JLG 24RS Operator Manual

®

Operation and Safety Manual

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

Boom Lift Models

24RS

ANSI

December 17, 2012

3121286

FOREWORD

FOREWORD

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

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

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

3121286 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

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

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
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 – 3121286

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

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

FOREWORD

• Standards and Regulations
Compliance Information

• Questions Regarding Spe­cial Product Applications

• Questions Regarding Prod­uct Modifications

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

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

Contact:

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

3121286 – JLG Lift – c

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

FOREWORD

REVISION LOG

Original Issue - December 17, 2012

d – JLG Lift – 3121286

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

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

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

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

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

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

Platform Control Indicator Panel . . . . . . . . . . . . 3-10

SECTION - 4 - MACHINE OPERATION

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

4.2 BOOM OPERATING CHARACTERISTICS AND

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

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

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-6

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

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

Drive Speed Cutback System . . . . . . . . . . . . . . . 4-8

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

3121286 – JLG Lift – i

TABLE OF CONTENTS

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

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

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

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

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

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . 4-12

4.9 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-12

Shut Down and Park . . . . . . . . . . . . . . . . . . . . 4-12

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

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

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.11 EMERGENCY TOWING PROCEDURES . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

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

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

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

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

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-9

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-16

Wheel and Tire Replacement . . . . . . . . . . . . . . 6-16

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-18

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Machine Nomenclature . . . . . . . . . . . . . . . . . . . . . .2-6

2-2. Daily Walk-Around Inspection Diagram. . . . . . . . . .2-7

2-3. Daily Walk-Around Inspection Points -

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

2-4. Daily Walk-Around Inspection Points -

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

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

ii – JLG Lift – 3121286

TABLE OF CONTENTS

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

3-2. Ground Control Indicator Panel. . . . . . . . . . . . . . . .3-6

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

3-4. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . .3-11

4-1. Position of Least Forward Stability . . . . . . . . . . . . .4-3

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

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-9

4-4. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . .4-14

4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . .4-15

4-6. Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . .4-16

4-7. Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . .4-17

4-8. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . .4-18

4-9. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . .4-19

4-10. Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . .4-20

4-11. Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . .4-21

4-12. Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . .4-22

6-1. Engine Oil Operating Temperature Specifications .6-5
6-2. Hydraulic Oil Operating Temperature

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-3. Operator Maintenance and Lubrication Diagram . .6-8

LIST OF TABLES

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

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

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

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

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

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Deutz D2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

6-7 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-7

6-8 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-9

6-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-17

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

3121286 – JLG Lift – iii

TABLE OF CONTENTS

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

This page left blank intentionally.

iv – JLG Lift – 3121286

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

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

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

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

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the
machine.

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

• Only authorized and qualified personnel can operate the
machine.

3121286 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

Workplace Inspection

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

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

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

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

Machine Inspection

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

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

• Be sure the footswitch and all other safety devices are
operating properly. Modification of these devices is a
safety violation.

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

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

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

1-2 – JLG Lift – 3121286

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

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

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

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

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

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

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

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

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

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

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

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

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

Trip and Fall Hazards

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

3121286 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

Electrocution Hazards

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

1-4 – JLG Lift – 3121286

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)

3121286 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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

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

Tipping Hazards

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

1-6 – JLG Lift – 3121286

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

• Do not raise the platform or drive from an elevated posi­tion unless the machine is on firm, level and smooth sur­faces.

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

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

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

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

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

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

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

Crushing and Collision Hazards

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

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

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

3121286 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

1.4 TOWING, LIFTING, AND HAULING

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

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

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

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

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

1-8 – JLG Lift – 3121286

SECTION 1 - SAFETY PRECAUTIONS

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

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

• Charge batteries only in a well ventilated area.

3121286 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

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

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

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically

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

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves r ustle

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

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

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

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

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

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

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

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121286

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, or dropoffs exist.

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

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

3121286 – 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 – 3121286

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection
(See Note)

Frequent Inspection In ser vice for 3 months or 150 hours, whichever

Annual Machine Inspection Annually, no later than 13 months from the date of

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

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

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified J LG

comes first;
or
Out of service for a period of more than 3 months;
or
Purchased used.

prior inspection.

