JLG E450AJ, E450A, M450A, M450AJ Operation And Safety Manual

Operation and Safety Manual

ANSI

®

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

Boom Lift Models
E450A
E450AJ
M450A
M450AJ

3121210

January 7, 2013

FOREWORD

3121210 – JLG Lift – a

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.

FOREWORD

b – JLG Lift – 3121210

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD

RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

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

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO­TECTION OF PROPERTY.

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

FOREWORD

3121210 – JLG Lift – c

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.

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:

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

For:

• Accident Reporting

• Product Safety Publica­tions

• Current Owner Updates

• Questions Regarding
Product Safety

• Standards and Regulations
Compliance Information

• Questions Regarding Spe­cial Product Applications

• Questions Regarding Prod­uct Modifications

FOREWORD

d – JLG Lift – 3121210

REVISION LOG

Original Issue - June 21, 2005

Revised - July 21, 2006

Revised - December 7, 2009

Revised - August 26, 2010

Revised - October 6, 2011

Revised - August 14, 2012

Revised - January 7, 2013

TABLE OF CONTENTS

3121210 – JLG Lift – i

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

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Platform Control Indicator Panel . . . . . . . . . . . . 3-12

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 MOTOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Power/Emergency Stop . . . . . . . . . . . . . . . . . . . 4-2

Platform/Ground Select Switch. . . . . . . . . . . . . . 4-5

Motor Activation. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

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

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Loading From Ground Level . . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . . 4-8

TABLE OF CONTENTS

ii – JLG Lift – 3121210

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

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

Raising and Lowering the Lower and Mid Boom 4-9

Raising and Lowering the Upper Boom . . . . . . 4-9

4.8 GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Automatic Operating Mode . . . . . . . . . . . . . . . 4-10

Battery Only Operating Mode . . . . . . . . . . . . . 4-10

Manual (Charge) Operating Mode. . . . . . . . . . 4-10

4.9 INVERTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

4.10 MACHINE FUNCTION SPEEDS . . . . . . . . . . . . . . 4-11

4.11 BOOM SYNCHRONIZING PROCEDURE . . . . . . . 4-11

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

4.13 MACHINE LIFTING AND TIE DOWN . . . . . . . . . . . 4-12

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

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

SECTION - 5 - EMERGENCY PROCEDURES

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

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

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

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

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

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

5.5 MANUAL DESCENT SYSTEM . . . . . . . . . . . . . . . . .5-2

5.6 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . .5-3

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE

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

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

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

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

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Torque Specifications. . . . . . . . . . . . . . . . . . . . . 6-5

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

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

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

Serial Number Locations . . . . . . . . . . . . . . . . . . 6-7

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

6.4 BATTERY MAINTENANCE AND CHARGING. . . . .6-14

Battery Maintenance, Quarterly . . . . . . . . . . . . 6-14

Optional On Board Generator . . . . . . . . . . . . . 6-15

Battery Charging (On Board Charger) . . . . . . . 6-15

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-16

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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

TABLE OF CONTENTS

3121210 – JLG Lift – iii

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

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-17

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.6 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-19

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-7

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

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

2-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-10

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

3-2. Ground Control Station w/ Function Enable . . . . . .3-4

3-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-7

3-4. Platform Control Console - w/Drive Orientation . . .3-8

3-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-13

3-6. Platform Control Indicator Panel w/Drive

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13

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

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

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-7

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

4-5. Chassis & Platform Tie Down - Sheet 1 of 2 . . . . .4-14

4-6. Chassis & Platform Tie Down - Sheet 2 of 2 . . . . .4-15

4-7. Decal Installation - Sheet 1 of 3 . . . . . . . . . . . . . . .4-16

4-8. Decal Installation - Sheet 2 of 3 . . . . . . . . . . . . . . .4-17

4-9. Decal Installation - Sheet 3 of 3 . . . . . . . . . . . . . . 4-18

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . 6-7

6-2. Operator Maintenance & Lubrication Diagram . . . 6-8

TABLE OF CONTENTS

iv – JLG Lift – 3121210

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

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

3-1 Simultaneous Functions . . . . . . . . . . . . . . . . . . . . 3-11

4-1 E450A/E450AJP Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-2 E450A/E450AJP Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-3 M450A/M450AJ Decal Legend - Prior to S/N

0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-4 M450A/M450AJ Decal Legend - S/N 0300141435 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36

6-1 Operating Specifications - Prior to

S/N 0300141435 . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Operating Specifications - S/N 0300141435

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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

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

6-5 Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-9 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . 6-6

6-10 Lubrication Specifications. . . . . . . . . . . . . . . . . . . . 6-9

6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-18

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

SECTION 1 - SAFETY PRECAUTIONS

3121210 – JLG Lift – 1-1

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.

SECTION 1 - SAFETY PRECAUTIONS

1-2 – JLG Lift – 3121210

• 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.

SECTION 1 - SAFETY PRECAUTIONS

3121210 – JLG Lift – 1-3

1.3 OPERATION

General

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

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

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

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

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

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

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

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

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

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

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

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

Trip and Fall Hazards

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

SECTION 1 - SAFETY PRECAUTIONS

1-4 – JLG Lift – 3121210

• 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.

SECTION 1 - SAFETY PRECAUTIONS

3121210 – JLG Lift – 1-5

• 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.

• 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.

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

Voltage Range

(Phase to Phase)

MINIMUM APPROACH DISTANCE

in Feet (Meters)

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.

SECTION 1 - SAFETY PRECAUTIONS

1-6 – JLG Lift – 3121210

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

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

Tipping Hazards

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

SECTION 1 - SAFETY PRECAUTIONS

3121210 – JLG Lift – 1-7

• 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.

SECTION 1 - SAFETY PRECAUTIONS

1-8 – JLG Lift – 3121210

• 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.

SECTION 1 - SAFETY PRECAUTIONS

3121210 – JLG Lift – 1-9

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

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

• Do not refuel the machine with the engine running.

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

• Charge batteries only in a well ventilated area.

SECTION 1 - SAFETY PRECAUTIONS

1-10 – JLG Lift – 3121210

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

Wind Speed

Description Land Conditions

mph m/s

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.

Umbrella use becomes difficult.

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.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121210 – JLG Lift – 2-1

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is
necessary that it be operated and maintained only by trained
personnel.

Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.

Operator Training

Operator training must cover:

1. Use and limitations of the controls in the platform and at
the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the
machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the

machine to recognize a malfunction or potential mal­function.

6. The safest means to operate the machine where over­head obstructions, other moving equipment, and obsta­cles, depressions, holes, drop-offs.

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

8. Specific job requirements or machine application.

Training Supervision

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

Operator Responsibility

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

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 – JLG Lift – 3121210

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.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121210 – JLG Lift – 2-3

Table 2-1.Inspection and Maintenance Table

Type Frequency

Primary

Responsibility

Service

Qualification

Reference

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

User or Operator User or Operator Operator and Safety Manual

Pre-Delivery Inspection
(See Note)

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

Mechanic

Service and Maintenance
Manual and applicable JLG
inspection form

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

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

Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance
Manual and applicable JLG
inspection form

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

prior inspection.

Owner, Dealer, or User Factory Qualified

Service Technician
(Recommended)

Service and Maintenance
Manual and applicable JLG
inspection form

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

tenance Manual.

Owner, Dealer, or User Qualified JLG

Mechanic

Service and Maintenance
Manual

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

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-4 – JLG Lift – 3121210

Pre-Start Inspection

The Pre-Start Inspection should include each of the follow­ing:

1. Cleanliness – Check all surfaces for leakage (oil, fuel,
or battery fluid) or foreign objects. Report any leakage to
the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents,
damage, weld or parent metal cracks or other discrep­ancies.

3. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible decals and placards are
cleaned or replaced.

4. 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.

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

6. Battery – Charge as required.

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

proper fuel as necessary.

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

9. 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.

Parent Metal Crack Weld Crack

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121210 – JLG Lift – 2-5

Function Check

A functional check of all systems should be performed, once
the walk-around inspection is complete, in an area free of
overhead and ground level obstructions. First, using the
ground controls, check all functions controlled by the ground
controls. Next, using the platform controls, check all func­tions controlled by the platform controls.

