JLG 450A-AJ Operator Manual

Operation and Safety Manual

®

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

Boom Lift Models
450A Series II
450AJ Series II
S/N 0300160835­S/N E0300001114
to Present

ANSI

3121289

October 1, 2014

NOTE: This manual also applies to machines with the following

Serial Numbers: 0300159794, 0300159795,
0300160088, 0300160456, and E300001067.

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.

3121289 – 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 – 3121289

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

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:

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

FOREWORD

• Standards and Regulations
Compliance Information

• Questions Regarding Special
Product Applications

• Questions Regarding Prod­uct Modifications

3121289 – JLG Lift – c

FOREWORD

Original Issue - June 19, 2012

Revised - June 29, 2012

Revised - April 1, 2013

Revised - October 1, 2014

REVISION LOG

d – JLG Lift – 3121289

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

GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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

SECTION - 4 - MACHINE OPERATION

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

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1

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

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

4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

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

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-7

3121289 – JLG Lift – i

TABLE OF CONTENTS

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

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-10

Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-10

Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-10

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.9 AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-11

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

4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Prior to Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-15

Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-15

Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-15

SECTION - 5 - EMERGENCY PROCEDURES

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

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

5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-2

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

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

SECTION - 6 - GENERAL SPECIFICATIONS
AND OPERATOR MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA. .

6-1

Reach Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

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

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

Serial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

ii – JLG Lift – 3121289

TABLE OF CONTENTS

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

6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34

Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 6-35

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6.5 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 6-37

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

6.6 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 6-38

6.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . .6-39

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . 2-6

2-2. Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . 2-7

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

2-4. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . . 2-9

2-5. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . 2-10

3-1. Ground Control Station - A Models . . . . . . . . . . . . . . . . . . . 3-3

3-1. Ground Control Station - AJ Models . . . . . . . . . . . . . . . . . . 3-4

3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-7

3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10

3-4. Platform Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-14

4-1. Position of Least Forward Stability. . . . . . . . . . . . . . . . . . . . 4-5

4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4-4. Lifting and Tie Down Chart. . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4-5. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

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

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

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

4-9. Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-19

4-10. Decal Installation - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-20

4-11. Decal Installation - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-21

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

3121289 – JLG Lift – iii

TABLE OF CONTENTS

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

6-2. Engine Operating Temperature Specifications - Caterpillar

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-3. Engine Operating Temperature Specifications - Caterpillar

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

6-4. Engine Operating Temperature Specifications - Deutz

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-5. Engine Operating Temperature Specifications - Deutz

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-6. Engine Operating Temperature Specifications - GM

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-7. Engine Operating Temperature Specifications - GM

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-8. Operator Maintenance and Lubrication Diagram -

Deutz D2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-9. Operator Maintenance and Lubrication Diagram -

Deutz D2011 and CAT C2.2 . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-10. Operator Maintenance and Lubrication Diagram -

GM Dual-Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

6-11. Deutz D2011 Engine Dipsticks . . . . . . . . . . . . . . . . . . . . . . 6-27

6-12. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

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

6-2 Reach Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

6-5 Component Weights - 450 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

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

6-7 Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-8 Caterpillar C2.2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

6-10 Deutz D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-12 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-13 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-14 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-15 UCon Hydrolube HP-5046. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

6-17 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-18 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-19 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6-20 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

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

LIST OF TABLES

iv – JLG Lift – 3121289

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.

3121618 – 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 – 3121618

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.

3121618 – 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 – 3121618

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.

3121618 – 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 R ange

(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 – 3121618

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.

3121618 – 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 – 3121618

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.

3121618 – 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 – 3121618

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.

3121618 – 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 – 3121618

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.

3121618 – JLG Lift – 1-13

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121618

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, dropoffs.

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.

3121289 – 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 TRAINED SERVICE TECHNICIAN AS A PER­SON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE
SPECIFIC JLG PRODUCT MODEL.

2-2 – JLG Lift – 3121289

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type F requen cy

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 Quali fied JLG Mechanic Service and Maintenance Manual

In service for 3 months or 150 hours, whichever comes first;
or
Out of service for a peri od of more 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.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Q ualified JLG Mechanic Service a nd Maintenance Manual

Owner, Dealer, or User Factory Trained

Owner, Dealer, or User Q ualified JLG Mechanic Service a nd Maintenance Manual

Service

Qualification

Service Technician
(Recommended)

Reference

and applicable JLG inspection form

and applicable JLG inspection form

Service and Maintenance Manual
and applicable JLG inspection form

3121289 – 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 2-3. and
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 Operator and
Safety Manual of each attachment for accessory installed
upon the machine for specific inspection, operation, and
maintenance instructions.

2-4 – JLG Lift – 3121289

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 check boom limit switches;

drive speed should switch to creep mode if lower boom
is elevated or main boom is above horizontal.

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is activated.

e. Ensure all boom functions stop when the function

enable switch is released.

