JLG 450A II Series, 450AJ II Series, 510AJ Operation And Safety Manual

Operation and Safety Manual

Keep this manual with the machine at all times.

Boom Lift Models
450A Series II
450AJ Series II
510AJ

ANSI

®

3121179

May 22, 2006

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.

3121179 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

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

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

RESULT IN SERIOUS INJURY OR DEATH. THIS

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

b – JLG Lift – 3121179

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

IMPORTANT

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.

IMPORTANT

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

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

• Standards and Regulations
Compliance Information

• Questions Regarding Spe­cial Product Applications

• Questions Regarding Prod­uct Modifications

Contact:

Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233

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]
E-mail: [e-mail]

FOREWORD

3121179 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - January 1, 2003

Revised - April 24, 2003

Revised - August 26, 2003

Revised - June 15, 2004

Revised - May 4, 2005

Revised - February 8, 2006

Revised - May 22, 2006

d – JLG Lift – 3121179

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2.2 PREPARATION, INSPECTION, AND

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

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

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

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

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

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

Platform Control Station . . . . . . . . . . . . . . . . . . . 3-8

Platform Control Indicator Panel . . . . . . . . . . . . 3-11

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

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

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

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

3121179 – JLG Lift – i

TABLE OF CONTENTS

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

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8

Raising and Lowering the Lower and Mid Boom 4-8
Raising and Lowering the Main (Upper) Boom . 4-8

Telescoping the Main Boom . . . . . . . . . . . . . . . 4-8

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-8

4.9 AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.10 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . 4-9

4.12 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-10

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.13 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Prior to Towing. . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-13

Changing From Gasoline to LP Gas . . . . . . . . 4-13

Changing From LP Gas to Gasoline . . . . . . . . 4-13

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 & 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

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

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

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

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

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

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

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-30

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-30

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-31

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-31

ii – JLG Lift – 3121179

TABLE OF CONTENTS

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

6.5 DRAINING OIL BUILD UP FROM THE PROPANE

REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33

6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-34

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

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

6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-36

SECTION - 7 - INSPECTION AND REPAIR LOG

3121179 – JLG Lift – iii

TABLE OF CONTENTS

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

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. . . . . . . . . . . . . 3-2

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

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

3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . . 3-9

3-4. Platform Control Indicator Panel - Sheet 1 of 2 . . 3-13
3-5. Platform Control Indicator Panel - Sheet 2 of 2 . . 3-14

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

4-2. Position of Least Backward Stability . . . . . . . . . . . . 4-5

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-11

4-5. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . 4-12

4-6. Decal Installation - Sheet 1 of 6. . . . . . . . . . . . . . . 4-14

4-7. Decal Installation - Sheet 2 of 6. . . . . . . . . . . . . . . 4-15

4-8. Decal Installation - Sheet 3 of 6. . . . . . . . . . . . . . . 4-16

4-9. Decal Installation - Sheet 4 of 6. . . . . . . . . . . . . . . 4-17

4-10. Decal Installation - Sheet 5 of 6. . . . . . . . . . . . . . . 4-18

4-11. Decal Installation - Sheet 6 of 6. . . . . . . . . . . . . . . 4-19

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

6-2. Engine Operating Temperature Specifications -

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

6-3. Engine Operating Temperature Specifications -

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

6-4. Engine Operating Temperature Specifications -

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

6-5. Engine Operating Temperature Specifications -

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

6-6. Engine Operating Temperature Specifications -

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

6-7. Engine Operating Temperature Specifications -

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

6-8. Engine Operating Temperature Specifications -

GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-18

6-9. Engine Operating Temperature Specifications -

GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-19

6-10. Operator Maintenance and Lubrication Diagram .6-20

6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . .6-34

iv – JLG Lift – 3121179

TABLE OF CONTENTS

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

LIST OF TABLES

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

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

6-1 Operating Specifications - 450A/450AJ . . . . . . . . . 6-1

6-2 Operating Specifications - 510AJ. . . . . . . . . . . . . . 6-2

6-3 Reach Specifications - 450. . . . . . . . . . . . . . . . . . . 6-2

6-4 Reach Specifications - 510. . . . . . . . . . . . . . . . . . . 6-2

6-5 Dimensional Data - 450 . . . . . . . . . . . . . . . . . . . . . 6-3

6-6 Dimensional Data - 510 . . . . . . . . . . . . . . . . . . . . . 6-3

6-7 Chassis Specifications - 450 . . . . . . . . . . . . . . . . . 6-3

6-8 Chassis Specifications - 510 . . . . . . . . . . . . . . . . . 6-4

6-9 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-10 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-11 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-5