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

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

1. Check boom limit switches. Raise and lower the Lower
Boom. Check for smooth operation.

NOTE: Perform checks from ground controls first, then from plat-

form controls.

2. Raise, extend, retract, and lower the Upper Boom.
Check for smooth operation.

3. If tower boom does not rest on stop with machine in the
stowed position, this indicates upright is out of plumb.

4. Telescope boom IN and OUT several cycles at various
degrees of elevation lengths. Check for smooth tele­scope operation.

5. Swing turntable to LEFT and RIGHT a minimum of 45
degrees. Check for smooth motion.

6. Check the chassis out of level indicator located on the
platform control console by driving, with the machine in
level position, up a suitable ramp of at least 6° slope.
Check the out of level alarm, with the machine on the
ramp, raise the upper boom until it is parallel with the
chassis. DO NOT RAISE ABOVE THE PARALLEL POSI­TION. If the light does not illuminate, return the machine
to a level surface, shut down the machine, and contact a
qualified technician before resuming operation.

For units equipped with optional tilt cutout, verify that the
drive function is cutout when the boom is elevated and
tilt alarm is activated.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-6 – JLG Lift – 3121210

DO NOT DRIVE ON GRADES WHICH EXCEED THE RATED GRADEABILITY
OF THE MACHINE AS INDICATED ON THE SERIAL NUMBER PLATE. DO
NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

7. Check that platform self-leveling system functions prop­erly during raising and lowering of boom.

8. Check rotator for smooth operation and assure platform
will rotate 75 degrees in both directions from centerline
of boom.

9. Drive forward and reverse; check for proper operation.

10. Steer left and right; check for proper operation.

11. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER­ATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF
SWITCH OPERATES WITHIN LAST 1/4" (6 MM) OF TRAVEL, TOP OR
BOTTOM, IT SHOULD BE ADJUSTED.

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC­TION CONTROL, OTHERWISE THE FUNCTION WILL NOT WORK.

With footswitch depressed, operate LIFT and hold control.
Remove foot from footswitch, motion should stop. If it
does not, shut down machine and contact a qualified ser­vice technician.

12. Place the GROUND/PLATFORM SELECT switch to
GROUND. Platform controls should not operate.

13. Place GROUND/PLATFORM SELECT switch to OFF.
Platform/Ground controls should not operate.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121210 – JLG Lift – 2-7

Figure 2-1. Basic Nomenclature

1 . P la t fo r m C on t ro l C o ns o le
2 . Pl a tf o r m
3 . Up p er B oo m

4. Telescope Cylinder
5 . Ma s te r Cy l in d e r
6 . Up p er U pr i gh t
7 . Up p er L if t C yl i n de r

8. Mid Lift Cylinder
9 . L ow er B oo m

10. Turntable

11. Frame

12. Steer Wheels

13. Drive Wheels

14. Battery Box

15. Lower Lift Cylinder

16. Lower Link

17. Lower Upright

18. Upper Link

19. Mid Boom

20. Slave Cylinder

21. Footswitch

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-8 – JLG Lift – 3121210

3, 4

5

6,7

8

9

10

11

12

13

15

10

19

7

20

10

10

23, 16

27

14212215

16

14

17, 18

1

7242

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

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121210 – JLG Lift – 2-9

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 “Walk-Around Inspection Checklist”.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR­ING "WALK-AROUND INSPECTION".

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE.
CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS
WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missing

parts, that they are securely fastened and that no visible
damage exists in addition to any other criteria men­tioned.

1. Platform and Gate Assembly - Platform mounting pins
secure. Footswitch in good working order; not modi­fied, disabled or blocked; Bar slides freely.

2. Platform & Ground Control Console - Switches and
levers return to neutral and are properly secured,
decals/placards secure and legible, control marking
legible.

3. Rotator - See Note.

4. Jib - See Note.

5. Jib Rotator - See Note.

6. Boom Sections - See Note.

7. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

8. Limit Switches - See Note.

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

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-10 – JLG Lift – 3121210

9. Drive Axle and Motor - See Note.

10. Wheel/Tire Assembly - No loose or missing lug nuts.

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

11. Swing Motor and Worm Gear - See Note.

12. Hydraulic Pump and Reservoir - Properly secured; no

visible damage or hydraulic leaks. Recommended
hydraulic fluid level on dipstick (system shut down,
boom in stowed position). Breather cap/dipstick
secure and working.

13. Turntable Bearing - No loose or missing hardware; no
visible damage; evidence of proper lubrication. No
loose bolts or looseness between bearing and struc­ture.

14. Battery Compartment Right Side - Batteries have
proper electrolyte level; cables tight; no visible dam­age or corrosion.

15. Cowling and Latches - See Note.

16. Battery Charger - See Note.

17. Valve - See Note.

18. Boom/Upright - No visible damage; All pins properly

secured. Upright in vertical position. If Upright does
not rest on stop with machine in the stowed position,
this indicates upright is out of plumb.

19. Counterweight - See Note.

20. Tie Rod Ends and Steering Spindles - See Note. Tie

rod end stubs locked.

21. Manual Descent Valve - See Note.

22. Control Valve - See Note.

23. Frame - See Note.

24. Platform Pivot Pins - Properly secured.

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

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-1

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE
APPLICATION AND OPERATION. THE USER AND OPERATOR ARE
RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to
understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that use

symbols to indicate control functions. On ANSI machines,
refer to decal located on the control box guard in front of
the control box or by the ground controls for these sym­bols and the corresponding functions.

Ground Control Station

(See Figure 3-1. and Figure 3-2.)

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

switch and Emergency Stop must be positioned to OFF.

NOTE: If equipped, the Function Enable switch must be held

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

1. System Distress Indicator (If Equipped)

The system distress indicator lights to signify an abnor­mal condition for the generator engine (high oil tempera­ture or low oil pressure) or, on electric machines, an
electrical system fault.

NOTE: The engine will automatically shut down under the follow-

ing conditions:

High Oil Temperature
Low Oil Pressure
Engine Overspeed
Overvoltage

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 – JLG Lift – 3121210

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. Generator/Engine Start Button

The generator/engine start push-button switch allows
the generator to be started manually to top-off the bat­tery charge. The generator will start automatically when
the batteries reach a low-charge state and the Generator
Enable switch on the platform console is in the on posi­tion.

NOTE: The engine will not start if the batteries are fully charged

or if the Generator Enable switch on the platform console
is not in the on position.

4. Battery Indicator and Hourmeter

An hourmeter, installed in the upper portion of the
Ground Control Box, registers the amount of machine
operating time. The hourmeter registers up to 9,999.9
hours and cannot be reset.

5. Te le s c op e

Provides for extension and retraction of Upper Boom
when positioned to IN or OUT.

6. Swing

The SWING control switch provides 360 degrees non­continuous turntable rotation. To activate SWING, posi­tion switch to LEFT or RIGHT.

7. Circuit Breakers

The circuit breakers open (pop out) to indicate a short or
overload somewhere on the machine.

8. Power/Emergency Stop Switch

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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-3

Figure 3-1. Ground Control Station

1. System Distress Indicator

2. Platform Overload Indicator

3. Engine/Generator Start Button

4. Battery Condition Indicator & Hourmeter

5. Telescope

6. Swing

7. Circuit Breakers

8. Emergency Stop

9. Platform/Ground Select

10. Lower/Mid Lift

11. Upper Boom Lift

12. Jib

13. Platform Leveling

14. Rotate

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-4 – JLG Lift – 3121210

Figure 3-2. Ground Control Station w/ Function Enable

1. System Distress Indicator

2. Platform Overload Indicator

3. Engine/Generator Start Button

4. Battery Condition Indicator & Hourmeter

5. Telescope

6. Swing

7. Circuit Breakers

8. Emergency Stop

9. Platform/Ground Select

10. Lower/Mid Lift

11. Upper Boom Lift

12. Jib

13. Platform Leveling

14. Rotate

15. Function Enable

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-5

9. Platform/Ground Select Switch

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

NOTE: With PLATFORM/GROUND SELECT switch in the center

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

10. Lower/Mid Boom Lift

Provides for raising and lowering of Lower Boom when
positioned to UP or DOWN.

