property of american airlines - amazon s3 · 2018-12-03 · foreword b – jlg lift – 3121658...

ANSI ®

Operation and Safety ManualOriginal Instructions - Keep this manual with the machine at all times.

Boom Lift Models450A450AJS/N 0300199221 to Present &S/N E300000001to Present

3121658January 23, 2017

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FOREWORD

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3121658 – JLG Lift –

FOREWORD

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

The purpose of this manual is to provide owners, users, operators, lessoprocedures essential for the safe and proper machine operation for its in

Due to continuous product improvements, JLG Industries, Inc. reservesprior notification. Contact JLG Industries, Inc. for updated information.

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FOREWORD

b 3121658

SIGNAL WORDS

INDIRESUGROU

INDIRESUGROU

TIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULTRATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.

AVE A YELLOW BACKGROUND.

IMPORTANTATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-ETY OF PERSONNEL OR PROTECTION OF PROPERTY.

potential personal injury avoid possible injury oran

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– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILLLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-ND.

CATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULDLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-ND.

INDICATES A POTENIN MINOR OR MODETHIS DECAL WILL H

INDICATES INFORMRECTLY TO THE SAF

This is the Safety Alert Symbol. It is used to alert you to the hazards. Obey all safety messages that follow this symbol todeath

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FOREWORD

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ct:uct Safety and Reliability Department

Industries, Inc.4 Fountainhead Plaza

erstown, MD 21742

ur Local JLG Office addresses on rear cover)

A:

Free: 877-JLG-SAFE (877-554-7233)

de USA:e: 240-420-2661

301-745-3713il: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

ions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Prod-uct Modificationsan

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3121658 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLGINDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FORTHIS PRODUCT.

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

IMPORTANTJLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHEREJLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURYOR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-SONAL PROPERTY OR THE JLG PRODUCT.

ContaProdJLG 1322HagUSA

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REVISION LOG

riginal Issue - February 2, 2015

vised - April 2, 2015

vised - July 6, 2015

vised - January 19, 2016

vised - July 19, 2016

vised - January 23, 2017

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312 i

SEC PARAGRAPH, SUBJECT PAGE

TABLE OF CONTENTS

SEC

SECA

SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

OSCILLATING AXLE LOCKOUT TEST . . . . . . . . . . . . . . . . . . 2-12

- MACHINE CONTROLS AND INDICATORS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-8Ground Control Console Display Gauge . . . . . . . . . . 3-12Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-20

- MACHINE OPERATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1BOOM OPERATING CHARACTERISTICS AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

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

ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-5

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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TION - PARAGRAPH, SUBJECT PAGE SECTION -TION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-111.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

TION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, ND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.3

SECTION - 3

3.13.2

SECTION - 4

4.14.2

4.3

4.4

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TABLE OF CONTENTS

SECTIO AGRAPH, SUBJECT PAGE4.54.6

4.7

4.84.9

4.14.1

4.1

SECTION

5.15.25.3

UAL SWING OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2RGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2HINE SAFETY SYSTEM OVERRIDE (MSSO)ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

NERAL SPECIFICATIONS & OPERATOR E

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1RATING SPECIFICATIONS AND PERFORMANCE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

perating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1imensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2pacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3gine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3draulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

ajor Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-8RATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21S & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34re Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34heel and Tire Replacement . . . . . . . . . . . . . . . . . . . . . 6-34heel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34PANE FUEL FILTER REPLACEMENT (GM ENGINE) . 6-36moval . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

stallation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37

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N - PARAGRAPH, SUBJECT PAGE SECTION - PARSTEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-11Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12

FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-12MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY) .4-12

0 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-131 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-142 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2

5.4 MAN5.5 EME5.6 MAC

(CE

SECTION - 6 - GEMAINTENANC

6.1 INTR6.2 OPE

DATODCaTiEnHyM

6.3 OPE6.4 TIRE

TiWW

6.5 PROReIn

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TION - PARAGRAPH, SUBJECT PAGE SECTION -6.6 PROPANE FUEL SYSTEM PRESSURE RELIEF

(GM ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-376.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-38

TION - 7 - INSPECTION AND REPAIR LOG

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N - PARAGRAPH, SUBJECT PAGE SECTION - PAR

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LIST OF FIGURES

FIG MBER - TITLE PAGEEngine Operating Temperature Specifications - Deutz 2.3L

- Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Engine Operating Temperature Specifications - Deutz 2.3L

- Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Engine Operating Temperature Specifications - GM - Sheet

1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11Engine Operating Temperature Specifications - GM - Sheet

2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12Engine Operating Temperature Specifications -

Deutz 2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13Hydraulic Oil Operation Chart - Sheet 1 of 2. . . . . . . . . . 6-14Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . 6-15Engine Oil Operation Chart - Kubota. . . . . . . . . . . . . . . . . 6-16Operator Maintenance and Lubrication Diagram - Deutz

2.3L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17Operator Maintenance and Lubrication Diagram - GM

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18Operator Maintenance and Lubrication Diagram - Deutz

2.9L Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19Operator Maintenance and Lubrication Diagram - Kubota

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

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URE NUMBER - TITLE PAGE FIGURE NU2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-82-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . . . . . . 2-92-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . . . . . 2-102-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . . . . . . 2-113-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33-2. Ground Control Console with MSSO (CE Only) . . . . . . . . 3-43-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-93-4. Ground Control Indicator Panel - Kubota Engine . . . . . 3-103-5. Splash Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123-6. Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133-7. Engine Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-133-8. Ground Control Console Display Gauge . . . . . . . . . . . . . 3-143-9. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-163-10. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-214-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-64-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-74-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-84-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-154-6. Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-164-7. Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-174-8. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-184-9. Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-194-10. Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-204-11. Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

6-1.

6-2.

6-3.

6-4.

6-5.

6-6.6-7.6-8.6-9.

6-10.

6-11.

6-12.

6-13.

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F FIGURES

NUMBER - TITLE PAGE FIGURE NUMB


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LIST OF TABLES

TAB MBER - TITLE PAGE

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LE NUMBER - TITLE PAGE TABLE NU1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-61-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-92-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-34-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-134-2 Decal Legend - Language Markets . . . . . . . . . . . . . . . . . . .4-224-3 Decal Legend - Kubota Engine-Powered Machines . . .4-256-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-5 Deutz D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-6 Deutz D2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-7 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-8 Kubota WG 2503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-11 DTE 10 Excel 15 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-12 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-13 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86-15 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86-16 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .6-216-17 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-357-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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F TABLES

UMBER - TITLE PAGE TABLE NUMBE


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SECTION 1 - SAFETY PRECAUTIONS

1-1

UTIONS

MPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR

-OPERATION

raining and Knowledge Operation and Safety Manual must be read and under-d in its entirety before operating the machine. For clarifi-

on, questions, or additional information regarding anytions of this manual, contact JLG Industries, Inc.

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SECTION 1. SAFETY PRECA

1.1 GENERALThis section outlines the necessary precautions for proper andsafe machine usage and maintenance. It is mandatory that a dailyroutine is established based on the content of this manual to pro-mote proper machine usage. A maintenance program, using theinformation provided in this manual and the Service and Mainte-nance Manual, must also be established by a qualified person andmust be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must notaccept operating responsibility until this manual has been read,training is accomplished, and operation of the machine has beencompleted under the supervision of an experienced and quali-fied operator.

This section contains the responsibilities of the owner, user, oper-ator, lessor, and lessee concerning safety, training, inspection,maintenance, application, and operation. If there are any ques-tions with regard to safety, training, inspection, maintenance,application, and operation, please contact JLG Industries, Inc.(“JLG”).

FAILURE TO COCOULD RESULTDEATH.

1.2 PRE

Operator T• The

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1-2 3121658

pectionns to avoid all hazards in the work area must be

the user before and during operation of the machine.

perate or raise the platform from a position on trucks,ailway cars, floating vessels, scaffolds or other equip-less the application is approved in writing by JLG.

peration, check work area for overhead hazards suchic lines, bridge cranes, and other potential overheadions.

erating surfaces for holes, bumps, drop-offs, obstruc-bris, concealed holes, and other potential hazards.

e work area for hazardous locations. Do not operateine in hazardous environments unless approved forose by JLG.

hat the ground conditions are adequate to supportimum tire load indicated on the tire load decalsn the chassis adjacent to each wheel. Do not travelported surfaces.

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• An operator must not accept operating responsibilities untiladequate training has been given by competent and autho-rized persons.

• Allow only those authorized and qualified personnel to oper-ate the machine who have demonstrated that they under-stand the safe and proper operation and maintenance of theunit.

• Read, understand, and obey all DANGERS, WARNINGS, CAU-TIONS, and operating instructions on the machine and in thismanual.

• Ensure that the machine is to be used in a manner which iswithin the scope of its intended application as determined byJLG.

• All operating personnel must be familiar with the emergencycontrols and emergency operation of the machine as specifiedin this manual.

• Read, understand, and obey all applicable employer, local, andgovernmental regulations as they pertain to your utilizationand application of the machine.

