Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
450A Series II
450AJ Series II
510AJ
ANSI
3121179
May 8, 2012
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.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
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.
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding
Product Safety
FOREWORD
• Standards and Regulations
Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
3121179 – JLG Lift – c
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com
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
Revised - August 2, 2007
Revised - January 11, 2008
Revised - October 29, 2009
Revised - November 25, 2009
Revised - July 30, 2010
Revised - September 8, 2011
Revised - March 5, 2012
Revised - May 8, 2012
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 . . . . . . . . . . . . . . . . . . . 3-9
Platform Control Indicator Panel . . . . . . . . . . . . 3-14
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
3121179 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
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 . . . . . . . . . . . . . . . . 4-9
4.9 AUXILIARY PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-10
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 . . . . . . . . . . . . . . . . . . . . . 6-3
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Major Component Weights. . . . . . . . . . . . . . . . . 6-9
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Serial Number Location . . . . . . . . . . . . . . . . . . 6-13
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-25
6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-37
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-37
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-38
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-38
6.5 DRAINING OIL BUILD UP FROM THE PROPANE REG-
ULATOR (PRIOR TO S/N 0300137808) . . . . . . . .6-40
6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-41
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-43
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-44
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 . . . . . . . . . . . . 3-2
3-1. Ground Control Station - AJ Models . . . . . . . . . . . 3-3
3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . . 3-6
3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . . 3-7
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-10
3-5. Platform Control Console - w/Drive Orientation . . 3-11
3-6. Platform Control Indicator Panel - Sheet 1 of 2 . . 3-16
3-7. Platform Control Indicator Panel - Sheet 2 of 2 . . 3-17
3-8. Platform Control Indicator Panel - w/Drive
Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
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
3121179 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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. . . . . . . . . . . . . . . . . . . . 6-13
6-2. Engine Operating Temperature Specifications - Deutz
- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-3. Engine Operating Temperature Specifications - Deutz
- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-4. Engine Operating Temperature Specifications - Ford -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5. Engine Operating Temperature Specifications - Ford -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-6. Engine Operating Temperature Specifications -
Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18
6-7. Engine Operating Temperature Specifications -
Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19
6-8. Engine Operating Temperature Specifications - GM -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-9. Engine Operating Temperature Specifications - GM -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-10. Engine Operating Temperature Specifications -
Perkins - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . 6-22
6-11. Engine Operating Temperature Specifications -
Perkins - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . 6-23
6-12. Operator Maintenance and Lubrication Diagram . 6-24
6-13. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-42
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10
2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3
4-1 Decal Legend - Prior to S/N 0300141424 . . . . . . 4-20
4-2 Decal Legend - S/N 0300141424 to Present . . . . 4-23
6-1 Operating Specifications - 450A/450AJ - Prior
to S/N 0300141424. . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Operating Specifications - 450A/450AJ - S/N
0300141424 to Present . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Operating Specifications - 510AJ. . . . . . . . . . . . . . 6-3
6-4 Reach Specifications - 450. . . . . . . . . . . . . . . . . . . 6-3
6-5 Reach Specifications - 510. . . . . . . . . . . . . . . . . . . 6-3
6-6 Dimensional Data - 450 . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Dimensional Data - 510 . . . . . . . . . . . . . . . . . . . . . 6-4
6-8 Chassis Specifications - 450 . . . . . . . . . . . . . . . . . 6-4
6-9 Chassis Specifications - 510 . . . . . . . . . . . . . . . . . 6-5
6-10 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-11 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-12 Ford LRG-425 (Gas or Dual Fuel) . . . . . . . . . . . . . 6-6
6-13 Deutz F3M1011F . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-14 Deutz F3M2011F/D2011L03. . . . . . . . . . . . . . . . . . 6-7
6-15 Caterpillar 3024/C2.2 . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-16 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-17 Perkins 404D-22 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-18 Component Weights - 450 . . . . . . . . . . . . . . . . . . . 6-9
6-19 Component Weights - 510 . . . . . . . . . . . . . . . . . . . 6-9
6-20 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-21 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . 6-10
6-22 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . 6-10
6-23 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-11
6-24 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . 6-11
6-25 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-12
6-26 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-27 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-25
6-28 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-39
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
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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.
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. Contact
JLG for approved material handling accessories.
• When two or more persons are in the platform, the operator shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.