11. Upper Boom Lift

Provides for raising and lowering of Upper Boom when
positioned to UP or DOWN.

12. Articulating Jib Boom (If equipped)

The Articulating Jib Boom control switch provides rais­ing and lowering of the jib when positioned up or down.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.

13. Platform Leveling Override

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

14. Rotate

A three position ROTATE control switch permits rotation
of the platform when positioned to left or right.

15. Function Enable (If Equipped)

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

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-6 – JLG Lift – 3121210

Platform Station

(See Figure 3-3.)

1. Posi-Track Control

Activating the Posi-Track switch allows the operator to
engage positive traction for the time period pre-set in the
controller. Posi-traction occurs by changing the drive
motors from a series to parallel arrangement, causing
available power to be distributed evenly between the
two drive wheels. The control system may also engage
the posi-track function automatically.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE
THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD
RESULT IN DEATH OR SERIOUS INJURY.

2. Platform Leveling Override

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

3. Horn

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

4. Power/Emergency Stop

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

Within about 2 seconds of pulling the switch out, the
machine will perform a diagnostic check of the various
electrical circuits, and if everything is OK, the platform
alarm will beep once. During this time the lights on the
indicator panel will also blink once as a bulb check.

5. Generator Enable Control

The Generator Enable control switch, when in the off
position, allows the operator to prevent the generator
engine from starting when using the machine indoors.
When in the on position (and the ground Emergency
Stop Switch on [pulled out]), the generator is enabled to
automatically start when the batteries need charged.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-7

1. Posi-Track

2. Platform Leveling Override

3. Horn

4. Po wer/Emergency Stop

5. Generator Enable

6. Lights

7. Drive/Steer

8. Telescope

9. Jib

10. Lower Boom Lift

11. Platform Rotate

12. Function Speed

13. Main Lift/Swing

Figure 3-3. Platform Control Console

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-8 – JLG Lift – 3121210

13

12 11

10

15 89

7

14

6

5

43

21

1705170 A

1702938

1. Posi-Track

2. Platform Leveling Override

3. Horn

4. Power/Emergency Stop

5. Generator Enable

6. Lights

7. Drive/Steer

8. Telescope

9. Jib

10. Lower Boom Lift

11. Platform Rotate

12. Function Speed

13. Main Lift/Swing

14. Drive Orientation Override

15. Soft To uch Override

Figure 3-4. Platform Control Console - w/Drive Orientation

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-9

6. Lights (If Equipped)

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

7. Drive/Steer

The DRIVE controller provides for driving either forward
or backward when positioned to FORWARD or
REVERSE. The controller is ‘ramped’ to allow infinitely
variable drive speed between fast and slow.

Positioning the steer control thumb operated switch
RIGHT or LEFT enables steering the machine to the
right or left respectively.

NOTE: When lower boom is raised above horizontal, or the upper

boom is raised approximately 16 inches (40.64 cm) above
boom rest, the high drive function will automatically
switch to low drive. This also occurs when Function
Speed Control is clicked on creep.

NOTE: DRIVE control lever is spring-loaded and will automati-

cally return to neutral (OFF) position when released.

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.

8. Tel e s c o p e C o n t r o l

The TELESCOPE control switch affords extension and
retraction of the main boom when positioned to IN or
OUT.

9. Jib (If Equipped)

Push forward to lift up, pull back to lift down. Variable lift
speed is using the Function Speed Control.

10. Lower Boom Lift

Provides for raising and lowering of Lower and Mid
Boom when positioned to UP or DOWN. Upper lift will
not function when operating lower lift.

11. Platform Rotate

The PLATFORM ROTATE control switch allows the oper­ator to rotate the basket to the left or right when posi­tioned to the desired direction.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-10 – JLG Lift – 3121210

12. Function Speed Control

Adjusts speed of Boom and Swing Functions. Rotate
CCW for slower speed and CW for faster speed. To
adjust Drive, Swing, and Main Lift to creep, turn knob
fully CCW until it clicks.

NOTE: Main Lift, Swing, and Drive control levers are spring-

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

13. Main Lift/Swing

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

NOTE: Main lift and swing functions may be selected in combina-

tion. The handle features a round gate so that maximum
speed is reduced when multiple functions are selected.

Lower lift will not function when operating upper lift.

14. 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.

15. 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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-11

Table 3-1. Simultaneous Functions

If This Function is Selected: These Functions Will Also Work at the Same Time:

Drive and Steer Swing Lower Lift** Upper Lift** Telescope

Swing

Drive and Steer

Lower Lift** Upper Lift** Telescope

Lower Lift

Drive and Steer

Swing* No Telescope*

Upper Lift

Drive and Steer

Swing No Te le sc o pe

Te le sc o pe

Drive and Steer

Swing* Lower Lift** Upper Lift**

Jib

Drive and Steer

Swing* Lower Lift** Upper Lift** Telescope

Platform Rotate

Drive and Steer

No No No No

Note: Boom functions may be slower when selected with another function than when operated individually, due to sharing of oil.

* These functions may move very slowly (or not at all) if the first function selected (Lower Lif t or Swing) is being operated at full speed, due to sharing
of oil.

** Lower Lift and Upper Lift will not function simultaneously. Upper Lift always prevails.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-12 – JLG Lift – 3121210

Platform Control Indicator Panel

(See Figure 3-5., Platform Control Indicator Panel)

NOTE: The platform control indicator panel 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.

1. Tilt Alarm Warning Light and Alarm

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

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR
EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN
REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING BOOM ABOVE HORIZONTAL.

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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-13

1. Tilt

2. Platform Overload

3. System Distress

4. Posi-Track

5. Enable

6. Low Battery

7. Creep

Figure 3-5. Platform Control Indicator Panel

1704239 E

+

-

1001110226A

+

-

7

9

6

1

5

4

38

2

1. Tilt

2. Platform Overload

3. System Distress

4. Posi-Track

5. Enable

6. Low Battery

7. Creep

8. Drive Orientation Override

9. Soft Touch Indicator

Figure 3-6. Platform Control Indicator Panel w/

Drive Orientation

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-14 – JLG Lift – 3121210

2. Platform Overload (If equipped)

Indicates the platform has been overloaded.

3. System Distress Indicator

The system distress indicator lights to signify an abnor­mal condition for the generator engine (high oil tempera­ture or low oil pressure) or, on all electric machines, an
electrical system fault.

The four likely causes of a system fault are:

a. The seven second enable time has been allowed to

lapse or a function was selected before depressing
the footswitch. The system reads this condition as a
fault, just as it would if the footswitch were jammed
in the depressed position or a function switch were
stuck in the on position. Re-depress the footswitch
to power the controls and extinguish the light.

b. The maximum power limit has been reached and

the machine is not moving. This could happen
when the machine is stuck or when attempting to
travel over rough terrain or on steep grades which
exceed the rated gradeability of the machine. This
condition is comparable to stalling the engine by
asking it to provide more power than it was
designed to do.

c. The batteries are nearly depleted, and should be

charged very soon to prevent having the machine
stop at an inconvenient place.

d. There is some other fault in one of the circuits. If so

determine the cause by counting the flash code, a
number of flashes followed by a pause followed by
another number of flashes, and refer to the service
manual.

NOTE: The engine will automatically shut down under the follow-

ing conditions:

High Engine Oil Temperature
Low Engine Oil Pressure
Engine Overspeed
Generator Overvoltage

4. Posi-Track Indicator

This indicator lights to show that posi-traction is operat­ing.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121210 – JLG Lift – 3-15

5. Enable Indicator/Footswitch

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

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

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

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

6. Low Battery Indicator

Indicates the batteries are low and need to be charged.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-16 – JLG Lift – 3121210

7. Creep Speed Indicator

When the Function Speed Control is turned to the creep
position, the indicator acts as a reminder that all func­tions are set to the slowest speed.

8. 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.

9. Soft Touch Indicator (If Equipped)

When illuminated (Yellow) the Soft Touch bumper is
against an object. All controls are disabled until the
override button is pushed, at which time controls are
active in the Creep mode.

