the damaged
decal and thoroughly clean the surface before installing a
new decal. Simply peel off the backing and press the
decal on to the surface.

NOTE: Placards and Decals can be ordered by using the

part numbers located by each placard or decal. See
Figure 3-8., Caution, Danger, Warning Decal Loca­tion - Sheet 1 of 2 and Figure 3-9., Caution, Danger,
Warning Decal Location - Sheet 2 of 2

3-14 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

3120635 – JLG Lift – 3-15

Figure 3-8. Caution, Danger, Wa rning Decal Location - Sheet 1 of 2

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

3-16 – JLG Lift – 3120635

Figure 3-9. Caution, Danger, Warning Decal Location - Sheet 2 of 2

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

3120635 – JLG Lift – 3-17

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

3-18 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-10. Common Symbols - Sheet 1

3120635 – JLG Lift – 3-19

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

Figure 3-11. Common Symbols - Sheet 2

3-20 – JLG Lift – 3120635

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

Figure 3-12. Common Symbols - Sheet 3

3120635 – JLG Lift – 3-21

SECTION 3 - USER RESPONSIBILITIES AN D MACHINE CONTROL

Figure 3-13. Common Symbols - Sheet 4

3-22 – JLG Lift – 3120635

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTIO N

This machine is a self-propelled aerial work platform on
the end of an elevating, telescoping and rotating boom.
The JLG Lift’s intended purpose is to position personnel
with their tools and supplies a t positions above ground
level. The machine can be us ed to reach work areas
located above and over machinery or equipment.

The JLG Lift has a primary operator Control Station in the
platform. From this Control Station, the operator can drive
and steer the machine in both forward and reverse direc­tions. The operator can raise, lower, extend or retract the
boom; swing the boom to the left or right; and when
equipped with a platform rotator, can rotate the platform
around the boom end. Standard bo om swin g is 360° co n­tinuous left and right of the stow ed positi on. The ma chine
has a Ground Control Station which will override the Plat­form Control Station. Ground Cont rols ope rate boom l ift,
telescope and swing and are to be used only in an eme r­gency to lower the platform to the ground should the
operator in the platform be unable to do so .

Instruction and hazard warnings are posted adjacent to
both operator control stat ions and at other places on the
machine. It is extremely important that operators know
what instructions and warnings are placed on the
machine, and review these periodical ly so that they are
fresh in their minds. Vibrations emitted by these machines
are not hazardous to an operator in the work platform.

The JLG Lift is designed to provide efficient and safe oper­ation when main taine d and op era ted in a ccordance with
warnings on the machine, in the Operators and Safety
Manual, and all jobsite and government rules and regula­tions. As with any type of machinery, the operator is very
important to efficient and safe operation. Owner/user/
operator must be familiar with Sections 6, 7, 8, 9, and 10
of ANSI A92.5-1992. These sections contain the responsi­bilities of the owner, users, operators, lessors and lessees
concerning safety, training, inspection, maintenance,
application and oper ation. It is absolut ely nece ssary tha t
the JLG Lift be regularly maintained in accordance with
this manual and the machine Service and Maintenance
manual, and that any evidence of lack of maintenance,
malfunction, excessive wear, damage or modification to
the machine be reported immediately to the machine
owner or the jobsi te s upervisor or safety man age r and that
the machine be taken out of service until all discrepancies
are corrected.

The JLG Lift is not intended to be used to lift material other
than supplies which personnel in the platform require to
do their job. Supplies or tools which extend outside the
platform are prohibited. It must not be used as a forklift,
crane, support for overhead structure, or to push or pull
another object or the lift itself.

The machine is equipped with an auxiliary battery oper­ated power unit which will provide hydraulic power in the
event of a primary engine power loss. Auxiliary power can
be controlled from either the Platform Control Station or
the Ground Control Statio n. Follow the instructions placed
at the control stations.

The JLG Lift is hydraulically powered using hydraulic
motors and cylinders for various machine motions. The
hydraulic comp onents are contr olled by electri cally ac ti­vated hydraulic valves using switches and contr ol levers.
The speeds of functions controlled by control levers are
variable from zero t o maximum spe ed depending upon
the position of the control lever. Functions controlled by
toggle switches are either on or off and higher or lower
speed is possible when the Function Speed control switch
is used in conjunction with the function toggle switch. A
foot operated switch in the platform must be depressed
before any controls will function and provides a means of
emergency stop when the operator’s foot is removed from
the footswitch.

The JLG Lift is a two wheel drive machine with drive powe r
being supplied by a hydraulic m otor for each drive wheel.
Each drive wheel is supplied with a hydrauli ca lly released,
spring-applied br ake. The swin g drive is also equip ped
with such a brake. These brakes a re au tomatically applied
any time the Drive or Swing Cont rol lever are retur ned to
the neutral position.