• When driving, always position boom over rear axle in line
with the direction of travel. Remember, if boom is over the
front axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using boom functions. Only pull the unit
from the tie-down lugs on the chassis.
• Do not place boom or platform against any structure to
steady the platform or to support the structure.
• Stow boom and shut off all power before leaving machine.
Trip and Fall Hazards
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.
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 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 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). Refer to Table 1-2, Beaufort Scale (For
Reference Only).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If boom assembly or platform is in a position that one or
more wheels are off the ground, all persons must be
removed before attempting to stabilize the machine. Use
cranes, forklift trucks, or other appropriate equipment to
stabilize machine.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and
bottom of platform when lifting or lowering platform, and
driving.
• During operation, keep all body parts inside platform railing.
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
SECTION 1 - SAFETY PRECAUTIONS
1.5 ADDITIONAL HAZARDS / SAFETY
• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations,
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.
• Charge batteries only in a well ventilated area.
3121179 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28
MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves r ustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
Wind Speed
mph m/s
Description Land Conditions
Umbrella use becomes difficult.
1-10 – JLG Lift – 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.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 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)
Freque nt Inspec tion
(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-Qualified
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
Figure 2-2. Basic Nomenclature - Sheet 2 of 2
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
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.
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.
Figure 2-4. Daily Walk-Around Inspection - Sheet 2 of 3
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
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.
Figure 2-5. Daily Walk-Around Inspection - Sheet 3 of 3
2-10 – JLG Lift – 3121179
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.
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
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.
SECTION 3 - MACHINE CONTROLS AND INDICATORS
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.
This section provides the necessary information needed to
understand control functions.
1. Platform Rotate
A three position switch controls rotation of the platform.
3.2 CONTROLS AND INDICATORS
Ground Control Station
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
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
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.
2. Platform Leveling Override
A three position switch allows the operator to adjust the
automatic self leveling system. This switch is used to
adjust the platform level in situations such as ascending/
descending a grade.
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1
HOURS
10
QUARTZ
89101112
1
2
4
5
6
7
OR
1. Platform Rotate
2. Platform Leveling Over ride
3. Not Used
4. Engine Star t/Auxiliary Power
or
E ng i n e S t a r t / A ux i l i a r y Po w e r / Fu n c t i o n E n a b l e
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
HOURS
10
QUARTZ
89101112
1
2
3
4
5
6
7
OR
Figure 3-1. Ground Control Station - AJ Models
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 / A ux i l i a r y Po w e r / Fu n c t i o n E n a b l e
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
3121179 – JLG Lift – 3-3
SECTION 3 - MACHINE CONTROLS AND INDICATORS
3. Articulating Jib Boom (If Equipped)
This switch provides raising and lowering of the jib.
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. Tow 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 le s c op 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 (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.
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
6. Low Fuel
7. Glow Plug Wait
8. Overload
9. Engine Air Filter By-Pass
Figure 3-2. Ground Control Indicator Panel - Sheet 1 of 2
Prior to S/N’s 0300099085 & 1300002506
3-6 – JLG Lift – 3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1. Battery Charging
2. Low Engine Oil Pressure
3. Engine Coolant Temp.
4. Engine Oil Temp.
5. Engine Malfunction
6. Low Fuel
7. Glow Plug Wait
8. Overload
9. Not Used
10. Drive and Steer Disable
Figure 3-3. Ground Control Indicator Panel - Sheet 2 of 2
S/N’s 0300099085 & 1300002506 to Present
3121179 – JLG Lift – 3-7
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.
10. Drive and Steer Disable Indicator (If equipped)
Indicates the Drive and Steer Disable function has been
activated.
3-8 – JLG Lift – 3121179
Platform Control Station
SECTION 3 - MACHINE CONTROLS AND INDICATORS
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.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.
2. Platform Leveling Override
A three position switch allows the operator to adjust the
automatic self leveling system. This switch is used to
adjust the platform level in situations such as ascending/
descending a grade.
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.