Workplace Ins• Precautio

taken by

• Do not otrailers, rment un

• Before oas electrobstruct

• Check options, de

• Check ththe machthat purp

• Ensure tthe maxlocated oon unsup

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1-3

RATION

hine operation requires your full attention. Bring thehine to a full stop before using any device, i.e. cell phones,-way radios, etc. that will distract your attention fromly operating the machine.

not use the machine for any purpose other than position-personnel, their tools, and equipment.

re operation, the user must be familiar with the machineabilities and operating characteristics of all functions.

er operate a malfunctioning machine. If a malfunctionrs, shut down the machine. Remove the unit from service

notify the proper authorities.

ot remove, modify, or disable any safety devices.

er slam a control switch or lever through neutral to anosite direction. Always return switch to neutral and stopre moving the switch to the next function. Operate con- with slow and even pressure.

not allow personnel to tamper with or operate thehine from the ground with personnel in the platform,pt in an emergency.

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3121658 – JLG Lift –

Machine Inspection • Do not operate this machine until the inspections and func-

tional checks as specified in Section 2 of this manual havebeen performed.

• Do not operate this machine until it has been serviced andmaintained according to the maintenance and inspectionrequirements as specified in the machine’s Service and Main-tenance Manual.

• Ensure all safety devices are operating properly. Modificationof these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADEONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instructionplacards or decals are missing or illegible.

• Check the machine for modifications to original components.Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil,grease, and other slippery substances from footwear and plat-form floor.

1.3 OPE

General • Mac

mactwosafe

• Do ing

• Befocap

• Nevoccuand

• Do n

• Nevoppbefotrols

• Do macexce

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1-4 3121658

c cylinders are subject to thermal expansion and con-This may result in changes to the boom and/or plat-sition while the machine is stationary. Factors thermal movement can include the length of timeine will remain stationary, hydraulic oil temperature,

air temperature, and boom and platform position.

azards peration, occupants in the platform must wear a fullness with a lanyard attached to an authorized lanyarde point. Attach only one (1) lanyard per lanyarde point.

d exit only through gate area. Use extreme cautiontering or leaving platform. Ensure that the platform is fully lowered. Face the machine when entering orhe platform. Always maintain “three point contact” machine, using two hands and one foot or two feethand at all times during entry and exit.

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• Do not carry materials directly on platform railing unlessapproved by JLG.

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

• Always ensure that power tools are properly stowed and neverleft hanging by their cord from the platform work area.

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

• Do not assist a stuck or disabled machine by pushing or pull-ing except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leavingmachine.

• Remove all rings, watches, and jewelry when operatingmachine. Do not wear loose fitting clothing or long hair unre-strained which may become caught or entangled in equip-ment.

• Persons under the influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

• Hydraulitraction. form poaffectingthe machambient

Trip and Fall H• During o

body haranchoraganchorag

• Enter anwhen enassemblyleaving twith theand one

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1-5

ion Hazards machine is not insulated and does not provide protection contact or proximity to electrical current.

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3121658 – JLG Lift –

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

• Keep both feet firmly positioned on the platform floor at alltimes. Never position ladders, boxes, steps, planks, or similaritems on unit to provide additional reach for any purpose.

• Keep oil, mud, and slippery substances cleaned from footwearand the platform floor.

Electrocut• This

from

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a clearance of at least 10 ft. (3m) between any part ofhine and its occupants, their tools, and their equip-m any electrical line or apparatus carrying up toolts. One foot additional clearance is required forditional 30,000 volts or less.

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

e Rangeto Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

50 KV 10 (3)

V to 200 KV 15 (5)

V to 350 KV 20 (6)

V to 500 KV 25 (8)

V to 750 KV 35 (11)

V to 1000 KV 45 (14)

requirement shall apply except whereloyer, local or governmental regulations are

re stringent.

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• Maintain distance from electrical lines, apparatus, or any ener-gized (exposed or insulated) parts according to the MinimumApproach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintainthe macment fro50,000 vevery ad

Table 1

Voltag(Phase

0 to

Over 50K

Over 200 K

Over 350 K

Over 500 K

Over 750 K

NOTE: Thisempmo

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1-7

azards user must be familiar with the surface before driving. Doexceed the allowable sideslope and grade while driving.

not elevate platform or drive with platform elevated whiler near a sloping, uneven, or soft surface. Ensure machine is

itioned on a firm, level and smooth surface before elevat-platform or driving with the platform in the elevated posi-.

re driving on floors, bridges, trucks, and other surfaces,ck allowable capacity of the surfaces.

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• The minimum approach distance may be reduced if insulatingbarriers are installed to prevent contact, and the barriers arerated for the voltage of the line being guarded. These barriersshall not be part of (or attached to) the machine. The mini-mum approach distance shall be reduced to a distance withinthe designed working dimensions of the insulating barrier.This determination shall be made by a qualified person inaccordance with the employer, local, or governmental require-ments 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 OTH-ERWISE.

Tipping H• The

not

• Do on oposing tion

• Befoche

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perate the machine when wind conditions, includingay exceed 28 mph (12.5 m/s). Factors affecting winde; platform elevation, surrounding structures, localevents, and approaching storms. Refer to Table 1-2, scale (For Reference Only) or use other means towind conditions.

eed can be significantly greater at height than atevel.

ed can change rapidly. Always consider approachingevents, the time required to lower the platform, and to monitor current and potential wind conditions.

increase surface area of the platform or the load. areas exposed to wind will decrease stability.

crease the platform size with unauthorized modifica-ttachments.

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• Never exceed the maximum work load as specified on theplatform. Keep all loads within the confines of the platform,unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m)from holes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards at the ground level.

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

• Never attempt to use the machine as a crane. Do not tie-offmachine to any adjacent structure. Never attach wire, cable, orany similar items to platform.

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

• Do not ogusts, mspeed arweather Beaufortmonitor

• Wind spground l

• Wind speweather methods

• Do not Increased

• Do not intions or a

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1-9

nce Only)

Land Conditions

vertically

le in smoke

ed skin. Leaves rustle

twigs in constant motion

er raised. Small branches begin to move.

.

otion. Flags waving near horizontal. Umbrella use

ion. Effort needed to walk against the wind.

trees. Cars veer on road.

age.

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3121658 – JLG Lift –

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

Table 1-2. Beaufort Scale (For Refere

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises

1 1-3 0.3-1.5 Light air Wind motion visib

2 4-7 1.6-3.3 Light breeze Wind felt on expos

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller

4 13-18 5.5-7.9 Moderate breeze Dust and loose pap

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

6 25-31 10.8-13.8 Strong breeze Large branches in mbecomes difficult.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in mot

8 39-46 17.2-20.7 Fresh Gale Twigs broken from

9 47-54 20.8-24.4 Strong Gale Light structure dam

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Cru n-operating personnel at least 6 ft. (1.8m) away from during all driving and swing operations.

ll travel conditions, the operator must limit travelcording to conditions of ground surface, congestion, slope, location of personnel, and other factors whichse collision or injury to personnel.

of stopping distances in all drive speeds. When driv-h speed, switch to low speed before stopping. Travel low speed only.

se high speed drive in restricted or close quarters orving in reverse.

extreme caution at all times to prevent obstacles fromr interfering with operating controls and persons in

orm.

that operators of other overhead and floor levels are aware of the aerial work platform’s presence. Dis-power to overhead cranes.

rsonnel not to work, stand, or walk under a raised platform. Position barricades on floor if necessary.

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shing and Collision Hazards• Approved head gear must be worn by all operating and

ground personnel.

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

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

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

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

• Keep nomachine

• Under aspeed acvisibility,may cau

• Be awareing in higgrades in

• Do not uwhen dri

• Exercise striking othe platf

• Be sure machineconnect

• Warn peboom or

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1-11

INTENANCEb-section contains general safety precautions which musterved during maintenance of this machine. Additional pre-ns to be observed during machine maintenance ared at the appropriate points in this manual and in the Ser-d Maintenance Manual. It is of utmost importance thatnance personnel pay strict attention to these precautionsd possible injury to personnel or damage to the machineerty. A maintenance program must be established by a

ied person and must be followed to ensure that thee is safe.

nce Hazardst off power to all controls and ensure that all moving partssecured from inadvertent motion prior to performing anystments or repairs.

er work under an elevated platform until it has been fullyered to the full down position, if possible, or otherwiseported and restrained from movement with appropriatety props, blocking, or overhead supports.

NOT attempt to repair or tighten any hydraulic hoses or fit-s while the machine is powered on or when the hydraulicem is under pressure.

ays relieve hydraulic pressure from all hydraulic circuitsre loosening or removing hydraulic components.

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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 ofemergency, malfunction, power failure, or loading/unloading.Refer to the Emergency Procedures section of this manual foremergency towing procedures.

• Ensure boom is in the stowed position and the turntablelocked prior to towing, lifting or hauling. The platform must becompletely empty of tools.

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

• Refer to the Machine Operation section of this manual for lift-ing information.

