JLG 1250AJP Operator Manual

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Operation and Safety Manual

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

Boom Lift Models 1250AJP

ANSI

3121170

September 11, 2014

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.

3121170 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD 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 – 3121170

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)

In USA:

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

Outside USA:

FOREWORD

Compliance Information

Product Applications

uct Modifications

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

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FOREWORD

REVISION LOG

Original Issue - March 1, 2004

Revised - May 4, 2005

Revised - January 12, 2006

Revised - May 9, 2006

Revised - July 21, 2006

Revised - November 30, 2006

Revised - April 10, 2007

Revised - March 19, 2008

Revised - November 19, 2009

Revised - August 31, 2010

Revised - August 18, 2011

Revised - August 9, 2012

Revised - September 11, 2014

d – JLG Lift – 3121170

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). . . . 2-10

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 HYDRAULIC SYSTEM WARM UP. . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 BOOM OPERATING CHARACTERISTICS AND

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

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

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

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

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Envelope Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Tower Path Control System . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Automatic Main Boom Control System . . . . . . . . . . . . . 4-5

Slow Down System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-6

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

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TABLE OF CONTENTS

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

4.4 AUXILIARY POWER OPERATION . . . . . . . . . . . . . . . . . . . . . 4-10

4.5 CAPACITY SELECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.6 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.7 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-15

4.8 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.9 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4.10 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-15

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.11 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-16

Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-16

Tower Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.12 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.13 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.14 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4.15 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4.16 STOWING THE JIB FOR TRANSPORT. . . . . . . . . . . . . . . . . . 4-19

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

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

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE

DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

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

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

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

Engine Data - Deutz 2011 Prior to S/N 0300127698 . 6-5 Engine Data - Deutz 2011 S/N 0300127698 to

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

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

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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

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TABLE OF CONTENTS

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 6-34

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-35

SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

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

This Page Left Blank Intentionally.

iv – JLG Lift – 3121170

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 2 . . . . . . . . . . 2-8

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

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

3-1. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-6

3-2. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

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

4-1. Tower Path vs. Main Boom Angle . . . . . . . . . . . . . . . . . . . . . 4-4

4-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-7

4-3. Position of Least Backward Stability - Sheet 1 of 2 . . . . . 4-8

4-4. Position of Least Backward Stability - Sheet 2 of 2 . . . . . 4-9

4-5. Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4-6. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

4-7. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18

4-8. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-9. Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4-10. Decal Location Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-11. Decal Location Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

4-12. Decal Location Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-13. Decal Location Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

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. Operator Maintenance and Lubrication Diagram -

Deutz 2011/CAT Engines. . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-6. Operator Maintenance and Lubrication Diagram -

Deutz 2.9 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7. Hydraulic Return Filter Condition Indicator -

Prior to S/N 139396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-8. Hydraulic Return Filter Condition Indicator -

S/N 139396 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

6-9. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-27

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LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

vi – JLG Lift – 3121170

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 0300141446 . . . . . . . . . . . . .4-26

4-2 Decal Legend - S/N 0300141446 to Present . . . . . . . . . .4-30

6-1 Operating Specifications - Prior to S/N 0300141446 . . . 6-1 6-2 Operating Specifications - S/N 0300141446 to Present. 6-2

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

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

6-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

6-7 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . .6-5

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

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

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

6-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

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

6-13 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

6-15 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-16 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

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

6-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17

6-19 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35

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

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LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally.

viii – JLG Lift – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – 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 – 3121170

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.

3121170 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121170

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.

3121170 – 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 – 3121170

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Typ e Frequen c y

Primary

Responsibility

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection (See Note)

Frequent Inspection (See Note)

Annual Machine Inspection (See Note)

Preventative Maintenance At intervals as specified in the Service 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 Qualified J LG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of mo re than 3 months; or 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 Qu alified JLG Mechanic Service and Maintenan ce Manual

Owner, Dealer, or User Factory-Qualified Service

Owner, Dealer, or User Qu alified JLG Mechanic Service and Maintenan ce Manual

Service

Qualification

Tec h ni c ia n (Recommended)

Reference

and applicable JLG inspection form

Service and Maintenance Manual and applicable JLG inspection form

3121170 – 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. Operation and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage container.