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Mechanic

Service Technician
(Recommended)

Mechanic

Reference

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual

3121286 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

The Pre-Start Inspection shall 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
(Domestic only), and ANSI Manual of Responsibilities
(Domestic only) is enclosed in the weather resistant
storage container.

5. “Walk-Around” Inspection – Refer to Figure 2-2. thru
Figure 2-4.

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 Operation
and Safety Manual of each attachment or accessory
installed upon the machine for specific inspection, oper­ation, and maintenance instructions.

2-4 – JLG Lift – 3121286

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 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 panel with no load in the plat­form:

a. Check that all guards protecting the switches or

locks are in place;

b. Operate all functions and ensure proper operation;

c. Check auxiliary descent and ensure proper opera-

tion;

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

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 ensure proper operation;

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is pushed in.

3. With the platform in the transport (stowed) position:

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

rated gradeability, and stop to ensure the brakes
hold;

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

tion.

NOTE: When the tilt sensor alarm is activated the Drive function

will be disabled if the boom is elevated above horizontal.

3121286 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1

2

3

4

5

7

8

6

9

10

12

13

11

Figure 2-1. Machine Nomenclature

1. Base Boom Section

2. Powertrack

3. Lift Cylinder

4. Master Cylinder

5. Ground Control Box

6. Frame

7. Front Drive/Steer Wheels

8. Turntable

9. Rear Drive Wheels

10. Fly Boom Section

11. Platform Level Cylinder

12. Platform

13. Platform Control Console

2-6 – JLG Lift – 3121286

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1

2

3

5

8

8

8

18

21

8

5

7

17

7

14

6

23

19

20

12

16

13

11

15

2

9

6

7

5

5

4

22

10

7

17

Figure 2-2. Daily Walk-Around Inspection Diagram

3121286 – JLG Lift – 2-7

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 .

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. Rotator - See Inspection Note.

4. Power Track - See Inspection Note.

5. All Hydraulic Cylinders - See Inspection Note.

6. King Pins - Evidence of proper lubrication.

7. Drive Motor, Brake, and Hub - See Inspection Note.

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

2-8 – JLG Lift – 3121286

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

8. Wheel/Tire Assemblies - Properly secured, no missing
lug nuts. Inspect for worn tread, cuts, tears or other
discrepancies. Inspect wheels for damage and corro­sion.

9. Tie Rod and Steering Linkage - See Inspection Note.

10. Turntable Lock - Operable.

11. Auxiliary Power Pump - See Inspection Note.

12. Swing Drive Motor and Brake - See Inspection Note.

13. Main Control Valve - See Inspection Note.

14. Turntable Bearing - Evidence of proper lubrication. No

evidence of loose bolts or looseness between bearing
and structure.

15. Fuel Tank - See Inspection Note.

16. Fuel Filter (Optional) - See Inspection Note.

17. Hood Assemblies - See Inspection Note.

18. Battery - Proper electrolyte levels if adjustable; cables

tight, no visible damage or corrosion.

19. Hydraulic Pump - See Inspection Note.

20. Turntable - See Inspection Note.

21. Frame - See Inspection Note.

22. Main Boom Sections - See Inspection Note.

23. Tower Boom - See Inspection Note.

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

3121286 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-10 – JLG Lift – 3121286

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

3121286 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Station

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.

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

NOTE: The Function Enable switch must be held

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

1. Indicator Panel

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

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.

2. 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. Platform Rotate

Provides rotation of the platform.

3-2 – JLG Lift – 3121286

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1

2

3

4

5

6

7

8

9

10

Figure 3-1. Ground Control Station

1. Indicator Panel

2. Platform Leveling Override

3. Platform Rotate

4. Engine Star t/Auxiliary Power Switch/Function Enable

5. Hourmeter

6. Power/Emergency Stop

7. Platform/Ground Select

8. Lift

9. Swing

10. Telescope

3121286 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. 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.

WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP
SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT
DRAINING THE BATTERIES.

5. Hourmeter

Registers the amount of time the machine
has been in use, with engine running. In
the event of a fault, the hourmeter also dis­plays the three digit fault code. Refer to
the Service Manual for a listing of fault codes. Addition­ally, there is a small, red indicator light that will blink
when there is a fault on the machine to draw operator
attention to the display,

6. 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.