1.5 MAThis sube obscautioinsertevice anmainteto avoior propqualifmachin

Maintena• Shu

are adju

• Nevlowsupsafe

• DO tingsyst

• Alwbefo

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1-1 3121658

se machine as a ground for welding.

rforming welding or metal cutting operations, pre- must be taken to protect the chassis from direct to weld and metal cutting spatter.

fuel the machine with the engine running.

approved non-flammable cleaning solvents.

eplace items critical to stability, such as batteries ors, with items of different weight or specification. Doify unit in any way to affect stability.

the Service and Maintenance Manual for the weightsl stability items.

LTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADERITTEN PERMISSION FROM THE MANUFACTURER.

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• DO NOT use your hand to check for leaks. Use a piece of card-board or paper to search for leaks. Wear gloves to help protecthands from spraying fluid.

• Ensure replacement parts or components are identical orequivalent to original parts or components.

• Never attempt to move heavy parts without the aid of amechanical device. Do not allow heavy objects to rest in anunstable position. Ensure adequate support is provided whenraising components of the machine.

• Do not u

• When pecautionsexposure

• Do not re

• Use only

• Do not rsolid tirenot mod

• Refer to of critica

MODIFICATION OR AONLY WITH PRIOR W

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1-13

ID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH AND SEEK MEDICAL ATTENTION.

rge batteries only in a well ventilated area.

id overfilling the battery fluid level. Add distilled water toeries only after the batteries are fully charged.an

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3121658 – JLG Lift –

Battery Hazards• Always disconnect batteries when servicing electrical compo-

nents or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery dur-ing charging or servicing.

• Do not contact tools or other metal objects across the batteryterminals.

• Always wear hand, eye, and face protection when servicingbatteries. Ensure that battery acid does not come in contactwith skin or clothing.

BATTERY FLUCLOTHING ATCLEAN WATER

• Cha

• Avobatt

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NOTES:

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S, MACHINE PREPARATION, AND INSPECTION

2-1

REPARATION, AND INSPECTION

e safest means to operate the machine where overheadstructions, other moving equipment, and obstacles,pressions, holes, or drop-offs exist.

eans to avoid the hazards of unprotected electrical con-ctors.

ecific job requirements or machine application.

upervisiong must be done under the supervision of a qualified per- an open area free of obstructions until the trainee hasped the ability to safely control and operate the machine.

esponsibilityerator must be instructed that he/she has the responsibil- authority to shut down the machine in case of a malfunc- other unsafe condition of either the machine or the job

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SECTION 2 - USER RESPONSIBILITIE
3121658 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE P

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it is neces-sary that it be operated and maintained only by trained person-nel.

Persons under the influence of drugs or alcohol or who are sub-ject to seizures, dizziness or loss of physical control must notoperate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at theground, 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 themachine to recognize a malfunction or potential malfunc-tion.

6. Thobde

7. Mdu

8. Sp

Training STraininson indevelo

Operator RThe opity andtion orsite.

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121658

2.2. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A

UCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL PRODUCT MODEL.

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PREPARATION, INSPECTION, AND MAINTENANCEThe following table covers the periodic machine inspections andmaintenance required by JLG Industries, Inc. Consult local regula-tions for further requirements for aerial work platforms. The fre-quency of inspections and maintenance must be increased asnecessary when the machine is used in a harsh or hostile environ-ment, if the machine is used with increased frequency, or if themachine is used in a severe manner.

JLG INDUSTRIES, INCPERSON WHO HAS SFOR THE SPECIFIC JLG

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2-3

nce Table

yility

Service Qualification

Reference

User or Operator Operator and Safety Manual

ser Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

ser Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

ser Factory TrainedService Technician(Recommended)

Service and Maintenance Manual and applicable JLG inspection form

ser Qualified JLG Mechanic Service and Maintenance Manual

ual to perform inspections.

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Table 2-1. Inspection and Maintena

Type FrequencyPrimar

Responsib

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operator

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer, or U

Frequent Inspection(See Note)

In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer, or U

Annual Machine Inspection(See Note)

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

Owner, Dealer, or U

Preventative Maintenance At intervals as specified in the Service and Maintenance Manual.

Owner, Dealer, or U

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Man

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2-4 3121658

Pre tion and Safety Manuals – Make sure a copy of theion and Safety Manual, AEM Safety Manual (ANSIs only), and ANSI Manual of Responsibilities (ANSIs only) is enclosed in the weather resistant storageer.

Around” Inspection – Refer to Figure 2-2.

y – Charge as required.

ombustion Engine Powered Machines) – Add the fuel as necessary.

Oil Supply - Ensure the engine oil level is at the Full n the dipstick and the filler cap is secure.

ulic Oil – Check the hydraulic oil level. Ensure hydrau- added as required.

ories/Attachments - Reference the Operator andManual of each attachment or accessory installedhe machine for specific inspection, operation, andnance instructions.

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

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-tery fluid) or foreign objects. Report any leakage to theproper maintenance personnel.

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

3. Decals and Placards – Check all for cleanliness and legibil-ity. Make sure none of the decals and placards are missing.Make sure all illegible decals and placards are cleaned orreplaced.

4. OperaOperatmarketmarketcontain

5. “Walk-

6. Batter

7. Fuel (Cproper

8. Enginemark o

9. Hydralic oil is

10. AccessSafety upon tmainte

Parent Metal Crack Weld Crack

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2-5

heck the Function Check as follows:

om the ground control console with no load in the plat-rm:

. Check that all guards protecting the switches or locksare in place;

. Operate all functions and ensure proper operation;

. Check auxiliary power and ensure proper operation;

. Ensure that all machine functions are disabled whenthe Emergency Stop Button is pushed in.

. Ensure all boom functions stop when the functionenable switch is released.

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3121658 – JLG Lift –

11. Function Check – Once the “Walk-Around” Inspection iscomplete, perform a functional check of all systems in anarea free of overhead and ground level obstructions. Refer toSection 4 for more specific operating instructions.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOTOPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.

Function CPerform

1. Frfo

a

b

c

d

e

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2-6 3121658

the boom over either of the rear tires and ensure thative Orientation indicator illuminates and that therientation Override switch must be used for the driven to operate.

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2. From the platform control console:

a. Ensure that the control console is firmly secured in theproper location;

b. Check that all guards protecting the switches or locksare in place;

c. Operate all functions and ensure proper operation;

d. Ensure that all machine functions are disabled whenthe Emergency Stop Button is pushed in.

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

3. With the platform in the stowed position:

a. Drive the machine on a grade, not to exceed the ratedgradeability, and stop to ensure the brakes hold;

b. Check that the tilt indicator is illuminated to ensureproper operation.

4. Swing the DrDrive Ofunctio

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2-7

quipped, ensure the SkyGuard beacon illuminates when Sky-ard is activated.

age the SkyGuard sensor, release controls, recycle the foot, make sure normal operation is available.

uard remains activated after function reversal or cutout,s and hold the SkyGuard Override Switch to allow normal machine functions until the SkyGuard sensor is disen-an

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3121658 – JLG Lift –

SkyGuard Function Test From the Platform Console:

Test the SkyGuard feature by operating the telescope out func-tions and then activating the SkyGuard sensor. The telescope outfunction will stop and the telescope in function will operate for ashort duration and the horn will sound until the SkyGuard sensorand footswitch are disengaged.

NOTE: If eGu

Disengswitch

If SkyGdepresuse ofgaged.

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1

1. Platform2. SkyGuard (If Equipped)3. Cross Rail (If Equipped)4. Platform Console5. Jib (If Equipped)6. Fly Boom Section7. Base Boom Section8. Powertrack9. Main Lift Cylinder10. Master Cylinder11. Upper Upright12. Lower Upright13. Tower Lift Cylinder14. Tower Boom15. Turntable16. Front Drive/Steer Wheels17. Rear Drive Wheels18. Frame

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4

5

67

8

9

10

1112

13

14

15

16

17

18

3

2

Figure 2-1. Basic Nomenclature

OR

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2-9

1

2

8

88

15

16

n - Sheet 1 of 3

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3121658 – JLG Lift –

2

3

4

5

55

56

6

6

6

7

78

8

8

8

9

10

10

11

12

13

14

Figure 2-2. Daily Walk-Around Inspectio

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2-1 3121658

Ge

TO A

DO

Sections/Uprights/Turntable - See Inspection

Motor and Worm Gear - No evidence of damage.

l/Tire Assemblies - Properly secured, no missing lugInspect for worn tread, cuts, tears or other discrepan-

spect wheels for damage and corrosion.

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

Assemblies - See Inspection Note.

draulic Cylinders - No visible damage; pivot pinsydraulic hoses undamaged, not leaking.

able Bearing - Evidence of proper lubrication. Nonce of loose bolts or looseness between bearing andine.

od Ends and Steering Spindles - See Inspection

eet 2 of 3

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neralBegin the "Walk-Around Inspection" at Item 1, as noted on thediagram. Continue checking each item in sequence for the con-ditions listed in the following checklist.

VOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are noloose or missing parts, that they are securely fastened, and no visi-ble damage, leaks or excessive wear exists in addition to any othercriteria mentioned.