6-12 Deutz F3M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-13 Deutz F3M2011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-14 Caterpillar 3024 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-15 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-16 Component Weights - 450 . . . . . . . . . . . . . . . . . . . 6-7

6-17 Component Weights - 510 . . . . . . . . . . . . . . . . . . . 6-7

6-18 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-19 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-20 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-9

6-21 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-9

6-22 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . 6-10

6-23 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . 6-10

6-24 Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-21

6-25 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-32

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

3121179 – JLG Lift – v

TABLE OF CONTENTS

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

This page left blank intentionally.

vi – JLG Lift – 3121179

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

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

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

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

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the
machine.

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

• Only authorized and qualified personnel can operate the
machine.

3121179 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

Workplace Inspection

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

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

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

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

o

• This machine can be operated in temperatures of 0

o

F (-20o C to 40o C). Consult JLG for operation out-

104
side this range.

F to

Machine Inspection

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

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

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

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

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

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

1-2 – JLG Lift – 3121179

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

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

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

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

• Hydraulic cylinders should never be left fully extended or
fully retracted before shutdown or for long periods of time.

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

• Do not carry materials directly on platform railing 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.

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

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

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

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

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

Trip and Fall Hazards

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

3121179 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

Electrocution Hazards

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

1-4 – JLG Lift – 3121179

SECTION 1 - SAFETY PRECAUTIONS

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

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

1.

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations
are more stringent.

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

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3121179 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulat­ing barriers are installed to prevent contact, and the barriers
are rated for the voltage of the line being guarded. These
barriers shall not be part of (or attached to) the machine. The
minimum approach distance shall be reduced to a distance
within the designed working dimensions of the insulating
barrier. This determination shall be made by a qualified per­son in accordance with the employer, local, or governmental
requirements for wok 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 should be familiar with the surface before driv­ing. Do not exceed the allowable sideslope and grade
while driving.

1-6 – JLG Lift – 3121179

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s).

• 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 and remove personnel.

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.

3121179 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

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

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

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

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

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

1.4 TOWING, LIFTING, AND HAULING

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

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

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

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

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

1-8 – JLG Lift – 3121179

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

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

• Charge batteries only in a well ventilated area.

SECTION 1 - SAFETY PRECAUTIONS

3121179 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

This page left blank intentionally.

1-10 – JLG Lift – 3121179

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.

3121179 – 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 recommended 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.

IMPORTANT

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

2-2 – JLG Lift – 3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection
(See Note)

Frequent Inspection
(See Note)

Annual Machine Inspection
(See Note)

Preventative Maintenance At inter vals as specified in the Service and Main-

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

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

In service for 3 months or 15 0 hours, whichever
comes first; or
Out of service for a period of more than 3 months;
or
Purchased used.

Annually, no later than 13 months from the date
of prior inspection.

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Cer tified

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Mechanic

Service Technician
(Recommended)

Mechanic

Reference

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual and applicable JLG
inspection form

Service and Maintenance
Manual

3121179 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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. 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.

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

4. “Walk-Around” Inspection – Refer to Figure 2-3. and
Figure 2-4.

5. Battery – Charge as required.

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

proper fuel as necessary.

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

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

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

10. 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.

2-4 – JLG Lift – 3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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.

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.

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

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

rated gradeability, and stop to ensure the brakes
hold;

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

tion.

3121179 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-6 – JLG Lift – 3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1. Steer Wheels

2. Drive Wheels

3. Lower Lif t Cylinder

4. Lower Upright

5. Mid Boom

6. Upper Lift Cylinder

7. Main Boom Assembly

8. Power Track

9. Level Cylinder

10. Jib Cylinder

11. Platform

12. Platform Console

13. Jib

14. Fly Boom

15. Base Boom

16. Master Cylinder

17. Tower or Lower Boom

18. Turntable

19. Frame

20. Tower Link

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

3121179 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-8 – JLG Lift – 3121179

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 - Lockbolts in place.
Footswitch works properly, not modified, disabled or
blocked. Latch, stop, and hinges in working condition.

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

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 leak-

age.