NOTE: When the Platform/Ground Select Switch is in the center

position, power is shut off to the controls at both operat­ing stations. Remove the key to prevent the controls from
being actuated. The key is removable in the platform posi­tion on CE specification machines. The key must be avail­able to ground personnel in the event of an emergency.

7. Platform/Ground Select Switch

The three position, key operated switch
supplies power to the platform control
console when positioned to Platform. With
the switch key turned to the Ground posi­tion only ground controls are operable.

3-4 – JLG Lift – 3121286

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Lift Control

Provides raising and lowering of the
boom.

9. Swing Control

Provides 355 degrees non-continu­ous turntable rotation.

10. Tel e s c o p e C o n tr o l

Provides extension and retraction of
the boom.

Ground Control Indicator Panel

(See Figure 3-2.)

1. Battery Malfunction 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 Coolant Temperature Indicator

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

4. System Distress Indicator

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

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

5. Glow Plug Indicator

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

3121286 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Malfunction

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. System Distress

5. Glow Plug

Figure 3-2. Ground Control Indicator Panel

3-6 – JLG Lift – 3121286

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Station

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

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

1. Drive Speed/Torque Select

The machine has a three posi­tion switch - 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.

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.

2. 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. Horn

A push-type Horn switch supplies electrical
power to an audible warning device when pressed.

4. Power/Emergency Stop Switch

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

3121286 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1001107677 A

1702676 D

1702566 B

1702565 B

1702567 B

1234

7

65

8

9

1011

1. Drive Speed/Torque Select

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Star t/Auxiliary Descent Enable

6. Drive Orientation Override

7. Drive/Steer

8. Telescope

9. Platform Rotate

10. Function Speed Control

11. Main Lif t/Swing Controller

Figure 3-3. Platform Control Console

3-8 – JLG Lift – 3121286

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Start/Auxiliary Descent Enable

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

When pushed back, it energizes Auxiliary
Descent Enable which allows the boom to
be lowered or swing to be operated in the
event of engine malfunction. Gravity is used
to control valves and lower the boom.

6. 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 joystick is spring loaded and will automatically

return to neutral (off) position when released.

7. Drive/Steer

Push forward to drive forward,
pull back to drive in reverse.
Steering is accomplished via a
thumb-activated rocker switch
on the end of the steer handle.

8. Te le s c op e

Provides extension and retraction of the
main boom.

9. Platform Rotate

Provides rotation of the platform when posi­tioned to the right or left.

3121286 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Function Speed Control

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

NOTE: To operate the Main Boom Lift/Swing joy-

stick, pull up on the locking ring below the
handle.

NOTE: The Main Boom Lift/Swing joystick is spring loaded and

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

11. Main Lift/Swing Controller

Provides main lift and swing.
Push forward to lift up, pull
backward to boom down.
Move right to swing right, move
left to swing left. Moving the
joystick activates switches to
provide the functions selected.

Platform Control Indicator Panel

(See Figure 3-4., Platform Light Panel)

1. AC Generator (If Equipped)

Indicates the generator is in operation.

2. Tilt Alarm Warning Light and Alarm

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

IF TILT WARNING LIGHT IS 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 ABOVE HORIZONTAL.

NOTE: When the tilt sensor alarm is activated the Drive function

will be disabled if the boom is elevated above horizontal.

3-10 – JLG Lift – 3121286

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123

4

5

6

7

1. AC Generator

2. Tilt Alarm Warning

3. Glow Plug/Wait to Start

4. Footswitch/Enable

5. Creep Speed

6. System Distress

7. Drive Orientation

Figure 3-4. Platform Light Panel

3121286 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Glow Plug/Wait to Start Indicator

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

4. Footswitch/Enable Indicator

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

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

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

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

5. 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.

6. System Distress Indicator

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

3-12 – JLG Lift – 3121286

7. 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).

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121286 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-14 – JLG Lift – 3121286

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 boom or swing the boom to the left
or right. Standard boom swing is 355 degree non-continu­ous. 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.

3121286 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Raising boom above horizontal with or without any load in
platform, is based on the following criteria:

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

2. Load is within manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Machine is as originally equipped from JLG.

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 Figure 4-1., and its
position of least Backward stability is shown in Figure 4-2.

