JLG 1200SJP Operator Manual

Operation and Safety Manual

®

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

Boom Lift Models
1200SJP
1350SJP

ANSI

3121141

September 11, 2014

FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.

3121141 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

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

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

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

b – JLG Lift – 3121141

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

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER­SONAL PROPERTY OR THE JLG PRODUCT.

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

• Standards and Regulations

• Questions Regarding Special

• Questions Regarding Prod-

Contact:

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

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

FOREWORD

Compliance Information

Product Applications

uct Modifications

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

Outside USA:

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

3121141 – JLG Lift – c

In USA:

FOREWORD

REVISION LOG

Original Issue - May 24, 2002

Revised - June 14, 2002

Revised - November 1, 2002

Revised - January 15, 2003

Revised - May 3, 2005

Revised - August 30, 2005

Revised - January 12, 2006

Revised - June 19, 2006

Revised - July 17, 2006

Revised - December 1, 2006

Revised - April 11, 2007

Revised - June 19, 2008

Revised - November 19, 2009

Revised - August 30, 2010

Revised - November 3, 2010

Revised - June 2, 2011

Revised - September 20, 2012

Revised - October 7, 2013

Revised - September 11, 2014

d – JLG Lift – 3121141

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

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

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

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

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

Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

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

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

Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11

1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11

Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,

AND INSPECTION

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

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

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

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

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2

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

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

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-11

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 BOOM OPERATING CHARACTERISTICS AND

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

4.4 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

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

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

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

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

Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-15

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Controlled Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

3121141 – JLG Lift – i

TABLE OF CONTENTS

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

Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-6

4.5 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9

4.6 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.7 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-11

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-12

Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.11 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.12 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.13 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.14 STOWING THE JIB FOR TRANSPORT . . . . . . . . . . . . . . . . . . 4-15

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

Boom Movement Prevented By Boom

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

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

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

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

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

Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

ii – JLG Lift – 3121141

TABLE OF CONTENTS

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

Engine Data - Deutz 2011 Prior to

S/N 0300127698 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Data - Deutz 2011 S/N 0300127698

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Engine Data - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

Major Component Weights . . . . . . . . . . . . . . . . . . . . . . 6-10

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-28

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-30

SECTION - 7 - INSPECTION AND REPAIR LOG

3121141 – JLG Lift – iii

TABLE OF CONTENTS

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

This Page Left Blank Intentionally.

iv – JLG Lift – 3121141

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

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

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

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

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

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

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

3-3. Platform Control Console - Prior to S/N 79596. . . . . . . . . 3-8

3-4. Platform Control Console - S/N 79596 to 93078 . . . . . . . 3-9

3-5. Platform Control Console - w/Boom Control Select. . . 3-10
3-6. Platform Control Indicator Panel - Prior

to S/N 79596 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-7. Platform Control Indicator Panel - S/N 79596

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-8. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19

4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-7

4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-8

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

4-5. Lifting and Tie Down Chart - Sheet 1 of 2 . . . . . . . . . . . .4-16

4-6. Lifting and Tie Down Chart - Sheet 2 of 2 . . . . . . . . . . . .4-17

4-7. Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-8. Decal Location Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-9. Decal Location Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-10. Decal Location Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-11. Decal Location Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

6-1. Engine Operating Temperature Specifications - Deutz -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-2. Engine Operating Temperature Specifications - Deutz -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-3. Engine Operating Temperature Specifications - Caterpillar

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-4. Engine Operating Temperature Specifications - Caterpillar

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-5. Lubrication and Maintenance Point Location . . . . . . . . 6-15

6-6. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

3121141 – JLG Lift – v

LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

vi – JLG Lift – 3121141

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6

1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9

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

4-1 Decal Legend - Prior to S/N 0300141473 . . . . . . . . . . . . .4-23

4-2 Decal Legend - S/N 0300141473 to Present . . . . . . . . . .4-27

6-1 Operating Specifications - Prior to S/N 0300141473 . . . 6-1
6-2 Operating Specifications - S/N 0300141473

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-6 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-7 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . .6-4

6-8 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-10 Caterpillar 3.4T Specifications . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-13 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

6-15 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-16 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-17 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

6-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-16

6-19 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-30

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

3121141 – JLG Lift – vii

LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

viii – JLG Lift – 3121141

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

This section outlines the necessary precautions for proper and
safe machine usage and maintenance. It is mandatory that a daily
routine is established based on the content of this manual to pro­mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte­nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation of the machine has been
completed under the supervision of an experienced and quali­fied operator.

This section contains the responsibilities of the owner, user, oper­ator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any ques­tions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).

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

1.2 PRE-OPERATION

Operator Training and Knowledge

• The Operation and Safety Manual must be read and under­stood in its entirety before operating the machine. For clarifi­cation, questions, or additional information regarding any
portions of this manual, contact JLG Industries, Inc.

3121141 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until
adequate training has been given by competent and autho­rized persons.

• Allow only those authorized and qualified personnel to oper­ate the machine who have demonstrated that they under­stand the safe and proper operation and maintenance of the
unit.

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

• Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined by
JLG.

• All operating personnel must be familiar with the emergency
controls and emergency operation of the machine as specified
in this manual.

• Read, understand, and obey all applicable employer, local, and
governmental regulations as they pertain to your utilization
and application of the machine.

Workplace Inspection

• Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.

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

• Before operation, check work area for overhead hazards such
as electric lines, bridge cranes, and other potential overhead
obstructions.

• Check operating surfaces for holes, bumps, drop-offs, obstruc­tions, debris, concealed holes, and other potential hazards.

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

• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.

1-2 – JLG Lift – 3121141

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Do not operate this machine until the inspections and func­tional checks as specified in Section 2 of this manual have
been performed.

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

• Ensure all safety devices are operating properly. Modification
of these devices is a safety violation.

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

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

• Check the machine for modifications to original components.
Ensure that any modifications have been approved by JLG.