1. Platform Assembly and Gate - Footswitch works prop-erly, not modified, disabled or blocked. Latch and hingesin working condition.

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

3. BoomNote.

4. Swing

5. Wheenuts. cies. In

6. Drive

7. Hood

8. All Hyand h

9. Turntevidemach

10. Tie RNote.

Figure 2-3. Daily Walk-Around Inspection - Sh

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2-11

attery - Batteries have proper electrolyte level; cablesight; see Inspection Note.

latform Rotator - See Inspection Note.

kyGuard (If Equipped) - See Inspection Note.

- Sheet 3 of 3

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3121658 – JLG Lift –

11. Hydraulic Pump - See Inspection Note.

12. Fuel Tank - See Inspection Note.

13. Hydraulic Reservoir - See Inspection Note.

14. Bt

15. P

16. S

Figure 2-4. Daily Walk-Around Inspection

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2-1 3121658

2.3

LOCKPONE

NOT

rive control lever to Reverse and drive machine off ofnd ramp.

n assistant check to see that left front or right rearremains elevated in position off of ground.

lly return boom to stowed position (centeredn rear wheels if swung or fully lowered if raised).boom reaches stowed position, lockout cylinders release and allow wheel to rest on ground, it may beary to activate Drive to release cylinders.

he 6 inches (15.2 cm) high block with ascension rampt of right front wheel.

Drive control lever to Forward and carefully drivee up ascension ramp until right front wheel is on top

k.

steps 4 thru 7 to check the opposite side of the oscil-xle.

ut cylinders do not function properly, have qualifiednel correct the malfunction prior to any further oper-

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OSCILLATING AXLE LOCKOUT TEST

OUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-NT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

E: Ensure boom is fully retracted, lowered, and centered betweenrear wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp infront of left front wheel.

2. From platform control console, start engine.

3. Place the Drive control lever to the forward position andcarefully drive machine up ascension ramp until left frontwheel is on top of block.

4. Carefully activate Swing control lever and position boomover right side of machine or raise the main boom enoughto get it out of the transport position.

5. Place Dblock a

6. Have awheel

7. CarefubetweeWhen shouldnecess

8. Place tin fron

9. Place machinof bloc

10. Repeatlating a

11. If lockopersonation.

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N 3 - MACHINE CONTROLS AND INDICATORS

3-1

ND INDICATORS

indicator panels use different shaped symbols to alert therator to different types of operational situations that could

se. The meaning of those symbols are explained below.Indicates a potentially hazardous situation, which ifnot corrected, could result in serious injury or death.This indicator will be red.

Indicates an abnormal operating condition, which ifnot corrected, may result in machine interruption ordamage. This indicator will be yellow.

Indicates important information regarding the oper-ating condition, i.e. procedures essential for safe oper-ation. This indicator will be green with the exception ofthe capacity indicator which will be green or yellowdepending upon platform position.

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3121658 – JLG Lift –

SECTION 3. MACHINE CONTROLS A

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION ANDOPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITHGOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control consoles that use sym-bols to indicate control functions. On ANSI machines refer todecal located on the control box guard in front of the control boxor by the ground controls for these symbols and the correspond-ing functions.

NOTE: Theopeari

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121658

TO ATOGGOFF P

Gro

(Str

NOT

Gauge

rs the amount of time the machineen in use, with engine running. Theeter registers up to 16,500 hours and be reset.

IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BEOFF POSITION TO PREVENT DRAINING THE BATTERIES.

Emergency Stop Switch

position red mushroom shaped switchs power to PLATFORM/GROUND switch when pulled out (on). When in (off ), power is shut off to the PLATFORM/GROUND switch.

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VOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THEOSITION WHEN RELEASED.

und Control Console

ee Figure 3-1., Ground Control Console and Figure 3-2., Ground Con-ol Console with MSSO (CE Only).)

1. Indicator Panel

The Indicator Panel contains indicator lights that signalproblem conditions or functions operating during machineoperation.

E: The Function Enable switch must be held down inorder to operate Main Boom Telescope, Tower Lift,Swing, Main Lift, Jib Lift, Platform Level Override,and Platform Rotate functions.

2. Display

Registehas behourmcannot

WHEN THE MACHINEPOSITIONED TO THE

3. Power/

A two-supplieSELECTpushedSELECT

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3-3

9

10

11

sole

1. Indicator Panel2. Display Gauge3. Power/Emergency Stop4. Platform/Ground Select5. Platform Level6. Platform Rotate7. Jib Lift (If Equipped)8. Telescope9. Main Boom Lift10. Tower Boom Lift11. Swing12. Engine Start/Auxiliary Power/ Function Enable

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3121658 – JLG Lift –

1

2

3

45

687

12

Figure 3-1. Ground Control Con

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3-4 3121658

9

10

11

(CE Only)

1. Indicator Panel2. Display Gauge3. Power/Emergency Stop4. Platform/Ground Select5. Platform Level6. Platform Rotate7. Jib Lift (If Equipped)8. Telescope9. Main Boom Lift10. Tower Boom Lift11. Swing12. Engine Start/Auxiliary Power/ Function Enable13. Machine Safety System Override (MSSO)

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1

2

3

45

687

1213

Figure 3-2. Ground Control Console with MSSO

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

atform Leveling Override

three position switch allows theerator to adjust the automatic self

veling system. This switch is used tojust platform level in situationsch as ascending/descending aade.

atform Rotate

ovides rotation of the platform.an

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SECTIO
3121658 – JLG Lift –

NOTE: When the Platform/Ground Select Switch is in the center posi-tion, power is shut off to the controls at both operating consoles.Remove the key to prevent the controls from being actuated.

4. Platform/Ground Select Switch

The three position, key operated switch sup-plies power to the platform control consolewhen positioned to PLATFORM. With theswitch key turned to the GROUND positiononly ground controls are operable.

ONLY USE THE THE PLATFORMFALL. FAILURE

5. Pl

A opleadsugr

6. Pl

Pr

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3-6 3121658

oom Lift

s raising/lowering of the mainwhen positioning up or down.

Boom Lift

s raising and lowering of theoom.

s 355 degrees non-continuousle rotation.

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7. Jib Lift (If Equipped)

Provides raising and lowering of thejib.

8. Telescope Control

Provides extension and retraction ofthe boom.

9. Main B

Provideboom

10. Tower

Providetower b

11. Swing

Provideturntab

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3-7

achine Safety System Override (MSSO) (CEnly)

ovides override of function controls thate locked out such as in the event of Loadnse System activation.

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SECTIO
3121658 – JLG Lift –

12. Engine Start/ Auxiliary Power /Function Enable

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

To use auxiliary power, the switch must beheld “DOWN” for duration of function use.

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

13. MO

PrarSe

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3-8 3121658

Gro

(S

Malfunction/Check Engine Indicator

es that engine oil pressure is below nor- engine coolant temperature is abnor-igh and service is required.

el Level Indicator

es the fuel level is low. The Fuele/Cut-Out System will shut the engine(or allow it start and run for an addi-minute, depending upon machine setup) before the

k is emptied.

lug Indicator

es the glow plugs are operating. After on ignition, wait until light goes out

cranking engine.an

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und Control Indicator Panel

ee Figure 3-3., Ground Control Indicator Panel)

1. Battery Malfunction Indicator

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

2. Low Engine Oil Pressure Indicator

Indicates that engine oil pressure is below nor-mal and service is required.

3. High Engine Temperature Indicator

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

4. Engine Oil Temperature Indicator (Deutz)

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

5. Engine

Indicatmal ormally h

6. Low Fu

IndicatReservdown tional fuel tan

7. Glow P

Indicatturningbefore

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3-9

or Panel

1. Battery Malfunction2. Low Engine Oil Pressure3. High Engine Coolant Temperature4. Engine Oil Temperature5. Engine Malfunction/Check Engine6. Low Fuel7. Glow Plug8. Platform Overload (If Equipped)9. Drive and Steer Disable (If Equipped)

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1 2 3 4 65

789

Figure 3-3. Ground Control Indicat

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3-1 3121658

bota Engine

1. Battery Malfunction2. Not Used3. Not Used4. Not Used5. Engine Malfunction/Check Engine6. Low Fuel7. Glow Plug8. Platform Overload (If Equipped)9. Drive and Steer Disable (If Equipped)10. System Distress

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0 – JLG Lift –

1 6105

789

Figure 3-4. Ground Control Indicator Panel - Ku

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3-11

stem Distress Indicator

e light indicates that the JLG Control Systems detected an abnormal condition and aagnostic Trouble Code has been set in thestem memory. Refer to the Service Manual for instructionsncerning the trouble codes and trouble code retrieval.

e system distress indicator light will illuminate for 2-3 sec-ds when the key is positioned to the on position to act as

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SECTIO
3121658 – JLG Lift –

8. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

9. Drive and Steer Disable Indicator (If Equipped)

Indicates the Drive and Steer Disable functionhas been activated.