3121179 – JLG Lift – 3-9
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
9. 9. Telescope
10. Jib
11. Tower Lift
12. Platform Rotate
13. Function Speed
14. Main Lift/Swing
Figure 3-4. Platform Control Console
3-10 – JLG Lift – 3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1702567 A
1702676-B
1704997
1705170 A
1702938
16
14
13
12 1117
10 9
8
7
6
15
4
5
3
12
1. Drive Speed
2. Platform Leveling Override
3. Horn
4. Power/Emergency Stop
5. Aux. Power
6. Fuel Select
7. Lights
8. Drive/Steer
9. Telescope
10. Jib
11. Tower Lift
12. Platform Rotate
13. Function Speed
14. Main Lift/Swing
15. Drive Orientation Override
16. Soft To uch Override
17. Soft Touch Indicator
Figure 3-5. Platform Control Console - w/Drive Orientation
3121179 – JLG Lift – 3-11
SECTION 3 - MACHINE CONTROLS AND INDICATORS
8. Drive/Steer
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.
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.
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. Tel e s c o p e C o n t r o l
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).
3-12 – JLG Lift – 3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
13. Function Speed Control
Controls the speed of Boom and Swing Functions.
Rotate CCW for slower speed and CW for faster speed.
To adjust to creep, turn knob fully CCW until it clicks.
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.
15. Drive Orientation Override
When the boom is swung over the rear tires or further in
either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and
release the switch, and within 3 seconds move the
Drive/Steer control to activate drive or steer. Before driving, locate the black/white orientation arrows on both
the chassis and the platform controls and match the
control direction arrow to the intended chassis direction.
16. 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.
17. 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.
3121179 – JLG Lift – 3-13
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 Light and Alarm
This orange illuminator indicates that the chassis is on a
slope. An alarm will also sound when the chassis is on a
slope and the boom is above horizontal. If lit when boom
is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before
continuing operation. If the boom is above horizontal
and the machine is on a slope, the tilt alarm warning
light will illuminate and an alarm will sound and CREEP
is automatically activated.
IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR
EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN
REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING BOOM ABOVE HORIZONTAL.
4. Glow Plug Indicator
Indicates the glow plugs are operating. After turning on
ignition, wait until light goes out before cranking engine.
3-14 – JLG Lift – 3121179
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.
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.
SECTION 3 - MACHINE CONTROLS AND INDICATORS
3121179 – JLG Lift – 3-15
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1. AC Generator
2. Overload
3. Tilt Alarm Warning
4. Glow Plug
5. Enable
6. Fuel Level
7. Creep Speed
8. System Malfunction
9. Soft Touch
Figure 3-6. Platform Control Indicator Panel - Sheet 1 of 2
Prior to S/N 0300065315
3-16 – JLG Lift – 3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1. AC Generator
2. Overload
3. Tilt Alarm Warning
4. Glow Plug
5. Enable
6. Fuel Level
7. Creep Speed
8. System Malfunction
9. Soft Touch
Figure 3-7. Platform Control Indicator Panel - Sheet 2 of 2
S/N 0300065315 & 1300000001 to Present
3121179 – JLG Lift – 3-17
SECTION 3 - MACHINE CONTROLS AND INDICATORS
1. AC Generator
2. Overload
3. Tilt Alarm Warning
4. Glow Plug
5. Enable
6. Fuel Level
7. Creep Speed
8. System Malfunction
9. Not Used
10. Drive Orientation
Figure 3-8. Platform Control Indicator Panel - w/Drive Orientation
1
2
4
7
3
5
6
10
8
3-18 – JLG Lift – 3121179
SECTION 3 - MACHINE CONTROLS AND INDICATORS
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.
10. 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 activate the Drive Orientation
Override Switch and verify the drive control direction is
correct.
3121179 – JLG Lift – 3-19
SECTION 3 - MACHINE CONTROLS AND INDICATORS
NOTES:
3-20 – 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.
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
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
Figure 4-2. Position of Least Backward Stability
.
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 (ANSI
MARKETS) OR 4 DEGREES (CE & AUSTRALIA MARKETS).
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.
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.
This machine is equipped with a Drive Orientation Indicator.
The yellow light on the platform control console indicates
that the boom is swung beyond the rear drive tires and the
machine may Drive/Steer in the opposite direction from the
movement of the controls. If the indicator is illuminated,
operate the Drive function in the following manner:
1. Match the black and white direction arrows on both platform control panel and the chassis to determine the
direction the machine will travel.
2. Push and release the Drive Orientation Override switch.
Within 3 seconds, slowly move the Drive control toward
the arrow matching the intended direction of machine
travel. The indicator light will flash during the 3 second
interval until the drive function is selected.