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

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.

2-4 – JLG Lift – 3121170

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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.

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 console with no load in the platform:

a. Check that all guards protecting the switches or locks

are in place;

b. Operate all functions and make sure the Boom Control

System warning light does not come on;

c. Check auxiliary power;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure all boom functions stop when the function

enable switch is released.

3121170 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2. 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 make sure the Boom Control

System warning light does not come on;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

3. 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 all boom functions are disabled with the

axles retracted and the boom out of transport mode.

NOTE: The machine is in transport mode until one of the following

three factors are exceeded: Main boom extended more than 4 ft. (1.2 m) OR Main boom 6° above horizontal (w/tower stowed) OR Tower above horizontal.

4. 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.

2-6 – JLG Lift – 3121170

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Basic Nomenclature

1. Front Drive\Steer Wheels

2. Rear Drive\Steer Wheels

3. Tower Lift Cylinder

4. Ground Console

5. Tower Base Boom Section

6. Tower Mid Boom Section

7. Tower Fly Boom Section

8. Tower Boom Assembly

9. Main Lift Cylinder

10. Main Base Boom Section

11. Main Boom Fly Section

12. Main Boom Assembly

13. Jib

14. Platform

15. Platform Console

3121170 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-8 – JLG Lift – 3121170

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue 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 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/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.

12. Main Hydraulic Pump - See Inspection Note.

13. Platform Rotator - See Inspection Note.

14. Jib Rotator - See Inspection Note.

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

3121170 – JLG Lift – 2-9

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.

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.

2-10 – JLG Lift – 3121170

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: All machines are equipped with control panels that use symbols

to indicate control functions. On ANSI machines 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.

NOTE: The indicator panels use different shaped symbols to alert the

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

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

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

Indicates important information regarding the o perating 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.

3121170 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Towe r Lif t Con tro l

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

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

1. Indicator Panel

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

NOTE: The Function Enable switch must be held down in

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

2. Main Boom Telescope Control

Provides extension and retraction of the main boom.

Provides raising and lowering of the tower boom.

4. Swing Control

Provides 360 degrees continuous turntable rotation.

5. Main Lift Control

Provides raising and lowering of the main boom.

6. Jib Lift

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.

7. 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.

3-2 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Indicator Panel

2. Main Boom Telescope

3. Tower Boom Lift

4. Swing

5. Main Boom Lift

6. Jib Lift

7. Platform Leveling Override

8. Platform Rotate

9. Jib Swing

10. Platform/Ground Select Switch

11. Hourmeter

12. Power/Emergency Stop

13. Engine Start/Auxiliary Power/Function Enable

Figure 3-1. Ground Control Station

3121170 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform Rotate

Allows rotation of the platform.

9. Jib Swing

Allows swinging of the jib.

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

power is shut off to controls at both operating stations.

10. 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.

11. 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.

12. Power/Emergency Stop Switch

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

3-4 – JLG Lift – 3121170

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 reduced hydraulic flow.

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

13. 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.

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

Ground Control Indicator Panel

(See Figure 3-1., Ground Control Indicator Panel)

1. Battery Charging Indicator

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. Glow Plug Indicator

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

3121170 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. High Engine Oil Temp.

5. Glow Plug Indicator

6. Axles Set

7. Platform Capacity

8. Platform Overload

9. Boom Control System Warning

Figure 3-1. Ground Control Indicator Panel

3-6 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. 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.

7. Platform Capacity Indicator

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

8. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

9. 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.

Platform Station

(See Figure 3-2., Platform Control Console)

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

1. Power/Emergency Stop

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

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.

3121170 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Power/Emergency Stop

2. Engine Start / Aux Power

3. Capacity Select

4. Drive Orientation Override

5. Drive/Steer

6. Main Boom Telescope

7. Lights

8. Jib Lift

9. Soft Touch Override

10. Jib Swing

11. Tower Boom Lift

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 Selec t

19. Platform Level Override

20. Axle Extend/Retract

21. Horn

22. Indicator Panel

Figure 3-2. Platform Control Console

3-8 – JLG Lift – 3121170

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.)

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

Provides for driving either forward or backward. The controller is infinitely proportional to allow variable drive speed.