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

4-2 – JLG Lift – 3121286

10°

Figure 4-1. Position of Least Forward Stability

TURNTABLE

ROTATED

90 DEGREES

MAIN BOOM

FULLY EXTENDED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

SECTION 4 - MACHINE OPERATION

3121286 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Backward Stability

MAIN BOOM FULLY ELEVATED

AND FULLY RETRACTED

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR

OPERATED ON AN

OUT-OF-LEVEL SURFACE

PLATFORM ROTATED

90 DEGREES

TURNTABLE ROTATED

90 DEGREES

.

4-4 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

NOTE: Initial starting should always be per-

formed from the Ground Control sta­tion.

Starting Procedure

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

NOTE: After turning on ignition, operator must wait

until glow plug indicator light goes out before
cranking engine.

1. Turn key of Platform/Ground Select switch
to Ground.

2. Pull the Power/Emergency Stop switch to
On.

3. Push the Engine Start switch until engine
starts.

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

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

5. Turn Platform/Ground Select switch to Plat­form.

3121286 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

6. From Platform, pull Power/Emergency Stop
switch out.

7. 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 Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for
detailed information.

4-6 – JLG Lift – 3121286

4.4 TRAVELING (DRIVING)

SECTION 4 - MACHINE OPERATION

See Figure 4-3., Grade and Side Slopes

NOTE: Refer to the Operating Specifications table for Gradeabil-

ity 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.

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.

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 IN THE OPERAT­ING SPECIFICATIONS SECTION OF THIS MANUAL.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

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.

3121286 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

IF WHEEL SLIPPAGE IS EVIDENT WHEN DRIV­ING ON UNEVEN OR MUDDY TERRAIN, MANU­ALLY POSITION THE DRIVE SPEED/TORQUE
SELECT SWITCH BACK TO THE MAXIMUM
TORQUE MODE TO CONTINUE TRAVEL.

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.

Drive Speed Cutback System

When the boom is positioned beyond Transport Position (boom
raised above 9° or telescoped beyond 16 in. [40.6 mm]) drive
speed is automatically reduced to 0.75 mph (1.2 kph).

4-8 – JLG Lift – 3121286

GRADE

LEVEL

SIDE SLOPE

Figure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION

3121286 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.5 STEERING

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

4.6 PLATFORM

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.

Platform Level Adjustment

To manually Level Up or Down - Position the
Platform/Level control switch Up or Down and
hold until the desired platform position is
obtained.

Platform Rotation

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

4.7 BOOM

A RED TILT WARNING LIGHT IS LOCATED ON THE CON­TROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS
ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE
BOOM ABOVE HORIZONTAL WHEN LIGHT IS LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE
CHASSIS. TILT ALARM INDICATES CHASSIS IS ON AN EXCESSIVE
SLOPE (3 DEGREE OR GREATER ON CE & AUSTRALIA SPEC MACHINES,
5 DEGREE OR GREATER ON ANSI, CSA, & JAPAN SPEC MACHINES).
CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM
ABOVE HORIZONTAL OR DRIVING WITH THE BOOM ELEVATED.

TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM
IS RAISED ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND
LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL
BEFORE RAISING BOOM.

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON
GRADES AND SIDE SLOPES SPECIFIED IN THE OPERATING SPECIFICA­TIONS SECTION OF THIS MANUAL.

4-10 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

Raising and Lowering the Main Boom

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

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

To raise or lower the Main Boom, position the Main
Boom Lift switch to Up or Down until the desired
height is reached.

Telescoping the Main Boom

THIS MACHINE USES A TWO-STAGE TELESCOPE CYLINDER. AS THE
CYLINDER SHIFTS BETWEEN STAGES, TELESCOPE SPEED WILL
CHANGE.

To extend or retract the main boom, use the Main
Telescope Control Switch to select IN or OUT
movement.

3121286 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

4.8 FUNCTION SPEED CONTROL

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

4.9 SHUT DOWN AND PARK

Shut Down and Park

The procedures to shut down and park the machine are as
follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Shut down Emergency Stop at Platform Controls.

4. Shut down Emergency Stop at Ground Controls. Posi-

tion Platform/Ground Select switch to the center Off
position.

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

4-12 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

4.10 LIFTING AND TIE DOWN

(See Figure 4-5.)