7. Wheel/Tire Assemblies - Properly secured, no miss­ing lug nuts, proper inflation (pneumatic).

8. Hood Assemblies - See Inspection Note.

3121179 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Oscillation Lockout Valve (If Equipped) (450 Models
Prior to S/N 0300077285, 510 Models Prior to S/N

1300000353) - Check the lockout valve plunger in the

depressed position. Swing the turntable until the axle
lockout bracket passes the plunger and make sure the
plunger is fully extended as shown below

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

10. Tie Rod Ends and Steering Spindles - See Inspection

Note.

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

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

13. Auxiliary Hydraulic Pump - See Inspection Note.

14. Main Hydraulic Pump - See Inspection Note.

15. Platform Rotator - See Inspection Note.

2-10 – JLG Lift – 3121179

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

IMPORTANT

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.

3121179 – 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 – 3121179

3.1 GENERAL

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

IMPORTANT

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.

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.

3.2 CONTROLS AND INDICATORS

2. Platform Leveling Override

Ground Control Station

NOTE: If equipped, the 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.

3121179 – JLG Lift – 3-1

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

3. Articulating Jib Boom (If Equipped)

This switch provides raising and lowering of the jib.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform Rotate

2. Platform Leveling Override

3. Not Used

4. Engine Star t/Auxiliary Power
or
Engine Start/Auxiliary Power/Function Enable

5. Power/Emergency Stop

6. Platform/Ground Select

7. Hourmeter

8. Swing

9. Tower Lift

10. Main Lift

11. Telescope

12. Indicator Panel

Figure 3-1. Ground Control Station - A Models

3-2 – JLG Lift – 3121179

1. Platform Rotate

2. Platform Leveling Override

3. Jib

4. Engine Star t/Auxiliary Power
or
E n gi n e S t a r t/Auxiliary Power/Function Enable

5. Power/Emergency Stop

6. Platform/Ground Select

7. Hourmeter

8. Swing

9. Tower Lift

10. Main Lift

11. Telescope

12. Indicator Panel

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-1. Ground Control Station - AJ Models

3121179 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

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

disabled 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.

6. Platform/Ground Select

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

NOTE: When machine is shut down the Platform/Ground Select

switch and Emergency Stop must be positioned to OFF.

NOTE: With PLATFORM/GROUND SELECT switch in the center

position, power is shut off to controls at both operating
stations.

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 non­continuous turntable rotation when positioned to the
right or left.

3-4 – JLG Lift – 3121179

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. To w e r L i f t

Provides for raising and lowering of the Lower and Mid
Booms.

10. Main Boom Lift

Provides for raising and lowering of the Main Boom.

11. Te l es c o p e

Provides for 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. Engine Coolant Temperature Indicator (Ford)

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.

3121179 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Batter y Charging

2. Low Engine Oil Pressure

3. Engine Coolant Temp.

4. Engine Oil Temp.

5. Engine Malfunction

Figure 3-2. Ground Control Indicator Panel

6. Low Fuel

7. Glow Plug Wait

8. Overload

9. Engine Air Filter By-Pass

3-6 – JLG Lift – 3121179

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Engine Malfunction Indicator

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

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

6. Low Fuel Level Indicator

Indicates that the fuel level is 1/8 full or less. Illuminates
when there are approximately four gallons of fuel
remaining.

7. Glow Plug Wait 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. Overload Indicator. (If Equipped)

Indicates the platform has been overloaded.

9. Engine Air Filter Indicator

Indicates that the air filter is too restrictive and needs to
be replaced.

3121179 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Station

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.

2. Platform Leveling Override

This switch adjusts the level of the platform.

3. Horn

If pressed, this switch supplies power to the horn.

4. Power/Emergency Stop

An on-off Power/Emergency Stop switch and a separate
Engine Start/Auxiliary Power toggle switch on the plat­form console supply electrical power to the starter sole­noid, when the ignition switch is placed in the ON
position and the ENGINE START switch is push forward.

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. Auxiliary Power

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.

3-8 – JLG Lift – 3121179

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Drive Speed

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Aux. Power

6. Fuel Select

7. Lights

8. Drive/Steer

Figure 3-3. Platform Control Console

9. 9. Telescope

10. Jib

11. Tower Lif t

12. Platform Rotate

13. Function Speed

14. Main Lift/Swing

3121179 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

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

7. Lights (If Equipped)

This switch operates control console panel lights and
head lights if the machine is so equipped.

8. Drive/Steer

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

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

9. Telescope Control

This switch allows extension and retraction of the main
boom.