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

3121170 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Main Telescope

Allows extension and retraction of the main boom.

7. Lights (If Equipped)

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 accomplished by using the Function Speed Control.

9. Soft Touch Override Switch (If equipped)

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

Allows the operator to swing the jib to the left or right.

11. Towe r Boo m Lif t

Allows raising and lowering of the tower boom by activating the tower lift and telescope cylinders as dictated by the Boom Control System.

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

Allows the operator to rotate the platform to the left or right.

3-10 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS

14. Jib Stow Override

Allows the operator to swing the jib to the right past the electronic stop to stow the jib beside 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 Boom 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 OUT OF TRANSPORT POSITION.

17. Drive Speed/Torque Select

The forward position gives maximum drive speed. The back position gives maximum torque for rough terrain and climbing grades. The center position allows the machine to be driven as quietly as possible.

3121170 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

18. Steer Select

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 close to 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.

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. Axle Extend/Retract

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.

21. Horn

If pressed, this switch supplies power to the horn.

22. Indicator Panel

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

3-12 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

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

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 out of transport mode.

IF THE LEVEL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUT DOWN THE MACHINE, RESET 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 (If Equipped)

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.

5. Tilt Alarm Warning Light

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 FROM THE TRANSPORT POSITION.

Indicates that the chassis is on a slope (over 3 to 5 degrees, depending upon boom angle). If the boom is out of transport position and the machine is on a slope, an alarm will sound and CREEP is automatically activated.

3121170 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Level System

2. AC Generator

3. Platform Overload

4. Platform Capacity

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed

10. System Distress

11. Drive Orientation

12. Axles Set

13. Boom Control System Warning

Figure 3-3. Platform Control Indicator Panel

3-14 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Glow Plug/Wait to Start Indicator

NOTE: If the engine fails to start due to cold temperatures or excessive

amounts of smoke are produced on startup, wait for the glow plug/wait to start indicator to go out before starting the engine.

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

7. Footswitch/Enable Indicator

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.

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.

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.

3121170 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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.

11. 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).

12. Axles Set Indicator

13. Boom Control System Warning Indicator

3-16 – JLG Lift – 3121170

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel 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 main or tower 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.

3121170 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

4.2 HYDRAULIC SYSTEM WARM UP

The control system monitors the hydraulic system in extremely cold temperatures and provides optimal performance by automatically limiting the function speeds of the high demand functions. The warm up mode automatically shuts off when system oil reaches allowable temperatures.

While the system is cold and in the warm up mode, the tower lift, main lift, and main telescope functions are limited to creep speeds and is indicated to the operator by flashing the creep light on the platform control panel.

Functions being operated when the warm up mode turns off will remain in the creep speed until the function is re-initiated.

4.3 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

The boom can be raised from the transport position 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.

4-2 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Envelope Control System

The Envelope Control System is the primary means of controlling the working positions of the tower and main boom within the stability and structural requirements of the machine.

The main boom must be controlled in maximum angle and minimum angle to avoid entering a position that could compromise backward stability and avoid main boom to tower boom interference. The tower boom must be controlled by permitting only specific combinations of tower length and tower angle to avoid entering a position that could compromise forward and backward stability (see Tower Path Control System).

Recognized failures within this system will result in control by the Electrical Retrieval System (refer to the Service Manual), reduced function speeds, and BCS warning light illumination. After retrieval the boom will be restricted from leaving the transport position until the failure is resolved.

Boom position violations outside of the allowable envelope will result in reduced function speeds, BCS warning light illumination, and restriction of functions. Attempts to operate restricted functions will cause the BCS warning light to flash and the platform alarm to sound.

Violations of the tower path (with a healthy control system) will cause the automatic combined operation of tower lift and tower telescope to be suspended. A forward tower path violation can be resolved by operating the tower lift up switch (tower tele-

scope out without auto tower lift up) or the tower lift down switch (tower lift down without auto tower telescope in). A backward tower path violation can be resolved by operating the tower lift up switch (tower lift up without auto tower telescope out) or the tower lift down switch (tower telescope in without auto tower lift down).

The restricted functions due to backward tower envelope violations are disallowing automatic tower lift down, automatic tower telescope out, main lift up and down, main telescope in, jib, swing, drive and steer.