10. Sy

ThhaDisyco

Thona

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3-1 3121658

Gro

(S

Figure 3-5. Splash Screenan

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2 – JLG Lift –

und Control Console Display Gauge

ee Figure 3-8., Ground Control Console Display Gauge)

The Display Gauge shows engine hours, fuel level (if applicable),and Diagnostic Trouble Codes (DTCs) from both the JLG ControlSystem and the engine control system. During machine start up,with no active DTCs in the control system, the splash screen willshow for 3 seconds and then switch to main screen. If there is anactive DTC while powering up the machine, the splash screen willshow for 3 seconds, and then launch the Diagnostics Screen. Theindicator lamp will light when there is an active DTC in the FaultLog.

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3-13

gine Diagnostics Screen will show SPN (Suspect Parameterer), FMI (Failure Mode Identifier), and Occurrence countation. Engine SPN text is not scrollable. If there is morene engine trouble code, the operator must exit from the DTC Screen to see other SPN and FMI information.

Figure 3-7. Engine Diagnostic Screen

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3121658 – JLG Lift –

The Diagnostic Screen will show active and inactive faults fromthe JLG Control System on the screen. An asterisk (*) will be dis-played to show active faults.

The EnNumbinformthan oEngine

Figure 3-6. Diagnostic Screen

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3-1 3121658

Gauge

NAVIGATE FORWARD ARROW

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Figure 3-8. Ground Control Console Display

INDICATOR LAMP

ENGINE HOURS

NAVIGATION BUTTONS

NAVIGATE BACK ARROW

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

atform Leveling Override

three position switch allows the operator tojust the automatic self leveling system. Thisitch is used to adjust platform level in situa-ns such as ascending/descending a grade.

el Select (Dual Fuel Engine Only) (Ifuipped)

oving the switch to the appropriate positionlects gasoline or liquid propane fuel.

rn

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

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3121658 – JLG Lift –

Platform Console

(See Figure 3-9., Platform Control Console)

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

1. Drive Speed Switch

The forward position gives maxi-mum drive speed. The back posi-tion gives maximum torque forrough terrain and climbinggrades. The center positionallows the machine to be drivenas quietly as possible.

ONLY USE THE THE PLATFORMFALL. FAILURE

2. Pl

A adswtio

3. FuEq

Mse

4. Ho

A po

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3-1 3121658

e (If Equipped)or (If Equipped)

14. Tower Boom Lift15. Platform Rotate16. Function Speed Control17. Main Lift/Swing Controller

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6 – JLG Lift –

1. Drive Speed/Torque Select2. Platform Leveling Override3. Fuel Select4. Horn5. Power/Emergency Stop

6. Start/Auxiliary Power7. Drive Orientation Override8. Drive/Steer9. Telescope

10. Lights (If Equipped)11. Jib Lift (If Equipped)12. Soft Touch/SkyGuard Overrid13. Soft Touch/SkyGuard Indicat

Figure 3-9. Platform Control Console

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3-17

ive Orientation Override

hen the boom is swung over the rear tires further in either direction, the Drive Orien-tion indicator will illuminate when the drivenction is selected. Push and release theitch, and within 3 seconds move the Drive/Steer control

activate drive or steer. Before driving, locate the black/hite orientation arrows on both the chassis and the plat-rm controls. Move the drive controls in a direction match-g the directional arrows for the intended direction ofvel.

operate the Drive joystick, pull up on the lock- ring below the handle.

Drive joystick is spring loaded and will auto-tically return to neutral (off ) position whenased.

ive/Steer

sh forward to drive forward,ll back to drive in reverse.

eering is accomplished via aumb-activated rocker switch one end of the steer handle.

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3121658 – JLG Lift –

5. Power/Emergency Stop Switch

A two-position red mushroom shaped switchfurnishes power to PLATFORM Controls whenpulled out (on). When pushed in (off ), power isshut off to the platform functions.

6. Start/Auxiliary Power

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

The Auxiliary Power control switch energizesthe electrically operated hydraulic pump.(Switch must be held ON for duration of auxil-iary pump use.)

The auxiliary pump functions to provide sufficient oil flow tooperate the basic machine functions should the main pumpor engine fail. The auxiliary pump will operate tower boomlift, tower telescope, main boom lift, main telescope andswing.

7. Dr

Wortafuswtowfointra

NOTE: To ing

NOTE: Themarele

8. Dr

PupuStthth

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3-1 3121658

pped with SkyGuard, the switchs functions cut out by the Sky-system to be operated again,g the operator to resume use ofe functions.

pped with both Soft Touch andrd, the switch operates likeed above and allows the opera-override the system that hasnced a cutout situation.

uch/SkyGuard Indicator (If Equipped)

es the Soft Touch bumper is against an object or therd sensor has been activated. All controls are cut oute override button is pushed. For Soft Touch, controlsn active in the Creep Mode or for SkyGuard, controlsrk normally.

Soft Touch is active, the indicator will be on continu-nd the alarm will sound. When SkyGuard is active, theor will flash, and the horn will sound continuously.

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8 – JLG Lift –

9. Telescope

Provides extension and retraction of the mainboom.

10. Lights (If Equipped)

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

11. Jib Lift (If Equipped)

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

12. Soft Touch/SkyGuard Override Switch (If Equipped)

The machine can be equipped with one of three options. Itmay have Soft Touch, SkyGuard, or both Soft Touch and Sky-Guard.

If equipped with Soft Touch, the switchenables the functions that were cut outby the Soft Touch system to operateagain at creep speed, allowing theoperator to move the platform away from the obstacle thatcaused the shutdown situation.

If equienableguard allowinmachin

If equiSkyGuadescribtor to experie

13. Soft To

IndicatSkyGuauntil thare thewill wo

When ously aindicat

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3-19

operate the Main Boom Lift/Swing joystick,l up on the locking ring below the handle.

Main Boom Lift/Swing joystick is springded and will automatically return to neutral

f) position when released.

ain Lift/Swing Controller

ovides main lift and swing. Push for-ard to lift up, pull backward to boomwn. Move right to swing right, move

ft to swing left. Moving the joysticktivates switches to provide the func-ns selected.

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SECTIO
3121658 – JLG Lift –

14. Tower Boom Lift

Provides for raising and lowering of towerboom when positioned up or down.

15. Platform Rotate

Provides rotation of the platform when posi-tioned to the right or left.

16. Function Speed Control

This control affects the speed of telescope,tower lift and jib lift. Turning the knob allthe way counterclockwise until it clicks putsdrive, main lift and swing into creep mode.

NOTE: To pul

NOTE: Theloa(of

17. M

Prwdoleactio

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3-2 3121658

Pla

(S

NOT

rm Warning Light and Alarm

d illuminator indicates that the chassis isope. An alarm will also sound when the is on an excessive slope and the boomf transport position. If lit when boom is out of trans-

osition, lower to below horizontal then repositione so that it is level before continuing operation. If the

is above horizontal and the machine is on a slope, therm warning light will illuminate and an alarm willand CREEP is automatically activated.

GHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED,R TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THATXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

Tilt Angle Market

5° All Markets

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0 – JLG Lift –

tform Control Indicator Panel

ee Figure 3-10., Platform Control Indicator Panel)

E: The indicator lights will illuminate for approximately 1 secondwhen the key is positioned to the on position to act as a self test.

1. AC Generator (If Equipped)

Indicates the generator is in operation.

2. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

3. Tilt Ala

This reon a slchassisis out oport pmachinboom tilt alasound

IF TILT WARNING LIRETRACT AND LOWEIT IS LEVEL BEFORE E

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3-21

1. AC Generator (If Equipped)2. Platform Overload (If Equipped)3. Tilt4. Glow Plug/Wait to Start5. Enable/Footswitch6. Fuel Level7. Creep8. System Distress9. Drive Orientation

Panel

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3121658 – JLG Lift –

Figure 3-10. Platform Control Indicator

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3-2 3121658

TO ABY B

FOOTOPER

vel Indicator

es a low fuel condition in the tank.

Speed Indicator

the Function Speed Control is turned toeep position, the indicator acts as aer that all functions are set to the slow-ed. The light will be on continuously if the operator creep speed or if the control system puts thee into creep speed. In addition, if the control system

ne or more individual functions in creep speed, theor flashes when that function is selected.

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4. Glow Plug/Wait to Start Indicator

Indicates the glow plugs are operating. Afterturning on ignition, wait until light goes outbefore starting engine.

5. Enable Indicator/Footswitch

To operate any function, the footswitch mustbe depressed and the function selected withinseven seconds. The enable indicator showsthat the controls are enabled. If a function is not selectedwithin seven seconds, or if a seven second lapse betweenending one function and beginning the next function, theenable light will go out and the footswitch must be releasedand depressed again to enable the controls.

Releasing the footswitch removes power from all controlsand applies the drive brakes.

VOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCHLOCKING OR ANY OTHER MEANS.

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

6. Fuel Le

Indicat

7. Creep

When the crremindest speselectsmachinputs oindicat

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3-23

ive Orientation Indicator

hen the boom is swung beyond the rearive tires or further in either direction, theive Orientation indicator will illuminate

hen the drive function is selected. This is a signal for theerator to verify that the drive control is being operated in

e proper direction (i.e. controls reversed situations).