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 check all limiting and cut-out

switches;

d. Ensure that all machine functions are disabled when

the Emergency Stop Button is pushed in.

e. Ensure that all machine functions stop when the foot-

switch is released.

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 that the tilt indicator is illuminated to ensure

proper operation.

3121289 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

4

3

16

1

18

2

17

11

10

12

9

8137

6145

15

Figure 2-1. Basic Nomenclature - Sheet 1 of 2

2-6 – JLG Lift – 3121289

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Basic Nomenclature - Sheet 2 of 2

1. Front Drive/Steer Wheels

2. Rear Drive Wheels

3. Tower Lift Cylinder

4. Lower Upright

5. Main Lift Cylinder

6. Main Boom Assembly

7. Power Track

8. Level Cylinder

9. Jib Cylinder

10. Platform

11. Platform Console

12. Jib

13. Fly Boom Section

14. Base Boom Section

15. Master Cylinder

16. Tower Boom

17. Turntable

18. Frame

3121289 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

234

14

1

5

7

6

6

7

7

3

10,11 12,13

7

9

3

3

3

2

16

3

8

15

8

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

2-8 – JLG Lift – 3121289

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

GENERAL

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

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

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

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

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

3. All Hydraulic Cylinders - No visible damage; pivot pins
and hydraulic hoses undamaged, not leaking.

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

5. Boom Limit Switches - Switches operate properly.

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

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

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

8. Hood Assemblies - See Inspection Note.

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

3121289 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Tie Rod Ends and Steering Spindles - See Inspection
Note.

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

11. Swing Motor and Worm Gear - Evidence of proper lubri­cation; No evidence of damage.

12. Auxiliary Hydraulic Pump - See Inspection Note.

13. Main Hydraulic Pump - See Inspection Note.

14. Platform Rotator - See Inspection Note.

15. Fuel Tank - See Inspection Note.

16. Hydraulic Reservoir - See Inspection Note.

Figure 2-5. Daily Walk-Around Inspection - Sheet 3 of 3

2-10 – JLG Lift – 3121289

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

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

NOTE: Ensure boom is fully retracted, lowered, and centered between

drive 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 activate Swing control lever and position boom
over right side of machine.

5. With boom over right side of machine, place Drive control
lever to Reverse and 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 ground.

7. Carefully activate Swing control lever and return boom to
stowed position (centered between drive wheels). When
boom reaches center, stowed position, lockout cylinders
should release and allow wheel to rest on ground, it may be
necessary to activate Drive to release cylinders.

8. Place the 6 inches (15.2 cm) high block with ascension ramp
in front of right front wheel.

9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on top
of block.

10. With boom over left side of machine, place Drive control
lever to Reverse and drive machine off of block and ramp.

3121289 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

12. Carefully activate Swing control lever and return boom to
stowed position (centered between drive wheels). When
boom reaches center, stowed position, lockout cylinders
should release and allow wheel to rest on ground, it may be
necessary activate Drive to release cylinders.

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

2-12 – JLG Lift – 3121289

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.

3121289 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

Ground Control Station

NOTE:Function Enable switch must be held down
in order to operate Telescope, Swing, Tower Lift,
Main Lift, Jib Lift, Platform Level Override, and

Platform Rotate functions.

DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLATFORM
EXCEPT IN AN EMERGENCY.

PERFORM AS MANY PRE-OPERATIONAL CHECK AND INSPECTIONS FROM GROUND CON­TROLS AS POSSIBLE.

1. Platform Rotate

A three position switch controls rotation of
the platform.

ONLY USE THE PLATFORM LEVELING 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

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

3. Jib Lift (If Equipped)

This switch provides raising and lowering
of the jib.

3-2 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1

HOURS

10

QUARTZ

89101112

1

2

4
5

6

7

1. Platform Rotate

2. Platform Leveling

3. Not Used

4. Engine Start/Auxiliary Power/Function Enable

5. Power/Emergency Stop

6. Platform/Ground Select

7. Hourmeter

8. Swing

9. Tower Boom Lift

10. Main Boom Lift

11. Telescope

12. Indicator Panel

Figure 3-1. Ground Control Station - A Models

3121289 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1

HOURS

10

QUARTZ

89101112

1

2

3

4
5

6

7

Figure 3-1. Ground Control Station - AJ Models

1. Platform Rotate

2. Platform Leveling

3. Jib Lift

4. Engine Start/Auxiliary Power/Function Enable

5. Power/Emergency Stop

6. Platform/Ground Select

7. Hourmeter

8. Swing

9. Tower Boom Lift

10. Main Boom Lift

11. Telescope

12. Indicator Panel

3-4 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1

HOURS

10

QUARTZ

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. Aux
power can only be used if the engine is not run­ning.

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

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

abled if engine is running.

5. Power/Emergency Stop

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

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

tion, 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.

6. Platform/Ground Select

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.