The restricted functions due to forward tower envelope violations are disallowing automatic tower lift up, automatic tower telescope in, main lift up and down, main telescope out, jib, swing, drive and steer.

The restricted functions due to maximum main boom envelope violations are disallowing tower lift up and down, main lift up, main telescope in, jib, swing and drive.

The restricted functions due to minimum main boom envelope violations are disallowing main lift down, swing and drive.

3121170 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

TOWER PATH FOR MAIN

BOOM ANGLES ABOVE 55

DEGREES

TOWER PATH FOR MAIN

BOOM ANGLES BELOW

15 DEGREES

Tower Path Control System

The Tower Path Control System uses the envelope control sensors to enhance the control of the tower boom for increased user efficiency and is used as an integral part of the envelope control system.

Both the ground and platform control panels use one function switch to control the tower. User commands for tower lift up or tower lift down causes the control system to automatically introduce the correct combination of tower telescope and tower lift for the tower boom to follow a pre-described path or trajectory of the tower nose.

4-4 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Automatic Main Boom Control System

During combined tower lift and main lift functions, the control system will maintain the tower lift speed and automatically vary the maximum main lift command as needed to compensate for the movement of the tower.

The interaction of the main boom and the tower boom is slightly different when the main boom is above or below 60° relative to gravity.

TOWER LIFT UP/DOWN - MAIN BOOM BELOW 60°

During tower lift up or down with the main boom below 60°, the control system will maintain the angle of the main boom read at the start of the tower lift command or as read at the conclusion of main lift during combined tower and main lift commands.

TOWER LIFT DOWN - MAIN BOOM ABOVE 60°

During tower lift down with the main boom initially above 60°, the control system will lower the main boom to approximately 60° before starting tower movement. The control system will then control the main boom to 60° for the remainder of the tower lift down command.

TOWER LIFT UP - MAIN BOOM ABOVE 60°

During tower lift up with the main boom already above 60°, the control system will delay automatic compensation of the main boom angle during tower lift until the main boom reaches approximately 60°. The control system will then control the main boom to 60° until the tower boom has reached its maximum height. Continuing to operate the tower lift up when the tower reaches its maximum height will cause the control system to automatically raise the main boom to its original angle.

Slow Down System

The control system uses the envelope control sensors to automatically slow down the tower lift up and tower lift down at the top of the tower path and to automatically slow down main lift up and main lift down as the minimum and maximum angles of the working envelope are approached. The control system indicates to the operator this slow down by flashing the creep light on the platform display. This applies to both platform and ground controls, however, no indication is made on the ground control panel.

3121170 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Controlled Angle

The Controlled Boom Angle System minimizes the interaction of swing and drive functions with the envelope edges. This interaction is due to two factors. First, the envelope is controlled relative to gravity regardless of ground slope and second, the turntable/ boom mounting is effected by swing and drive functions when the ground slope varies. This can cause the boom position to vary within the envelope or even violate the envelope edges when swinging or driving without intentionally moving the boom. The controlled boom angle system automatically activates either the tower or main boom lift up or down during swing and drive commands to maintain a constant boom angle relative to gravity.

Controlled boom angle is disabled with any envelope violation or failure.

Swing Speed Proportioning

The boom control system sensors sense the distance the platform is extended from the centerline of rotation, allowing higher swing speeds with the platform nearest to the centerline of rotation and gradually slower swing speeds the further the platform gets from the centerline of rotation.

Stability

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

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

4-6 – JLG Lift – 3121170

Figure 4-2. Position of Least Forward Stability

MACHINE WILL

TIP OVER IN

DIRECTION OF ARROWS IF OVERLOADED

OR OPERATED

ON AN OUT-OF-LEVEL

SURFACE

MAIN BOOM

FULLY EXTENDED

TURNTABLE ROTATED

90 DEGREES FROM STOWED POSITION

TOWER BOOM

FULLY LOWERED TO

FULLY RAISED

SECTION 4 - MACHINE OPERATION

3121170 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-3. Position of Least Backward Stability - Sheet 1 of 2