4.5 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
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.
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.
3121179 – JLG Lift – 4-7
SECTION 4 - MACHINE OPERATION
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.
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
Swinging the Boom
To swing boom, use SWING control switch to select RIGHT
or LEFT direction.
To extend or retract the main boom, use the Main Telescope
Control Switch to select IN or OUT movement.
4-8 – JLG Lift – 3121179
SECTION 4 - MACHINE OPERATION
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
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. Position Auxiliary Power switch to the on position and
hold.
5. Operate appropriate control switch or lever for desired
function 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.
3121179 – JLG Lift – 4-9
SECTION 4 - MACHINE OPERATION
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.
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.
4-10 – JLG Lift – 3121179
SECTION 4 - MACHINE OPERATION
Figure 4-4. Lifting and Tie Down Chart
3121179 – JLG Lift – 4-11
SECTION 4 - MACHINE OPERATION
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.)
4-12 – 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
14
26
48
37
35
38
36
18
672
44
51
47
Figure 4-6. Decal Installation - Sheet 1 of 6
4-14 – JLG Lift – 3121179
43
45
15
40
3
Figure 4-7. Decal Installation - Sheet 2 of 6
SECTION 4 - MACHINE OPERATION
3121179 – JLG Lift – 4-15
SECTION 4 - MACHINE OPERATION
25
24
20 22
21
33
48
26
35
25
24
7
9
Figure 4-8. Decal Installation - Sheet 3 of 6
4-16 – JLG Lift – 3121179
26
26
27
27
4
443
Figure 4-9. Decal Installation - Sheet 4 of 6
SECTION 4 - MACHINE OPERATION
3121179 – JLG Lift – 4-17
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
4-18 – JLG Lift – 3121179
12
13
4
11
29
30 31
32
23
28
31
32
49
Figure 4-11. Decal Installation - Sheet 6 of 6
SECTION 4 - MACHINE OPERATION
3121179 – JLG Lift – 4-19
SECTION 4 - MACHINE OPERATION
Table 4-1. Decal Legend - Prior to S/N 0300141424
Item # ANSI
0272573-11
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 - - - - - - - - - - - - - - - - - -
1 0 - - - - - - - - - - - - - - - - - -
11 1702868 - - - - - - 1704000 - - 1704002 - - 1704001
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1701645 - - 1707059 1707058 1707055 1707060 1707134 - - 1707056
14 1707013 - - 1707054 1707042 1707047 1707044 1707133 - - 1707049
15 - - - - - - - - - - - - - - 1705084 - -
16 - - - - - - - -- -- - - - - - - -
Australian
0272574-6
Japan
0272575-9
Korean
0272576-9
French/
English
0272577-11
Chinese
0272578-9
Portuguese/
Spanish
0272579-10
CE
0273452-4
English/
Spanish
0271189-6
4-20 – JLG Lift – 3121179
SECTION 4 - MACHINE OPERATION
Table 4-1. Decal Legend - Prior to S/N 0300141424
Item # ANSI
0272573-11
1 7 - - - - - - - - - - - - - - - - - -
18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504
19 - - - - - - - - 1704006 - - 1704008 - - 1704007
20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
2 1 - - - - - - - - - - - - - - - - - -
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
2 7 - - - - - - - - - - - - - - - - - -
2 8 - - - - - - - - - - - - - - - - - -
2 9 - - - - - - - - - - - - - - - - - -
3 0 - - - - - - - - - - - - - - - - - -
3 1 - - - - - - - - - - - - - - - - - -
3 2 - - - - - - - - - - - - - - - - - -
3 3 - - - - - - - - - - - - - - - - - -
34 3252347 - - 1703980 1703981 1703984 1703982 1703985 1705828 1703983
Australian
0272574-6
Japan
0272575-9
Korean
0272576-9
French/
English
0272577-11
Chinese
0272578-9
Portuguese/
Spanish
0272579-10
CE
0273452-4
English/
Spanish
0271189-6
3121179 – JLG Lift – 4-21
SECTION 4 - MACHINE OPERATION
Table 4-1. Decal Legend - Prior to S/N 0300141424
Item # ANSI
0272573-11