7. Hourmeter

The hourmeter registers up to 9,999.9
hours and cannot be reset.

8. Swing Control

The Swing control switch provides 360
degrees non-continuous turntable rota­tion when positioned to the right or left.

3121289 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Towe r Boom L ift

Provides raising and lowering of the Lower
and Mid Booms.

10. Main Boom Lift

Provides raising and lowering of the Main
Boom.

11. Telescope

Provides extension and retraction of the
Main Boom.

Ground Control Indicator Panel

1. Battery Charging Indicator

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

2. Engine Oil Pressure Indicator

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

3. High Engine Coolant Temperature Indicator
(Liquid Cooled Engines)

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

4. Engine Oil Temperature Indicator (Deutz)

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

3-6 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. Engine Oil Temp.

5. System Distress

6. Low Fuel

7. Gl o w P l ug Wa i t t o St a r t

8. Platform Overload

9. Drive and Steer Disable

Figure 3-2. Ground Control Indicator Panel

3121289 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. 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.

6. Low Fuel Level Indicator

Indicates that the fuel level is 1/8 full or less.

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

information.

7. Glow Plug Wait to Start Indicator

Indicates the glow plugs are on. The glow
plugs are automatically turned on with the
ignition circuit and remain on for approxi­mately seven seconds. Start the engine only after the light
goes out.

8. Platform Overload Indicator. (If Equipped)

Indicates the platform has been overloaded.

9. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function
has been activated.

3-8 – JLG Lift – 3121289

Platform 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 OR
NEUTRAL POSITION WHEN RELEASED.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

ONLY USE THE PLATFORM LEVELING 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

1. Drive Speed Switch

(4WD Machines) - The forward

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

(2WD Machines) - The forward position selects maximum
speed by operating at high engine rpm. The backward posi­tion selects mid engine rpm.

A three position switch allows the operator to
adjust the automatic self leveling system. This
switch is used to adjust the 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

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.

3121289 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1702567 A

1702676-B

1704997

1705170 A

1702938

12

17

16

15

13

14

11 9

8

10

6

7

4

5

3

12

1. Drive Speed/Torque Select

2. Platform Leveling

3. Horn

4. Power/Emergency Stop

5. Start/Auxiliary Power

6. Fuel Select

7. Drive Orientation Override

8. Drive/Steer

9. Telescope

10. Lights

11. Jib Lift

12. Soft Touch Override

13. Soft Touch Indicator

14. Tower Boom Lift

15. Platform Rotate

16. Function Speed

17. Main Lift/Swing Controller

Figure 3-3. Platform Control Console

3-10 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Drive Orientation Override

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.

5. Start/Auxiliary Power

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

The Auxiliary Power control switch energizes
the electrically operated hydraulic pump.
(Switch must be held ON for duration of auxil­iary pump use.)

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

6. Fuel Select (Dual Fuel Engine Only) (If
Equipped)

Moving the switch to the appropriate position
selects gasoline or liquid propane fuel.

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 and
match the control direction arrow to the intended chassis
direction.

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.

8. 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.

3121289 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Telescope Control

This switch allows extension and retraction of
the main boom.

10. Lights (If Equipped)

This switch operates the chassis lights if the
machine is so equipped.

11. Jib Lift (if equipped)

Provides for raising or lowering of the jib by
positioning up/down.

12. Soft Touch Override Switch (If equipped)

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

13. 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.

14. Towe r Boom L ift

Provides for raising and lowering of the tower
boom when positioned up or down.

15. Platform Rotate

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

3-12 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

16. Function Speed Control

This control affects the speed of telescope,
tower lift and jib lift. Turning the knob all
the way counterclockwise until it clicks puts
drive, tower lift and swing into creep mode.
This slow speed is used for fine positioning
of the platform when close to obstacles.

NOTE: Main lift and swing functions may be selected at the same time.

Maximum speed is reduced when both functions are selected.

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

ring below the handle.

17. 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

1. AC Generator (Green) (If equipped)

Indicates the generator is in operation.

2. Platform Overload Indicator. (If equipped)

Indicates the platform has been overloaded.

3121289 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. AC Generator

2. Platform Overload

3. Tilt Alarm Warning

4. Glow Plug/Wait to Start

5. Enable/Footswitch

6. Fuel Level

7. Creep Speed

8. System Distress

9. Drive Orientation

Figure 3-4. Platform Control Indicator Panel

1

2

4

7

3

5

6

9

8

3-14 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Tilt Angle Market

3° CE & Australia
5° ANSI, CSA & Japan

3. 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 severe 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 severe 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.

4. Glow Plug/Wait to Start Indicator

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

3121289 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Enable Indicator/Footswitch

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.

NOTE: For engine starting, the footswitch must be in the released (up)

position.

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.

6. Low Fuel Indicator (Yellow)

Indicates fuel tank is 1/8 full or less.

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

information.

7. 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.

3-16 – JLG Lift – 3121289

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. 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

9. 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).