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SECTIO
3121658 – JLG Lift –

8. System Distress Indicator

The light indicates that the JLG Control Systemhas detected an abnormal condition and aDiagnostic Trouble Code has been set in thesystem memory. Refer to the Service Manual for instructionsconcerning the trouble codes and trouble code retrieval.

9. Dr

WdrDrwopth

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3-2 3121658

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NOTES:

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SECTION 4 - MACHINE OPERATION

4-1

RATIONmary operator control console is in the platform. From thisl console, the operator can drive and steer the machine in

rward and reverse directions. The operator can raise orhe boom or swing the boom to the left or right. Standardswing is 355 degree non-continuous. The machine has a Control Console which will override the Platform Control

e. Ground Controls operate all functions except drive andnd are to be used in an emergency to lower the platform tound should the operator in the platform be unable to do

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3121658 – JLG Lift –

SECTION 4. MACHINE OPE

4.1 DESCRIPTIONThis machine is a mobile elevating work platform used to posi-tion personnel, along with their necessary tools and materials atwork locations.

The pricontroboth folower tboom GroundConsolsteer athe groso.

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4-2 3121658

4.2

Cap

bility is based on two (2) conditions which are calledand BACKWARD stability. The machine’s position ofARD stability is shown in Figure 4-1., and its positionKWARD stability is shown in Figure 4-2.

OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER- AN OUT-OF-LEVEL SURFACE.an

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– JLG Lift –

BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

acities

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

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

2. Load is within manufacturers rated design capacity.

3. All machine systems are functioning properly.

4. Machine is as originally equipped from JLG.

StabilityMachine staFORWARD least FORWof least BAC

TO AVOID FORWARD ATE THE MACHINE ON

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4-3

ll the Power/Emergency Stop switch to On.

sh the Engine Start switch until engine starts.

TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING

ter engine has had sufficient time to warm, push in the Power/Emergency Stop switchd shut engine off.

rn Platform/Ground Select switch to Plat-rm.

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3121658 – JLG Lift –

4.3 ENGINE OPERATION

NOTE: Initial starting must always beperformed from the Ground Con-trol station.

Starting Procedure

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

NOTE: Diesel engines only: After turning on ignition,operator must wait until glow plug indicator lightgoes out before cranking engine.

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

2. Pu

3. Pu

ALLOW ENGINEANY LOAD.

4. Afupan

5. Tufo

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4-4 3121658

NOT

cedure

UNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINERECT IT BEFORE RESTARTING THE ENGINE.

e all load and allow engine to operate at low speed minutes; this allows further reduction of internal temperature.

ower/Emergency Stop switch in.

atform/Ground Select switch to Off.

ine Manufacturer’s manual for detailed.

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6. Pull out the Ground Console Power/Emer-gency Stop switch to provide power to theplatform controls.

7. From Platform, pull Power/Emergency Stopswitch out.

8. Push the Engine Start switch until engine starts.

E: Footswitch must be in released (up) position before starter willoperate. If starter operates with footswitch in the depressed posi-tion, DO NOT OPERATE MACHINE.

Shutdown Pro

IF AN ENGINE MALFTHE CAUSE AND COR

1. Removfor 3-5engine

2. Push P

3. Turn Pl

Refer to Enginformation

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4-5

Engine Restart - When the engine shuts down, the opera-tor will be permitted to cycle power and restart the enginefor approximately 2 minutes of run time. After the 2 min-utes of run time is complete, the operator may cycle powerand restart the engine for an additional 2 minutes of runtime. The operator can repeat this process until there is nomore fuel available.

Engine Stop - When the engine shuts down, no restartswill be permitted until fuel is added to the tank.an

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3121658 – JLG Lift –

Fuel Reserve / Shut-Off System

NOTE: Reference the Service and Maintenance Manual along with aqualified JLG Mechanic to verify your machine setup.

The Fuel Shutoff System monitors the fuel in thetank and senses when the fuel level is gettinglow. The JLG Control System automatically shutsthe engine down before the fuel tank is emptiedunless the machine is set up for Engine Restart.

If fuel level reaches the Empty range, the Low Fuel light will beginto flash once a second and there will be approximately 60 min-utes of engine run time left. If the system is in this condition andautomatically shuts down the engine or if the operator manuallyshuts down the engine before the 60 minute run time is com-plete, the Low Fuel light will flash 10 times a second and theengine will react according to machine setup. Setup options areas follows:

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

•

•

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4-6 3121658

Stability

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Figure 4-1. Position of Least Forward

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4-7

VELING (DRIVING)

4-3., Grade and Side Slopes

er to the Operating Specifications table for Gradeability andeslope ratings.

ratings for Gradeability and Sideslope are based upon thechine’s boom being in the stowed position, fully lowered, and

racted.

ng is limited by two factors:

adeability, which is the percent of grade of the incline the achine can climb.

deslope, which is the angle of the slope the machine can driven across.

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3121658 – JLG Lift –

. 4.4 TRA

See Figure

NOTE: RefSid

All maret

Traveli

1. Grm

2. Sibe

Figure 4-2. Position of Least Backward Stability

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4-8 3121658

s

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Figure 4-3. Grade and Side Slope

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4-9

sition Drive controller to Forward Reverse as desired.

achine is equipped with a Drive Orientation Indicator. The light on the platform control console indicates that theis swung beyond the rear drive tires and the machine mayteer in the opposite direction from the movement of the

ls. If the indicator is illuminated, operate the Drive functionollowing manner:

atch the black and hite direction arrows both platform con-l console and the assis to determine e direction the achine will travel.

sh and release the Drive Orientation Over-e switch. Within 3 seconds, slowly move theive control toward the arrow matching thetended direction of machine travel. The indi-tor light will flash during the 3 second inter-l until the drive function is selected.

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3121658 – JLG Lift –

DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRMAND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ONGRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTIONOF THIS MANUAL.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THECHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC-TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OFTRAVEL.

Traveling Forward and Reverse1. At Platform Controls, pull out Emergency Stop

switch, start the engine, and activate foot-switch.

2. Poor

This myellowboom Drive/Scontroin the f

1. Mwontrochthm

2. PuridDrincava

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4-1 3121658

Tra

Wwlinclex

IF THMOV

NGmb switch on Drive/Steer controller toering right, or to Left for steering left.

RM

l Adjustment

ORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OFORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR SO COULD RESULT IN DEATH OR SERIOUS INJURY.

or Down - Position the Platform/Levelch Up or Down and hold until the plat-

l.

tion

e platform to the left or right, use thetate control switch to select the direc-

ld until desired position is reached.

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0 – JLG Lift –

veling on a Grade

hen traveling a grade, maximum braking and traction are obtainedith the boom stowed, in position over the rear (drive) axle, and ine with the direction of travel. Drive the machine forward when

imbing a grade, and in reverse when descending a grade. Do notceed the machine's maximum rated gradability.

E BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVEEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS.

4.5 STEERIPosition thuRight for ste

4.6 PLATFO

Platform Leve

ONLY USE THE PLATFTHE PLATFORM. INCFALL. FAILURE TO DO

To Level Upcontrol switform is leve

Platform Rota

To rotate thPlatform Rotion and ho

Figure 4-4. Traveling on a Grade

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4-11

LLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROLVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-

ITCH TO STOP THE MACHINE.

the Boom

ng boom, use Swing control switch to selectr Left direction.

d Lowering the Tower Boome or lower the Tower Boom, position Tower

Lift switch to Up or Down until desired height isd.

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3121658 – JLG Lift –

4.7 BOOM

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

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILTALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREES OR GREATER).CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTALOR DRIVING WITH THE BOOM ELEVATED.

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

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

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

TO AVOID A COSWITCH OR LEGENCY STOP SW

Swinging

To swiRight o

Raising anTo raisBoom reache

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4-1 3121658

Rai

Tel

4.8

E SAFETY SYSTEM OVERRIDE (MSSO)(CE

e Safety System Override (MSSO) isrride function controls for Emergencyetrieval only. Refer to Section 5.5,afety System Override (MSSO)(CEerating procedures.

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sing and Lowering the Main Boom

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

escoping the Main Boom

To extend or retract the main boom, use the MainTelescope Control Switch to select IN or OUT move-ment.

FUNCTION SPEED CONTROLThis control affects the speed of telescope, towerboom lift and jib lift. Turning the knob all theway counterclockwise until it clicks puts drive,main lift, platform rotate, and swing into creepmode.

4.9 MACHINONLY)

The Machinused to ovePlatform RMachine SOnly)for op

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4-13

the time of actuation will reverse or cutout. The tableoutlines these functions.

able

TowerLift

Down

PlatformLevel

PlatformRotate

JibLift

C C C C

no other functions active.an

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3121658 – JLG Lift –

4.10 SKYGUARD OPERATIONSkyguard is used to provide enhanced control panel protection.When the SkyGuard sensor is activated, functions that were in

use atbelow

Table 4-1. Skyguard Function T

MainLift

MainTele

In

MainTeleOut

Swing

Drive Forward

DriveReverse Tower

LiftUpDOS

Enabled

DOSNot

Enabled

R C R R R C* R R R

R = Indicates Reversal is Activated

C = Indicates Cutout is Activated

* Disregard when boom is in line and driving forward with or without steering and

Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.