Refer to the capacity decal in the platform and at the
ground control station for the rated capacity. See instruc­tions in this manual and on the machine for checking pro­cedures.

4.2 GENERAL

This section provides the necessary information needed
to operate the machine. Included in this section are the
procedures for starting, stopping, traveling, steering, park­ing, platform loading and transporting. It is important that
the user read and understand the proper procedures
before operating the machine.

Updated 4-20-00

3120635 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure.

1. Check engine oil. If necessary, add oil in accor­dance with the Engine Manufacturer’s manual.

2. Check fuel level. Add fuel if necessary.

3. Check that air cleaner components are in place and
securely fastened.

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

4. Place HIGH ENGINE control switch on platform con­sole to LOW position.

5. Position the SELECT SWITCH to GROUND. Position
IGNITION switch to ON, then push the START switch
to the upward position until engine starts.

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

6. After engine has had suffic ient time to warm up, shut
engine off.

7. Position SELECT SWITCH to PLATFORM.

8. From Platform position IGNITION switch to ON, then
push the START switch to the forward position until
engine starts.

Shutdown Procedure

IF AN ENGINE MALFUNCTION NECESSITATES
UNSCHEDULED SHUTDOWN, DETERMINE AND COR­RECT CAUSE BEFORE RESUMING ANY OPERAT ION.

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

2. Position IGNITION switch to OFF.

3. Turn key of MASTER SWITCH to OFF position.

NOTE: Refer to Engine Manufacturer’s manual for detailed

information.

4.4 TRAVELING (DRIVING)

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

TO AVO ID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES
AND SIDE SLOPES, DO NOT DRIVE MACHINE ON GRADES OR
SIDE SLOPES EXCEEDING THOSE SPECIFI ED ON WARNING
PLACARD AT PL ATFORM.

ASSURE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGIN­NING ANY EXTE NDED TRAVELING. AVOID ANY TERRAI N FEA­TURES WHICH COULD CAUSE THE MACHINE TO UPSET.

TRAVEL GRADES IN “LOW” WHEEL MOTOR SPEED AND “HIGH”
ENGINE SPEED ONLY. USE EXTREME CAUTION WHEN DRIVING
IN REVERSE AT ALL TIMES WHEN DRIVING WITH PLATFORM
ELEVATED AND ESPECIALLY WHEN DRIVING WITH ANY PART OF
MACHINE WITHIN 6 FEET (2 M) OF AN OBSTRUCTION. DO NO T
USE DRIVE TO MANEUVER PLATFORM CLOSE TO AN OBSTRUC-

TION....USE ONE OF THE BOOM FUNCTIONS.

NOTE: The footswitch must be in released (up) position

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

4-2 – JLG Lift – 3120635

Figure 4-1. Grade and Side Slope

SECTION 4 - MACHINE OPERATION

BEFORE DRIVING, MAK E SURE BOOM IS POS ITIONED OVER
REAR AXLE. IF BOOM IS OVER FRONT AXLE (STEER WHEELS),
STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIREC­TIONS TO MACHINE CONTROLS.

Traveling Forward or Reverse

1. With engine running, depress footswitch and posi­tion DRIVE control to FORWARD and hold for the
duration of fo r ward travel desired.

NOTE: When DRIVE or STEER functions are being oper-

ated there is an interlock which prevents operation of
boom functions.

2. Depress footswitch and position DRIVE control to
REVERSE and hold for duration of reverse travel
desired.

3. Depress footswitch and position STEER control to
RIGHT for traveling right and LEFT for traveling left.

4. To obtain maximum travel speed, position the DRIVE
controller to FAST and activate the following
switches:

b. Po si tio n WHEEL MOTOR SPEED switch to LOW.
c. Position PUMP VOLUME switch to LOW.

6. For traveling up grades, position switches as fol­lows:

a. Position HIGH ENGINE switch to HIGH.
b. Po si tio n WHEEL MOTOR SPEED switch to LOW.
c. Position PUMP VOLUME switch to LOW.

NOTE: For smoother operation when driving with fully

extended boom, place DRIVE control to SLOW
before stopping.

4.5 STEERING

Depress footswitch to steer machine, push on the left side
of the switch to steer left, on the right side to steer right.

BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSI­TIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE
(STEER WHEELS), STEER AND DRIVE CONTROLS WILL MO VE IN
OPPOSITE DIRECTION THAN INDICATED ON MACHINE PLAC­ARDS.

a. Position HIGH ENGINE switch to HIGH.
b. Position WHEEL MOTOR SPEED switch to

HIGH.

c. Position PUMP VOLUME switch to HIGH.

5. Prior to stopping the machine, position switches as
follows:

a. Position HIGH ENGINE switch to LOW.

3120635 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

4.6 PARKING AND STOWING

Park and stow machine as follows:

1. Park machine in travel position; boom lowered over
rear, all access panels and doors closed and
secured, ignition off, turntable locked.