3121289 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-18 – JLG Lift – 3121289

SECTION 4. MACHINE OPERATION

SECTION 4 - MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic lift equipped with a
work platform on the end of an elevating, articulating 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 360 degree non 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. The Ground Control is also to be
used in Pre-Start Inspection.

4.2 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 manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG.

3121289 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Stability

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

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

4.3 ENGINE OPERATION

NOTE: Initial starting must always be performed from the Ground Con-

trol station.

Starting Procedure

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

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

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

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

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

4-2 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

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 Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

3121289 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Fuel Reserve / Shut-Off System

NOTE: Reference the Service and Maintenance Manual along with a

qualified JLG Mechanic to verify your machine setup.

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

If fuel level reaches the Empty range, the Low Fuel light will begin
to flash once a second and there will be approximately 60 min­utes of engine run time left. If the system is in this condition and
automatically shuts down the engine or if the operator manually
shuts down the engine before the 60 minute run time is com­plete, the Low Fuel light will flash 10 times a second and the
engine will react according to machine setup. Setup options are
as follows:

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

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

• Engine Stop - When the engine shuts down, no restarts
will be permitted until fuel is added to the tank.

4-4 – JLG Lift – 3121289

TELESCOPE

FULLY EXTENDED

TOWER BOOM

STOWED POSITION

MAIN BOOM

HORIZONTAL

MACHINE TIP OVER INWILL

THIS DIRECTION IF OVERLOADED

OR OPERATED

ON AN SURFACEOUT-OF-LEVEL

Figure 4-1. Position of Least Forward Stability

SECTION 4 - MACHINE OPERATION

3121289 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

ROTATE PLATFORM

90 DEGREES

MAIN BOOM

FULLY ELEVATED

MACHINE TIP OVER WILL

IN THIS DIRECTION IF

OPERATED ON AN

OUT-OF-LEVEL SURFACE

TOWER BOOM

FULLY ELEVATED

Figure 4-2. Position of Least Backward Stability

.

4.4 TRAVELING (DRIVING)

NOTE: Refer to the Operating Specifications table in Section 6 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.

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.

4-6 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

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

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES
EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER TAG OR AS NOTED IN THE OPERA­TORS MANUA L.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES (ANSI MARKETS) OR 4 DEGREES
(CE & AUSTRALIA MARKETS).

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLAT­FORM IS ELEVATED ESPECIALLY WHEN DRIVING WITH ANY PART OF MACHINE WITHIN 6
FEET (2 M) OF AN OBSTRUCTION.

TRAVEL GRADES WITH DRIVE SPEED/TORQUE SELECT SWITCH IN THE FORWARD POSI­TION.

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.

1. With the engine running, 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.

3121289 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

LEVEL

G

R

A

D

E

S

I

D

E

S

L

O

P

E

Figure 4-3. Grade and Side Slopes

4-8 – JLG Lift – 3121289

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

This switch is used to adjust the platform level in situations such
as ascending/descending a grade. To Level Up or Down - Position
the Platform/Level control switch Up or Down and hold until the
platform is level.

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.

3121289 – JLG Lift – 4-9

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 Main Lift/Swing controller to select RIGHT or
LEFT direction.

Raising and Lowering the Tower Boom

To raise or lower the Tower Boom, use Tower Boom Lift switch to
select UP or DOWN movement.

To raise or lower the Main Boom, use Main Boom Lift switch to
select UP or DOWN movement.

Telescoping the Main Boom

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

4.8 FUNCTION SPEED CONTROL

This control affects the speed of all boom functions to the right of
the control and, also, Platform Level. When in the Counterclock­wise maximum position, Drive and all boom functions are placed
in creep speed.

4-10 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

4.9 AUXILIARY PUMP

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

The main function of auxiliary power is to lower the platform in
the event of primary power failure. Determine the reason for pri­mary power failure and have the problem corrected by a certified
JLG service technician. Operate as follows:

1. Position Platform/Ground switch to Platform.

2. Position Power/Emergency Stop switch to the on position.

3. Depress and hold footswitch.

4. Position Auxiliary Power switch to the on position and hold.

5. Operate appropriate control switch or lever for desired func-

tion and hold.

6. Release Auxiliary Power switch, selected control switch or
lever, and footswitch.

7. Position Power/Emergency Stop switch to the off position.

4.10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

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

Refer to Section 2.3, Oscillating Axle Lockout Test (If Equipped) for
procedure.

3121289 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

4.11 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. 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.

4.12 LIFTING AND TIE DOWN

Lifting

1. Refer to the Serial Number Tag, call JLG Industries, or weigh
the individual unit to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position.

3. Remove all loose items from the machine.

4. 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.

2. Remove all loose items from the machine.

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

adequate strength.