JIB ELEVATED

MACHINE WILL

TIP OVER IN

DIRECTION OF ARROW IF OVERLOADED

OR OPERATED

ON AN OUT-OF-LEVEL

SURFACE

MAIN BOOM

FULLY ELEVATED

TURNTABLE ROTATED

90 DEGREES FROM

STOWED POSITION

TOWER BOOM

FULLY LOWERED

TO FULLY RAISED

4-8 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Figure 4-4. Position of Least Backward Stability - Sheet 2 of 2

JIB ELEVATED

MACHINE WILL TIP OVER IN

DIRECTION OF ARROW IF OVERLOADED

OR OPERATED

ON AN OUT-OF-LEVEL

SURFACE

MAIN BOOM

FULLY ELEVATED

TURNTABLE ROTATED

90 DEGREES FROM

STOWED POSITION

TOWER BOOM

FULLY LOWERED TO

FULLY RAISED

3121170 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.4 AUXILIARY POWER OPERATION

The Auxiliary Power System provides a means of moving the platform in the event of an engine malfunction. This system uses an electric motor/pump unit capable of operating all boom functions needed to allow the platform to be lowered to ground level.

With auxiliary power activated, the control system will attempt to use the force of gravity to operate main lift down, tower lift down, and tower telescope in. If appropriate movement is not detected by the boom sensors, the auxiliary power system will supply hydraulic flow to power boom movement. Allow sufficient operating time for system to respond.

NOTE: To ensure sufficient battery life, where possible, use the Main Lift

and Main Telescope functions to lower the platform to ground level before using Tower Lift. Movements of the boom using auxiliary power will be SLOW and the movements will momentarily stop and alternate between other functions as needed. When operating Tower Lift, the movements will alternate between tower lift, tower telescope, and main lift. When operating Main Lift, the movements will alternate between main lift, tower lift, and platform level.

4.5 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.

4-10 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Figure 4-5. Range Diagram

3121170 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

4.6 ENGINE OPERATION

NOTE: Initial starting should always be performed from the Ground

Control console.

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: If the engine fails to start due to cold temperatures or excessive

amounts of smoke are produced on startup, wait for the glow plug/wait to start indicator to go out before starting the 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.

4-12 – JLG Lift – 3121170

4.7 TRAVELING (DRIVING)

See Figure 4-6., Grade and Side Slopes

NOTE: Refer to the Operating Specifications table for Gradeability and

Sideslope ratings.

All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted.

DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE 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.

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.

SECTION 4 - MACHINE OPERATION

Traveling is limited by two factors:

1. Gradeability, which is the percent of grade of the incline the machine can climb.

2. Sideslope, which is the angle of the slope the machine can be driven across.

When the boom is raised or extended, the machine must not be operated on grades or sideslopes that are greater than that detected by the tilt alarm. The tilt alarm will sound to alert the operator when the machine is on an unsafe slope. The machines high drive function will also be cut back to low drive.

3121170 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Figure 4-6. Grade and Side Slopes

4-14 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

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.

4.8 STEERING

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

4.9 EXTENDING THE AXLES

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

order to extend the axles.

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

4.10 PLATFORM

Platform Level Adjustment

NOTE: Platform Leveling is active during all functions except during

main boom telescope operations.

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.

3121170 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

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.

4.11 BOOM

DO NOT SWING OR RAISE BOOM OUT OF TRANSPORT MODE 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.

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 Main Boom

NOTE: The main lift function is not operable with the boom out of the

transport mode if the axles are not fully extended.

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

Telescoping the Main 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.

4-16 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Tower Lift

NOTE: The control system automatically uses a combination of tower

telescope and tower lift for the tower boom to follow a predescribed path.

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

Swinging the Jib

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

Australia 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.

4.12 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.

4.13 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.

3121170 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-7. Drive Disconnect Hub

3. Reconnect the drive hubs by inverting the disconnect cap

when towing is complete.

4.14 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.

4-18 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

4.15 LIFTING AND TIE DOWN

(See Figure 4-8.)

Lifting

1. The weight of the machine is stamped on the serial number plate. If the plate is missing or illegible, 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.

Tie Down

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

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.

4.16 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 Override control switch until the jib and platform are in the stowed position under the boom.