2. Check that brakes hold machine in position.

3. Chock wheels front and rear.

4. Turn off SELECT SWITCH and remove key.

4.7 PLATFORM
Loading From Ground Level

1. Position chassis on a smooth, firm and level surface.

2. If total load (personnel, tools and supplies) is less
then rated capacity, distribute load uniformly on plat­form floor and proceed to work position.

Loading From Positions Above Ground Level

Before loading weight to platform above ground level:

1. Determine what the total rated capacity weight will
be after additional w e ight is loaded (personnel, tools
and supplies).

2. If total weight in platform will be less then rated
capacity, proceed with adding weight.

Platform Level Adjustment

Platform Rotation

1. Depress footswitch to rotate platform to the left,
PLATFORM ROTATE control is positioned to the
LEFT and held until desired position is reached.

2. Depress footswitch to rotate platform to the right,
PLATFORM ROTATE control is positioned to the
RIGHT and held until desired position is reached.

4.8 AXLES, EXTENDING AND RETRACTING

NOTE: Throughout the text, there are references made to

fixed axle machines. Fixed axle machines have
retaining pins for the axles, steer cylinders, and tie
rods. Machines equipped with oscillating axles do
not have these retaining pins.

Machines Without Jack s

1. From ground control, activate the machine hydraulic
system. Raise the boom and extend the boom no
more than 8 feet.

2. Position STEER/AXLES valve, located at the front of
the frame, to AXLES.

3. Position boom over drive wheel end of machine.
Remove axle lock pins.

DO NOT USE EXTEND-A-REACH (IF EQUIPPED) TO LIFT
MACHINE WHEN EXTENDING AND RETRACTING AXLES.

1. Leveling UP. Depress footswitch to raise platform,
position PLATFORM LEVEL control switch UP and
hold until platform is level.

2. Leveling DOWN. Depress footswitch to lower plat­form, position PLATFORM LEVEL control switch to
DOWN and hold until platform is level.

Figure 4-2. Lifting the Axle

4. Position LIFT control to DOWN and hold until drive
wheels rise from the ground; it may be necessary to
feather the lift control to maintain drive wheel eleva­tion.

5. With the aid of an assistant, position EX TENDABLE
AXLE/STEER switch located on platform control

4-4 – JLG Lift – 3120635

SECTION 4 - MACHINE OPERATION

console to EXTEND until axles are fully extended
and the AXLES SET light is on. Install axle lock pins.

6. Position LIFT control to UP to lower the machine;
elevate the boom sufficiently and reposition the
boom over the steer wheel end of the machine.

7. Remove the tie rod lock pins, steer cylinder loc k pin,
and axle lock pins.

8. Position LIFT control to DOWN and hold until the
steer wheels rise from the ground; it may be neces­sary to feather the LIFT control to maintain wheel
elevation.

9. With the aid of an assistant, position EXTENDABLE
AXLE/STEER switch on pla tform c ons ole to EX TEND
until axles are fully extended.

10. Align steer wheels and insert tie rod lock pin, axle
lock pins, and stee r cy linder lock pins.

11. Position LIFT control to UP to lower the machine
steer wheels; position STEER/AXLES valve to
STEER.

12. Cycle steer system in both directions to ensure tie
rod and steer cylinder are properly locked. You are
now ready to operate all machine func tions.

13. To retract extendable axles:

a. Position STEER/AXLES valve located adjacent

to right front wheel to AXLES.

b. Activate the machine hydraulic system and raise

the boom and extend the boom no more than
eight (8) feet.

c. Position the boom over the steer wheel end of

the machine; on machines with fixed axles,
remove tie rod lock pins, steer cylinder p in and
axle lock pins.

e. Position EXTENDABLE AXLE/STEER switch

located on platform control console to
RETRACT, until axles are fully retracted.

f. Align steer wheels and insert tie rod lock pins

and steer cylinder pin. Install axle lock pins.

g. Position LIFT control to UP to lower the

machine; elevate the boom sufficien tly and rep o­sition the boom over the drive wheel end of the
machine.

h. P osition LIFT control to DOWN and hold until the

drive wheels rise from the ground; it may be n ec­essary to feather the LIFT control to maintain
drive wheel elevation.

i. Position EXTENDABLE AXLES/STEER switch,

on platform control console, to RETRACT, until
axles are fully retracted. Install axle lock pins.

j. Position LIFT control to UP to lower the machine

drive wheels; position STEER/ AXLES valve to
STEER.

k. Cycle the steer system in both directions to

ensure the tie rods are properly locked.

Machines With Jacks

NOTE: For machines equipped with a front jack only, refer to

the instructions under Machines Without Jacks to
extend the rear axle.