4-12 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

1001143110 A

450A

SERIES II

510AJ

A
B

450AJ

SERIES II

62.8 in

(1595 mm)

64.3 in

(1634 mm)

63.7 in

(1618 mm)

47.2 in

(1199 mm)

48.1 in

(1222 mm)

47.1 in

(1196 mm)

C

L

CG

1702300

1701500

1702300

1701500

BA

Figure 4-4. Lifting and Tie Down Chart

3121289 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Figure 4-5. Drive Disconnect Hub

4.13 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.) FOR NO LONGER THAN 30-45 MINUTES.

MAXIMUM TOWING GRADE 25%.

Prior to Towing

Prior to towing the machine, complete the following:

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

1. Retract, lower and position boom over rear drive wheels in
line with direction of travel.

2. Disconnect drive hubs by inverting disconnect cap. (See Fig­ure 4-5.) After towing the machine, complete the following:

3. Reconnect drive hubs by inverting disconnect cap. (See Fig­ure 4-5.)

4-14 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

The dual fuel system enables the standard gasoline engine to run
on either gasoline or LP gas.

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

Changing From Gasoline to LP Gas

1. Start engine from Ground Control Station.

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

clockwise.

3. While engine is operating on GASOLINE under a no-load
condition, place FUEL SELECT switch at Platform Control to
LP position.

Changing From LP Gas to Gasoline

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

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

3121289 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

14

26

37

38

36

18

672

44

51

47

Figure 4-6. Decal Installation - Sheet 1 of 6

4-16 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

43

52

45

15

40

3

Figure 4-7. Decal Installation - Sheet 2 of 6

3121289 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

25

24

20 22

21

33

48

26

35

35

25

24

7

9

Figure 4-8. Decal Installation - Sheet 3 of 6

4-18 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

26

26

27

27

4

443

Figure 4-9. Decal Installation - Sheet 4 of 6

3121289 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

1

13

40

45

9

34

10

41

11

12

42

39

5

41

50

12

Figure 4-10. Decal Installation - Sheet 5 of 6

4-20 – JLG Lift – 3121289

SECTION 4 - MACHINE OPERATION

12

13

4

11

23

28

31

32

49

Figure 4-11. Decal Installation - Sheet 6 of 6

3121289 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

1001143099-D

1 1703797 1703992 1703926 1703927 1703924 1703925 1703928 1705821 1703923
2 1703798 1705332 1703932 1703933 1703930 1703931 1703934 1705822 1703929
3 1703805 - - 1703938 1703939 1703936 1703937 1703940 - - 1703935
4 1703804 1701518 1703950 1703951 1703948 1703949 1703952 1701518 1703947
5 1001108493 - - - - - - 1001108493 - - - - - - 1001108493
6 1706941 - - - - - - 1706941 - - - - - - 1706941
7- -- -- -- -- -- -- -- -- ­8- -- -- -- -- -- -- -- -- -

9- -- -- -- -- -- -- -- -- ­10- -- -- -- -- -- -- -- -- ­11 1702868 - - - - - - 1704000 - - 1704002 - - 1704001
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1001121801 - - 1001121808 1001121918 1001121803 1001121810 1001121920 - - 1001121805
14 1001121814 - - 1001121821 1001121821 1001121816 1001121823 1001121923 - - 1001121818
15 - - - - - - - - - - - - - - 1705084 - ­16- -- -- -- -- -- -- -- -- ­17- -- -- -- -- -- -- -- -- -

Australian

1001143100-D

Japanese

1001143101-D

Korean

1001143102-D

French

1001143103-D

Chinese

1001143104-D

Port uguese /

Spanish

1001143105-D

CE

1001143106-D

English/
Spanish

1001143107-D

4-22 – JLG Lift – 3121289

Table 4-1. Decal Legend

SECTION 4 - MACHINE OPERATION

Item # ANSI

1001143099-D

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504
19 - - - - - - - - 1704006 - - 1704008 - - 1704007
20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
21 1001131269 -- -- -- 1001131269 -- -- -- -­22 - - 1702958 - - - - - - - - - - - - - ­23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300
25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500
26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
27 3251243 3251242 - - - - 3251243 - - 3251243 - - 3251243
28- -- -- -- -- -- -- -- -- ­29- -- -- -- -- -- -- -- -- ­30- -- -- -- -- -- -- -- -- ­31- -- -- -- -- -- -- -- -- ­32- -- -- -- -- -- -- -- -- ­33- -- -- -- -- -- -- -- -- ­34 3252347 3252347 1703980 1703981 1703984 1703982 1703985 1705828 1703983
35- -- -- -- -- -- -- -- -- -