10. Articulating Jib Boom (if equipped)

This switch controls the raising or lowering of the jib.

11. Tower or Lower Boom Lift

Provides for raising and lowering of the lower and mid
booms when positioned up or down.

12. Platform Rotate

This switch controls the rotation of the basket (left or
right).

13. Function Speed Control

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

14. Main Lift/Swing

The dual axis joystick is provided for main lift and swing.
Push forward to lift up, pull backward to lower. Move
right to swing right, move left to swing left. Proportional
control of these functions can be attained by using the
Function Speed control.

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

time. Maximum speed is reduced when both functions are
selected.

3-10 – JLG Lift – 3121179

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

NOTE: The platform control indicator panel (S/N 0300065315 to

Present) uses 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.

1. AC Generator (Green)

Indicates the generator is in operation.

2. Overload Indicator. (If equipped)

Indicates the platform has been overloaded.

3. Tilt Alarm Warning

Indicates that the chassis is on a slope (over 4 degrees
CE/Australia, 5 degrees all other markets). If the boom is
above horizontal and the machine is on a 5 degree
slope, an alarm will sound and CREEP speed is auto­matically activated.

4. Glow Plug Indicator

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

5. Footswitch/Enable Indicator

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

3121179 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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 the fuel tank is 1/8 full or less. When the light
first illuminates, there are approximately four usable gal­lons of fuel remaining.

7. Creep Speed Indicator

Illuminates when the Function Speed Control is turned
to the creep position.

8. System Malfunction Indicator

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

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

9. Soft Touch Indicator (If Equipped)

Illuminates when 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.

3-12 – JLG Lift – 3121179

SECTION 3 - MACHINE CONTROLS AND INDICATORS

S/N 0300065315 & 1300000001 to Present

1. AC Generator

2. Overload

3. Tilt Alarm Warning

Figure 3-4. Platform Control Indicator Panel - Sheet 1 of 2

4. Glow Plug

5. Enable

6. Fuel Level

7. Creep Speed

8. System Malfunction

9. Soft Touch

3121179 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Prior to S/N 0300065315

1. AC Generator

2. Overload

3. Tilt Alarm Warning

Figure 3-5. Platform Control Indicator Panel - Sheet 2 of 2

4. Glow Plug

5. Enable

6. Fuel Level

7. Creep Speed

8. System Malfunction

9. Soft Touch

3-14 – JLG Lift – 3121179

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. Vibrations emitted by these machines are not
hazardous to an operator in the work platform. The equiva­lent continuous A-Weighted sound pressure level at the work
platform is less than 70dB(A).

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 357 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

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

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.

3121179 – 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 should always be performed from the

Ground Control station.

Starting Procedure

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

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

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

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

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

4-2 – JLG Lift – 3121179

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 MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed informa­tion.

3121179 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

4-4 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

.

4.4 TRAVELING (DRIVING)

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 MANUAL.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

TRAVEL GRADES WITH DRIVE SPEED/TORQUE SELECT SWITCH IN
THE FORWARD POSITION. USE CAUTION WHEN DRIVING IN REVERSE
AND WHEN DRIVING WITH PLATFORM ELEVATED, ESPECIALLY WHEN
DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET (2 M) OF AN
OBSTRUCTION.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR
DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE
CONTROLS WILL BE REVERSED.

Figure 4-2. Position of Least Backward Stability

3121179 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

4-6 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

1. With the engine running, activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as

desired.

4.5 STEERING

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

4.6 PLATFORM

Platform Level Adjustment

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

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

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

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

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

3121179 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Swinging the Boom

To s wi ng b o o m , us e S WI N G c o n t rol switch to select RIGHT
or LEFT direction.

IMPORTANT

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

Raising and Lowering the Lower and Mid Boom

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

Raising and Lowering the Main (Upper) Boom

To raise or lower the Upper Boom, use Upper 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 Platform Rotate. When in the CCW
maximum position, Drive is placed in creep speed.

4.9 AUXILIARY PUMP

IMPORTANT

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 posi-

tion.

3. Depress and hold footswitch.

4. Operate appropriate control switch or lever for desired

function and hold.

4-8 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

5. Position Auxiliary Power switch to the on position 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)

IMPORTANT

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.

4.11 SHUT DOWN AND PARK

1. Drive machine to a reasonably well protected area.

2. Be sure the main boom is fully retracted and lowered

over rear drive axle.