1. Position STEER/AXLES valve, located on the front of
the frame, to AXLES.

2. Remove the axle lock pins on the applicable axle. If
extending the steer axle, also remove the tie ro d lock
pins and steer cylinder lock pin.

3. Position the JACK/AXLES Select Switch to JACK
and position the JACK/AXLES control switch to
down and hold until the wheels on the selected axle
rise from the gr ound.

NOTE: It may be necessary to elevate the wheels and jog

the steer control for removal of lock pins.

d. Position the LIFT control to DOWN and hold until

the steer wheels rise from the ground; it may be
necessary to feather the LIFT control to maintain
wheel elevation.

3120635 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

4. Position the JACK/AXLES Select switch to AXLES.
Then, position the JACK/AXLES c on trol switch to left
until the axles are fully extended. Install axle lock
pins. If extending the steer axle, also install the tie
rod lock pins and steer cylinder lock pin.

ENSURE THE JACK IS FULLY RETRACTED BEFORE OPERATING
THE MACHINE. FAILURE TO DO SO COULD RESULT IN DAMAGE
TO THE MACHINE.

5. Position the JACK control to the up position to lower
the machine. Ensure the jack is fully retracted before
operating the machine.

6. Repeat steps 2 thru 5 and ex te nd the opposite axle.

7. Position the STEER/AXLES valve to STEER.

8. Cycle the steer system in both directions to ensure
the tie rod and steer cylinder are properly locked.

9. Yo u are now ready to operate all machine functions.

10. To retract extendable axles:
a. Position STEER/AXLES valve located on the

front of the frame to AXLES.

b. If retracting the drive axles, remove the axle lock

pins. If retracting the steer axles, remove the tie
rod lock pins, steer cylinder pin and axle lock
pins.

NOTE: It may be necessary to elevate the wheels and jog

the steer control for removal of lock pins.

c. Position the JACK/AXLES Select Switch to JACK

and position the JACK/ AXLES cont rol switch to
down and hold until th e wheels on the sel ected
axle rise from the ground.

d. Position the JACK/AXLES Select Switch to

AXLES. Then, position the JACK/AXLES cont rol
switch to the right until the axles are fully
retracted.

e. If retracting the steer axles, align the steer

wheels and insert the tie rod lock pins and steer
cylinder pin. Install axle lock pins.

ENSURE THE JACK IS FULLY RETRACTED BEFORE OPERAT ING
THE MACHINE. FAILURE TO DO SO COULD RESULT IN DAMAG E
TO THE MACHINE.

f. Position the JACK/AXLES Select Switch to JACK

and the JACK/AXLES control switch to the UP
position to lower the machine. Ensure the jack is
fully retracted before operating the machine.

g. Rep eat steps b thru f and retract the axles at the

opposite end of t he machine.

4-6 – JLG Lift – 3120635

SECTION 4 - MACHINE OPERATION

Figure 4-3. Lifting Chart - 100HX and 110HX

3120635 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-4. Lifting Chart - 100H X+10

4-8 – JLG Lift – 3120635

SECTION 4 - MACHINE OPERATION

4.9 BOOM

A RED TILT ALARM WARNING LIGH T, LOCATE D ON THE C ON­TROL CONSOL E, LIGHTS WHEN TH E CHASSIS IS ON A S EVERE
SLOPE (5 DEGREES OR GREATER). DO NOT SWING, EXTEND OR
RAISE BOOM ABOVE HORIZONTAL WHEN LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR
THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A
SEVERE SLOPE (5 DEGREE S OR GREATER). CHASSIS MUST BE
LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM
ABOVE HORIZONTAL.

TO AVOID UPSET, I F RED TILT ALARM WARNING LIG HT LIGH TS
WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZON­TAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND
LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS
LEVEL BEFORE EXTENDING OR RAISING BOOM.

TRAVELING WITH BOOM RETRACTED AND BELOW HORIZONTAL
IS PERMITTED ON GRADE S AND SIDE SLOPE S SPECIFIED ON
CAUTION PLACARD AT PLATFORM.

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

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

Raising and Lowering the Main Boom

To raise and low er Boom, posit ion LIF T contr ol switch or
controller to UP OR DOWN and hol d until desired h eigh t is
reached.

Telescoping the Main Boom

To extend or ret ract Bo om, positi on TELES COPE c ontrol
switch to IN or OUT and hold until platform reaches
desired position.

4.10 SHUT DOWN AND PARK

1. Drive machine to a protected area.

2. Position HIGH ENGINE speed control switch on
Platform Control Console to LOW.

3. Assure main boom is fully retracted and lowered
over rear (Drive) axle; all access panels and doors
closed and secured.

4. Remove all load and allow engine to operate 3-5
minutes at LOW setting to permit reduction of
engine internal temperatures.