Lifting

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

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

3. Remove all loose items from the machine.

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

nated lifting points.

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

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.

The following procedures are to be used ONLY for emergency
movement to a suitable maintenance area.

3121286 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Figure 4-4. Drive Disconnect Hub

4.11 EMERGENCY TOWING PROCEDURES

THE ALLOWABLE TOWING SPEED IS 1.9 MPH (3 KPH). THE MAXIMUM
ALLOWABLE TOWING DISTANCE IS 0.6 MILES (1 KM).

1. Chock wheels securely.

2. Engage the mechanical release on both drive hubs by

loosening, completely reversing, and tightening the two
bolts on each hub. Refer to Figure 4-4., Drive Discon­nect Hub

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

After moving machine, complete the following procedure:

1. Position machine on a firm level surface.

2. Chock wheels securely.

3. Disengage the mechanical release on both drive hubs

by loosening, completely reversing, and tightening the
two bolts on each hub.

4. Remove chocks from wheels as desired.

4-14 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

Figure 4-5. Lifting and Tie Down Chart

3121286 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

17

42

3

42

35

22

21

34

13

4

Figure 4-6. Decal Location Sheet 1 of 6

4-16 – JLG Lift – 3121286

16

42

3

22

42

4

33

Figure 4-7. Decal Location Sheet 2 of 6

SECTION 4 - MACHINE OPERATION

3121286 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

LIFTING LUG FOR 80RS/24RS

21

20

3

3

20

21

41

11

2

12

25

38

36

14

26

282221

2

11

41

3

12

Figure 4-8. Decal Location Sheet 3 of 6

4-18 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

LIFTING LUG FOR 80RS/24RS

21

20

3

3

20

21

41

11

2

12

25

38

36

14

26

282221

2

11

41

3

12

Figure 4-9. Decal Location Sheet 3 of 6

3121286 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

39

20

20

18

18

40

15

26

14

29

9

44

23

23

27

19

39

37

Figure 4-10. Decal Location Sheet 4 of 6

4-20 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

45

8

6

7

5

24

Figure 4-11. Decal Location Sheet 5 of 6

3121286 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

TOP VIEW OF FRAME

10

10

Figure 4-12. Decal Location Sheet 6 of 6

4-22 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001139024-A

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3 1701500 1701500 1701500 1701500 1701500 1701500 1701500