Australian

1001143100-D

Japanese

1001143101-D

Korean

1001143102-D

French

1001143103-D

Chinese

1001143104-D

Port uguese /

Spanish

1001143105-D

CE

1001143106-D

English/
Spanish

1001143107-D

3121289 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend

Item # ANSI

1001143099-D

36- -- -- -- -- -- -- -- -- ­37- -- -- -- -- -- -- -- -- ­38- -- -- -- -- -- -- -- -- ­39 - - - - - - - - 1705514 - - - - - - - ­40- -- -- -- -- -- -- -- -- ­41- -- -- -- -- -- -- -- -- ­42- -- -- -- -- -- -- -- -- ­43- -- -- -- -- -- -- -- -- ­44 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110 1001143110
45 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
46- -- -- -- -- -- -- -- -- ­47- -- -- -- -- -- -- -- -- ­48- -- -- -- -- -- -- -- -- ­49- -- -- -- -- -- -- -- -- ­50 1705351 -- 1705426 1705427 1705429 1705430 1705905 - - 1705910
51 - - 1001112551 - - - - - - - - - - - - - ­52 -- -- -- -- -- -- -- -- --

Australian

1001143100-D

Japanese

1001143101-D

Korean

1001143102-D

French

1001143103-D

Chinese

1001143104-D

Port uguese /

Spanish

1001143105-D

CE

1001143106-D

English/
Spanish

1001143107-D

4-24 – JLG Lift – 3121289

SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL

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

3121289 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES

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.

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 – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS AND 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:

450A/450AJ Service and Maintenance Manual....................3121290

450A/450AJ Illustrated Parts Manual ......................................3121291

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Table 6-1. Operating Specifications

Unrestricted Rated Capacity

ANSI

CE & Au s tr a li a
Maximum Travel Grade (Gradeab ility)

with Boom retracted and approximately hori­zontal. Tower Boom fully lowered (if
equipped).
2W D
4W D

Maximum Travel Grade (Sideslope) with
Boom retracted and approximately horizon­tal. Tower Boom fully lowered (if equipped) ­ANSI Markets.

Maximum Travel Grade (Sideslope) with
Boom retracted and approximately horizon­tal. Tower Boom fully lowered (if equipped) ­CE & Australia Markets.

500 lb (227 kg)
500 lb (230 kg)

30%
45%

5°

4°

3121289 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Table 6-1. Operating Specifications

Ground Bearing Pressure
Pneumatic
Fo a m F i ll e d
Maximum Drive Speed: 4.5 mph (2.0 m/s)
Maximum Hyd. Operating Pressure 4500 psi (310 bar)
Electrical System Voltage 12 volts

65 psi (4.57 kg/cm2)
65 psi (4.57 kg/cm

Reach Specifications

2

)

Max. Platform Height 45ft (13.72 m)
Max. Horizontal Reach-450A SII 24 ft-7.25 in. (7.50 m)
Max. Horizontal Reach-450AJ SII 24 ft-6 in (7.47 m)
Up & Over Height-450A SII 25 ft-9.5 in (7.56 m)
Up & Over Height-450AJ SII 25 ft-10 in (7.57 m)
Main Boom Up Angle 75°
Main Boom Down Angle -24°

Table 6-2. Reach Specifications

6-2 – JLG Lift – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Dimensional Data Chassis

Table 6-3. Dimensional Data

Overall Width 7 ft-8.25 in (2.34 m)
Tai ls wi ng 0
Stowed Height 7 ft-6 in (2.29 m)
Stowed Length-450A SII 21 ft-11 in (6.68 m)
Stowed Length-450AJ SII 22 ft-0.25 in (6.71 m)
Wheel base 7 ft-8 in (2.34 m)
Ground Clearance 11.5 in (0.29 m)

Table 6-4. Chassis Specifications

Swing 360° non-continuous
Rated Gradeability

2W D
4W D

Max. Tire Load 7200 lb (3266 kg)
Axle Oscillation 8 in (0.2 m)
Sys te m Vo lta ge 12 Volt s
Max. Hydraulic System Operating Pressure 4500 psi

Gross Machine Weight - 450A SII
Pn e um a ti c Ti re s
Fo a m- Fi l le d Ti r es

Gross Machine Weight - 450AJ SII
Pn e um a ti c Ti re s
Fo a m- Fi l le d Ti r es

12,750 lb (5783 kg)
13,000 lb (5897 kg)

13,250 lb (6010 kg)
13,550 lb (6146 kg)

30%
45%

(310 bar)

3121289 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Major Component Weights Capacities

Table 6-5. Component Weights

Component lb kg

Frame (Bare) 1531 695
Turntable (Bare) 1355 615
Boom Link 180 82
Boom Timing Link 30 14
Upper Upright 217 98
Lower Upright 115 52
Lower Boom 497 225
Mid Boom 385 175
Upper Boom 1065 484
4 Wheel Drive Axle 266 121
2 Wheel Drive Axle 258 117
Counterweight 2297 1042

Fuel Tank 17 gal (64.3 L)
Hydraulic Tank 27 gal (102 L)

Drive Hub 23.75 oz (0.7 L)
Drive Brake 2.7 oz (0.08 L)

Tires

Size Type Pressure Weight

12x16.5 Pneumatic 90 psi (6 bar) 128 lb (58 kg)
12x16.5 Foam-Filled N/A 32 8 lb (149 kg)
33/1550x16.5 Pneumatic 90 psi (6 bar) 135 lb (61 kg)
33/1550x16.5 Foam-Filled N/A 3 95 lb (179 kg)
14x17.5 Pneumatic 90psi (6 bar) 170 lb (77.2 kg)
14x17.5 Foam-Filled N/A 44 0 lb (200 kg)

Table 6-6. Capacities

23.6 gal (89 L) to the mid point of upper
sight window (cold)

Table 6-7. Tires

6-4 – JLG Lift – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Engine

NOTE: RPM Tolerances are ± 100.