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-1

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel lift
equipped with a work platform on the end of an elevating
and rotating boom.

The primary operator control station is in the platform. From
this control station, the operator can drive and steer the
machine in both forward and reverse directions. The opera­tor can raise or lower the upper or lower 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 Upper
and Lower 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.

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 manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG.

SECTION 4 - MACHINE OPERATION

4-2 – JLG Lift – 3121210

Stability

Machine stability is based on two positions which are called
FORWARD and BACKWARD stability. The machines position
of least FORWARD stability is shown in Figure 4-1., Position
of Least Forward Stability, and its position of least BACK­WARD stability is shown in Figure 4-2., Position of Least
Backward Stability.

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

4.3 MOTOR OPERATION

Power/Emergency Stop

The Power/Emergency Stop switch, when pulled out (on),
provides battery power for all machine functions. The switch
should be pushed in (off) when recharging the batteries or
parking the machine overnight.

NOTE: If equipped with the optional on-board generator, the

Emergency Stop switch must be left on (pulled out) to
allow for automatic charging of the batteries.

Within about 2 seconds of pulling the switch out, the
machine will perform a diagnostic check of the various elec­trical circuits, and if everything is OK, the platform alarm will
beep once. During this time the lights on the indicator panel
will also blink once as a bulb check.

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-3

Figure 4-1. Position of Least Forward Stability

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OPERATED ON AN

OUT-OF-LEVEL

SURFACE

FLY BOOM

FULLY EXTENDED

UPPER BOOM

HORIZONTAL

TOWER AND MID

BOOM AT

33 DEGREES

SECTION 4 - MACHINE OPERATION

4-4 – JLG Lift – 3121210

Figure 4-2. Position of Least Backward Stability

LOW ER B OOM

FULLY ELEVATED

MID BOOM

FULLY ELEVATED

UPPER BOOM

FULLY ELEVATED

AND RETRACTED

PLATFORM

ROTATED

90 DEGREES

MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OPERATED ON AN

OUT-OF-LEVEL SURFACE

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-5

Platform/Ground Select Switch

The Platform/Ground Select switch directs battery power to
the desired control station when the POWER/EMERGENCY
STOP switch is pulled out (on). With the switch held in the
GROUND position battery power is supplied to the ground
control station. When the switch is in the PLATFORM posi­tion, battery power is supplied to the platform control station.

Motor Activation

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC­TION, OTHERWISE FUNCTION WILL NOT OPERATE.

The motor becomes activated and operates the desired
function when the Emergency Stop switch is pulled out (on),
the Platform/Ground select switch is in the appropriate posi­tion and the Footswitch is depressed.

IF A MOTOR MALFUNCTION NECESSITATES UNSCHEDULED SHUT­DOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY
OPERATION.

4.4 TRAVELING (DRIVING)

NOTE: For units equipped with optional tilt cutout, verify that the

drive function is cut out when the boom is elevated and tilt
alarm is activated.

NOTE: When lower boom is raised above horizontal, or the upper

boom is raised approximately 16 inches (40.6 cm) above
boom rest, the high drive function will automatically be in
low drive.

IF THE MACHINE IS OPERATED AT A VERY SLOW SPEED OR STALLED
WHEN CLIMBING A GRADE OF 20% OR GREATER, DRIVE FUNCTION
WILL STOP. REMOVE FOOT FROM FOOT-SWITCH, AND DEPRESS FOOT­SWITCH TO RESET.

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

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER” ON GRADES AND
SIDE SLOPES, DO NOT DRIVE MACHINE ON GRADES EXCEEDING
THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

SECTION 4 - MACHINE OPERATION

4-6 – JLG Lift – 3121210

AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE
TO TIP OVER.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL
TIMES WHEN DRIVING WITH PLATFORM ELEVATED AND WHEN DRIV­ING WITH ANY PART OF MACHINE WITHIN 6 FEET OF ANY OBSTRUC­TION.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR
DRIVE AXLE. IF BOOM IS OVER STEER WHEELS, STEER AND DRIVE
CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE
MOTION.

Traveling Forward and Reverse

FOOTSWITCH MUST BE DEPRESSED PRIOR TO ACTIVATING ANY FUNC­TION, OTHERWISE FUNCTION WILL NOT OPERATE.

1. If machine is shut down, pull out Emergency Stop at
Ground Controls and place Platform/Ground Select
switch to PLATFORM.

2. At Platform Controls, pull out Emergency Stop switch
and activate footswitch.

3. Position Drive controller to FORWARD or REVERSE as
desired. Angle of controller will determine travel speed.

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

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

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-7

Figure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION

4-8 – JLG Lift – 3121210

4.6 PLATFORM

Loading From Ground Level

1. Position chassis on a smooth, firm and level surface.

2. If total load (personnel, tools and supplies) is 500 LB.

(227 kg for ANSI markets and 230 kg for CE and Austra­lia markets) or less, distribute load uniformly on platform
floor and proceed to work position.

Loading From Positions Above Ground Level

Before loading weight to platform above ground level:

1. Determine what the total weight will be after additional
weight is loaded (personnel, tools and supplies).

2. If total weight in platform will be 500 LBS. (227 kg for
ANSI markets and 230 kg for CE and Australia markets)
or less, proceed with adding weight.

Platform Level Adjustment

1. Leveling UP. Depress footswitch to raise platform, posi­tion PLATFORM/LEVEL control switch UP and hold until
platform is level.

2. Leveling DOWN. Depress footswitch to lower platform,
position PLATFORM/LEVEL control switch to DOWN
and hold until platform is level.

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD
CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO
COULD RESULT IN DEATH OR SERIOUS INJURY.

Platform Rotation

1. Depress footswitch to rotate platform to the left, PLAT­FORM ROTATE control switch is positioned to the LEFT
and held until desired position is reached.

2. Depress footswitch to rotate platform to the right, PLAT­FORM ROTATE control switch is positioned to the
RIGHT and held until desired position is reached.

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-9

4.7 BOOM

A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE
WHICH LIGHTS WHEN THE CHASSIS IS ON A 5 DEGREE OR GREATER
SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN
LIGHT IS LIT OR AUDIBLE ALARM SOUNDS.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE
CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5
DEGREE OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING,
OR RAISING BOOM ABOVE HORIZONTAL.

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

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON
GRADES NOT EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER
PLATE.

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

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

Swinging the Boom

Depress footswitch to swing boom, with footswitch activated,
position SWING control switch to RIGHT or LEFT for direc­tion desired.

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

Depress footswitch to raise or lower the Lower and Mid
Boom, with footswitch activated, position Lower Boom Lift
switch to UP or DOWN as desired.

Raising and Lowering the Upper Boom

Depress footswitch to raise or lower the Upper Boom, with
footswitch activated, position Upper Boom Lift switch to UP
or DOWN until desired height is reached.

SECTION 4 - MACHINE OPERATION

4-10 – JLG Lift – 3121210

4.8 GENERATOR

The machine is equipped with an engine powered DC generator
connected in parallel to the 48V DC battery bank.

Automatic Operating Mode

The generator will operate in automatic mode always when
the following two conditions apply.

1. Ground Control EMS is pulled out (on), and

:

2. The Generator Enable switch on the platform control
console is in the On or Enable position.

When the above conditions apply, the generator’s controller
will monitor status of the batteries, will turn on automatically
when the battery voltage drops as a result of discharge and
will turn off when batteries are fully charged.

Battery Only Operating Mode

The machine will operate in the battery only mode when the
following two conditions apply:

1. Ground Control EMS is pulled out, and:

2. The switch on the platform control console is in the Off

or Disable position.

In this mode the machine will operate as a conventional bat­tery operated unit. The batteries can be used until they are
fully discharged.

Manual (Charge) Operating Mode

The generator will operate in manual mode always when the
following three conditions apply.

1. Ground Control EMS is pulled out, and

:

2. The switch on the platform control console is in the On
or Enable position and

:

3. The Manual Charge push button is activated.

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-11

Activation of the Manual Charge button will start the engine
and initiate the charging cycle even if the batteries are
charged above the level of automatic start. The operator can
initiate the charge cycle to charge the batteries to the maxi­mum level. The charging cycle will include finishing phase
similar to conventional chargers.