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

1.3 OPERATION

General

• Machine operation requires your full attention. Bring the
machine to a full stop before using any device, i.e. cell phones,
two-way radios, etc. that will distract your attention from
safely operating the machine.

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

• Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.

• Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from service
and notify the proper authorities.

• Do not remove, modify, or disable any safety devices.

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

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

3121141 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless
approved by JLG.

• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and never
left hanging by their cord from the platform work area.

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

• Do not assist a stuck or disabled machine by pushing or pull­ing except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leaving
machine.

• Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair unre­strained which may become caught or entangled in equip­ment.

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

Trip and Fall Hazards

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

• Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the machine when entering or
leaving the platform. Always maintain “three point contact”
with the machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.

1-4 – JLG Lift – 3121141

SECTION 1 - SAFETY PRECAUTIONS

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

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

• Keep oil, mud, and slippery substances cleaned from footwear
and the platform floor.

Electrocution Hazards

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

3121141 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

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

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are
more stringent.

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

MINIMUM APPROACH DISTANCE

in Feet (Meters)

1-6 – JLG Lift – 3121141

SECTION 1 - SAFETY PRECAUTIONS

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

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

Tipping Hazards

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

• Do not elevate platform or drive with platform elevated while
on or near a sloping, uneven, or soft surface. Ensure machine is
positioned on a firm, level and smooth surface before elevat­ing platform or driving with the platform in the elevated posi­tion.

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

3121141 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the
platform. Keep all loads within the confines of the platform,
unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
from holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards at the ground level.

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

• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure. Never attach wire, cable, or
any similar items to platform.

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

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

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

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

1-8 – JLG Lift – 3121141

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

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

SECTION 1 - SAFETY PRECAUTIONS

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken fro m trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

becomes difficult.

3121141 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards

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

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

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

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

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

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

• Under all travel conditions, the operator must limit travel
speed according to conditions of ground surface, congestion,
visibility, slope, location of personnel, and other factors which
may cause collision or injury to personnel.

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

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

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

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

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

1-10 – JLG Lift – 3121141

SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING

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

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

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

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

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

1.5 MAINTENANCE

This sub-section contains general safety precautions which must
be observed during maintenance of this machine. Additional pre­cautions to be observed during machine maintenance are
inserted at the appropriate points in this manual and in the Ser­vice and Maintenance Manual. It is of utmost importance that
maintenance personnel pay strict attention to these precautions
to avoid possible injury to personnel or damage to the machine
or property. A maintenance program must be established by a
qualified person and must be followed to ensure that the
machine is safe.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts
are secured from inadvertent motion prior to performing any
adjustments or repairs.

• Never work under an elevated platform until it has been fully
lowered to the full down position, if possible, or otherwise
supported and restrained from movement with appropriate
safety props, blocking, or overhead supports.

• DO NOT attempt to repair or tighten any hydraulic hoses or fit­tings while the machine is powered on or when the hydraulic
system is under pressure.

• Always relieve hydraulic pressure from all hydraulic circuits
before loosening or removing hydraulic components.

3121141 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of card­board or paper to search for leaks. Wear gloves to help protect
hands from spraying fluid.

• Ensure replacement parts or components are identical or
equivalent to original parts or components.

• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in an
unstable position. Ensure adequate support is provided when
raising components of the machine.

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

• Use only approved non-flammable cleaning solvents.

• Do not replace items critical to stability, such as batteries or
solid tires, with items of different weight or specification. Do
not modify unit in any way to affect stability.

• Refer to the Service and Maintenance Manual for the weights
of critical stability items.

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

1-12 – JLG Lift – 3121141

Battery Hazards

SECTION 1 - SAFETY PRECAUTIONS

• Always disconnect batteries when servicing electrical compo­nents or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery dur­ing charging or servicing.

• Do not contact tools or other metal objects across the battery
terminals.

• Always wear hand, eye, and face protection when servicing
batteries. Ensure that battery acid does not come in contact
with skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
CLEAN WATER AND SEEK MEDICAL ATTENTION.

• Charge batteries only in a well ventilated area.

• Avoid overfilling the battery fluid level. Add distilled water to
batteries only after the batteries are fully charged.

3121141 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

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

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

Operator Training

Operator training must cover:

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

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

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential malfunc­tion.

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

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

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121141 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

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

2-2 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequenc y Primary Responsibility Service Qualification Reference

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspectio n (See
Note)

Frequent Inspection
(See Note)

Annual Machine Inspection
(See Note)

Preventative Maintenance At intervals as specified in the S ervice and Maintenance

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

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualifie d JLG Mechanic Service and Maintenance Manual

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

An n ua l ly , n o la t er t ha n 13 m on t hs f ro m th e da te o f p r i or
inspection.

Manual.

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Q ualified JLG Mechanic Service and Mai ntenance Manual

Owner, Dealer, or User Factory-Qualified Service

Tec h ni c ia n
(Recommended)

Owner, Dealer, or User Q ualified JLG Mechanic Service and Mai ntenance Manual

and applicable JLG inspection form

and applicable JLG inspection form

Service and Maintenance Manual
and applicable JLG inspection form

3121141 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

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

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

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

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

4. Operators and Safety Manuals – Make sure a copy of the
Operator and Safety Manual, EMI Safety Manual (Domestic
only), and ANSI Manual of Responsibilities (Domestic only) is
enclosed in the weather resistant storage container.

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

6. Battery – Charge as required.

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

proper fuel as necessary.

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

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

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

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

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

2-4 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

Function Check

Perform the Function Check as follows:

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

a. Check that all guards protecting the switches or locks

are in place;

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

switches;

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is activated.