Table 6-8. Caterpillar C2.2

Fuel Diesel
No. of Cylinders 4
BHP 46.5 hp (34 kW)
Bore 3.307 in (84 mm)
Stroke 3.9370 in (112 mm)
Displacement 134.3 cu. in (2.2 L)
Oil Capacity 3.8 qt (3.6 L) crankcase only
Compression Ratio 19:1
Firing Order 1 -3-4-2
Max. RPM 2800

Table 6-9. Deutz TCD2.9L4

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 cm³)
Firing Order 1-3-4-2
Output 74.2 hp (55.4 kW)
Oil Capacity 2.4 gal (8.9 L)
Coolant Capacity (System) 3.2 gal (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

3121289 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Table 6-10. Deutz D2011L03

Fuel Diesel
No. of Cylinders 3
Bore 3.7 in (94 mm)
Stroke 4.4 in (112 mm)
Displacement 142 cu. in (2331 cm³)
Oil Capacity

cr a nk c as e
co o le r
to t al c ap a c it y

Low RPM 1200
Mid RPM

Tower Lift, Upper Lift, Tele
Sw i ng , B a s ke t Le ve l, B a sk et
Ro t at e , J i b L i ft

High RPM 2800

6.3 qt (6 L)

4.75 qt (4.5 L)
11 qt (10.5 L)

1800
1500

Table 6-11. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas
No. of Cylinders 4
BHP

Ga s ol i ne
LP

Bore 4.0 in (101.6 mm)
Stroke 3.6 in (91.44 mm)
Displacement 181 cu.in(3.0 L, 2966 cc)
Oil Capacity w/filter 4.5 qt (4.25 L)
Minimum Oil Pressure

at i dl e
Ho t

Compression Ratio 9.2:1
Firing Order 1-3-4-2
Max. RPM 2800

83 hp @ 3000 rpm
75 hp @ 3000 rpm

6 psi (0.4 bar) @ 1000 rpm

18 psi (1.2 bar) @ 2000 rpm

6-6 – JLG Lift – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Table 6-13. 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 152

Hydraulic Oil

Table 6-12. Hydraulic Oil

Hydraulic System Operating

Temperature Range

+0° to + 180° F

(-18° to +83° C)
+0° to + 210° F

(-18° to +99° C)

+50° to + 210° F

(+10° to +99° C

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

3121289 – JLG Lift – 6-7

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

S.A.E. Viscosity

Grade

10W

10W-20, 10W30

20W-20

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 AND OPERATOR MAINTENANCE

Table 6-14. 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 140

Table 6-15. UCon Hydrolube HP-5046

Type Synthetic Biodegrad able

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Viscosity

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

Viscos ity I ndex 170

6-8 – JLG Lift – 3121289

Table 6-16. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

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

Wei ght

7.64 lb/gal
(0.9 kg/L)

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscos ity I ndex 153

Table 6-17. 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.

3121289 – JLG Lift – 6-9

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

Table 6-18. Quintolubric 888-46

Density

0.91 @ 15°C (59°F)

Pour Po int

<-20°C (<-4°F)

Flash Point

275°C (527°F)

Fire Point

325°C (617°F)

Autoignition Temperature

450°C (842°F)

Viscosity

at 0° C (32°F) 360 cSt

at 20° C (68°F) 102 cSt

at 40° C (104°F) 46 cSt

at 100° C (212°F) 10 cSt

Viscosity Index 220

6-10 – JLG Lift – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

xxxxx

SERIAL NUMBER

PLATE

SERIAL NUMBER STAMPED

ON FRAME

Figure 6-1. Serial Number Locations

Serial Number Location

A serial number plate is affixed to the left rear side of the frame. If
the serial number plate is damaged or missing, the machine serial
number is stamped on the left side of the frame.