3 5 - - - - - - - - - - - - - - - - - -
3 6 - - - - - - - - - - - - - - - - - -
3 7 - - - - - - - - - - - - - - - - - -
3 8 - - - - - - - - - - - - - - - - - -
39 - - - - - - - - 1705514 - - - - - - - -
4 0 - - - - - - - - - - - - - - - - - -
4 1 - - - - - - - - - - - - - - - - - -
4 2 - - - - - - - - - - - - - - - - - -
4 3 - - - - - - - - - - - - - - - - - -
44 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768
45 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
4 6 - - - - - - - - - - - - - - - - - -
4 7 - - - - - - - - - - - - - - - - - -
4 8 - - - - - - - - - - - - - - - - - -
4 9 - - - - - - - - - - - - - - - - - -
50 170 5351 - - 1705426 1705427 1705429 1705430 1705905 - - 1705910
51 - - 1001112551 - - - - - - - - - - - - - -
Australian
0272574-6
Japan
0272575-9
Korean
0272576-9
French/
English
0272577-11
Chinese
0272578-9
Portuguese/
Spanish
0272579-10
CE
0273452-4
English/
Spanish
0271189-6
4-22 – JLG Lift – 3121179
SECTION 4 - MACHINE OPERATION
Table 4-2. Decal Legend - S/N 0300141424 to Present
Item # ANSI
0272573-12
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 - - - - - - - - - - - - - - - - - -
1 0 - - - - - - - - - - - - - - - - - -
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 1001121921 1001121816 1001121823 1001121923 - - 1001121818
15 - - - - - - - - - - - - - - 1705084 - -
16 - - - - - - - - - - - - - - - - - -
Australian
0272574-6
Japan
0272575-10
Korean
0272576-10
French/
0272577-12
Chinese
0272578-10
Portuguese/
Spanish
0272579-11
CE
0273452-4
English/
Spanish
0271189-7
3121179 – JLG Lift – 4-23
SECTION 4 - MACHINE OPERATION
Table 4-2. Decal Legend - S/N 0300141424 to Present
Item # ANSI
0272573-12
1 7 - - - - - - - - - - - - - - - - - -
18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504
19 - - - - - - - - 1704006 - - 1704008 - - 1704007
20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
2 1 - - - - - - - - - - - - - - - - - -
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
2 7 - - - - - - - - - - - - - - - - - -
2 8 - - - - - - - - - - - - - - - - - -
2 9 - - - - - - - - - - - - - - - - - -
3 0 - - - - - - - - - - - - - - - - - -
3 1 - - - - - - - - - - - - - - - - - -
3 2 - - - - - - - - - - - - - - - - - -
3 3 - - - - - - - - - - - - - - - - - -
34 3252 347 - - 1703980 1703981 1703984 1703982 1703985 1705828 1703983
Australian
0272574-6
Japan
0272575-10
Korean
0272576-10
French/
0272577-12
Chinese
0272578-10
Portuguese/
Spanish
0272579-11
CE
0273452-4
English/
Spanish
0271189-7
4-24 – JLG Lift – 3121179
SECTION 4 - MACHINE OPERATION
Table 4-2. Decal Legend - S/N 0300141424 to Present
Item # ANSI
0272573-12
3 5 - - - - - - - - - - - - - - - - - -
3 6 - - - - - - - - - - - - - - - - - -
3 7 - - - - - - - - - - - - - - - - - -
3 8 - - - - - - - - - - - - - - - - - -
39 - - - - - - - - 1705514 - - - - - - - -
4 0 - - - - - - - - - - - - - - - - - -
4 1 - - - - - - - - - - - - - - - - - -
4 2 - - - - - - - - - - - - - - - - - -
4 3 - - - - - - - - - - - - - - - - - -
44 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768
45 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
4 6 - - - - - - - - - - - - - - - - - -
4 7 - - - - - - - - - - - - - - - - - -
4 8 - - - - - - - - - - - - - - - - - -
4 9 - - - - - - - - - - - - - - - - - -
50 1705 351 - - 1705426 1705427 1705429 17 05430 1705905 - - 1705910
51 - - 1001112551 - - - - - - - - - - - - - -
Australian
0272574-6
Japan
0272575-10
Korean
0272576-10
French/
0272577-12
Chinese
0272578-10
Portuguese/
Spanish
0272579-11
CE
0273452-4
English/
Spanish
0271189-7
3121179 – JLG Lift – 4-25
SECTION 4 - MACHINE OPERATION
NOTES:
4-26 – 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:
240-420-2661
E-mail:
ProductSafety@JLG.com
Failure to notify the manufacturer of an incident involving a
JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular
machine.
FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE
AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS,
THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 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
(Prior to S/N 0300124000-USA,
S/N 1300006000-Belgium)..................................... 3121243
450A/450AJ Illustrated Parts Manual
(S/N 0300124000-USA,
S/N 1300006000-Belgium to Present) ................... 3121244
510AJ Illustrated Parts Manual ................................ 3121182
6.2 OPERATING SPECIFICATIONS AND PERFORMANCE DATA
Table 6-1. Operating Specifications - 450A/450AJ - Prior to S/N
0300141424
Unrestricted Rated Capacity 500 lb. (230 kg)
Maximum Capacity 500 lb. (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) - ANSI Markets.
Maximum Travel Grade (Sideslope)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped) - CE & Australia
Markets.
(Gradeability)
30%
45%
5°
4°
3121179 – JLG Lift – 6-1
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-1. Operating Specifications - 450A/450AJ - Prior to S/N
0300141424
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)
Table 6-2. Operating Specifications - 450A/450AJ - S/N
0300141424 to Present
Unrestricted Rated Capacity
ANSI
C E & A us t ra l ia
Maximum Capacity
A NS I
C E & A us t ra l ia
Maximum Travel Grade
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped).
2 WD
4 WD
(Gradeability)
14,500 lb. (6577 kg)
16,500 lb. (7484 kg)
500 lb. (227 kg)
500 lb. (230 kg)
500 lb. (227 kg)
500 lb. (230 kg)
30%
45%
Table 6-2. Operating Specifications - 450A/450AJ - S/N
0300141424 to Present
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.
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)
14,500 lb. (6577 kg)
16,500 lb. (7484 kg)
5°
4°
6-2 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-3. Operating Specifications - 510AJ
Unrestricted Rated Capacity 500 lb. (230 kg)
Maximum Capacity 500 lb. (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) - ANSI Markets.
Maximum Travel Grade (Sideslope)
with Boom retracted and approximately horizontal. Tower Boom fully
lowered (if equipped) - CE & Australia Markets.
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 6-4. Reach Specifications - 450
Max. Platform Height 45ft. (13.72 M)
Max. Horizontal Reach 24.5ft. (7.47 M)
Up & Over Height 25 ft. 2 in. (7.7 M)
Main Boom Up Angle 75°
5°
4°
Main Boom Down Angle -24°
Table 6-5. 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°)
3121179 – JLG Lift – 6-3
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Dimensional Data
Table 6-6. Dimensional Data - 450
Overall Width
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)
Ta il sw in g 0
Stowed Height 7 f t. 4.4 in. (2.25 m)
Stowed Length 21 ft. 4 in. (6.5 m)
Wheel base 78 in. (1.98 m)
Tr ac k Wi dt h
(12 x 16.5 tire)
(33/1550 tire)
(14 x 16.1 tire)
Ground Clearance 14 in. (0.36 m)
Table 6-7. Dimensional Data - 510
Overall Width 7.4 ft. (2.2 6 m)
Ta il sw in g 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 6-7. 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 ft. (0.36 m)
65.3 in. (1.66 m)
66.3 in. (1.69 m)
66.6 in. (1.69 m)
Chassis
Table 6-8. Chassis Specifications - 450
Swing 360° non-continuous
Rated Gradeability
2 WD
4 WD
Max. Tire Load 7900 lb. (3583 kg)
Axle Oscillation 8 in. (0.2 m)
Sy stem Volt age 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)
(310 bar)
30%
45%
4500 psi
6-4 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-9. Chassis Specifications - 510
Swing 357° non-continuous
Gradeability (boom in stowed position)
Max. Tire Load 7900 lb. (3583 kg)
Max. Ground Bearing Pressure
1 2 x1 6 .5 T ir e
33/1550x16.5 - Tire
Drive Speed 4.5 mph (7.2 kph)
Axle Oscillation 4 in. (0.1 m)
Tur n ing Ra di us
I n si d e
O ut s i de
Sy stem Volt age 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 6-10. 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)
Drive Hub 23.75 oz. (0.7 liters)
Drive Brake 2.7 oz. (0.08 liters)
23.6 gal. (89 liters) to the Full line
27 gallons (102 liters)
on the sight gauge
Tires
Table 6-11. Tires
Size Ty pe 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)
33 x 6 x 11 Solid N/A 280 lbs. (127 kg)
3121179 – JLG Lift – 6-5
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Engine
NOTE: RPM Tolerances are ± 100.