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

3. From the platform control console:

a. Ensure that the control console is firmly secured in the

proper location;

b. Check that all guards protecting the switches or locks

are in place;

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

switches;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

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

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

gradeability, and stop to ensure the brakes hold;

b. Check the tilt sensor alarm to ensure proper operation.

c. Check that the boom telescope (beyond transport

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

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

3121141 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Boom Control System Check Procedure

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

1. Extend all axles fully.

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

rest to horizontal.

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

4. Extend the boom until it stops.

5. Boom must stop on colored stripe matching the capacity

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

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

2-6 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Front Steer Wheels

2. Rear Drive Wheels

3. L if t Cy li n d er

4. Ground Console

5. B a se B oo m Se c t io n

6. Inner Mid Boom Section

7. Outer Mid Boom Section

8. F ly B oo m S ec t io n

9. B o om A ss e mb l y

10. Power Track

11. Jib

12. Platform

13. Platform Console

3121141 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-8 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

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

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

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

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

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

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

4. Swing Drive - No evidence of damage.

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

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

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

7. Hood Assemblies - See Inspection Note.

8. Auxiliary Hydraulic Pump - See Inspection Note.

9. All Hydraulic Cylinders - No visible damage; pivot pins and

hydraulic hoses undamaged, not leaking.

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

11. Steering Spindles and Sensors - See Inspection Note.

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

3121141 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Horizontal and Capacity Limit Switches - Switches oper­ate properly.

13. Main Hydraulic Pump - See Inspection Note.

14. Platform Rotator - See Inspection Note.

15. Jib Rotator - See Description.

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

2-10 – JLG Lift – 3121141

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

The front axles will oscillate when the boom is in the transport posi­tion (i.e. when the boom is less than 15° above horizontal and not
extended beyond 12" [30.4 cm] on the1350SJP or 24" [60.9 cm] on
the 1200SJP) and drive is selected.

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

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

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

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

2. From platform control station, start engine.

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

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

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

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

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

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

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

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

3121141 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-12 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

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

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

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that use symbols

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

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

Ground Control Station

NOTE: If equipped, the Function Enable switch must be

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

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

1. Indicator Panel

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

2. Boom Control System Test Button

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

3. Telescope Control

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

3121141 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706911 A

1

13

3

2

4

5

6

7

8

9

10

11

12

OR

Figure 3-1. Ground Control Station

1. Indicator Panel

2. Boom Control System Test Button

3. Telescope

4. Swing

5. Lift

6. Platform/Ground Select Switch

7. Hourmeter

8. Power/Emergency Stop

9. Engine Start/Auxiliary Power
o r

Engine Start/Auxiliary Power/Function Enable

10. Articulating Jib

11. Platform Leveling Override

12. Platform Rotate

13. Jib Swing

3-2 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. Swing Control

Provides 360 degrees continuous turntable rotation.

5. Lift Control

Provides raising and lowering of the main boom.

NOTE: With PLATFORM/GROUND SELECT switch in the center position,

power is shut off to controls at both operating stations.

6. Platform/Ground Select Switch

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

7. Hourmeter

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

NOTE: When Power/Emergency Stop switch is in the “ON” position and

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

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

8. Power/Emergency Stop Switch

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

3121141 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: Auxiliary power only works if there is no engine oil pressure, and

is disabled if engine is running.

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

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

9. Engine Start/Auxiliary Power Switch
or
Engine Start/ Auxiliary Power Switch /Function Enable

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

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

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

10. Articulating Jib

This switch provides raising and lowering of the jib.

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

11. Platform Leveling Override

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

12. Platform Rotate

A three position switch permits rotation of the platform.

13. Jib Rotate

A three position switch permits rotation of the jib and plat­form.

3-4 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

65432

1

7

89

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. High Engine Oil Temp.

5. Axles Set

6. Platform Capacity

7. Platform Overload

8. Boom Control System Warning

9. Boom Control System Calibrated

Figure 3-2. Ground Control Indicator Panel

Ground Control Indicator Panel

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

1. Battery Charging Indicator

3121141 – JLG Lift – 3-5

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

2. Low Engine Oil Pressure Indicator

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

3. High Engine Temperature Indicator

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

4. Engine Oil Temperature Indicator

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

5. Axles Set Indicator

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

6. Platform Capacity Indicator

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

SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

8. Boom Control System Warning Indicator

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

9. Boom Control System Calibrated Indicator

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

Platform Station

(See Figure 3-3., Platform Control Console - Prior to S/N 79596, Figure
3-4., Platform Control Console - S/N 79596 to 93078, and Figure 3-5.,
Platform Control Console - w/Boom Control Select)

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

1. Power/Emergency Stop

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

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

3-6 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Start/Auxiliary Power

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

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

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

3. Capacity Select

This switch allows the operator to select between an operat­ing envelope with a 500 lb. (227 kg for ANSI markets and 230
kg for CE and Australia markets) capacity restriction or a
1000 lb. (454 kg for ANSI markets and 450 kg for CE and Aus­tralia markets) capacity restriction.

4. Drive Orientation Override

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

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

the handle.

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

cally return to neutral (OFF) position when released.