5. At Ground Controls, turn MASTER SWITCH to (cen­ter) OFF. Position, the IGNITION switch (down) to
OFF.

6. Cover the Platform Control Console to protect
instruction placards, warning decals and operating
controls from hostile environment.

Swinging the Boom

ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE
STARTING ANY SWING OPERATION.

1. Depress footswitch to swing bo om, p osition S WING
control switch or controller to RIGHT or LEFT for
direction desired.

NOTE: When boom functions are being operated there is an

interlock that prevents the use of DRIVE and STEER
functions.

3120635 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.11 TIE DOWN AND LIFTING

When transporting machine, boom must be in the stowed
mode with turntable lock pin engaged and machine
securely tied down to truck or traile r deck. Four tie down
eyes are provided in the frame slab, one at each corner of
the machine.

If it becomes necessary to lift the machine using an over­head or mobile crane, it is very important that the lifting
devices are attached only to the designated lifting eyes,
and that the turntable lock pi n is engaged. See Figure 4-3
and 4-4, Lifting Chart.

NOTE: Lifting eyes are provided at the front and rear in the

frame slab. Each of the four chains or slings used for
lifting machine must be adjusted individually so
machine remains level when elevated.

SECURE TURNTABLE WITH TURNTABLE LO CK BEFORE TRAV­ELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/
TRAILER.

4.13 TOWING (IF EQUIPPED)

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.).

Prior to towing the machine, complete the
following:

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

1. Retract, lower and position boom over rear drive
wheels in line wi t h direction of travel; lock turntable.

2. Connect towbar to front of frame with attach pins,
and towbar to towing vehicle.

3. Disconnect drive hubs by inverting disconnect cap.
(See Figure 4-6.)

4.12 STEER/TOW SELECTOR (IF EQUIPPED)

DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH
COMPLETE TOW PACKAGE FROM MANUFACTURER. FAILURE
TO DO SO COULD DAMAGE THE MACHINE.

A push-pull type selector valve located adjacent to the
steer cylinder assembly and linkage regulates oil flow in
the steer circuit for steering and towing applications.
When steering the unit (self-propelled operation) the valve
knob is pushed IN. When towing the unit the valve knob is
pulled OUT to th e fl oat position.

4. Actuate steer/tow selector valve for towing; pull
valve knob OUT to float position. (This opens the
steer circuit to reservoir, allowing the steer cylinder
rod free travel.) The machine is now in the towing
mode.

4-10 – JLG Lift – 3120635

SECTION 4 - MACHINE OPERATION

Figure 4-5. Machine Tie Dow n

3120635 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

After towing the machine, complete the
following:

1. Actuate steer/tow selector valve for steering; push
valve knob IN to the actuated position.

2. Reconnect drive hubs by inverting disc onnect cap.
(See Figure 4-5.)

3. Disconnect towbar from steering hitc h and fr om tow ­ing vehicle. The machine is no w in the driving mode.

Figure 4-6. Drive Discon nect Hug

4-12 – JLG Lift – 3120635

SECTION 5 - OPTIONAL EQUIPMENT

SECTION 5. OPTIONAL EQUIPMENT

5.1 ROTATOR

A Platform rotator allows for platf orm rotation 90 degree s
from center in either direction. The rotator is designed to
give added jobsite versatility. The platform should be
returned to the center position for all other operations.

5.2 DUAL FUEL SYSTEM (GAS ENGINE
ONLY)

Description

The dual fuel system enables the standard gasoline
engine to run on eit her gasolin e or LP ga s. The syst em
includes pressurized cylinders mounted on the frame, and
the valves and switches needed to switc h the fuel supply
from gasoline to LP gas or from LP gas to gasoline.

A two position, FUEL toggle switch at the groun d control
station supplies electrical power to open the gasoline gas
shut-off solenoid and close the LP gas shut off solenoid
when positioned to the GASOLINE position. This switch
supplies electrical power to open the LP gas shut-off sole­noid and close the gasoline shut-off solenoid when posi­tioned to the LP position.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE
TO THE OTHER WITHOUT ALLOWING THE ENGINE TO
STOP. EXTREME CARE MUST BE TAKEN AND THE FOL­LOWING INSTRUCTI ONS MUST BE FOLLOWED.

Changing From Gasoline to LP Gas

2. If engine stumbles because of lack of gasoline,
place the switch to LP position until engine regains
smoothness, then return switch to GASOLINE posi­tion. Repeat as necessary until engine runs
smoothly on gasoline.

3. Close hand valve on LP gas supply tank by turning
clockwise.

5.3 TOW PACKAGE

The tow package is required when it is necessary to move
the machine without use of the drive and steer system.

TOWING IS PERMITTED ONLY FOR EMERGENCY TRAVEL ON THE
JOBSITE. NO HIGHWAY TOWING IS PERMITTED.

The towing package consists of the tow bar, attaching
hardware, a tow bar which connects to the eyes on front
of frame and the towing vehicle, and a t ow/steer selector
valve which permits the steering system to ‘float free’
when towing the machine.