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4-1 3121658

4.1

Shu

AND TIE DOWN-5.)

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

he boom in the stowed position.

e all loose items from the machine.

ly adjust the rigging to prevent damage to thee and so the machine remains level.

G THE MACHINE IN THE STOWED POSITION, THE BOOM MUST BEO THE BOOM REST.

he boom in the stowed position or storage position.

e all loose items from the machine.

the chassis and the platform using straps or chains ofte strength.

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1 SHUT DOWN AND PARK

t Down and ParkThe procedures to shut down and park the machine are as fol-lows:

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. PositionPlatform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instructionplacards, warning decals, and operating controls from hos-tile environment.

4.12 LIFTING(See Figure 4

Lifting1. Refer t

sectionout the

2. Place t

3. Remov

4. Propermachin

Tie Down

WHEN TRANSPORTINFULLY LOWERED INT

1. Place t

2. Remov

3. Secureadequa

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4-15

1001172217B

450AJ

57.9 in(1471 mm)

45.5 in(1156 mm)

520AJ

A

B

53.7 in(1366 mm)

49.6 in(1261 mm)

Chart

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3121658 – JLG Lift –

1702

300

1701

500

1702

300

1701

500

A

Figure 4-5. Lifting and Tie Down

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4-1 3121658

12

47

of 6

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6 – JLG Lift –

16 1718 2020 4221 4829

38

2742

36

44

Figure 4-6. Decal Location Sheet 1

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4-17

3

6

47

51 50 32

39

14

12

46

44

of 6

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3121658 – JLG Lift –

33

2

49


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4-1 3121658

23

37

43

20 20

3 of 6

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3

14

2120 20

3

14

33

Figure 4-8. Decal Location Sheet

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4-19

8 37 33

9

1141

5

34

33

12

of 6

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3121658 – JLG Lift –

33

30

28

33

10

10

433 33


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4-2 3121658

24

19

5 of 6

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12

402526

12

1

Figure 4-10. Decal Location Sheet

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4-21

15 35

heet 6 of 6

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3121658 – JLG Lift –

22

22

Figure 4-11. Decal Location S

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4-2 3121658

kets

It inese162526-D

Portuguese1001162527-F

CE1001162528-G

Spanish1001162529-F

03925 1703928 1001162429 1703923

1116849 1705349 1705822 1705917

03937 1703940 1705961 1703935

03949 1703952 - - 1703947

- - - - - - 1001173262

- - - - - - 1001174313

- - - - - - - -

- - - - - - - -

- - - - 1702773 - -

05968 1704002 - - 1704001

04277 1704277 1704277 1704277

1162416 1001162426 1001190913 1001162415

- - - - - - - -

03953 1705903 1701518 1703941

01504 1701504 1701504 1701504

02631 1702631 1702631 1702631

- - - - - - - -

- - - - - - - -

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Table 4-2. Decal Legend - Language Mar

em # ANSI1001162521-G

Australia1001162522-E

Japan1001162523-C

Korea1001162524-C

French1001162525-D

Ch1001

1 1703797 1001162429 1703926 1703927 1703924 17

2 1705336 1705822 1705344 1705345 1705347 100

3 1703805 1705961 1703938 1703939 1703936 17

4 1703804 - - 1703950 1703951 1703848 17

5 1001173262 - - - - - - 1001173262

6 1001174313 - - - - - - 1001174313

7 - - - - - - - - - -

8 - - - - - - - - - -

9 - - - - - - - - - -

10 1702868 - - - - 1705969 1704000 17

11 1704277 1704277 1704277 1704277 1704277 17

12 1001162416 1001190913 1001162418 1001162420 1001162422 100

13 - - - - - - - - - -

14 1703953 1701518 1703944 1703945 1703942 17

15 1701504 1701504 1701504 1701504 1701504 17

16 1702631 1702631 1702631 1702631 1702631 17

17 1001131269 - - - - - - 1001131269

18 - - - - - - - - - -

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4-23

1701509 1701509 1701509 1701509

1702300 1702300 1702300 1702300

1701500 1701500 1701500 1701500

1703687 1703687 1703687 1703687

- - 3251243 - - 3251243

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

1703982 1703985 1705828 1703983

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

1704412 1704412 1704412 1704412

1001172217 1001172217 1001172217 1001172217

Markets

Chinese1001162526-D


CE1001162528-G

Spanish1001162529-F

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3121658 – JLG Lift –

19 1701509 1701509 1701509 1701509 1701509

20 1702300 1702300 1702300 1702300 1702300

21 1701500 1701500 1701500 1701500 1701500

22 1703687 1703687 1703687 1703687 1703687

23 3251243 - - - - - - 3251243

24 - - - - - - - - - -

25 - - - - - - - - - -

26 - - - - - - - - - -

27 - - - - - - - - - -

28 - - - - 1703980 1703981 1703984

29 - - - - - - - - - -

30 1705514 - - - - - - 1705514

31 - - - - - - - - - -

32 - - - - - - - - - -

33 - - - - - - - - - -

34 - - - - - - - - - -

35 1704412 1704412 1704412 1704412 1704412

36 1001172217 1001172217 1001172217 1001172217 1001172217

Table 4-2. Decal Legend - Language

Item # ANSI1001162521-G


Japan1001162523-C

Korea1001162524-C

French1001162525-D

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4-2 3121658

04885 1704885 1704885 1704885

- - - - - - - -

- - - - - - - -

- - - - - - - -

05430 1705905 - - 1705910

01499 1701499 1701499 1701499

- - 3251813 1001204510 3251813

- - - - - - - -

- - - - - - - -

- - - - 1001189882 - -

- - - - - - - -

01529 1701529 1701529 1701529

- - - - - - - -

- - - - - - - -

1224050 1001224052 - - 1001224049

kets

It inese162526-D


CE1001162528-G

Spanish1001162529-F

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37 1704885 1704885 1704885 1704885 1704885 17

38 - - - - - - - - - -

39 - - - - - - - - - -

40 - - - - - - - - - -

41 1705351 - - 1705426 1705427 1705351 17

42 1701499 1701499 1701499 1701499 1701499 17

43 3251813 - - - - - - 3251813

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - 1001112551 - - - - - -

47 - - - - - - - -

48 1701529 1701529 1701529 1701529 1701529 17

49 - - - - - - - - - -

50 - - - - - - - - - -

51 1001223055 - - 1001224053 1001224048 1001223971 100

Table 4-2. Decal Legend - Language Mar

em # ANSI1001162521-G


Japan1001162523-C

Korea1001162524-C

French1001162525-D

Ch1001

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4-25

18 - - - -

19 1701509 1701509

20 1702300 1702300

21 1701500 1701500

22 1703687 1703687

23 3251243 3251243

24 - - - -

25 - - - -

26 - - - -

27 - - - -

28 - - 1703984

29 - - - -

30 1705514 1705514

31 - - - -

32 - - - -

33 - - - -

34 - - - -

. Decal Legend - Kubota Engine-Powered Machines

Item #ANSI

ANSI ExportChina

1001218927-B

CSAFrench

1001218928-B

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3121658 – JLG Lift –

Table 4-3. Decal Legend - Kubota Engine-Powered Machines

Item #ANSI

ANSI ExportChina

1001218927-B

CSAFrench

1001218928-B

1 1703797 1703924

2 1705336 1705347

3 1703805 1703936

4 1703804 1703848

5 1001173262 1001173262

6 1001216408 1001216408

7 - - - -

8 - - - -

9 - - - -

10 1702868 1704000

11 1704277 1704277

12 1001162416 1001162422

13 - - - -

14 1703953 1703942

15 1701504 1701504

16 1702631 1702631

17 1001131269 1001131269

Table 4-3

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4-2 3121658

T

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35 1704412 1704412

36 1001172217 1001172217

37 1704885 1704885

38 - - - -

39 - - - -

40 - - - -

41 1705351 1705429

42 1701499 1701499

43 3251813 3251813

44 - - - -

45 - - - -

46 - - - -

47 - - - -

48 1701529 1701529

49 - - - -

50 - - - -

51 1001223055 1001223971

able 4-3. Decal Legend - Kubota Engine-Powered Machines

Item #ANSI

ANSI ExportChina

1001218927-B

CSAFrench

1001218928-B

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SECTION 5 - EMERGENCY PROCEDURES

5-1

OCEDURES

NY INCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALLST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-

LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HASD, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-

ERGENCY OPERATION

nable to Control MachinePLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TOTE OR CONTROL MACHINE:

ther personnel should operate the machine from ground ntrols only as required.

ther qualified personnel on the platform may use the plat-rm controls. DO NOT CONTINUE OPERATION IF CONTROLS

NOT FUNCTION PROPERLY.

anes, forklift trucks or other equipment can be used to sta-lize motion of the machine.