3. Remove all load and allow engine to operate 3-5 min­utes at LOW setting to permit reduction of internal
engine temperatures.

4. At Ground Controls, turn KEY SELECT switch to OFF.
Push in the Emergency Stop. Remove key.

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

3121179 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

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

IMPORTANT

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.

4-10 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

Figure 4-4. Lifting and Tie Down Chart

3121179 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

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.)

Figure 4-5. Drive Disconnect Hub

4-12 – JLG Lift – 3121179

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

counterclockwise.

3. While engine is operating on GASOLINE under a no­load 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.

3121179 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

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

4-14 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

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

3121179 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

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

4-16 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

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

3121179 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

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

4-18 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

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

3121179 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Item # ANSI

0272573-5

1 1703797 1703992 1705821 1703926 1703927 1703924 1703925 1703928

2 1703798 1705332 1705822 1703932 1703933 1703930 1703931 1703934

3 170 3805 - - - - 1703938 1703939 1703936 1703937 1703940

4 1703804 1701518 1701518 1703950 1703951 1703948 1703949 1703952

5 170 2784 - - - - - - - - 1702784 - - - -

6 170 3808 - - - - - - - - 1703808 - - - -

7 - - - - - - - - - - - - - - - -

8 - - - - - - - - - - - - - - - -

9 - - - - - - - - - - - - - - - -

1 0 - - - - - - - - - - - - - - - -

11 1702868 - - - - - - - - 1704000 - - 1704002

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1701645 - - - - 1703996 1703996 1703996 1703996 1703996

14 1702688 - - - - - - - - 1704112 - - 1704112

15 - - - - 1705084 - - - - - - - - - -

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

Australian
0272574-3CE0273452-2

Japan

0272575-4

Korean

0272576-4

French/

0272577-6

Chinese

0272578-4

Portuguese/

Spanish

0272579-5

4-20 – JLG Lift – 3121179

SECTION 4 - MACHINE OPERATION

Item # ANSI

0272573-5

19 1702153 - - - - - - - - 1704006 - - 1704008

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

2 1 - - - - - - - - - - - - - - - -

22 - - 1702958 - - - - - - - - - - - -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

2 7 - - - - - - - - - - - - - - - -

2 8 - - - - - - - - - - - - - - - -

2 9 - - - - - - - - - - - - - - - -

3 0 - - - - - - - - - - - - - - - -

3 1 - - - - - - - - - - - - - - - -

3 2 - - - - - - - - - - - - - - - -

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

34 - - - - 1705828 1703980 1703981 1703984 1703982 1703985

3 5 - - - - - - - - - - - - - - - -

3 6 - - - - - - - - - - - - - - - -

3 7 - - - - - - - - - - - - - - - -

Australian
0272574-3CE0273452-2

Japan

0272575-4

Korean

0272576-4

French/

0272577-6

Chinese

0272578-4

Portuguese/

Spanish

0272579-5

3121179 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Item # ANSI

0272573-5

3 8 - - - - - - - - - - - - - - - -

39 - - - - - - - - - - 1705514 - - - -

4 0 - - - - - - - - - - - - - - - -

4 1 - - - - - - - - - - - - - - - -

4 2 - - - - - - - - - - - - - - - -

4 3 - - - - - - - - - - - - - - - -

44 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768

45 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

4 6 - - - - - - - - - - - - - - - -

4 7 - - - - - - - - - - - - - - - -

4 8 - - - - - - - - - - - - - - - -

4 9 - - - - - - - - - - - - - - - -

Australian
0272574-3CE0273452-2

Japan

0272575-4

Korean

0272576-4

French/

0272577-6

Chinese

0272578-4

Portuguese/

Spanish

0272579-5

4-22 – JLG Lift – 3121179

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)
(8am till 4:45pm EST)

Outside USA:
717-485-5161

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.

IMPORTANT

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.