5. Drive/Steer

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

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

3121141 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1705175 A

1705171 A

17

18 19 20

21

5

6

7

98101314 12 111516

123

4

1. Power/Emergency Stop

2. Engine Start / Aux Power

3. Capacity Select

4. Drive Orientation Override

5. Drive/Steer

6. Telescope

7. Lights

8. Jib Lif t

9. Soft Touch Override

10. Jib Swing

11. Axle Extend/Retract

12. Soft Touch Indicator

13. Platform Rotate

14. Jib Stow Override

15. Function Speed Control

16. Main Lift / Swing

17. Drive Speed / Torque Select

18. Steer Select

19. Platform Level Override

20. Horn

21. Indicator Panel

Figure 3-3. Platform Control Console - Prior to S/N 79596

3-8 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1705744 A

1705745 B

1702938

1705170 A

1705171 A

17

18 19 20

21

56

7

981013

14 12

11

1516

123

4

1. Power/Emergency Stop

2. Engine Start / Aux Power

3. Capacity Select

4. Drive Orientation Override

5. Drive/Steer

6. Telescope

7. Lights

8. Jib Lif t

9. Soft Touch Override

10. Jib Swing

11. Axle Extend/Retract

12. Soft Touch Indicator

13. Platform Rotate

14. Jib Stow Override

15. Function Speed Control

16. Main Lift / Swing

17. Drive Speed / Torque Select

18. Steer Select

19. Platform Level Override

20. Horn

21. Indicator Panel

Figure 3-4. Platform Control Console - S/N 79596 to 93078

3121141 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1705744 A

1705745 B

1702938

1705170 A

1705171 A

1706741

A

17

18 19 20

21

56

7

981013

14 12

11

1516

1

2

22

3

4

1. Power/Emergency Stop

2. Engine Start / Aux Power

3. Capacity Select

4. Drive Orientation Override

5. Drive/Steer

6. Telescope

7. Lights

8. Jib Lif t

9. Soft Touch Override

10. Jib Swing

11. Axle Extend/Retract

12. Soft Touch Indicator

13. Platform Rotate

14. Jib Stow Override

15. Function Speed Control

16. Main Lift / Swing

17. Drive Speed / Torque Select

18. Steer Select

19. Platform Level Override

20. Horn

21. Indicator Panel

22. Boom Control Select

Figure 3-5. Platform Control Console - w/Boom Control Select

3-10 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Main Telescope

This control allows extension and retraction of the main
boom.

7. Lights (If Equipped)

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

8. Jib Lift

Push forward to lift up, pull back to lift down. Variable lift
speed is using the Function Speed Control.

9. Soft Touch Override Switch (If equipped)

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

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

control is in the 1000 lb. (454 kg for ANSI markets and 450 kg
for CE and Australia markets) position.

10. Jib Swing

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

11. Axle Extend/Retract

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

12. Soft Touch Indicator (If Equipped)

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

13. Platform Rotate

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

3121141 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

14. Jib Stow Override

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

15. Function Speed Control

Controls the speed of Boom and Swing Functions. Rotate
CCW for slower speed and CW for faster speed. To adjust to
creep, turn knob fully CCW until it clicks.

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

ring below the handle.

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

automatically return to neutral (OFF) position when released.

16. Main Lift/Swing Controller

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

NOTE: When boom is positioned above transport position or telescoped

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

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

17. Drive Speed/Torque Select

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

3-12 – JLG Lift – 3121141

18. Steer Select

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

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

19. Platform Leveling Override

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

20. Horn

If pressed, this switch supplies power to the horn.

3121141 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

21. Indicator Panel

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

22. Boom Control Select

Automatic Mode:

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

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

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

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

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

Manual Mode:

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

NOTE: When positioned to Manual, boom functions will be stopped

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

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

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

3-14 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

(See Figure 3-6. or Figure 3-7.)

NOTE: The platform control indicator panel uses different shaped sym-

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

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

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

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

1. Level System Fault Indicator

Indicates a fault in the electronic leveling system. The fault
indicator will flash and an alarm sound. All functions will

default to creep if the boom is extended past transport
mode (24 inches [61 cm] 1200; 12 inches [30.5 cm] 1350) or
elevated more than 15° above horizontal.

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

2. AC Generator

Indicates the generator is in operation.

3. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

4. Platform Capacity Indicator

Indicates the maximum platform capacity selected for the
platform.

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

3121141 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 456

789

1011121314

*

**

* UNRESTRICTED CAPACITY
** RESTRICTED CAPACITY

1. Level System

2. AC Generator

3. Platform Overload

4. Platform Capacity

5. Tilt Alarm Warning

6. Glow Plu g

7. Enable

8. Fuel Level

9. Creep Speed

10. System Distress

11. Cable Service

12. Drive Orientation

13. Axles Set

14. Boom Control System Warning

Figure 3-6. Platform Control Indicator Panel - Prior to S/N 79596

3-16 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 456

789

1011121314

*

**

* UNRESTRICTED CAPACITY
** RESTRICTED CAPACITY

1. Level System

2. AC Generator

3. Platform Over load

4. Platform Capacit y

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed

10. System Distress

11. Cable Service

12. Drive Orientation

13. Axles Set

14. Boom Control System Warning

Figure 3-7. Platform Control Indicator Panel - S/N 79596 to Present

3121141 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Tilt Alarm Warning Light and Alarm

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

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

6. Glow Plug Indicator

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

7. Footswitch/Enable Indicator

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

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

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

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

3-18 – JLG Lift – 3121141

SECTION 3 - MACHINE CONTROLS AND INDICATORS

LOW FU EL

(FLASHES ONCE

PER SECOND)

1/4 TANK

½ TANK3/4 TANKFULL TANK

EMPTY

(FLASHES TEN

TIMES

PER SECOND)

Figure 3-8. Fuel Level Indicator

NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more

detailed information concerning the Low Fuel Indicator.

8. Fuel Level Indicator

Indicates the level of fuel in the fuel tank.

9. Creep Speed Indicator

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

10. System Distress Indicator

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

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

3121141 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS AND INDICATORS

11. Cable Service Indicator

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

12. Drive Orientation Indicator

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

13. Axles Set Indicator

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

14. Boom Control System Warning Indicator

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

3-20 – JLG Lift – 3121141

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

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

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

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

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

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

2. Axles are extended.

3. Load is within manufacturer’s rated capacity.

4. All machine systems are functioning properly.

5. Proper tire pressure.

6. Machine is as originally equipped from JLG.

3121141 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Controlled Arc

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

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

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

4-2 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

BUFFER LINE

ENVELOPE

SLOWDOWN LINE

BUFFER
ZONE

SLOWDOWN
ZONE

Envelope Tracking

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

NOTE: Boom Control System in Automatic Mode: When the boom is

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

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

Controlled Angle

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

Swing Speed Proportioning

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

3121141 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Stability

Machine stability is based on two (2) conditions which are called
FORWARD and BACKWARD stability. The machine’s position of
least FORWARD stability is shown in (See Figure 4-1.), and its posi­tion of least BACKWARD stability is shown in (See Figure 4-2.)

TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER­ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

4.3 CAPACITY SELECT

The Boom Control System allows the operator to select operation in
a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Australia
markets) capacity restriction envelope or a 1000 lb. (454 kg for ANSI
markets and 450 kg for CE and Australia markets) capacity restriction
envelope. The operator selects the desired capacity restriction by
positioning the Capacity Select switch on the platform console. The
Capacity Indicator shows the capacity selected, and both capacity
lights will flash and an alarm sound if the platform is out of the
selected capacity range.

NOTE: Operation in the 1000 lb. (454 kg for ANSI markets and 450 kg for

CE and Australia markets) envelope requires the jib to be fixed in
the centered position.

4-4 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

4.4 ENGINE OPERATION

NOTE: Initial starting should always be performed from the Ground

Control station.

Starting Procedure

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

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

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

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

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

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

3. Turn SELECT switch to PLATFORM.

4. From Platform, pull POWER/EMERGENCY STOP switch out,

then push the ENGINE START switch until engine starts.

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

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

Shutdown Procedure

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

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

2. Push POWER/EMERGENCY STOP switch in.

3. Turn MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

3121141 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Fuel Reserve / Shut-Off System

NOTE: Reference the Service and Maintenance Manual along with a

qualified JLG Mechanic to verify your machine setup.

The Fuel Shutoff System monitors the fuel in the tank and senses
when the fuel level is getting low. The JLG Control System auto­matically shuts the engine down before the fuel tank is emptied
unless the machine is set up for Engine Restart.

If fuel level reaches the Low Fuel range the ¼ tank
indicator will flash once a second and there will be
approximately 5 minutes of engine run time left. If
the system is in this condition and automatically
shuts down the engine, or the engine is manually
shut down before the 5 minute run time is com­plete, the ¼ tank indicator will flash 10 times a sec­ond and the engine will react according to
machine setup. Setup options are as follows:

• Engine One Restart - When the engine shuts down, the
operator will be permitted to cycle power and restart the
engine once with approximately 2 minutes of run time.
After the 2 minute run time is complete or if the engine is
shut down by the operator prior to the completion of the 2
minute run time, it cannot be restarted until fuel is added
to the tank.

• Engine Restart - When the engine shuts down, the opera­tor will be permitted to cycle power and restart the engine
for approximately 2 minutes of run time. After the 2 min­utes of run time is complete, the operator may cycle power
and restart the engine for an additional 2 minutes of run
time. The operator can repeat this process until there is no
more fuel available.

CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO
MORE FUEL IS AVAILABLE.

• Engine Stop - The engine will shut down. No restarts will
be permitted until fuel is added to the tank.

4-6 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

3121141 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability

.

4.5 TRAVELING (DRIVING)

NOTE: When the upper boom is raised approximately 15 degrees above

horizontal, the high drive function will automatically be in low
drive.

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

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON
GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

4-8 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

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

Traveling Forward and Reverse

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

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

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

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

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

4.6 STEERING

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

4.7 EXTENDING THE AXLES

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

order to extend the axles.

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

3121141 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

4-10 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

4.8 PLATFORM

Platform Level Adjustment

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

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

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

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

Platform Rotation

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

4.9 BOOM

DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF
LEVEL.

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

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TO
A LEVEL SURFACE BEFORE RAISING BOOM.

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

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

3121141 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Swinging the Boom

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

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

Raising and Lowering the Boom

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

tal if the axles are not fully extended.

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

Telescoping the Boom

NOTE: The telescope function is not operable beyond the transport

position if the axles are not fully extended.

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

Swinging the Jib

NOTE: For 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Aus-

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

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

4.10 FUNCTION SPEED CONTROL

This control affects the speed of all boom functions and Platform
Rotate. When in the CCW maximum position, Drive is placed in
creep speed.

4-12 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

Figure 4-4. Drive Disconnect Hub

4.11 EMERGENCY TOWING

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

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

MAXIMUM TOWING GRADE 25%.

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

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

2. Disconnect drive hubs by inverting disconnect cap.

3. Reconnect the drive hubs by inverting the disconnect cap

when towing is complete.

3121141 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

4.12 SHUT DOWN AND PARK

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

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Position

Platform/Ground Select switch to center OFF.

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

4.13 LIFTING AND TIE DOWN

See Figure 4-5. and Figure 4-6.

Lifting

1. Call JLG Industries or weigh the individual unit to find out
the Gross Vehicle Weight.

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

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the designated

lifting points.

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

4-14 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

Tie Down

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

NOTE: Prior to loading the machine onto a trailer, it will be necessary to

rotate the turntable 180 degrees to provide better weight distri­bution.

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

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or chains of

adequate strength and attached to the designated tie down
points.

4.14 STOWING THE JIB FOR TRANSPORT

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

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

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

control is in the 1000 lb. (454 kg for ANSI markets and 450 kg
for CE and Australia markets) position.

NOTE: Automatic platform leveling is disabled when stowing the jib.