Table 6-12. Ford LRG-425 (Gas or Dual Fuel)
Type 4 cylinder, 4 stroke, spark igni-
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 quarts (4.26 L)
Low RPM 1000
Mid RPM
Tower Lift, Upper Lift, Tele
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)
tion
1800
1500
Table 6-13. Deutz F3M1011F
Fuel Diesel
No. of Cylinders 3
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
To w er L if t , Up p er L i ft , Te le
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
6-6 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-14. Deutz F3M2011F/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
crankcase
c o ol e r
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 Lift, Tele
S wi ng , Ba sk e t L e ve l, B as ke t
Rotate, Jib Lift
High RPM 2800
Table 6-15. Caterpillar 3024/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. (2.2L)
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
3121179 – JLG Lift – 6-7
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-16. 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
Table 6-17. Perkins 404D-22
Fuel Diesel
No. of Cylinders 4
BHP 50 HP (37.3 kW)
Bore 3.3 in. (84 mm)
Stroke 3.9 in. (100 mm)
Firing Order 1-3-4-2
Displacement 135 cu.in. (2.2 L)
Oil Capacity w/filter 10 qt. (9.4 L)
Compression Ratio 23.3:1
6-8 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Major Component Weights Hydraulic Oil
Table 6-18. 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 6-19. Component Weights - 510
Component Pounds Kilograms
Engine Only 440 200
Upper Boom 1257 570
Frame (Bare) 2105 955
Turntable (Bare) 1533 695.5
NOTE: Hydraulic oils must have anti-wear qualities at least to API
NOTE: When temperatures remain consistently below 20
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
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.
degrees F. (-7 degrees C.), JLG Industries recommends
the use of Mobil DTE13.
Table 6-20. Hydraulic Oil
S.A.E. Viscosity
Grade
10W
10W-20, 10W30
20W-20
3121179 – JLG Lift – 6-9
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-21. 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
Table 6-22. 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
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.
6-10 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-23. UCon Hydrolube HP-5046
Type 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
Table 6-24. 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)
Weight
7.64 lb. per gal.
(0.9 kg per liter)
Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121179 – JLG Lift – 6-11
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
Table 6-25. 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.
Table 6-26. Quintolubric 888-46
Density
0.91 @ 15°C (59°F)
Pour Point
<-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
6-12 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & 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.
3121179 – JLG Lift – 6-13
SECTION 6 - GENERAL SPECIFICATIONS & 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 A T 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 OPERA T IO N BELOW THIS
AMBIENT TEMPERATURE
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE
Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2
6-14 – JLG Lift – 3121179
SECTION 6 - GENERAL SPECIFICATIONS & 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 TEMPERA TURES
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) RECOMMENDAT ION S AR E FOR AMBIE NT TEMPERATURES
CO NSIS TANTLY WIT HIN SHOWN LIMITS
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
0+32
-5
-10
-15
-20
-25
-30
+23
+14
+5
-4
-13
-22
CF
0 102030405060
% OF ADDED KEROSENE
A
M
B
I
E
N
T
T
E
M
P
E
R
A
T
U
R
E
SUMMER-GRADE
FUEL
WINT ER-GRADE
FUEL
Figure 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2
4150548-E
3121179 – JLG Lift – 6-15
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
-40
F(-40C)
-30 F(-34 C)
-20 F(-29 C)
-10 F(-23 C)
0F(-18C)
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.
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 6-4. Engine Operating Temperature Specifications - Ford - Sheet 1 of 2
6-16 – JLG Lift – 3121179
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE
C)
C)
C)
C)
C)
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
CONSISTANTLY 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 6-5. Engine Operating Temperature Specifications - Ford - Sheet 2 of 2
4150548-E
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
3121179 – JLG Lift – 6-17
SECTION 6 - GENERAL SPECIFICATIONS & 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 6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2
6-18 – JLG Lift – 3121179
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