3121170 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-8. Lifting and Tie Down Chart

4-20 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Location Sheet 1 of 5

3121170 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location Sheet 2 of 5

4-22 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Location Sheet 3 of 5

3121170 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Location Sheet 4 of 5

4-24 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION

Figure 4-13. Decal Location Sheet 5 of 5

3121170 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Prior to S/N 0300141446

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

4-26 – JLG Lift – 3121170

Table 4-1. Decal Legend - Prior to S/N 0300141446

SECTION 4 - MACHINE OPERATION

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

Japan

0274729-7

3121170 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Prior to S/N 0300141446

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

4-28 – JLG Lift – 3121170

Table 4-1. Decal Legend - Prior to S/N 0300141446

SECTION 4 - MACHINE OPERATION

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

3121170 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - S/N 0300141446 to Present

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

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 – 3121170

Table 4-2. Decal Legend - S/N 0300141446 to Present

SECTION 4 - MACHINE OPERATION

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

3121170 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - S/N 0300141446 to Present

Item # ANSI

0274722-B

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

4-32 – JLG Lift – 3121170

Table 4-2. Decal Legend - S/N 0300141446 to Present

SECTION 4 - MACHINE OPERATION

Item # ANSI

0274722-B

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

3121170 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

NOTES:

4-34 – JLG Lift – 3121170

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:

ProductSafety@JLG.com

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.

3121170 – 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.

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 – 3121170

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 .............................................3121171

Illustrated Parts Manual ................................................................3121172

Troubleshooting Guide.................................................................3128411

Troubleshooting CD.......................................................................3128444

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Table 6-1. Operating Specifications - Prior to S/N 0300141446

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

Max.Vertical Platform Height (Unrestricted) 125 ft. (38.1 m) Max.Vertical Platform Height (Restricted) 125 ft. (38.1 m) Max.Horizontal Platform Reach (Unrestricted) 63 ft. 2 in. (19.3 m) Max.Horizontal Platform Reach (Restricted) 53 ft. 2 in. (16.2 m) Up and Over Height 60 ft. 7 in. (18.5 m) Main Boom Range (At Maximum Up & Over) +75° / -55° Maximum Boom Swing 360° Continuous 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

Max. Hydraulic System Pressure 4600 psi (317 Bar)

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

8ft. (2.44m) 125° working, 210° stowed 130° (+75/-55)

3121170 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications - Prior to S/N 0300141446

Maximum Wind Speed 28 mph (12.5 m/s) Maximum Manual Force 400 N Electrical System Voltage 12 Volts Max Tire Load 23,700 lbs. (10750 kg) Maximum Platform Rotation ±90°

Table 6-2. Operating Specifications - S/N 0300141446 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

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

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

Table 6-2. Operating Specifications - S/N 0300141446 to Present

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

Max. Hydraulic System Pressure 4600 psi (317 Bar) Maximum Wind Speed 28 mph (12 .5 m/s) Maximum Manual Force 400 N Electrical System Voltage 12 Volts Max Tire Load 23,700 lbs. (1075 0 kg) Maximum Platform Rotation ±90°

8ft. (2.44m) 125° working, 210° stowed 130° (+75/-55)

6-2 – JLG Lift – 3121170

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Dimensional Data Chassis

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. (3.05 m) Stowed Length (Transport Mode) 37 ft. 7 in. (11.46 m) Stowed Length (Working Mode) 47 ft. 6 in. (14.48 m) Wheelbase 12ft. 6in. (3.81 m) Tai ls wi ng

Tow e r U p Tow e r D o wn

Oscillating Axle ±6 in. (0.15 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)

7 ft. (2.13 m) 11 ft. 3 in. (3.43 m)

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) O ut s id e In s id e

Turning Radius (Axles Extended) In s id e O ut s id e

Max Tire Load 23700 lbs. (10750 kg) Max Ground Bearing Pressure

Maximum Drive Speed St o we d El e va te d

Gross Machine Weight Pl a tf o rm E mp t y Pl a tf o rm E mp t y w/ S ky p ow er

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

19 ft. 4 in. (5.9 m)

100 psi (7.03 kg/cm2)

3.25 mph (5.2 kph)

0.75 mph (1.2 kph)

44,000 lbs. (19,958 kg) 44,215 lbs. (20,056 kg)

45%

8 ft. (2.4 m)