4 1701501 1701501 1701501 1701501 1701501 1701501 1701501

5 1701502 1701502 1701502 1701502 1701502 1701502 1701502

6 1701503 1701503 1701503 1701503 1701503 1701503 1701503

7 1701504 1701504 1701504 1701504 1701504 1701504 1701504

8 1701505 1701505 1701505 1701505 1701505 1701505 1701505

9 1701509 1701509 1701509 1701509 1701509 1701509 1701509

10 1701529 1701529 1701529 1701529 1701529 1701529 1701529

11 1702300 1702300 1702300 1702300 1702300 1702300 1702300

12 1702391 1001113509 1001113168 1702391 1001113171 1001113169 1001113166

13 1702361 1702361 1702361 1702361 1702361 1702361 1702361

14 1702773 1702773 1702773 1702773 1702773 1702773 1702773

15 1702774 1702774 1702774 1702774 1702774 1702774 1702774

16 1702861 1702861 1702861 1702861 1702861 1702861 1702861

17 1702862 1702862 1702862 1702862 1702862 1702862 1702862

18 1702868 1705969 1702868 1705967 1704001 1704000 - -

19 1703797 1703927 1703925 1705895 1703923 1703924 1703926

Korea

1001139026-A

Chinese

1001139027-A

Portuguese

1001139028-A

Spanish

1001139029-A

French

1001139030-

Japan

1001139031-

3121286 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001139024-A

20 1703804 1703951 1703949 1705898 1703947 1703948 1703950

21 1703805 1703939 1703937 1705897 1703935 1703936 1703938

22 1703953 1703945 1703943 1705903 1703941 1703942 1703944

23 1704277 1704277 1704277 1704277 1704277 1704277 1704277

24 1704412 1704412 1704412 1704412 1704412 1704412 1704412

25 1704575 1705345 1001116849 1705896 1705917 1705347 1705344

26 1704885 1704885 1704885 1704885 1704885 1704885 1704885

27 1705351 1705427 1705351 1705905 1705910 1705429 1705426

28- -- -- -- -- -- -- -

29 - - - - - - 1705902 - - 1703984 1703980

30- -- -- -- -- -- -- -

31- -- -- -- -- -- -- -

32- -- -- -- -- -- -- -

33- -- -- -- -- -- -- -

34 - - - - 1001131269 1001131269 10 01131269 1001131269 1001131269

35- -- -- -- -- -- -- -

36 - - - - 1001140402 1001140402 10 01140402 1001140402 1001140402

37 - - - - 1001140403 1001140403 10 01140403 1001140403 1001140403

38 - - - - 1001121823 1001121823 10 01121818 1001121816 1001121821

39 - - - - 1001121810 1001121920 10 01121805 1001121803 1001121808

Korea

1001139026-A

Chinese

1001139027-A

Portuguese

1001139028-A

Spanish

1001139029-A

French

1001139030-

Japan

1001139031-

4-24 – JLG Lift – 3121286

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001139024-A

40 - - - - 1001140429 1001140429 1001140429 1001140429 100 1140429

41- -- -- -- -- -- -- -

42- -- -- -- -- -- -- -

43- -- -- -- -- -- -- -

44- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -

46- -- -- -- -- -- -- -

47- -- -- -- -- -- -- -

Korea

1001139026-A

Chinese

1001139027-A

Portuguese

1001139028-A

Spanish

1001139029-A

French

1001139030-

Japan

1001139031-

3121286 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

NOTES:

4-26 – JLG Lift – 3121286

5.1 GENERAL

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

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

5.2 INCIDENT NOTIFICATION

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

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

Outside USA:
240-420-2661

E-mail:

[e-mail]

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

FOLLOWING ANY INCIDENT, 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
stabilize motion of the machine.

3121286 – 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. However, provisions for mov­ing the machine have been incorporated. Refer to Emergency
Towing Procedures in Section 4.

5-2 – JLG Lift – 3121286

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 ............................ 3121287

Illustrated Parts Manual ............................................ 3121288

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Operating Specifications

Table 6-1. Operating Specifications

Capacity: Unrestricted:
A NS I
A NS I E xp o r t

Maximum Travel Grade, stowed
Position (Gradeability) see Figure 4-3.

Maximum Travel Grade, stowed
Position (Side Slope) see Figure 4-3.

Drive Speed - Stowed 2.8 mph (4.5 kph)

Elevated Drive Speed 0.75 mph (1.2 kph)

Gross Machine Weight - Approximate 23300 lbs. (10568 kg)

Ground Bearing Pressure 83 psi (5.83 kg/cm

System Voltage 12V DC

Maximum Main Relief Hyd. Pressure 3000 psi (207 Bar)

500 lbs. (227 kg)
500 lbs. (227 kg)

45%

5°

2

)

3121286 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Dimensional Data Capacities

Table 6-2. Dimensional Data

Turning Radius (Inside Left Turn) 12’ 9" (3.89 m)

Turning Radius (Inside Right Turn) 12’ 11" (3.93 m)

Turning Radius (Outside Left Turn) 22’ 10" (6.95 m)

Turning Radius (Outside Right Tur n) 22’ 6" (6.85 m)

Machine Height (stowed) 9’ (2.76 m)

Machine Height (storage) 8’ 2" (2.5 m)

Machine Length (stowed) 38’ 8" (11.85 m)

Horizontal Reach 58’ 5" (17.8 m)

Machine Width (Normal Operation) 8’ 2" (2.49 m)

Machine Width (Shipping) 7’ 1" (2.2 m)

Wheel Base 9’ 6" (2.9 m)

Platform Height 80’ 5" (24.5 m)

Platform Height w/LSS 80’ 6" (24.5 m)

Ground Clearance 11.2" (28.5 cm)

Table 6-3. Capacities

Hydraulic Oil Tank (to Full Level) 32.5 Gal. (123 L)

Drive Hub*

20.5 oz. (0.6 L)

*Drive hubs should be one half full of lubricant.