4.9 INVERTER

The inverter converts 48 VDC to 110 VAC to allow operation
of power tools from the machine’s batteries.

• The inverter is operational when the emergency stop
switch is pulled out.

• The machine and inverter can be operated at the same
time.

• The inverter will shut off at approximately 42 VDC and stay
off until the emergency stop switch is recycled. It will oper­ate again until voltage drops to 42 VDC.

• The machine will operate down to 36 VDC.

• The inverter will shut down if the high temperature light
indicated overheating. It will automatically turn back on
when cooled.

• The overload light indicates an output wiring short circuit
or a load that is too large for the rating of the inverter.

4.10 MACHINE FUNCTION SPEEDS

The Function Speed Control affects the speed of boom func­tions Lower Lift, Telescope, and Rotate. Turn the control CW
to increase function speed or CCW to decrease function
speed. When in the CCW maximum position, Drive is placed
in creep speed.

4.11 BOOM SYNCHRONIZING PROCEDURE

NOTE: If the Lower Boom assembly does not fully lower:

1. Remove all personnel from the platform.

2. Pull the red knob located beside the main control valve.

3. From Ground Control, activate the lift control switch,

raise Lower Boom 1.8 m (6 feet).

4. After raising Lower Boom, release the red knob.

5. Activate Lower Boom Down, fully lower boom.

6. Repeat step 1 thru 5 if necessary.

SECTION 4 - MACHINE OPERATION

4-12 – JLG Lift – 3121210

4.12 SHUT DOWN AND PARK

NOTE: When parking battery powered units overnight, batteries

should be charged in accordance with instructions in
Section 2 to ensure readiness for following workday.

NOTE: Electric machines are equipped with a static strap due to

static electricity build-ups. Strap is located under rear of
machine chassis.

To shut down and park the machine, the procedures are as
follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Shut down Emergency Stop at Platform Controls.

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

tion Platform/Ground Select switch to center OFF.

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

4.13 MACHINE LIFTING AND TIE DOWN

Lifting

1. Call JLG Industries, see machine’s serial number plate,
or weigh the individual unit to obtain GVW.

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

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.

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-13

Figure 4-4. Lifting Chart

SECTION 4 - MACHINE OPERATION

4-14 – JLG Lift – 3121210

Figure 4-5. Chassis & Platform Tie Down - Sheet 1 of 2

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-15

Figure 4-6. Chassis & Platform Tie Down - Sheet 2 of 2

SECTION 4 - MACHINE OPERATION

4-16 – JLG Lift – 3121210

Figure 4-7. Decal Installation - Sheet 1 of 3

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-17

Figure 4-8. Decal Installation - Sheet 2 of 3

SECTION 4 - MACHINE OPERATION

4-18 – JLG Lift – 3121210

Figure 4-9. Decal Installation - Sheet 3 of 3

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-19

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

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

2 1703805 - - 1703938 1703939 1703935 1703936 1703937 1703940

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

4 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934

5- -- -- -- -- -1705514- -- -

6 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

7 1706948 - - 1706948 1706948 1706948 1706948 1706948 1706948

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

9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642

11 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

12- - - -- -- -- -- -- -- -

13 1701644 1701644 1701644 1701644 1001104864 1701644 1701644 1701644

14 3251813 - - - - - - - - 3251813 - - 3251813

SECTION 4 - MACHINE OPERATION

4-20 – JLG Lift – 3121210

15 - - 1705828 1703980 1703981 1703983 1703984 1703982 1703985

16 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

17 - - - - - - - - 1704007 1704006 - - 1704008

18- - - -- -- -- -- -- -- -

19- - - -- -- -- -- -- -- -

20 - - - - - - - - 3251243 3251243 - - 3251243

21- - - -- -- -- -- -- -- -

22 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702868 - - - - - - 17 04001 1704000 - - 17 04002

25 1704254 1704254 1704254 1704254 1704254 1704254 1704254 1704254

26 1704253 - - 1704253 - - 1704253 17042 53 - - 1704253

27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453

28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-21

29- - - -- -- -- -- -- -- -

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

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

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

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

34- - - -- -- -- -- -- -- -

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

36- - - -- -- -- -- -- -- -

37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500

38 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

39 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

403252347- -- -- -- -- -- -- -

41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

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

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

SECTION 4 - MACHINE OPERATION

4-22 – JLG Lift – 3121210

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

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

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

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

47 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991

48- - - -- -- -- -- -- -- -

49- - - -- -- -- -- -- -- -

50 1702300 1703814 1702300 1702300 1702300 1702300 1702300 1702300

51- - - -- -- -- -- -- -- -

52 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

53 1707013 1705978 1707054 1707042 1707049 1707047 1707044 1707133

54- - - -- -- -- -- -- -- -

55- - - -- -- -- -- -- -- -

56- - - -- -- -- -- -- -- -

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-23

57- - - -- -- -- -- -- -- -

58- - - -- -- -- -- -- -- -

59- - - -- -- -- -- -- -- -

60- - - -- -- -- -- -- -- -

61- - - -- -- -- -- -- -- -

62- - - -- -- -- -- -- -- -

63- - - -- -- -- -- -- -- -

64 1706950 - - - - - - 1706 950 1704252 - - 17 06950

65 1701645 1705978 1707059 1707058 1707056 1707055 1707060 1707134

66 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

67 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

68- - - -- -- -- -- -- -- -

69- - - -- -- -- -- -- -- -

70- - - -- -- -- -- -- -- -

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

SECTION 4 - MACHINE OPERATION

4-24 – JLG Lift – 3121210

71- - - -- -- -- -- -- -- -

72- - - -- -- -- -- -- -- -

73- - - -- -- -- -- -- -- -

74- - - -- -- -- -- -- -- -

75- - - -- -- -- -- -- -- -

76- - - -- -- -- -- -- -- -

77 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

781704830- -- -- -- -- -- -- -

79 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

80- - - -- -- -- -- -- -- -

81 1705351 - - 1705426 1705427 1705910 1705429 1 705430 1001113680

Table 4-1. E450A/E450AJP Decal Legend - Prior to S/N 0300141435

Item # ANSI

0259301-20

CE/AusI

0275070-6

Japanese

0259536-12

Korean

0259538-12

Eng/

Lat. Spanish

0259497-14

Eng/

CSA French

0259495-14

Chinese

/Eng

0259540-12

Spa/
Portuguese
0259499-14

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-25

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

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

2 1703805 - - 1703938 1703939 1703935 1703936 1703937 1703940

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

4 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934

5- -- -- -- -- -1705514- -- -

6 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

7 1706948 - - 1706948 1706948 1706948 1706948 1706948 1706948

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

9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642

11 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

12- - - -- -- -- -- -- -- -

13 1701644 1701644 1701644 1701644 1001104864 1701644 1701644 1701644

14 3251813 - - - - - - - - 32518 13 - - 3251813

SECTION 4 - MACHINE OPERATION

4-26 – JLG Lift – 3121210

15 - - 1705828 1703980 1703981 1703983 1703984 1703982 1703985

16 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

17 - - - - - - - - 1704007 1704006 - - 1704008

18- - - -- -- -- -- -- -- -

19- - - -- -- -- -- -- -- -

20 - - - - - - - - 3251243 3251243 - - 3251243

21- - - -- -- -- -- -- -- -

22 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702868 - - - - - - 17 04001 1704000 - - 17 04002

25 1704254 1704254 1704254 1704254 1704254 1704254 1704254 1704254

26 1704253 - - 1704253 - - 1704253 17042 53 - - 1704253

27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453

28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-27

29- - - -- -- -- -- -- -- -

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

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

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

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

34- - - -- -- -- -- -- -- -

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

36- - - -- -- -- -- -- -- -

37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500

38 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

39 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

403252347- -- -- -- -- -- -- -

41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

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

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

SECTION 4 - MACHINE OPERATION

4-28 – JLG Lift – 3121210

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

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

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

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

47 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991

48- - - -- -- -- -- -- -- -

49- - - -- -- -- -- -- -- -

50 1702300 1703814 1702300 1702300 1702300 1702300 1702300 1702300

51- - - -- -- -- -- -- -- -

52 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

53 1001121814 1705978 1001121854 1001121921 1001121818 1001121816 1001121823 1001121923