5°

3121170 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-5. Capacities

Hydraulic Tank 53.3 gallo ns (201.7 liters) Fuel Tank 31 gallons (117 liters) Hydraulic System 65.4 gallons (247.5 liters) Drive Hub

B on f ig l io l i Re g gi a na R i du t to r i

2.1 quarts (2 liters) ± 10%

0.5 quarts (0.5 l iters) ± 10%

Table 6-6. Tire Specifications

Size 445/50D710 Load R ange J Ply Rating 18 Foam Fill Polyurethane HD (55 Durometer) Foam Diameter 46.45 in. (117.9 cm) Width 18 in. (45.7 cm) Rim Size 15x28 Tire & Wheel Weight 867 lbs. (393 kg) Max Tire Load 23,700 lbs. (10750 kg) Size 445/65-24 Typ e So li d Diameter 45.3 in. (115.1 cm) Width 17.3 in. (43.9 cm) Rim Size 12.00-24 Tire & Wheel Weight 960 lbs. (435.4 kg) Max Tire Load 23,700 lbs. (10750 kg)

Capacities Tires

6-4 – JLG Lift – 3121170

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

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 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

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 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

3121170 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

Table 6-10. Caterpillar 3.4T

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

Engine Data - Deutz TCD2.9L4 Engine Data - Caterpillar

6-6 – JLG Lift – 3121170

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

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)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscos ity I ndex 1 52

Hydraulic Oil

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

3121170 – JLG Lift – 6-7

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)

Viscosity

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

cp at -20° F 6,200

Viscos ity I ndex 1 40

Table 6-14. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Viscosit y

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

Viscosity Index 170

6-8 – JLG Lift – 3121170

Table 6-15. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be checked on a

yearly basis for viscosity.

3121170 – JLG Lift – 6-9

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-16. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade

Specific Gravity

Pour Point

Flash Point

Operating Temp.

Weig ht

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

0 to 180°F (-17 to 162°C)

Viscosit y

.910

-44°F (-42°C)

500°F (260°C)

7.64 lb. per gal.

(0.9 kg per liter)

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Major Component Weights

Table 6-17. Component Weights

Component Pound s Kilograms

Tire & Wheel 867 393 Drive Hub & Motor 275.5 123 Engine Assembly 1275 579 Main Boom 5186 2357 Tower Boom 6990 3173 Towe r Telescope Cylinder 915 415 Axle Oscillation Cylinder 74 34 Axle Extend Cylinder 92 42 Level Cylinder 89 40 Platform 36 x 96 245 111 Platform 36 x 72 195 89 Counterweight * 3320 1506 * For actual weight, see stamping on counter weight

6-10 – JLG Lift – 3121170

JLG 1250AJP Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.1 GENERAL

SECTION 1. SAFETY PRECAUTIONS

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 MAINTENANCE

Maintenance Hazards

Battery Hazards

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

Function Check

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Ground Control Indicator Panel

Platform Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 HYDRAULIC SYSTEM WARM UP

4.3 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Envelope Control System

Tower Path Control System

Automatic Main Boom Control System

Slow Down System

Controlled Angle

Swing Speed Proportioning

Stability

4.4 AUXILIARY POWER OPERATION

4.5 CAPACITY SELECT

4.6 ENGINE OPERATION

Starting Procedure

Shutdown Procedure

4.7 TRAVELING (DRIVING)

Traveling Forward and Reverse

4.8 STEERING

4.9 EXTENDING THE AXLES

4.10 PLATFORM

Platform Level Adjustment

Platform Rotation

4.11 BOOM

Swinging the Boom

Raising and Lowering the Main Boom

Telescoping the Main Boom

Tower Lift

Swinging the Jib

4.12 FUNCTION SPEED CONTROL

4.13 EMERGENCY TOWING

4.14 SHUT DOWN AND PARK

4.15 LIFTING AND TIE DOWN

Lifting

Tie Down

4.16 STOWING THE JIB FOR TRANSPORT

5.1 GENERAL

SECTION 5. EMERGENCY PROCEDURES

5.2 INCIDENT NOTIFICATION

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

Platform or Boom Caught Overhead

5.4 EMERGENCY TOWING PROCEDURES