3121289 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

-40

°°F(-40 C)

-30° °F(-34 C)

-20°

F(-29°C)

-10°

F(-23°C)

0°

F(-18°C)

10°

F(-12°C)

20°F(-7°C)

30°F(-1°C)

40°F(4°C)

50

°F(10°C)

60

°F(16°C)

70

°F(21°C)

80

°F(27°C)

90°F(32°C)

100°F(38°C)

110°F(43°C)

120°F(49°C)

ENGINE

SPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATURE

WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER

PACKAGE (IE. ENGINE BLOCK HEA TER, BATTERY WARMER AND

HYDRAULIC OIL TANK HEATER)

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

Figure 6-2. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2

6-12 – JLG Lift – 3121289

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

PROLONGED OPERATION IN
AMBIENT AIR TEMPERATURES
OF 100° F (38° C) OR ABOVE.

EXTENDED DRIVING WITH
HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

MOBIL 424 10W-30

HYDRAULIC
SPECIFICATIONS

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMP E RATURE

EXXON UNIVIS HVI 26

MOBIL DTE 13

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTENTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

Figure 6-3. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2

4150548-E

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121289 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

-40°F(-40°C)

-30F°(-34°C)

-20°F(-29°C)

-10°F(-23°C)

0°F(-18°C)

10°F(-12°C)

20°F(-7°C)

30°F(-1°C)

40°F(4°C)

50°F(10°C)

60°F(16°C)

70°F(21°C)

80°F(27°C)

90°F(32°C)

100°F(38°C)

110°F(43°C)

120°F(49°C)

ENGINE

SPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATURE

WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER

PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR

ENGINE WILL START AND OPERATE UNAIDED AT THIS

TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

AMBIENT AIR

TEMPERATURE

SUMMER

GRADE

FUEL

WINTER

GRADE

FUEL

WINTER

GRADE

FUEL
WITH

KEROSENE

ADDED

NO OPERATION BELOW THIS

AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS

AMBIENT TEMPERATURE

Figure 6-4. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2

6-14 – JLG Lift – 3121289

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS

EXIST JLG HIGHLY RECOMMENDS

THE ADDITION OF A HYDRAULIC

OIL COOLER (CONSULT JLG SERVICE

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

PROLONGED OPERATION IN
AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE.

EXTENDED DRIVING WITH
HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82°C) OR ABOVE.

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

M

O

B

I

L

4

2

4

1

0

W

-

3

0

HYDRAULIC
SPECIFICATIONS

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE

E

X

X

O

N

U

N

I

V

I

S

H

V

I

2

6

M

O

B

I

L

D

T

E

1

3

NOT E:

1) RECOMME NDAT ION S AR E FOR AMB IENT TEMP ERATURES
CONSIS TANT LY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED T O B E AT SEA LEVE L.

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 102030405060

% OF ADDED KE ROSENE

A

M

B

IE

N

T

T

E

M

P

E

R

A

T

U

R

E

SUMMER-GRADE
FUEL

WINT ER-GR ADE
FUEL

Figure 6-5. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2

4150548-E

3121289 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

-40 F(-40 C)

-30 F(-34 C)

-20 F(-29 C)

-10 F(-23 C)

0 F(-18 C)

10 F(-12 C)

20 F(-7 C)

30 F(-1 C)

40 F(4 C)

50 F(10 C)

60 F(16 C)

70 F(21 C)

80 F(27 C)

90 F(32 C)

100 F(38 C)

110 F(43 C)

120 F(49 C)

ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE

WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.

NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.

ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE

WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS,

A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE

(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

ENGINE
SPECIFICATIONS

AMBIENT AIR

TEMPERATURE

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

Figure 6-6. Engine Operating Temperature Specifications - GM - Sheet 1 of 2

6-16 – JLG Lift – 3121289

(HYD. OIL TANK TEMP.)

IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

180°F(82° C)

PROLONGED OPERATION IN
AMBIENT AIR TEMPERATURES
OF 100° F(38° C) OR ABOVE.

EXTENDED DRIVING WITH
HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82° C) OR ABOVE.

NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

M

O

B

I

L

4

2

4

1

0

W

-

3

0

HYDRAULIC
SPECIFICATIONS

NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS WITH MOBILE 424
HYDRAULIC OIL BELOW THIS TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEM
WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE

E

X

X

O

N

U

N

I

V

I

S

H

V

I

2

6

M

O

B

I

L

D

T

E

1

3

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
CONSISTENTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIR

TEMPERATURE

Figure 6-7. Engine Operating Temperature Specifications - GM - Sheet 2 of 2

4150548-E

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121289 – JLG Lift – 6-17

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

1

2

3

4

5

6

7

4

4

4

3

13

1418

19

9

19A

Figure 6-8. Operator Maintenance and Lubrication Diagram - Deutz D2.9

6-18 – JLG Lift – 3121289

1

2

3

4

5

6

7

4

4

4

3

14,15

8,10

19

Figure 6-9. Operator Maintenance and Lubrication Diagram - Deutz D2011 and CAT C2.2

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

3121289 – JLG Lift – 6-19

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

1

2

34

5

6

7

4

443

17

19

20,21

11

Figure 6-10. Operator Maintenance and Lubrication Diagram - GM Dual-Fuel

6-20 – JLG Lift – 3121289