5.4 TRAVEL ALARM

A 12-volt alarm horn, mounted on the turntable, pr ovides
an audible warning when the machine is in the travel
(DRIVE) mode. It will function in FOR WARD or REVERSE
to warn jobsite personnel the machine is traveling.

1. Start engine from Ground Contro l Stati on.

2. Open hand valve on LP gas supply tank by turning
counterclockwise.

BE SURE GASOLINE IS EXHAUSTED BEFORE SWITCHING TO LP
GAS. SEE STEP (3) BELOW.

3. While engine is operating, place DUAL FUEL switch
at Ground Control to center OFF position. Allow
engine to operate without load, until engine begins
to stumble from lack of gasoline. As engine begins
to stumble, place the switch to LP position, allowing
LP gas to flow to the fuel regulator.

Changing From LP Gas to Gasoline

1. With engine operating on LP under a no- load condi­tion, position DUAL FUEL switch at Ground Control
Station to GASOLINE position.

5.5 TILT ALARM

Senses when the machine is out of le vel in any dir ection
approximately 5 degrees and illuminates a w arning lig ht at
the platform control station and sounds the machine’s
horn, signaling the operator. A second s wi t ch mounted on
the machine senses when the machine is out of level 5
degrees and will cut out two speed drive when activated.

5.6 ELECTRIC GENERATOR

An electric generator mounted on the machine functions
to supply electrical power to the platform. This device will
provide enough power to run assorted power tools.

5.7 FOAM FILLED TIRES

Eliminates flats by filling tires with polyurethane foam. For
use where sharp objects are frequently encountered on
operating su rf ace of jobsite.

3120635 – JLG Lift – 5-1

SECTION 5 - OPTIONAL EQUIPMENT

5.8 ROTATING BEACON

An amber or red rotating beacon may be installed on the
hood or platform, and can be controlled by a two position
toggle switch mounted on the platform control console.
When the switch is placed in t he ON posit ion, the light i s
activated and provides a visual warning to the ma chine’s
operation.

5.9 CYLINDER BELLOWS

A one piece accordion shaped rubber bellows may be
attached to the rod end of the cylinder barrel and to the
cylinder rod as close to the rod attach b ushing as possi­ble. The bellows affords protection to the cylinder rod in
either the extended or retracted position. The bellows are
installed on the lift cylinder, slave cylinder, master cylinder
and steer cylinder.

5.10 BOOM WIPERS

A one piece U-shaped neoprene strip, be attached to the
front of the base boom section, wipes the top and both
sides of the fly section. The bottom side of the fly section
is protected by a straight neoprene strip which also
attaches to the base section.

5.11 HOSTILE ENVIRONMENT PACKAGE

The hostile environment package provides additional pro­tection against the entry o f d us t, dirt, sand and other abra­sive materials into the hyd raulic syste m, control han dles
and switches, cy lin ders, bo om wir e rop es an d w ea r pads,
and the air inlet of the engine. The package is intended for
machines that will be exposed to painting, sandblasting or
other similar hostile conditions. The ho stile environment
package includes boom wipers, cylinder bellows, heavy
duty reservoir breather, an engine air cleaner and control
console cover, as required.

5.12 MOTION ALARM

A motion alarm horn provides an audible warning when
the platform controls are selected at the PLATFORM/
GROUND SELECT switch, the POWER/EMERGENCY
STOP switch is ON, and the footswitch is depressed. The
alarm warns personnel in the jobsite area to avoid the
operating ma chine.

5.13 DESERT ENVIRONMENT PACKAGE

The Desert E nviro nment packa ge is design ed to p rovi de
additional protection to the machines vital components
under extreme hot, dry and sandy conditions. This pack­age includes the boom wipers, cy linder bell ows, heavy

duty air cleaner, console cover, and air breather described
in the Hostile Environme nt package in this se ction. In
addition to these items a hydraulic oil cooler fitted wit h a
sand and dust filter is instal led on the machine turntable.
A hydraulically driven motor serves to turn the fan which
draws air down through the sand and dust filter. The air is
then forced down through the heat exchanger cooling the
constant flow of hydraulic oi l within.

5.14 110 VOLT/60HZ GENERATOR

A 110 volt generator, mounted beside the engine, is belt
driven from the output shaft of the engine. This applic ation
provides for a 110 volt recept acle at the gr ound control
and also at the platform. The lead from the ground control
and also at the platform. The lead from the ground control
to the platform is routed along the boom power track thus
eliminating the use of extension cords hanging freely from
the platform.

5.15 220 VOLT RECEPTACLE

A 220 volt receptacle may be mounted on the platform
support to eliminate extension cords hanging from the
platform. The lead from the receptacle is routed along the
boom power track to the engine compartment. In the
engine compartment, a plug is installed on the lead for
attachment to an extension cord or a receptacle from a
220 volt power source. When not in use the p lug is stored
in a junction box mounted on the engine compartment
frame.