6-2 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tires Engine Data

Table 6-4. Tires

Size 39 x 15-22.5

Maximum Tire Load 13,000 lbs. (5896.7 kg)

Type Foam Filled

Table 6-5. Deutz D2011

Type Liquid Cooled

Number of Cylinders 4

Bore 3.7in. (94 mm)

Stroke 4.4 in. (112 mm)

Total Displacement 189.6 cu. in. (3.1 L)

Compression Ratio 19.0:1

Firing Order 1-3-4-2

Output 36.4 hp (48.8 kW)

Low Idle RPM 1200 ± 50

High Idle RPM 2500 ± 50

3121286 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-6. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

Hydraulic Oil

NOTE: Hydraulic oils require anti-wear qualities at least API Ser-

vice Classification GL-3, and sufficient chemical stability
for mobile hydraulic system service.

NOTE: Machines may be equipped with Mobil EAL biodegrad-

able and non-toxic hydraulic oil. This is a fully synthetic
hydraulic oil that possesses the same anti-wear and rust
protection characteristics as mineral oils, but will not
adversely affect the ground water or the environment
when spilled or leaked in small amounts.

6-4 – JLG Lift – 3121286

NOTE: 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 Mobil 424 is
desired, contact JLG Industries for proper recommenda­tions.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-1. Engine Oil Operating Temperature Specifications

1001151190-A

3121286 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-2. Hydraulic Oil Operating Temperature Specifications

1001151189-A

6-6 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Major Component Weights

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF­FERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES,
FILLED TIRES, PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO
AFFECT STABILITY.

Table 6-7. Critical Stability Weights

Components LBS. KG.

Tire & Wheel (Foam-Filled) 513 233

Engine Assembly (w/tray) 1125 510

Battery 41 18.5

Chassis complete (w/swing bearing) 4950 2245

Chassis & Turntable (w/o booms) 11735 5323

Left Counterweights 907 411.5

Right Counterweights 907 411.5

To we r Bo om 2013 913

Table 6-7. Critical Stability Weights

Components LBS. KG.

Upright 1715 778

Main Boom Assembly 3475 1576

Platform 224 102

Platform Support 68 31

Platform Rotator 55 25

To we r Li nk 893 405

3121286 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-3. Operator Maintenance and Lubrication Diagram

6-8 – JLG Lift – 3121286

6.3 OPERATOR MAINTENANCE

Table 6-8. Lubrication Specifications.

KEY SPECIFICATIONS

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460.

HO Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid

424.

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Clas-

sification GL-5 or Mil-Spec Mil-L-2105.

MPG Multipurpose Grease having a minimum dripping point of

350° F (177° C). Excellent water resistance and adhesive
qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)

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

2 10 4. Di es e l - AP I C C /C D c la s s, MI L-L- 21 0 4B /M IL- L­2104C.

*MPG may be substituted for these lubricants, if necessary, but service
intervals wi ll be reduced.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

3., Operator Maintenance and Lubrication Diagram.

3121286 – JLG Lift – 6-9

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

1. Swing Bearing

Lube Point(s) - 2 Fittings
Capacity - A/R
Lube - BG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply grease and rotate in 90 degree

intervals until bearing is completely lubricated

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

DRAIN

FILL

2. Swing Gearbox

Lube Point(s) - Fill Plug
Capacity - 32 ounces (946 cc)
Lube - EPGL
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.

3. Hydraulic Tank

Lube Point(s) - Fill Cap
Capacity - 36 Gal. (136.3 L), 32.5 Gal. (123 L) to Full Level;

26.5 Gal (100.3 L) to Refill Mark
Lube - HO
Interval - Check Level daily; Change every 2 years or 1200

hours of operation.

Comments - On new machines, those recently over-

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

6-10 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Hydraulic Tank Return Filter and Breather

Interval - Change after first 50 hrs. and every 6 months or

300 hrs. thereafter.

Comments - For breather element, remove wing nut and

cover to replace. Under certain conditions, it may be
necessary to replace both elements on a more frequent
basis.

