JLG 120HX Operator Manual

Operators and Safety Manual

Model

120HX

ANSI

3120685

April 20, 2000

– JLG Lift –

FOREWORD

FOREWORD

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

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

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

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

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

Safety of personnel and proper u se of the m achine are of primary concern, DANGER, WARNING, CAU­TION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throug hout this manual to emph asize these

areas. They are defined as follows:

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

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

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

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

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

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

3120685 – JLG Lift – a

FOREWORD

This page left blank intentionally.

b – JLG Lift – 3120685

FOREWORD

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

READ & HEED!

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

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

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

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

7. Instruction and warning placards must be legi­ble.

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

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

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

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

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

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

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

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

1926.28, and 29 CFR 1926.453.

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

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

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

4. The controls shall be tested each day prior to
use to determ in e that they are in s a f e o pe ra ting
condition.

3120685 – JLG Lift – c

FOREWORD

REVISON LOG

June 1992 - Original Issue
September, 1997 - Revised
November, 1997 - Revised
March 1, 1999 - Revised
April 11, 2000 - Revised
Prop65 page added - Updated 4-20-00
4-1 - Updated 4-20-00

d – JLG Lift – 3120685

TABLE OF CONTENTS

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

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

SECTION 2 - PREPARATION AND INSPECTION

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

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

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

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

2.5 Daily Func t ional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

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

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

SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL

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

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

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

3.4 Contro ls and Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3.5 Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15

SECTION 4 - MACHINE OPERATION

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

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

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

4.4 Traveling (Driving/Steerin g) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.5 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

4.6 Parking and St owing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.7 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

4.8 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.9 Shut Dow n a nd Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4.10 Tie Down and Lift ing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

4.11 Swing-Away Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12

SECTION 5 - OPTIONAL EQUIPMENT

5.1 Cold Start Kit (Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Travel/m ot ion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.3 Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.4 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.5 Hostile Environment Package. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.6 110 Volt Gene rator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

SECTION 6 - EMERGENCY PROCEDURES

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

6.2 Emergen cy Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

3120685 – JLG Lift – i

TABLE OF CONTENTS

(Continued)

TABLE OF CONTEN TS (continued)

SUBJECT - SECTION, PARAGRAPH PAGE NO.

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

6.4 Emergency Ope ra t ion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

6.5 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

SECTION 7 - IN SPECTION AND REPAIR LOG

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

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

2-2. Daily Walk-Around Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-3. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-4. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

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

3-2. Positi on of Least Backward Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-3. Ground Control Station - Prior to May 1994. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-4. Ground Control Sta t ion - May 1994 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-5. Axle Extension/ Axle Jac ks Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

3-6. Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

3-7. Platfo rm St at ion - Prior to May 1994. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12

3-8. Platform Station - May 1994 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

3-9. Caution Decal Location - Sheet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16

3-10. Caution Decal Location - Sheet 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

3-11. Control Panel Symbols - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20

3-12. Control Panel Symbols - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21

4-1. Spindle Stop Pin Usag e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

4-3. Machine Tie Down - Sheet 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-4. Machine Tie Down - Sheet 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-5. Machine Tie Down - Sheet 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-6. Machine Tie Down - Sheet 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11

4-7. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -12

4-8. Swing-Away Jib. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13

6-1. Disconnecting the Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Distances (M.S.A.D.) to energized

(exposed or insulated) power lines and parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

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

ii – JLG Lift – 3120685

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

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

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

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

1.2 DRIVING/TOWING

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

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

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

common sense and its careful application.

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

SPECIAL NOTE:

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

3120685 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

Voltage Range

(Phase to Phase)

0 to 300V AVOID CONTACT

Over 300V to 50 KV 10 (3)

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

Over 750 KV to 1000 KV 45 (14)

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

1.3 ELECTROCUTION HAZARD

MINIMUM SAFE APPROACH DIST ANCE

in Feet (Meters)

FROM CONTACT WITH OR PROXIMITY TO AN ELEC­TRICALLY CHARGED CONDUCTOR.