3121179 – 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
remove platform occupants and 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 – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

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

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

Other Publications Available:

450A/450AJ Service and Maintenance Manual........ 3121180

510AJ Service and Maintenance Manual ................. 3121181

450A/450AJ Illustrated Parts Manual

(ANSI, CSA Spec) .................................................. 3121131

450A/450AJ Illustrated Parts Manual (CE Spec)...... 3121833

510AJ Illustrated Parts Manual ................................ 3121182

6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA

Table 6-1. Operating Specifications - 450A/450AJ

Unrestricted Rated Capacity 500lb. (230kg)

Maximum Capacity 500lb. (230 kg)

Maximum Travel Grade
with Boom retracted and approxi­mately horizontal. Tower Boom fully
lowered (if equipped).
2 WD
4 WD

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

Maximum Drive Speed: 4.5 mph (2.0 m/s)

Maximum Hyd. Operating Pressure 4500 psi (310 Bar)

Electrical System Voltage 12 volts

Gross Machine Weight
( 45 0 A )
( 45 0 A J)

(Gradeability)

14,500 lb. (6577 kg)
16,500 lb. (7484 kg)

30%
45%

5°

3121179 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-2. Operating Specifications - 510AJ

Unrestricted Rated Capacity 500lb. (230kg)

Maximum Capacity 500lb. (230 kg)

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

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

Maximum Drive Speed: 4.5 mph (2.0 m/s)

Maximum Hyd. Operating Pressure 4500 psi (310 Bar)

Electrical System Voltage 12 volts

Gross Machine Weight 16,104 lb. (7305 kg)

45%

Reach Specifications

Table 6-3. Reach Specifications - 450

Max. Platform Height 45ft. (13.7 M)

Max. Horizontal Reach 24.5ft. (7.5 M)

Up & Over Height 25 ft. 2 in. (7.7 M)

Main Boom Up Angle 75°

Main Boom Down Angle -24°

5°

Table 6-4. Reach Specifications - 510

Max. Platform Height 51.8 ft. (15.81 m)

Platform Rotation 180°

Max. Horizontal Reach 31.1 ft. (9.48 m)

Up & Over Height 24.08 ft. (7.34 m)

Jib Length 4.5 ft. (1.37 m)

Jib Angle 135° (+70°, -65°)

6-2 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Dimensional Data

Table 6-5. Dimensional Data - 450

Overall Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)

Ta il sw i ng 0

Stowed Height 7 ft. 4.4 in. (2.25 m)

Stowed Length 21 ft. 4 in. (6.5 m)

Wheel base 78 in. (1.98 m)

Tr ack Wi dt h
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)

Ground Clearance 14 in. (0.36 m)

Table 6-6. Dimensional Data - 510

Overall Width 7.4 ft. (2.26 m)

Ta il sw i ng 0

Stowed Height 7.4 ft. (2.26 m)

Stowed Length 25.1 ft. (7.68 m)

Wheel base 7.67 ft. (2.3 4 m)

6 ft. 6 in. (1.98 m)
6 ft. 10 in. (2.08 m)
6 ft. 11 in. (2.11 m)

65.3 in. (1.66 m)

66.3 in. (1.69 m)

66.6 in. (1.69 m)

Table 6-6. Dimensional Data - 510

Tr ac k W id th
(12 x 16.5 tire)
(33/1550 tire)
( 14 x 1 6. 1 ti r e)

Ground Clearance 1.18 f t. (0.36 m)

65.3 in. (1.66 m)

66.3 in. (1.69 m)

66.6 in. (1.69 m)

Chassis

Table 6-7. Chassis Specifications - 450

Swing 357° non-continuous

Rated Gradeability
2 WD
4 WD

Max. Tire Load 7900 lb. (3583 kg)

Axle Oscillation 8 in. (0.2 m)

System Voltage 12 Volts

Max. Hydraulic System Operating
Pressure

Gross Machine Weight
4 50 A S II
4 50 A J SI I

14,500 lbs. (6577 kg)
16,500 lbs. (7484 kg)

30%
45%

4500 psi

(310 bar)

3121179 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-8. Chassis Specifications - 510

Swing 357° non-continuous

Gradeability (boom in stowed posi­tion)

Max. Tire Load 7900 l b. (3583 kg)

Max. Ground Bearing Pressure
12x16.5 Tire
33/1550x16.5 - Tire

Drive Speed 4.5 mph (7.2 kph)

Axle Oscillation 4 in. (0.1 m)

Tu rn in g R ad iu s
I n si d e
Outside

System Voltage 12 Volts

Max. Hydraulic System Operating
Pressure

Gross Machine Weight 16,104 lbs. (7305 kg)

48 psi (3.37 kg/cm
36 psi (2.53 kg/cm

6.5 ft. (2.0 m)

16.4 ft. (5.0 m)

40%

4500 psi

(310 bar)

Capacities

Table 6-9. Capacities

Fuel Tank 17 gallons (64.3 liters)

Hydraulic Tank
(machines to S/N 0300070586) 28 gallons (106 liters)