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

3121141 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

Figure 4-5. Lifting and Tie Down Chart - Sheet 1 of 2

4-16 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

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

3121141 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-7. Decal Location Sheet 1 of 5

4-18 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Location Sheet 2 of 5

3121141 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Location Sheet 3 of 5

4-20 – JLG Lift – 3121141

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location Sheet 4 of 5

3121141 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Location Sheet 5 of 5

4-22 – JLG Lift – 3121141

Table 4-1. Decal Legend - Prior to S/N 0300141473

SECTION 4 - MACHINE OPERATION

Item # ANSI

0274722-7

1- -- -- -- -- -- -- -- ­2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3- -- -- -- -- -- -- -- ­4- -- -- -- -- -- -- -- ­5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
11- -- -- -- -- -- -17055515- ­12- -- -- -- -- -1705514- -- ­13 3251243 3251243 3251243 3251243 3251243 3251243 - - 3251243
14- -- -- -- -- -- -- -- ­15 1705337 1705337 1705342 1705904 1705337 1705341 - - 1705338
16 - - - - 1705507 1705906 1705916 1705505 - - 1705493

Korean

0274723-7

Chinese

0274724-7

Portu guese

0274725-7

English/
Spanish

0274726-8

French/English

0274727-7

CE/Australian

0274728-8

Japan

0274729-7

3121141 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Prior to S/N 0300141473

Item # ANSI

0274722-7

17 - - 1702153 - - 1705901 1704007 1704006 - - - ­18 1703953 1703953 1703943 1705903 1703941 1703942 - - 1703944
19 1702868 1702868 1705968 1705967 1704001 1704000 - - - ­20 1703797 1703797 1703925 1705895 1703923 1703924 1705921 1703926
21 1705336 1705336 1705348 1705896 1705917 1705347 1705822 1705344
22 1703804 1703804 1703949 1705898 1703947 1703948 1701518 1703950
23 1703805 1703805 1703937 1705897 1703935 1703936 1705961 1703938
24 3252347 - - 1703982 1705902 1703983 1703984 1705828 1703980
25 3251813 3251813 3251813 3251813 3251813 3251813 - - 3251813
26 1705492 1705492 1705508 1705907 1705915 1705506 - - 1705494
27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
28 1705168 1705168 1705334 1705899 1705908 1705333 1706770 1705330
29 1705181 1705181 1705478 1705900 1705919 1705477 1705468 1705480
30 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584
31 1706751 1706751 1706751 1706751 1706751 1706751 - - 1706751
32 1705868 1705868 1705868 1705868 1705868 1705868 - - 1705868
33 1705351 1705351 1705430 1705905 1705910 1705429 - - 1705426
34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505

Korean

0274723-7

Chinese

0274724-7

Portu guese

0274725-7

English/
Spanish

0274726-8

French/English

0274727-7

CE/Australian

0274728-8

0274729-7

Japan

4-24 – JLG Lift – 3121141

Table 4-1. Decal Legend - Prior to S/N 0300141473

SECTION 4 - MACHINE OPERATION

Item # ANSI

0274722-7

35 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972
36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511
37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501
38- -- -- -- -- -- -- -- ­39- -- -- -- -- -- -- -- ­40- -- -- -- -- -- -- -- ­41- -- -- -- -- -- -- -- ­42- -- -- -- -- -- -- -- ­43- -- -- -- -- -- -- -- ­44- -- -- -- -- -- -- -- ­45- -- -- -- -- -- -- -- ­46- -- -- -- -- -- -- -- ­47- -- -- -- -- -- -- -- ­48- -- -- -- -- -- -- -- ­49- -- -- -- -- -- -- -- ­50- -- -- -- -- -- -- -- ­51- -- -- -- -- -- -- -- ­52- -- -- -- -- -- -- -- -

Korean

0274723-7

Chinese

0274724-7

Portu guese

0274725-7

English/
Spanish

0274726-8

French/English

0274727-7

CE/Australian

0274728-8

Japan

0274729-7

3121141 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Prior to S/N 0300141473

Item # ANSI

0274722-7

53- -- -- -- -- -- -- -- ­54- -- -- -- -- -- -- -- ­55- -- -- -- -- -- -- -- ­56- -- -- -- -- -- -- -- ­57- -- -- -- -- -- -- -- ­58- -- -- -- -- -- -- -- ­59- -- -- -- -- -- -- -- ­60- -- -- -- -- -- -- -- -

Korean

0274723-7

Chinese

0274724-7

Portu guese

0274725-7

English/
Spanish

0274726-8

French/English

0274727-7

CE/Australian

0274728-8

Japan

0274729-7

4-26 – JLG Lift – 3121141

Table 4-2. Decal Legend - S/N 0300141473 to Present

SECTION 4 - MACHINE OPERATION

Item # ANSI

0274722-B

1- -- -- -- -- -- -- -- -

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
11- -- -- -- -- -- -17055515- ­12- -- -- -- -- -1705514- -- ­13 3251243 3251243 3251243 3251243 3251243 3251243 - - 3251243
14- -- -- -- -- -- -- -- ­15 1705337 1705337 1705342 1705904 1705337 1705341 - - 1705338
16 - - - - 1001117035 1705906 1705916 1705505 - - 1705493

Korean

0274723-B

Chinese

0274724-B

Portu guese

0274725-B

English/
Spanish

0274726-B

French/English

0274727-B

CE/Australian

0274728-B

Japan

0274729-B

3121141 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - S/N 0300141473 to Present

Item # ANSI

0274722-B

17 - - 1702153 - - - - - - - - - - - ­18 1703953 1703953 1703943 1705903 1703941 1703942 - - 1703944
19 1702868 1702868 1001116846 1705967 1704001 1704000 - - - ­20 1703797 1703797 1703925 1705895 1703923 1703924 1705921 1703926
21 1705336 1705336 1001116849 1705896 1705917 1705347 1705822 1705344
22 1703804 1703804 1703949 1705898 1703947 1703948 1701518 1703950
23 1703805 1703805 1001116851 1705897 1703935 1703936 1705961 1703938
24 3252347 - - 1703982 1705902 1703983 1703984 1705828 1703980
25- -- -- -- -- -- -- -- ­26 1705492 1705492 1705508 1705907 1705915 1705506 - - 1705494
27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
28 1001122369 1001122370 1001122371 1001122372 1001122373 1001122374 1706770 1001122375
29 1001122376 1001122377 1001122378 1001122379 1001122380 1001122381 1705468 1001122382
30 1001131269 - - - - - - - - 1700584 - - - ­31 1706751 1706751 1706751 1706751 1706751 1706751 - - 1706751
32 1705868 1705868 1705868 1705868 1705868 1705868 - - 1705868
33 1705351 1705351 1705430 1705905 1705910 1705429 - - 1705426
34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505