54- - - -- -- -- -- -- -- -

55- - - -- -- -- -- -- -- -

56- - - -- -- -- -- -- -- -

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-29

57- - - -- -- -- -- -- -- -

58- - - -- -- -- -- -- -- -

59- - - -- -- -- -- -- -- -

60- - - -- -- -- -- -- -- -

61- - - -- -- -- -- -- -- -

62- - - -- -- -- -- -- -- -

63- - - -- -- -- -- -- -- -

64 1706950 - - - - - - 1706 950 1704252 - - 17 06950

65 1001121801 1705978 1001121808 1001121918 1001121805 1001121803 1001121810 1001121920

66 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

67 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

68- - - -- -- -- -- -- -- -

69- - - -- -- -- -- -- -- -

70- - - -- -- -- -- -- -- -

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

SECTION 4 - MACHINE OPERATION

4-30 – JLG Lift – 3121210

71- - - -- -- -- -- -- -- -

72- - - -- -- -- -- -- -- -

73- - - -- -- -- -- -- -- -

74- - - -- -- -- -- -- -- -

75- - - -- -- -- -- -- -- -

76- - - -- -- -- -- -- -- -

77 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

781704830- -- -- -- -- -- -- -

79 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

80- - - -- -- -- -- -- -- -

81 1705351 - - 1705426 1705427 1705910 1705429 1 705430 1001113680

Table 4-2. E450A/E450AJP Decal Legend - S/N 0300141435 to Present

Item # ANSI

0259301-21

CE/AusI

0275070-6

Japanese

0259536-13

Korean

0259538-13

Eng/

Lat. Spanish

0259497-15

Eng/

CSA French

0259495-15

Chinese

/Eng

0259540-13

Spa/
Portuguese
0259499-15

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-31

Table 4-3. M450A/M450AJ Decal Legend - Prior to S/N 0300141435

Item # ANSI

0258973-21

CE/AusI

0275069-7

Japanese

0259535-15

Korean

0259537-15

Eng/

Spanish

0259496-18

Eng/

French

0259494-18

Chinese

0259539-15

Spa/
Portuguese
0259498-17

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

2 1703805 - - 1 703938 1703939 1703935 1703936 1703937 1703940

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

4 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934

5- -- -- -- -- -1705514- -- -

6 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

7 1706948 - - 1 706948 1706948 1706948 1706948 1706948 1706948

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

9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642

11 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

12- -- -- -- -- -- -- -- -

13 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644

14 3251 813 - - - - - - 3251813 3 251813 - - 3251813

15 - - 1705828 1703980 1703981 1703983 1703984 1703982 1703985

16 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

17 - - - - - - - - 1704007 1704006 - - 1704008

SECTION 4 - MACHINE OPERATION

4-32 – JLG Lift – 3121210

18- -- -- -- -- -- -- -- -

19- -- -- -- -- -- -- -- -

20 - - - - - - - - 3251243 3251243 3251243 3251 243

21- -- -- -- -- -- -- -- -

22 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702 868 - - - - - - 1704001 1 704000 1704000 1704002

25 1704254 1704254 1704254 1704254 1704254 1704254 1704254 1704254

26 1704 253 - - - - - - 1704253 1 704253 - - 1704253

27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453

28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431

29- -- -- -- -- -- -- -- -

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

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

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

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

34- -- -- -- -- -- -- -- -

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

Table 4-3. M450A/M450AJ Decal Legend - Prior to S/N 0300141435

Item # ANSI

0258973-21

CE/AusI

0275069-7

Japanese

0259535-15

Korean

0259537-15

Eng/

Spanish

0259496-18

Eng/

French

0259494-18

Chinese

0259539-15

Spa/
Portuguese
0259498-17

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-33

36- -- -- -- -- -- -- -- -

37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500

38 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

39 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

403252347- -- -- -- -- -- -- -

41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

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

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

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

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

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

47 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50 1702300 1703814 1702300 1702300 1702300 1702300 1702300 1702300

51- -- -- -- -- -- -- -- -

52 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

53 1707013 1705978 1707054 1707042 1707049 1707047 1707044 1707133

Table 4-3. M450A/M450AJ Decal Legend - Prior to S/N 0300141435

Item # ANSI

0258973-21

CE/AusI

0275069-7

Japanese

0259535-15

Korean

0259537-15

Eng/

Spanish

0259496-18

Eng/

French

0259494-18

Chinese

0259539-15

Spa/
Portuguese
0259498-17

SECTION 4 - MACHINE OPERATION

4-34 – JLG Lift – 3121210

54- -- -- -- -- -- -- -- -

55- -- -- -- -- -- -- -- -

56- -- -- -- -- -- -- -- -

57- -- -- -- -- -- -- -- -

58- -- -- -- -- -- -- -- -

59- -- -- -- -- -- -- -- -

60- -- -- -- -- -- -- -- -

61- -- -- -- -- -- -- -- -

62- -- -- -- -- -- -- -- -

63- -- -- -- -- -- -- -- -

64 1706 950 - - - - - - 1706950 1 706950 - - 1706950

65 1701645 1705978 1707059 1707058 1707056 1707055 1707060 1707134

66 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

67 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

68- -- -- -- -- -- -- -- -

69- -- -- -- -- -- -- -- -

70 1704 286 - - 1001093687 10010 93687 1704371 1001093687 1 001093687 1001093687

71- -- -- -- -- -- -- -- -

Table 4-3. M450A/M450AJ Decal Legend - Prior to S/N 0300141435

Item # ANSI

0258973-21

CE/AusI

0275069-7

Japanese

0259535-15

Korean

0259537-15

Eng/

Spanish

0259496-18

Eng/

French

0259494-18

Chinese

0259539-15

Spa/
Portuguese
0259498-17

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-35

72- -- -- -- -- -- -- -- -

731702962- -- -- -- -- -- -- -

74- -- -- -- -- -- -- -- -

75 - - - - 1705084 1705084 - - - - - - - -

76- -- -- -- -- -- -- -- -

77 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

78 1001121510 1001121510 1001121510 1001221510 1001121510 1001121510 1001121510 1001121510