2)

2)

Hydraulic Tank
(S/N 0300070586 &
SN 1300000001to Present)

27 gallons (102 liters)

23.6 gal. (89 liters) to the Full line
on the sight gauge

Tires

Table 6-10. Tires

Size Type Pressure Weight

12x16.5 Pneumatic 90 psi (6 Bar) 128 lbs. (58 kg)

12x16.5 Foam-Filled N/A 328 lbs. (149 kg)

33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lbs. (61 kg)

33/1550x16.5 Foam-Filled N/A 395 lbs. (179 kg)

14 x 16.1 Pneumatic 40 lbs. (3 bar) 91.5 lbs. (41.5 kg)

14 x 16.1 Foam-Filled N/A 426 lbs. (193 kg)

6-4 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Engine

NOTE: RPM Tolerances are ± 100.

Table 6-11. Ford LRG-425 (Gas or Dual Fuel)

Type 4 cylinder, 4 stroke, spark ignition

Fuel Gasoline or Gasoline/LP Gas

Bore 3 in. (96 mm)

Stroke 3.4 in. (86.4 mm)

Displacement 153 cu. in. (2.5 L)

Firing Order 1-3-4-2

BHP at Max. RPM 82

Oil Capacity 4.5 quar ts (4.26 L)

Low RPM 1000

Mid RPM
Tower Lift, Upper Lif t, Tel e
S wi ng , Ba sk e t L e ve l, B as ke t
Rotate, Jib Lift

High RPM 3000

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

1800
1500

Table 6-12. Deutz F3M1011F

Fuel Diesel

No. of Cylinders 3s

Bore 3.6 in. (91 mm)

Stroke 4.4 in. (112 mm)

Displacement 133 cu. in. (2184 cm³)

BHP at Max. RPM 48

Oil Capacity
c ra n k ca s e
c oo l e r
t ot a l ca p ac i ty

Low RPM 1200

Mid RPM
Tower Lift, Upper Lift, Tele
S wi n g , B a sk e t L e v el , Ba s ke t
Rotate, Jib Lift

High RPM 2800

6.3 quar ts (6 L)

4.75 quarts (4.5 L)
11 quarts (10.5 L)

1800
1500

3121179 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-13. Deutz F3M2011F

Fuel Diesel

No. of Cylinders 3s

Bore 3.7 in. (94 mm)

Stroke 4.4 in. (112 mm)

Displacement 142 cu. in. (2331 cm³)

Oil Capacity
crankcase
cooler
total capacity

6.3 quar ts (6 L)

4.75 quarts (4.5 L)
11 quarts (10.5 L)

Low RPM 1200

Mid RPM
Tower Lift, Upper Lif t, Tel e
S wi ng , Ba sk e t L e ve l, B as ke t
Rotate, Jib Lift

High RPM 2800

Table 6-14. Caterpillar 3024

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 13 4.3 cu. in. (2.2L)

Oil Capacity 3.8 quarts (3.6 L) crankcase only

Compression Ratio 19:1

Firing Order 1-3-4-2

Max. RPM 2800

1800
1500

6-6 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-15. GM 3.0L

Fuel Gasoline or Gasoline/LP Gas

No. of Cylinders 4

BHP
G as o l in e
L P

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 qts. (4.25 L)

Minimum Oil Pressure
a t i d l e
H ot

Compression Ratio 9.2:1

Firing Order 1-3-4-2

Max. RPM 2800

18 psi (1.2 Bar) @ 2000 rpm

83 hp @ 3000 rpm
75 hp @ 3000 rpm

6 psi (0.4 Bar) @ 1000 rpm

Major Component Weights

Table 6-16. Component Weights - 450

Component Pounds Kilograms

Frame (Bare) 2325 1055

Turntable (Bare) 1500 680

Boom Link 180 82

Boom Timing Link 30 14

Upper Upright 217 98

Lower Upright 11 5 5 2

Lower Boom 497 225

Mid Boom 385 175

Upper Boom 1065 484

4 Wheel Drive Axle 200 91

2 Wheel Drive Axle 235 107

Table 6-17. Component Weights - 510

Component Pounds Kilograms

Engine Only 440 200

Upper Boom 1257 570

Frame (Bare) 2105 955

Turntable (Bare) 1533 695.5

3121179 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Hydraulic Oil

Table 6-18. 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

Service Classification GL-3, and sufficient chemical stabil­ity for mobile hydraulic system service. JLG Industries
recommends Mobilfluid 424 hydraulic oil, which has an
SAE viscosity index of 152.