Korean

0274723-B

Chinese

0274724-B

Portu guese

0274725-B

English/
Spanish

0274726-B

French/English

0274727-B

CE/Australian

0274728-B

Japan

0274729-B

4-28 – JLG Lift – 3121141

Table 4-2. Decal Legend - S/N 0300141473 to Present

SECTION 4 - MACHINE OPERATION

Item # ANSI

0274722-B

35 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972
36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511
37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501
38- -- -- -- -- -- -- -- ­39- -- -- -- -- -- -- -- ­40- -- -- -- -- -- -- -- ­41- -- -- -- -- -- -- -- ­42- -- -- -- -- -- -- -- ­43- -- -- -- -- -- -- -- ­44- -- -- -- -- -- -- -- ­45- -- -- -- -- -- -- -- ­46- -- -- -- -- -- -- -- ­47- -- -- -- -- -- -- -- ­48- -- -- -- -- -- -- -- ­49- -- -- -- -- -- -- -- ­50- -- -- -- -- -- -- -- ­51- -- -- -- -- -- -- -- ­52- -- -- -- -- -- -- -- -

Korean

0274723-B

Chinese

0274724-B

Portu guese

0274725-B

English/
Spanish

0274726-B

French/English

0274727-B

CE/Australian

0274728-B

Japan

0274729-B

3121141 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - S/N 0300141473 to Present

Item # ANSI

0274722-B

53- -- -- -- -- -- -- -- ­54- -- -- -- -- -- -- -- ­55- -- -- -- -- -- -- -- ­56- -- -- -- -- -- -- -- ­57- -- -- -- -- -- -- -- ­58- -- -- -- -- -- -- -- ­59- -- -- -- -- -- -- -- ­60- -- -- -- -- -- -- -- -

Korean

0274723-B

Chinese

0274724-B

Portu guese

0274725-B

English/
Spanish

0274726-B

French/English

0274727-B

CE/Australian

0274728-B

Japan

0274729-B

4-30 – JLG Lift – 3121141

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

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

5.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro­vided with all necessary details.

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

(8am till 4:45pm EST)

Outside USA:

240-420-2661

E-mail:

[e-mail]

Failure to notify the manufacturer of an incident involving a JLG
Industries product within 48 hours of such an occurrence may
void any warranty consideration on that particular machine.

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

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

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

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

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

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

3121141 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead

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

Boom Movement Prevented By Boom Control System

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

1. Shut off the engine.

2. Rescue platform occupants prior to freeing machine.

3. Use cranes, forklifts or other equipment to stabilize motion

of the machine as required.

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

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

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

5.4 EMERGENCY TOWING PROCEDURES

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

5-2 – JLG Lift – 3121141

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary infor­mation to the operator for proper operation and maintenance of
this machine.

The maintenance portion of this section is intended as informa­tion to assist the machine operator to perform daily maintenance
tasks only, and does not replace the more thorough Preventive
Maintenance and Inspection Schedule included in the Service
and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual .............................................3121142

Illustrated Parts Manual ................................................................3121208

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications - Prior to S/N 0300141473

Maximum Work Load (Capacity)
Un r es t ri c te d
Re s tr i c te d

Max.Vertical Platform Height (Unrestricted)
1200SJP
1350SJP

Max.Vertical Platform Height (Restricted)
1200SJP
1350SJP

Max.Horizontal Platform Reach (Unrestricted)
1200SJP
1350SJP

Max.Horizontal Platform Reach (Restricted)
1200SJP
1350SJP

JibPLUS
Le n gt h
Ho r iz o nt a l M o ti o n
Ve r ti c al M ot i on

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

120 ft. (36.6 m)
135 ft. (41.2 m)

115 ft. (35.1 m)
125 ft. (38.1 m)

75 ft. (22.9 m)
80 ft. (24.4 m)

65 ft. (19.8 m)
70 ft. (21.3 m)

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

3121141 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-2. Operating Specifications - S/N 0300141473 to Present

Maximum Work Load (Capacity) - ANSI
Un r es t ri c te d
Re s tr i c te d

Maximum Work Load (Capacity)­CE & Australia
Un r es t ri c te d
Re s tr i c te d

Max.Vertical Platform Height (Unrestricted)
1200SJP
1350SJP

Max.Vertical Platform Height (Restricted)
1200SJP
1350SJP

Max.Horizontal Platform Reach (Unrestricted)
1200SJP
1350SJP

Max.Horizontal Platform Reach (Restricted)
1200SJP
1350SJP

JibPLUS
Le n gt h
Horizontal Motion
Ve r ti c al M ot i on

500 lb (227 kg)
1000 lb. (454 kg)

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

120 ft. (36.6 m)
135 ft. (41.2 m)

115 ft. (35.1 m)
125 ft. (38.1 m)

75 ft. (22.9 m)
80 ft. (24.4 m)

65 ft. (19.8 m)
70 ft. (21.3 m)

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

Dimensional Data

Table 6-3. Dimensional Data

Overall Width
Ax l es R e tr ac t e d
Ax l es E x te n de d

Stowed Height 10ft. (3.04 m)
Stowed Length (Transpor t Mode)

12 0 0S J P
13 5 0S J P

Stowed Length (Working Mode)
12 0 0S J P
13 5 0S J P

Wheelbase 12ft. 6in. (3.81 m)
Tailswing 5ft. 6 in. (1.6 m)
Ground Clearance (Axle) 12 in. (30.4 cm)
Ground Clearance (Chassis) 25.5 in. (64.7 cm)