79 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

80- -- -- -- -- -- -- -- -

81 1705 351 - - 1705426 1705427 1705910 - - 1705430 1001113680

Table 4-3. M450A/M450AJ Decal Legend - Prior to S/N 0300141435

Item # ANSI

0258973-21

CE/AusI

0275069-7

Japanese

0259535-15

Korean

0259537-15

Eng/

Spanish

0259496-18

Eng/

French

0259494-18

Chinese

0259539-15

Spa/
Portuguese
0259498-17

SECTION 4 - MACHINE OPERATION

4-36 – JLG Lift – 3121210

Table 4-4. M450A/M450AJ Decal Legend - S/N 0300141435 to Present

Item # ANSI

0258973-22

CE/AusI

0275069-7

Japanese

0259535-16

Korean

0259537-16

Eng/

Spanish

0259496-19

Eng/

French

0259494-19

Chinese

0259539-16

Spa/
Portuguese
0259498-18

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

2 1703805 - - 1 703938 1703939 1703935 1703936 1703937 1703940

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

4 1703798 1705822 1703932 1703933 1703929 1703930 1703931 1703934

5- -- -- -- -- -1705514- -- -

6 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

7 1706948 - - 1 706948 1706948 1706948 1706948 1706948 1706948

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

9 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

10 1701642 1701642 1701642 1701642 1701642 1701642 1701642 1701642

11 1703797 1705921 1703926 1703927 1703923 1703924 1703925 1703928

12- -- -- -- -- -- -- -- -

13 1701644 1701644 1701644 1701644 1701644 1701644 1701644 1701644

14 3251 813 - - - - - - 3251813 3 251813 - - 3251813

15 - - 1705828 1703980 1703981 1703983 1703984 1703982 1703985

16 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

17 - - - - - - - - 1704007 1704006 - - 1704008

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-37

18- -- -- -- -- -- -- -- -

19- -- -- -- -- -- -- -- -

20 - - - - - - - - 3251243 3251243 3251243 3251 243

21- -- -- -- -- -- -- -- -

22 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

23 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864 1001104864

24 1702 868 - - - - - - 1704001 1 704000 1704000 1704002

25 1704254 1704254 1704254 1704254 1704254 1704254 1704254 1704254

26 1704 253 - - - - - - 1704253 1 704253 - - 1704253

27 1704446 1706378 1704417 1704418 1704454 1704452 1704419 1704453

28 1704431 1704431 1704431 1704431 1704431 1704431 1704431 1704431

29- -- -- -- -- -- -- -- -

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

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

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

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

34- -- -- -- -- -- -- -- -

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

Table 4-4. M450A/M450AJ Decal Legend - S/N 0300141435 to Present

Item # ANSI

0258973-22

CE/AusI

0275069-7

Japanese

0259535-16

Korean

0259537-16

Eng/

Spanish

0259496-19

Eng/

French

0259494-19

Chinese

0259539-16

Spa/
Portuguese
0259498-18

SECTION 4 - MACHINE OPERATION

4-38 – JLG Lift – 3121210

36- -- -- -- -- -- -- -- -

37 1701500 1703811 1701500 1701500 1701500 1701500 1701500 1701500

38 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

39 1703813 1705670 1704342 1704343 1704339 1704340 1704344 1704341

403252347- -- -- -- -- -- -- -

41 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952

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

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

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

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

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

47 1702265 1705977 1702271 1703987 1702265 1702265 1703988 1703991

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50 1702300 1703814 1702300 1702300 1702300 1702300 1702300 1702300

51- -- -- -- -- -- -- -- -

52 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

53 1001121814 1705978 1001121854 1001121921 1001121818 1707047 1001121823 1001121923

Table 4-4. M450A/M450AJ Decal Legend - S/N 0300141435 to Present

Item # ANSI

0258973-22

CE/AusI

0275069-7

Japanese

0259535-16

Korean

0259537-16

Eng/

Spanish

0259496-19

Eng/

French

0259494-19

Chinese

0259539-16

Spa/
Portuguese
0259498-18

SECTION 4 - MACHINE OPERATION

3121210 – JLG Lift – 4-39

54- -- -- -- -- -- -- -- -

55- -- -- -- -- -- -- -- -

56- -- -- -- -- -- -- -- -

57- -- -- -- -- -- -- -- -

58- -- -- -- -- -- -- -- -

59- -- -- -- -- -- -- -- -

60- -- -- -- -- -- -- -- -

61- -- -- -- -- -- -- -- -

62- -- -- -- -- -- -- -- -

63- -- -- -- -- -- -- -- -

64 1706 950 - - - - - - 1706950 1 706950 - - 1706950

65 1001121801 1705978 1001121808 1707058 1001121805 1707055 1001121810 1001121920

66 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

67 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

68- -- -- -- -- -- -- -- -

69- -- -- -- -- -- -- -- -

70 1704 286 - - 1001093687 10010 93687 1704371 1001093687 1 001093687 1001093687

71- -- -- -- -- -- -- -- -

Table 4-4. M450A/M450AJ Decal Legend - S/N 0300141435 to Present

Item # ANSI

0258973-22

CE/AusI

0275069-7

Japanese

0259535-16

Korean

0259537-16

Eng/

Spanish

0259496-19

Eng/

French

0259494-19

Chinese

0259539-16

Spa/
Portuguese
0259498-18

SECTION 4 - MACHINE OPERATION

4-40 – JLG Lift – 3121210

72- -- -- -- -- -- -- -- -

731702962- -- -- -- -- -- -- -

74- -- -- -- -- -- -- -- -

75 - - - - 1705084 1705084 - - - - - - - -

76- -- -- -- -- -- -- -- -

77 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

78 1001121510 1001121510 1001121510 1001221510 1001121510 1001121510 1001121510 1001121510

79 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

80- -- -- - - -- -- -- -

81 1705 351 - - 1705426 1705427 1705910 - - 1705430 1001113680

Table 4-4. M450A/M450AJ Decal Legend - S/N 0300141435 to Present

Item # ANSI

0258973-22

CE/AusI

0275069-7

Japanese

0259535-16

Korean

0259537-16

Eng/

Spanish

0259496-19

Eng/

French

0259494-19

Chinese

0259539-16

Spa/
Portuguese
0259498-18

SECTION 5 - EMERGENCY PROCEDURES

3121210 – JLG Lift – 5-1

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:

[e-mail]

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

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

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:

1. Other personnel should operate the machine from
ground controls only as required.

2. Other qualified personnel on the platform may use the
platform controls. DO NOT CONTINUE OPERATION IF
CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to
remove platform occupants and stabilize motion of the
machine.

SECTION 5 - EMERGENCY PROCEDURES

5-2 – JLG Lift – 3121210

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, in case of a
malfunction or power failure, have been incorporated. The
following procedures are to be used ONLY for emergency
movement to a suitable maintenance area.

1. Chock wheels securely.

2. Disengage drive hubs by reversing disconnect caps.

3. Connect suitable equipment, remove chocks, and move

machine.

After moving machine, complete the following procedures:

1. Position machine on a firm and level surface.

2. Chock wheels securely.

3. Engage drive hubs by reversing disconnect caps on

hubs.

4. Remove chocks from wheels as needed.

5.5 MANUAL DESCENT SYSTEM

The manual descent system is used, in the event of total power
failure, to lower the upper and lower booms using gravity. To
operate the manual descent system, proceed as follows:

Machines prior to S/N 0300062850 and from S/N
0300127572 to Present:

1. Locate manual descent knob on main valve and turn
CW (clockwise). Install handle into manual descent
pump and lower the Mid and Lower Booms by pumping
the handle until they are completely lowered.

2. Turn manual descent knob CCW (counterclockwise) and
lower the Upper (or main) Boom by pumping the handle
until it is completely lowered. Return manual descent
knob to center position and stow handle in bracket pro­vided.

S/N 0300062850 to S/N 0300127572:

1. Locate manual descent knob on main valve and turn
CCW (counterclockwise). Install handle into manual
descent pump and lower the Mid and Lower Booms by
pumping the handle until they are completely lowered.

2. Turn manual descent knob CW (clockwise) and lower
the Upper (or main) Boom by pumping the handle until it

SECTION 5 - EMERGENCY PROCEDURES

3121210 – JLG Lift – 5-3

is completely lowered. Return manual descent knob to
center position and stow handle in bracket provided.

5.6 MANUAL SWING OVERRIDE

The manual swing override is used to manually swing boom
and turntable assembly in the event of a total power failure when
the platform is positioned over a structure or obstacle. To oper­ate the manual swing override, proceed as follows:

1. Using a 7/8 inch socket and ratchet wrench, locate nut
on swing worm gear on left side of machine.

2. Install wrench on nut and ratchet in the direction
desired.

SECTION 5 - EMERGENCY PROCEDURES

5-4 – JLG Lift – 3121210

NOTES:

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121210 – JLG Lift – 6-1

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

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

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

Other Publications Available:

Service and Maintenance Manual -

ANSI, CSA Spec ............................................... 3121127

Service and Maintenance Manual - CE Spec........... 3121829

Illustrated Parts Manual - ANSI, CSA Spec .............. 3121128

Illustrated Parts Manual - CE Spec........................... 3121830

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications - Prior to S/N 0300141435

Maximum Work Load (Capacity)
U n re s tr i ct e d : 5 00 l b . ( 2 30 k g )

Travel Speed 3.2 mph (5.2 kph)

Maximum Travel Grade (Gradeablility 30%

Maximum Travel Grade (Side Slope) 5°

Maximum Height: (stowed)
E450A/M450A
E 4 50 A J/ M 45 0 AJ

6 ft. 6.25 i n. (1.9 m)

6 ft. 7 in. (2.0 m)

Maximum Horizontal Platform Reach
E 4 50 A
E 4 50 A J

23 ft. 1in.(7.0 m)

23 ft. 9 in. (7.24 m)