5. King Pins

Lube Point(s) - 2 Grease Fittings
Capacity - As Required
Lube - MPG
Interval - Every 3 months or 150 hrs of operation

3121286 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

FILL PORT

15°

OIL SHOULD BE
TO THIS HEIGHT

6. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug
Capacity - 20.5 oz. (0.6 L)
Lube - Mineral Oil ISO VG150
Interval - Check level every 3 months or 150 hrs of opera­tion; change every 2 years or 1200 hours of operation

7. Oil Change with Filter

Lube Point(s) - Fill Cap/Spin-on Element
Total Capacity (Engine & Oil Cooler)- 15 Quarts (14.2 L) w/
Filter
Lube - EO
Interval - Check level daily; change every 600 hours or six

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

6-12 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. Fuel Filter/Water Separator

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

9. Air Filter

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation

3121286 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

10. Charge Filter

Interval - Change after first 50 hrs. and every 6 months or

300 hrs. thereafter.

11. Main Valve Filter

Interval - Change after first 50 hrs. and every 6 months or

300 hrs. thereafter.

6-14 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

12. Optional Fuel Filter

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

3121286 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.4 TIRES & WHEELS

Tire Replacement

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

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

• Tire tread contact width equal or greater than original

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

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

Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneu­matic tire. When selecting and installing a replacement tire,
ensure that all tires are inflated to the pressure recommended
by JLG. Due to size variations between tire brands, both tires
on the same axle should be the same.

Wheel and Tire Replacement

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

Wheel Installation

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

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI­BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE
TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE
WHEEL.

Tighten the lug nuts to the proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten the fasteners. If
you do not have a torque wrench, tighten the fasteners with a
lug wrench, then immediately have a service garage or dealer
tighten the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming the

6-16 – JLG Lift – 3121286

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1

2

3

4

5

6

7

8

9

mounting stud holes in the wheels. The proper procedure for
attaching wheels is as follows:

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

2. Tighten nuts in the following sequence.

3. The tightening of the nuts should be done in stages. Fol-

lowing the recommended sequence, tighten nuts per
wheel torque.

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

Table 6-9. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

3121286 – JLG Lift – 6-17

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.5 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/
EC and is only applicable to CE machines.

For electric powered machines, the equivalent continuous A­Weighted sound pressure level at the work platform is less
than 70dB(A)

For combustion engine powered machines, guaranteed
Sound Power Level (LWA) per European Directive 2000/14/
EC (Noise Emission in the Environment by Equipment for
Use Outdoors) based on test methods in accordance with
Annex III, Part B, Method 1 and 0 of the directive, is 104 dB.

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

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

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

2

. The highest root mean

2

.

6-18 – JLG Lift – 3121286

SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 7-1. Inspection and Repair Log

Date Comments

SECTION 7 - INSPECTION AND REPAIR LOG

3121286 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3121286

Corporate Office

3121286

JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA

[phone]

JLG Worldwide Locations

JLG Industries (Australia)
P.O. Box 5119
11 Bolwarra Road
Port Macquarie
N.S.W. 2444
Australia

[phone]

[phone]

JLG Deutschland GmbH
Max-Planck-Str. 21
D - 27721 Ritterhude - Ihlpohl
Germany

[phone]

[phone]

JLG Latino Americana Ltda.
Rua Eng. Carlos Stevenson,
80-Suite 71
13092-310 Campinas-SP
Brazil

[phone]

[phone]

JLG Equipment Services Ltd.
Rm 1107 Landmark North
39 Lung Sum Avenue
Sheung Shui N. T.
Hong Kong

(852) 2639 5783

(852) 2639 5797

Plataformas Elevadoras
JLG Iberica, S.L.
Trapadella, 2
P.I. Castellbisbal Sur
08755 Castellbisbal, Barcelona
Spain

[phone]

[phone]

[phone]

JLG Industries (UK) Ltd
Bentley House
Bentley Avenue
Middleton
Greater Manchester
M24 2GP - England

[phone]

[phone]

JLG Industries (Italia) s.r.l.
Via Po. 22
20010 Pregnana Milanese - MI
Italy

[phone]

[phone]

JLG Sverige AB
Enkopingsvagen 150
Box 704
SE - 176 27 Jarfalla
Sweden

[phone]

[phone]

JLG France SAS
Z.I. de Baulieu
47400 Fauillet
France

[phone]

[phone]

Oshkosh-JLG Singapore Technology
Equipment Pte Ltd
29 Tuas Ave 4,
Jurong Industrial Estate
Singapore, 639379

[phone]

[phone]

www.jlg.com