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

1.4 PRE-OPERATIONAL

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

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

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

1-2 – JLG Lift – 3120685

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

3120685 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

.

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

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

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

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

1.5 DRIVING

• WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN DRIVING.

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

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

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

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

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

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

1-4 – JLG Lift – 3120685

SECTION 1 - SAFETY PRECAUTIONS

1.6 OPERATION.

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

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

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

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

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

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

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

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

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

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

3120685 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

• NEVER PLACE HANDS OR ARMS IN TOWER BOOM
OR UPRIGHT MECHANISM.

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

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

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

1-6 – JLG Lift – 3120685

SECTION 1 - SAFETY PRECAUTIONS

.

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

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

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

FERING WITH OPERATING CONTROLS AND PER­SONS IN PLATFORM.

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

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

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

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

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

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

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

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

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

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

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

• NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.

3120685 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

1.7 TOWING AND HAULING

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

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

1-8 – JLG Lift – 3120685

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

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

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

2.2 PREPARATION FOR USE

Before a new machine is put into operation it must be
carefully inspected fo r any evi dence of dam age resu lting
from shipment and inspecte d periodicall y therea fter, as
outlined in Delivery and Frequent Inspection (see section
2-3). During initial start-up and run, the unit should be
thoroughly checked for hydraulic leaks. A chec k of all
components should be made to ensure their security.

All preparation necess ary to pl ace the machin e in opera­tion readiness status is the responsibility of management
personnel. Preparation requires good common sense,
(i.e. telescope works smoothly and brakes operate prop­erly) coupled with a series of visual inspections. The man­datory requirements are given in the D aily Walk Around
Inspection (see section 2-4).

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

2.3 DELIVERY AND FREQUENT INSPECTION

NOTE: This machine requires periodic safety and mainte-

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

An annual inspecti on shall be perform ed on the aeri al plat­form no later than thirteen (13) months from the date of
the prior annual inspection. the inspection shall be per­formed by person(s) qualified as a mechanic on the spe­cific make and model of the aerial platf orm.

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

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

Chassis

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

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

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

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

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

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

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

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

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

3120685 – JLG Lift – 2-1

SECTION 2 - PREPARATION AND INSPECTION

Turntable

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

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

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

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

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

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

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

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

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

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

NOTE: JLG recommends replacing the hydraulic filter ele-

ment after the first 50 hours of operation and then
every 300 hours thereafter, unless system indicator
require earlier replacement.

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

Boom

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

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

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

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

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

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

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

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

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

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

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

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

Extend-A-Reach

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

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

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

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

2-2 – JLG Lift – 3120685

SECTION 2 - PREPARATION AND INSPECTION

PLATFORM

CONTROL

BOX

EXTEND-A-REACH

FLY BOOM

OUTER MID BOOM

INNER MID BOOM

BASE BOOM

PLATFORM

FOOTSWITCH

TELESCOPE

CYLINDER

(inside)

GROUND

CONTROL

BOX

TURNTABLE

DRIVE/STEER

WHEELS

LIFT

CYLINDER

SWING

BEARING

DRIVE/STEER

WHEELS

FRAME

Figure 2-1. Machine Nomenclature.

3120685 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

Platform

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

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

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

4. Check capacity in dicator for correct operation, any
damage and that decals are not defaced. Ensure
indicator dial is zeroed with boom at horizontal and
indicator dial moves in accordance with boom
angle.

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

6. Check platform rotator mechanism for proper opera ­tion, damage, security. Check hydraulic lines for
leakage, damage and securi ty.

NOTE: Check all DANGER, WARNING, CAUTION and

INSTRUCTION placards for legibility and security on
the entire machine.