NOTE: When temperatures remain consistently below 20

degrees F. (-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.

Table 6-19. 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

Viscosity Index 152

6-8 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-20. 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

Viscosity Index 140

Table 6-21. UCon Hydrolube HP-5046

Typ e Synthetic Biodegradable

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)

Viscosity Index 170

3121179 – JLG Lift – 6-9

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-22. Mobil EAL H 46 Specs

Typ e Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

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

Weight

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

7.64 lb. per gal.

(0.9 kg per liter)

Table 6-23. 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.

6-10 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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.

Figure 6-1. Serial Number Locations

3121179 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

6-12 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4150548-C

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

3121179 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

6-14 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

4150548-C

3121179 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

6-16 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4150548-C

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

3121179 – JLG Lift – 6-17

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-8. Engine Operating Temperature Specifications - GM - Sheet 1 of 2

6-18 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-9. Engine Operating Temperature Specifications - GM - Sheet 2 of 2

4150548-C

3121179 – JLG Lift – 6-19

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-10. Operator Maintenance and Lubrication Diagram

6-20 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.3 OPERATOR MAINTENANCE

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

10., Operator Maintenance and Lubrication Diagram.

Table 6-24. Lubrication Specifications

KEY SPECIFICATIONS

MPG M ultipurpose Grease having a minimum dripping point of 350° F

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

EPGL Extreme Pressure Gear Lube (oil) meeting API service classifica-

tion GL-5 or MIL-Spec MIL-L-2105

HO Hydraulic Oil. API ser vice classification GL-3, e.g. Mobilfluid 424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104.

Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.

OGL Open Gear Lubricant - Mobiltac 375 or equivalent.

IMPORTANT

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

NOTE: It is recommended as a good practice to replace all filters

at the same time.

1. Swing Bearing - Internal Ball Bearing

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

3121179 – JLG Lift – 6-21

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. A. Swing Bearing - Teeth

Lube Point(s) - Spray On
Capacity - A/R
Lube - OGL
Interval - Every 3 months or 150 hrs of operation
Comments - More frequent lubrication intervals may be
required

B. End Bearings - Worm Gear*

Lube Point(s) - 2 Grease Fittings
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hrs of operation
Comments - Remove grease fittings and install plugs
after greasing

*If necessary install grease fittings into worm gear hous­ing and grease bearings.

DO NOT OVERGREASE END BEARINGS. OVERGREASING BEARINGS
WILL RESULT IN BLOWING OUTER SEAL IN HOUSING.

3. Wheel Bearings (2WD Only)

Lube Point(s) - Repack
Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation

4. Wheel Drive Hub

Lube Point(s) - Level/Fill Plug
Capacity - 17 oz. (0.5 L) - 1/2 Full
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of
operation; change every 2 years or 1200 hours of
operation

6-22 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

5. Hydraulic Return Filter

Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter or as indicated by Condition
Indicator.

6. Hydraulic Charge Filter

Interval - Change after first 50 hrs. and every 6 months
or 300 hrs. thereafter or as indicated by Condition
Indicator.

3121179 – JLG Lift – 6-23

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7. Hydraulic Tank

Lube Point(s) - Fill Cap
Capacity - 27 gallons (102 liters); 23.6 gal. (89 liters) to
the Full line on the sight gauge
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.

8. Suction Strainers

Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.

6-24 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

9. Oil Change w/Filter - Ford

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7014501)
Capacity - 4.5 Quarts (4.25 L)
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

10. Oil Change w/Filter - Deutz

Fill Cap/Spin-on Element (JLG P/N

7016641)
Capacity - 11 Quarts(10.5 L) Crankcase; 5 Quarts (4.7 L)
Cooler
Lube - EO
Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

3121179 – JLG Lift – 6-25

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

11. Oil Change w/Filter - Caterpillar

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N

7026855)
Capacity - 10.6 Quarts
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

12. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7027965)
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.

6-26 – JLG Lift – 3121179

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

13. Fuel Filter - Ford

Lube Point(s) - Replaceable Element
Interval - Every Year or 1200 hours of operation

14. Fuel Filter - Deutz

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

15. Fuel Filter - Caterpillar

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

3121179 – JLG Lift – 6-27

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

16. Fuel Filter - GM

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

17. Air Filter

Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator

6-28 – JLG Lift – 3121179