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

34ft. 11in. (10.64 m)
38ft. 11in. (11.86 m)

44ft. 11in. (13.69 m)
48ft. 11in. (14.91 m)

6-2 – JLG Lift – 3121141

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-5. Capacities

Hydraulic Tank 55 gall ons (208 liters)
Fuel Tank 31 gallons (117 liters)
Hydraulic System 66 gallons (250 liters)

Chassis

Table 6-4. Chassis Specifications

Maximum Travel Grade With boom in stowed
position (Gradeability)

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

Turning Radius (Axles Retracted)
Ou t si d e
In s id e

Turning Radius (Axles Extended)
In s id e
Ou t si d e

Max Tire Load
1200SJP
1350SJP

Max Ground Bearing Pressure
1200SJP
1350SJP

Maximum Drive Speed 3.25 mph (5.2 kph)
Max. Hydraulic System Pressure 4600 psi (317 Bar)

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

8 ft. (2.4 m)

19 ft. 4 in. (5.9 m)

25,000 lbs. (11,340 kg)
26,250 lbs. (11,907 kg)

100 psi (7.03 kg/cm
105 psi (7.38 kg/cm

45%

Table 6-4. Chassis Specifications

Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Manual Force 400 N
Electrical System Voltage 12 Volts
Gross Machine Weight (Platform Empty)

5°

12 0 0 SJ P
13 5 0 SJ P

Capacities

2

)

2

)

41,100 lb. (18,643 kg)
44,750 lb. (20,298 kg)

3121141 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-6. Tire Specifications

Size 445/50D710
Load R ange J
Ply Rating 18
Load Rating 26,500 lbs. @ 100 psi (12020 kg @ 6.9 Bar)
Foam Fill Polyurethane HD (55 Durometer) Foam
Max Tire Load

1200SJP
1350SJP

25,000 lbs. (11,340 kg)
26,250 lbs. (11,907 kg)

Table 6-7. Deutz BF4M2011 Specifications

Type Liquid Cooled
Number of Cylinders 4
Bore 3. 7 in. (94 mm)
Stroke 4.4 in. (112 mm)
Total Displacement 190 cu. in. (3108 cm)
Compression Ratio 17.5:1
Firing Order 1-3-4-2
Output 87hp (65 kW)
Oil Capacity

Cooling System
w/ F il t er
To ta l Ca p ac i ty

5 Quarts (4.5 L)
11 Quarts (10.5 L)

16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475

Tires Engine Data - Deutz 2011 Prior to S/N 0300127698

6-4 – JLG Lift – 3121141

Engine Data - Deutz 2011 S/N 0300127698 to Present Engine Data - Deutz TCD2.9L4

Table 6-8. Deutz TD2011L4 Specifications

Type Liquid Cooled
Number of Cylinders 4
Bore 3. 7 in. (94 mm)
Stroke 4.4 in. (112 mm)
Total Displacement 190 cu. in. (3108 cm)
Compression Ratio 17.5:1
Firing Order 1-3-4-2
Output 75hp (56 kW)
Oil Capacity

Cooling System
w/ F il t er
To ta l Ca p ac i ty

5 Quarts (4.5 L)

11 Quarts (10.5 L)

16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475

Table 6-9. Deutz TCD2.9L4 Specifications

Type Liquid Cooled
Number of Cylinders 4
Bore 3. 6 in. (92 mm)
Stroke 4.3 in. (110 mm)
Total Displacement 178 cu. in. (2925 cm)
Firing Order 1-3-4-2
Output 74.2hp (55.4 kW)
Oil Capacity 2.4 Gallon (8.9 L)
Coolant Capacity (System) 3.2Gallon (12.1 L)
Average Fuel Consumption 1.2 gph (4.1 lph)
Min. Low Engine RPM 1200
Mid Engine RPM 1800
Max. High Engine RPM 2500

3121141 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-10. Caterpillar 3.4T Specifications

Type Liquid Cooled, Antifreeze
Number of Cylinders 4
Bore 3. 7 in. (94 mm)
Stroke 4.7 in. (120 mm)
Total Displacement 201 cu. in. (3294 cm)
Compression Ratio 19.5:1
Firing Order 1-3-4-2
Output 73.7hp (55 kW)
Oil Capacity 10.5 Quarts (10 L)
Average Fuel Consumption 1.36 gph (5.14 lph)
Idle Engine RPM 1200
Mid Engine RPM 1800
High Engine RPM 2475

Table 6-11. Hydraulic Oil Specifications

Hydraulic System Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Engine Data - Caterpillar Hydraulic Oil

6-6 – JLG Lift – 3121141

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

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

152.

NOTE: When temperatures remain consistently below 20 degrees F. (-7

degrees C.), JLG Industries recommends the use of Mobil DTE13.

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

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-13. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877
Pour Point, Max

-40°F (-40°C)

Flash Point, Min.

330°F (166°C)

Viscos ity

at 40° C 33cSt
at 100° C 6.6 cSt
at 100° F 169 SUS
at 210° F 48 SUS

cp at -20° F 6,200

Viscos ity I ndex 1 40

Table 6-12. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Visc osity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

3121141 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-14. UCon Hydrolube HP-5046

Typ e Synthetic Biodegradable

Specific Gravity 1.082
Pour Point, Max -58°F (-50°C)

pH 9.1

Viscos ity

at 0° C (32° F) 340 cSt (1600SUS)
at 40° C (104° F) 46 cSt (215SUS)
at 65° C (150° F) 22 cSt (106SUS)

Viscos ity I ndex 1 70

Table 6-15. Mobil EAL H 46 Specs

Typ e Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)
Flash Point 500°F (260°C)

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

Weight 7.64 lb. per gal.

(0.9 kg per liter)

Viscos ity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscos ity I ndex 1 53

6-8 – JLG Lift – 3121141