5.16 SPARK ARRESTOR MUFFLER

The spark arrestor is mounted directly aft of the standard
muffler and serves to contain any sparks the engine might
emit that a standard muffler norm ally woul d not. T he spark
arrestor is a vital option for machines which are operated
in areas where combustible materials are used. The spark
arrestor is availa ble for gasoline, L P gas, and diesel
engines.

5.17 110 VOLT RECEPTACLE

A 110 volt receptacle may be mounted on the platform
control console to eliminate extension cords hanging from
the platform. The lead from the receptacle is routed along
the boom power track to the battery and ground control
compartment at the front of the machine. A plug is
installed on the end of the lead for attachment to an exten­sion cord or a receptacle from a 110 volt power source.
When not in use the excess wire and plug are to be
stowed beside the battery.

5-2 – JLG Lift – 3120635

SECTION 6 - EMERGENCY PROCEDURES

SECTION 6. EMERGENCY PROCEDURES

6.1 GENERAL

This section provides information on the procedures to be
followed and on the systems and controls to be used in
the event an emergency situation is encountered during
machine operation. Prior to operation of the m achine and
periodically thereafter, the entire operating manual, includ ­ing this section, should be reviewed by all personnel
whose responsibilities include any work or contact with
the machine.

6.2 EMERGENCY TOWING PROCEDURES

Towing this machine is prohibited, unless properly
equipped. However, provisions for moving the machine, in
case of a malfunction or power failure, have been incorpo­rated. The following proce dures are t o be used ONLY for
emergency movement to a suitable maintenance area.

1. Chock wheels securely.

2. Disengage drive hubs by reversing disconn ect caps.

3. Connect suitable equipment, remove chocks, and
move machine.

After moving machine, complete the following proce­dures:

1. Position machine on a firm and level surface.

2. Chock wheels securely.

3. Engage drive hubs by reversing disconnect caps on
hubs.

4. Remove chocks from wheels as needed.

controlling th e pla tform level , boom and sw ing fu ncti ons
from the ground. Place the SELECT switch to GROUND
position and operat e the proper switch to li ft, swing, or
telescope the boom, or level the platform.

Auxiliary Power

A toggle type auxiliary power control switch is located on
the platform control station and another is located on the
ground control station. Operation of either switch turns on
the electrically driven auxiliary hydraulic pump. This
should be used in case of failure of the main power plant.
The auxiliary pump will op erate boom lift, telescope and
swing. To activate auxiliary power:

1. Position the platform/ground SELECT SWITCH to
PLATFORM.

2. Position the EMERGENCY STOP switch to ON.

3. Depress and hold footswitch.

4. Operate appropriate control switch, lever or control­ler for desired function and hold.

5. Position the AUXILIARY POWER switch to ON and
hold.

6. Release the AUXILIARY POWER switch, selected
control switch, lever or controller, and footswitch.

7. Position the EMERGENCY STOP switch to OFF.

To activate auxili ary power from the ground control sta­tion:

1. Position the platform/ground SELECT SWITCH to
GROUND.

2. Position EMERGENCY STOP switch to ON.

6.3 EMERGENCY CONTROLS AND THEIR
LOCATIONS

Emergency Stop Switches

There is an emergency stop switch at both the Ground
Controls and Platform Contro ls. When positio ned to OFF it
will immediately stop the machine.

CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP
SWITCH GUARD IS I N PLACE AND THAT GROUND CONT ROL
INSTRUCTIONS ARE IN PLACE AND LEGIBLE.

Ground Control Station

The Ground Control Station is located on the right front
side of the turntable. The controls on this panel provide
the means for overriding the platform controls, and for

3. Operate appropriate control switch or c ontroller for
desired function and hold.

4. Position the AUXILIARY POWER switch to ON and
hold.

5. Release the AUXILIARY POWER switch, and ap pro­priate control switch or controller.

6. Position the EMERGENCY STOP switch to OFF.

6.4 EMERGENCY OPERATION
Use of Ground Controls

KNOW HOW TO USE THE GROUND CONTROLS IN AN
EMERGENCY SITUATION.

Ground personnel must be thoro ughly familiar with th e
machine operating characteris tics and the ground control

3120635 – JLG Lift – 6-1

SECTION 6 - EMERGENCY PROCEDURES

functions. Training should include operation of the
machine, review and und erstandin g of this se ction and
hands-on oper atio n of t he con tr ols in simu late d e mer ge n­cies.

Operator Unable to Control Machine

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

DO NOT OPERATE WITH PRIMARY POWER SOURCE (ENGINE) IF
PERSONS ARE PINNED OR TRAPPED. USE AUXILIARY POWER
INSTEAD.