Torque Requireme nts

The Torque Chart (Figure 2-4.) consists of standard torque
values based on bolt diameter and grade, also specifying
dry and wet torque values in accordance with recom­mended shop practices. This chart is provide d as an aid
to the operator in the event he/she notices a condition that
requires prompt attention during the walk-around inspec­tion or during operati on, until th e prop er servic e person nel
can be notified. The Service and Maintenance manual
provides specific torque values and periodic maintenance

procedures with a listing of individual components. Utiliz­ing this Torque Chart in conjunction with the prev entive
maintenance section in the Service and Maintenance
manual will enhance safety, reliability, and performance of
the machine.

2.4 DAILY WALK-AROUND INSPECTION

It is the operator’s responsibility to inspect the machine
before the start of each workday. It is recommended that
each operator inspect the machine before o per ation, even
if the machine has already been put into service under
another operator. This Daily Walk-Around In spec tion is the
preferred method of inspection. (See Figure 2-2.)

In addition to the Daily Walk - Aroun d Inspec tion, be sure to
include the following as part of the daily inspection:

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

lic oil spillage and foreign objects. Ensure overall
cleanliness.

2. Placards.
Keep all information and operating placards clean

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

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

1992 Responsibilities are enclosed in the manual
storage box.

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

check to see that it is current and that no entries
have been left uncleared, leaving machine in an

2-4 – JLG Lift – 3120685

SECTION 2 - PREPARATION AND INSPECTION

5. Start each day with a full fuel tank.

TO AVOID INJURY, DO NOT OPERATE A MACHINE UNTIL ALL
MALFUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.

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

NOTE: Check boom horizontal limit switch for proper opera-

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

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

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

NOTE: On new machines, those recently overhauled, or

after changing hydraulic oil, operate all systems a

minimum of two complete cycles and recheck oil
level in reservoir.

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

to API Service Classification GL-3, and sufficient
chemical stability for mobile hydraulic system ser­vice. JLG Industries recommends Mobilfluid 424
hydraulic oil, which has an SAE viscosity index of
152 or Kendall Hyken 052 hydraulic oil, which has an
SAE viscosity of 10W-20 and viscosity index of 152.

When temperatures remain consistently below -7
degrees C., JLG Industries recommends the use of
Mobil DTE 11.

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 of be of
comparable viscosities. If use of hydraulic oil other
than Mobilfluid 424 is desired, contact JLG industries
for proper recommendations.

8. Assure that all items requiring lubrication are ser­viced. Refer to Lubrication Chart, Figure 2-3., for
specific requirements.

3120685 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

25

26

28

29

27

30

24

23

31

11

22

21

20

17, 18, 19

16

15

14

13

4

12

5

10

33

32

34

35

36

37

8

7

6

2

Figure 2-2. Daily Walk-Around Inspection

3

9

1

(Sheet 1 of 3)

2-6 – JLG Lift – 3120685

SECTION 2 - 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 “Walk-Around Inspection Check­list”.

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

NOTE: Do not overlook visual inspection of chassis under-

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

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

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

3. Slave Leveling Cylinder, Extend-A-Reach - Prop-
erly secured, no visible damage, no evidence of
leakage.

4. Extend-A-Reach Lift Cylinder - Properly secured,
no visible damage, or signs of leakage, evidence of
proper lubrication.

5. Extend-A-Reach Pivot - No loose, damaged, or
missing parts, evidence of proper lubrication.

6. Hose and Cable Guards/Clamps - Properly
secured, no visible da mage.

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

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

9. Drive Hu b, Ri gh t R ear - No visible damage, no evi­dence of leakage.

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

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

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

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

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

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

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

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

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

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

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

21. Turntable Springs - Properly secured, no loose or
missing nuts or bolts.

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

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

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

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

Figure 2-2. Daily Walk-Around Inspec tion (Sheet 2 of 3)

3120685 – JLG Lift – 2-7

SECTION 2 - PREPARATION AND INSPECTION

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

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

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

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

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

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

Figure 2-2. Daily Walk-Around Inspec tion (Sheet 3 of 3)

32. Drive Hub, Le ft Rear - No visible damage, no evi­dence of leakage.

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

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

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

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

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

2-8 – JLG Lift – 3120685