Turning Radius (Curb to Curb) 15 ft. 3 in. (4.65 m)

Turning Radius (inside) 2 ft. (0.61 m)

Maximum Tire Load:
M 45 0 A , E 4 50 A
M450AJ, E450AJ

6100 lbs. (2,767 kg)
6900 lbs. (3,130 kg)

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 – JLG Lift – 3121210

Ground Bearing Pressure
M 45 0 A , E 4 50 A
M 45 0 A J, E 45 0 AJ

64 psi (4.5 kg/cm

2

)

75 psi (5.2 kg/cm

2

)

System Voltage 48 volts

Battery Life per Charge 7 hours continuous

Battery Recharge Time
C ha r g er
G en e r at o r

17 hours from full discharge

6.2 hours

Gross Machine Weight (

Platform Empty)

E450A/M450A
E450AJ/M450AJ

13,100 lb. (5942 kg)
15,100 lb. (6804 kg)

Table 6-2. Operating Specifications - S/N 0300141435 to

Present

Maximum Work Load (Capacity)
A NS I M ar k et s
U n re s tr i ct e d : 5 00 l b . ( 2 27 k g)

Maximum Work Load (Capacity)
CE & Australia Markets
U n re s tr i ct e d : 5 00 l b . ( 2 30 k g)

Travel Speed 3.2 mph (5.2 kph)

Table 6-1. Operating Specifications - Prior to S/N 0300141435

Maximum Travel Grade (Gradeablility 30%

Maximum Travel Grade (Side Slope) 5°

Maximum Height: (stowed)
E450A/M450A
E 4 50 A J/ M 45 0 AJ

6 ft. 6.25 in . (1.9 m)

6 ft. 7 in. (2.0 m)

Maximum Horizontal Platform Reach
E 4 50 A
E 4 50 A J

23 ft. 1in.(7.0 m)

23 ft. 9 in. (7.24 m)

Turning Radius (Curb to Curb) 15 ft. 3 in. (4.65 m)

Turning Radius (inside) 2 ft. (0.61 m)

Maximum Tire Load:
M 45 0 A , E 4 50 A
M450AJ, E450AJ

6100 lbs. (2,767 kg)
6900 lbs. (3,130 kg)

Ground Bearing Pressure
M 45 0 A , E 4 50 A
M450AJ, E450AJ

64 psi (4.5 kg/cm

2

)

75 psi (5.2 kg/cm

2

)

System Voltage 48 volts

Battery Life per Charge 7 hours continuous

Table 6-2. Operating Specifications - S/N 0300141435 to

Present

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121210 – JLG Lift – 6-3

Capacities

Battery Recharge Time
C ha r g er
G en e r at o r

17 hours from full discharge

6.2 hours

Gross Machine Weight (Platform Empty)
E 45 0 A /M 4 50 A
E450AJ/M450AJ

13,100 lb. (5942 kg)
15,100 lb. (6804 kg)

Table 6-2. Operating Specifications - S/N 0300141435 to

Present

Table 6-3. Capacities

Generator Fuel Tank 4 Gallons (15.1 L)

Hydraulic Oil Tank 5 Gallons (19 L) w/ 10% air space

Hydraulic System (Including Tank) 9 Gallons (34.1 L)

To rq ue H ub , D r iv e

*

17 ounces (0.50 L)

*Torque hubs should be one half full of lubricant.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-4 – JLG Lift – 3121210

Tires

Dimensional Data

Table 6-4. Tire Specifications

Size IN240/55-17.5 IN240/55-17.5 26x7x20

Load Range E E N/A

Ply Rating 10 10 N/A

Tire Pressure 90 psi (6.2 Bar) Foam-Filled Solid

Table 6-5. Dimensional Data

Machine Length (stowed)
M 45 0 A , E 4 50 A
M 45 0 A J, E 45 0 AJ

18 ft. 8.0 in. (5.69 m)

21 ft. 2 in. (6.45 m)

Up and Over Platform Height
M 45 0 A , E 4 50 A
M 45 0 A J, E 45 0 AJ

24 ft. 7 in. (7.49 m)

25 ft. 3 in. (7.7 m)

Horizontal Reach @ Maximum
Up and Over
M 45 0 A , E 4 50 A
M 45 0 A J, E 45 0 AJ

23 ft. 1 in. (7.0 m)

23 ft. 9 in. (7.24 m)

Machine Width 5 ft. 9 in. (1.75 m)

Wheel Base 6 ft. 7.0 in. (2.00 m)

Working Height 51 ft. 0 in. (15.54 m)

Platform Height 45 ft. 0 in. (13.72 m)

Track Width 5 ft. 0 in. (1.51 m)

Tail Swing (Any Position) 0

Ground Clearance
M450, E450
M450AJ, E450AJ

8.5 in. (0.22 m)
8 in. (0.20 m)

Table 6-5. Dimensional Data

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121210 – JLG Lift – 6-5

Torque Specifications Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities at least to API

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

Aside from JLG recommendations, it is not advisable to
mix oils of different brands or types, as they may not con­tain the same required additives or be of comparable vis­cosities. If use of hydraulic oil other than Mobil DTE 11M
is desired, contact JLG Industries for proper recommen­dations.

Table 6-6. Torque Requirements

Description Torque Value Interval Hours

Wheel Lugs 170 ft. lbs.

(230 Nm)

150

Swing Bearing

((Loctite)

190 ft. lbs.

(260 Nm)

50/600*

* Check swing bearing bolts for security after
first 50 hours of operation and every 600 hours
thereafter.

Table 6-7. Hydraulic Oil

Hydraulic System

Operating

Temperature Range

S.A.E. Viscosity

Grade

+0° to + 180° F
(-18° to +83° C)

10W

+0° to + 210° F
(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F

(+10° to +99° C

20W-20

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-6 – JLG Lift – 3121210

Lubrication Specifications

NOTE: Refer to Figure 6-2., Operator Maintenance & Lubrication

Diagram, for specific lubrication procedures.

Critical Stability Weights

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

Table 6-8. Mobil DTE 11M Specs

ISO Viscosity Grade #15

Gravity API 31.9

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

Viscosity Index 140

Table 6-9. Critical Stability Weights

Component LB. KG.

Counterweight 3850 1746

Tire & Wheel (foam-filled) 207 94

P la t fo r m (4 f t [1 . 2 m] ) 90 41

Platform (5 ft [1.5 m]) 100 45

Battery (each) 120 54

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121210 – JLG Lift – 6-7

Serial Number Locations

For machine identification, a serial number plate is affixed to
the left rear of frame, in front of left rear wheel. If the serial
number plate is damaged or missing, the machine serial
number is stamped on the top left side of the frame and the
top left side of the turntable. In addition, the serial number is

stamped on top of the end of the upper boom, mid boom,
and lower boom at the left rear of the booms.

Figure 6-1. Serial Number Locations

SERIAL NUMBER PLATE

SERIAL NUMBER FRAME

SERIAL NUMBER

TURNTABLE

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-8 – JLG Lift – 3121210

Figure 6-2. Operator Maintenance & Lubrication Diagram

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

3121210 – JLG Lift – 6-9

6.3 OPERATOR MAINTENANCE

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

2., Operator Maintenance & Lubrication Diagram.

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

1. Swing Bearing

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

Table 6-10. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of

350 degrees F. Excellent water resistance and adhesive qual­ities; and being of extreme pressure type (Timken OK 40
pounds minimum).

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

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

HO Hydraulic Oil. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Com-

pound. (JLG Part No. 3020027)

BG* Bearing Grease (JLG Par t No. 3020029) Mobilith SHA 460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part

No. 3020022)

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

D ie se l - A PI CC /C D c l as s, MI L- L-2 10 4B /M I L-L- 21 04 C.

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

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-10 – JLG Lift – 3121210

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - Grease Fittings
Capacity - Spray On
Lube - OG or Mobiltac375NC
Interval - A/R
Comments - If necessary install grease fittings into worm
gear housing and grease bearings.

NOTE: OG will allow better cycle times than Mobiltac375NC,

however Mobiltac375NC must be used in dusty environ­ments. If the swing function becomes noisy and/or rough
lubricate the bearing teeth.

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