1. Operate the machine from ground controls ONLY
with the assistance of other personnel and equip­ment (cranes, overhead hoists, etc.) as may be
required to safely remove the danger or emergency
condition.

2. Other qualified personnel on the platform may use
the platform controls with regular or auxiliary power.
DO NOT CONTINUE OPERATION IF CONTROLS
DO NOT FUNCTION NORMALLY.

until you are sure t hat all dama ge has been repaired, if
required, and that all controls are operating correctly.

6.5 INCIDENT NOTIFICATION

It is imperative that JLG Industries, Inc. be notified imme­diately of any in ciden t inv olvin g a JLG pr oduc t. Even if no
injury or property damage is evident, the factory should
be contacted by telephone and provided with all neces­sary details.

It should be noted that failure to notify the manufactur er of
an incident involving a JLG Industries product within 48
hours of such an occurrence may void any warranty con­sideration on that partic ular machine.

3. Cranes, forklift trucks or other equipment which may
be available are to be used to remove platform
occupants and stabilize motion of the machine in
case machine controls are inadequate or malfunc­tion when used.

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in
overhead structures or equipment, do not continue opera­tion of the machine from either the platform or the ground
until the operator and all personnel are safely moved to a
secure location. Only then should an attempt be mad e to
free the platform using any necessary equipment and per­sonnel. Do not operate controls to cause one or more
wheels to leave the ground.

Righting a Tipped Machine

No attempt should be made to right the machine using
platform or ground controls. A fork truck of suitable
capacity or equivalent equipment may be placed under
the elevated side of the chassis. A crane or other lifting
equipment may also be used to lift the platform while t he
chassis is lowered by a fork truck, jacks, or other means.
Remove all personnel and equipment from the area
before starting operat ion.

Post Incident Inspection and Repair

Following any incident, thoroughly inspect the machine
and test all functions first from the ground controls, then
from the platform controls. Do not lift above 10 feet (3 m)

6-2 – JLG Lift – 3120635

SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Table 7-1.Inspection and Repair Log

Date Comments

3120635 – JLG Lift – 7-1

SECTION 7 - INSPECTIO N AND REPAIR LOG

Table 7-1.Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3120635

JLG Industries, Inc.

I

TRANSFER OF OWNERSHIP

To: JLG, Gradall, Lull and Sky Trak 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 (717) 485­6573 or mail to address as specified on the back of this form.

Thank you,
Product Safety & Reliability Department

JLG I

ndustries, IInc.
1 JLG Drive
McConnellsburg, PA 17233-9533
Telephone: [phone]
Fax: [phone]

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

Mfg. Model:

Serial Number:

Previous Owner:

Address:

City: State:

Zip: Telephone: ( )

Date Of Transfer:

Current Owner:

Address:

City: State:

Zip: Telephone: ( )

Please cut on the dotted line and fax to 717-485-6573

Who in your organization should we notify?

Name:



Title:

McConnellsburg PA. 17233-9533

JLG Worldwide Locations

Corporate Office

JLG Industries, Inc.

1 JLG Drive

USA

Phone: [phone]

Fax: [phone]

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Por t M acqua ri e
N.S.W. 2444
Australia
Phone: [phone]
Fax: [phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil
Phone: [phone]
Fax: [phone]

JLG Industries (Europe)
Kilmartin Place,
Tannochside Park
Uddingston G71 5PH
Scotland
Phone: [phone]
Fax: [phone]

JLG Industries (UK)
Unit 12, Southside
Bredbury Park Industrial Estate
Bredbury
Stockport
SK6 2sP
England
Phone: [phone]
Fax: [phone]

JLG Europe B.V.
Jupiterstraat 234
2132 HJ Foofddorp
The Netherlands
Phone: [phone]
Fax: [phone]

JLG Industries (Pty) Ltd.
Unit 1, 24 Industrial Complex
Herman Street
Meadowdale
Germiston
South Africa
Phone: [phone]
Fax: [phone]

JLG Deutschland GmbH
Max Planck Strasse 21
D-27721 Ritterhude/lhlpohl
Bei Bremen
Germany
Phone: [phone]
Fax: [phone]

JLG Industries (Norge AS)
Sofeimyrveien 12
N-1412 Sofienyr
Norway
Phone: [phone]
Fax: [phone]

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755Castellbisbal
Spain
Phone: [phone]
Fax: [phone]

JLG Industries (Italia)
Via Po. 22
20010 Pregnana Milanese - MI
Italy
Phone: [phone]
Fax: [phone]

JLG Polska
UI. Krolewska
00-060 Warsawa
Pol and
Phone: [phone]
Fax: [phone]

JLG Industries (Sweden)
Enkopingsvagen 150
Box 704
SE - 175 27 Jarfalla
Sweden
Phone: [phone]
Fax: [phone]