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3121658 – JLG Lift –

SECTION 5. EMERGENC Y PR

5.1 GENERALThis section explains the steps to be taken in case of an emer-gency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any incidentinvolving a JLG product. Even if no injury or property damage isevident, the factory should be contacted by telephone and pro-vided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) Outside USA: 240-420-2661

E-mail:

[email protected]

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

FOLLOWING AFUNCTIONS FIRTROLS. DO NOTBEEN REPAIRERECTLY.

5.3 EM

Operator UIF THE OPERA

1. Oco

2. OfoDO

3. Crbi

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5-2 3121658

Pla

5.4

Thtupm

5.5

Tothtona

THE TOW

wheels securely.

the mechanical release on both drive hubs by loos-completely reversing, and tightening the two bolts onub.

ct suitable equipment, remove chocks, and movee.

g machine, complete the following procedure:

n machine on a firm level surface.

wheels securely.

age the mechanical release on both drive hubs bying, completely reversing, and tightening the twon each hub.

e chocks from wheels as desired.an

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– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged in over-head structures or equipment, rescue platform occupants prior tofreeing the machine.

MANUAL SWING OVERRIDE

e manual swing override is used to manually swing the boom andrntable assembly in the event of a total power failure when the

latform is positioned over a structure or obstacle. To operate theanual swing override, proceed as follows:

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

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

EMERGENCY TOWING PROCEDURES

wing this machine is prohibited. However, provisions for movinge machine have been incorporated. The following procedures are be used ONLY for emergency movement to a suitable mainte-nce area.

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

1. Chock

2. Engageening, each h

3. Connemachin

After movin

1. Positio

2. Chock

3. Disengloosenbolts o

4. Remov

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5-3

rate the MSSO:

om the ground control console, place the Platform/ound Select switch in the Ground position.

ll out the Power/Emergency Stop control.

art the engine or MSSO will function through the Auxiliary wer system.

ess and hold the MSSO switch and the control switch for e desired function.an

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3121658 – JLG Lift –

5.6 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

The Machine Safety System Override (MSSO) isonly to be used to retrieve an operator that ispinned, trapped, or unable to operate themachine. The MSSO will override function con-trols that are locked out from the platform andground consoles. An example of this would be in the case of LoadSense System activation.

NOTE: If the MSSO functionality is used, the fault indicator will flashand a fault code is set in the JLG Control System which must bereset by a qualified JLG Service Technician.

NOTE: No functional checks of the MSSO system are necessary. The JLGControl system will set a Diagnostic Trouble Code if the controlswitch is faulty.

To ope

1. FrGr

2. Pu

3. StPo

4. Prth

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5-4 3121658

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NOTES:

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PECIFICATIONS & OPERATOR MAINTENANCE

6-1

PERATOR MAINTENANCE

RATING SPECIFICATIONS AND PERFORMANCE A Specifications

Table 6-1. Operating Specifications

stricted: 550 lbs. (249.5 kg)

el Grade, stowedeability)

45%

el Grade, stowed Slope)

5°

towed 4.25 mph (6.8 kph)

Weight - Approximate 13,250 lbs. (6010 kg)

und Bearing Pressure 65 psi (4.6 kg/cm2)

7200 lbs. (3266 kg)

e 12V DC

n Relief Hyd. Pressure 4060 psi (280 Bar)

onsumption 0.85 gph (3.2 lph)

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SECTION 6 - GENERAL S
3121658 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS & O

6.1 INTRODUCTIONThis section of the manual provides additional necessary infor-mation to the operator for proper operation and maintenance ofthis machine.

The maintenance portion of this section is intended as informa-tion to assist the machine operator to perform daily maintenancetasks only, and does not replace the more thorough PreventiveMaintenance and Inspection Schedule included in the Serviceand Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual .............................................3121659

Illustrated Parts Manual ................................................................3121660

6.2 OPEDAT

Operating

Capacity: Unre

Maximum Trav Position (Grad

Maximum Trav Position (Side

Drive Speed - S

Gross Machine

Maximum Gro

Max. Tire Load

System Voltag

Maximum Mai

Average Fuel C

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121658

Dim

Table 6-3. Capacities

38 gal. (143.8 L)

o Full Level) 31.7 Gal. (119.9 L)

24 oz. (0.7 L)

27 oz. (0.8 L)

2.9 gal. (11.3L)2.4 gal. (9.1L)

2.25 gal. (8.5 L)

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ensional Data Capacities

Table 6-2. Dimensional Data

Turning Radius (Inside) 6’ 9" (2.06 m)

Turning Radius (Outside) 15’ 8" (4.78 m)

Machine Height (stowed) 89.3" (2269 mm)

Machine Length (stowed) 258.9" (6576mm)

Up and Over Platform Height 24’ (7.3 m)

Horizontal Reach 25’ (7.62 m)

Machine Width 92.6" (2353 m)

Wheel Base 93.0" (2362 mm)

Platform Height 45’ 9" (13.72 m)

Ground Clearance 16.4" (417 mm)

Hydraulic System

Hydraulic Oil Tank (t

Drive Hub

Drive Brake

Engine Coolant Deutz 2.9L GM 3.0L Kubota

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6-3

ta

Table 6-5. Deutz D2011L03

Diesel

rs 3

3.7 in (94 mm)

4.4 in (112 mm)

t 142 cu. in (2331 cm3)

ty

6.3 qt (6 L)3.7 qt (3.5 L)10 qt (9.5 L)

1200

pper Lift, Teleet Level, Basketift

18001500

2800

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3121658 – JLG Lift –

Tires Engine Da

Table 6-4. Tires

Size Type Pressure Weight

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

Foam-Filled N/A 395 lbs. (179 kg)

12 x 16.5 Foam-Filled N/A 328 lbs. (149 kg)

33/16LL x 16.1 Pneumatic 40 psi (3 Bar) 155 lbs. (70 kg)

315/55 D20 Foam-Filled N/A 286 lbs. (130 kg)

Solid N/A 286 lbs. (130 kg)

33x12-20 Solid N/A 285lbs. (129 kg)

Fuel

No. of Cylinde

Bore

Stroke

Displacemen

Oil Capacity crankcase cooler total capaci

Low RPM

Mid RPM Tower Lift, U Swing, Bask Rotate, Jib L

High RPM

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6-4 3121658

Type

Num

Bore

Stro

Tota

Firin

Out

Oil C

Coo

Ave

Min

Mid

Max

Table 6-7. GM 3.0L

Gasoline or Gasoline/LP Gas

4

82 hp @ 3000 rpm75 hp @ 3000 rpm

4.0 in (101.6 mm)

3.6 in (91.44 mm)

181 cu.in(3.0 L, 2966 cc)

4.5 qt (4.25 L)

re6 psi (0.4 bar) @ 1000 rpm

18 psi (1.2 bar) @ 2000 rpm

9.2:1

1-3-4-2

2800

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Table 6-6. Deutz D2.9L4

Liquid Cooled

ber of Cylinders 4

3.6 in (92 mm)

ke 4.3 in (110 mm)

l Displacement 178 cu. in (2925 cm3)

g Order 1-3-4-2

put 49 hp (36.5 kW)

apacity 2.4 gal (8.9 L)

lant Capacity (System) 3.2 gal (12.1 L)

rage Fuel Consumption 1.2 gph (4.1 Lph)

. Low Engine RPM 1200

Engine RPM 1800

. High Engine RPM 2500

Fuel

No. of Cylinders

BHP Gasoline LP

Bore

Stroke

Displacement

Oil Capacity w/filter

Minimum Oil Pressu at idle Hot

Compression Ratio

Firing Order

Max. RPM

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6-5

Oil

raulic oils require anti-wear qualities at least API Servicessification GL-3, and sufficient chemical stability for mobileraulic system service.

chines may be equipped with Mobil EAL biodegradable and-toxic hydraulic oil. This is a fully synthetic hydraulic oil thatsesses the same anti-wear and rust protection characteristics

mineral oils, but will not adversely affect the ground water or environment when spilled or leaked in small amounts.

Table 6-9. Hydraulic Oil

Hydraulic SystemOperating

Temperature Range

S.A.E. ViscosityGrade

+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

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3121658 – JLG Lift –

Hydraulic

NOTE: HydClahyd

NOTE: Manonposas the

Table 6-8. Kubota WG 2503

Fuel Gasoline or Gasoline/LP Gas

BHP Gasoline LP

45.5 kW @ 2700 rpm46 Kw @ 2700 rpm

Bore 3.46 in (88 mm)

Stroke 4.03 in (102.4 mm)

Displacement 153 cu.in(2.5 L)

Oil Capacity w/filter 2.5 gal (9.5 L)

Coolant Capacity (engine only) 1.4 gal (5.4 L)

Max. RPM 2700

Fuel Consumption - Gasoline In Drive 2.35 Gal/Hr 8.92 L/Hr - -

@ Idle 0.48 Gal/Hr 1.83 L/Hr - -

Fuel Consumption - LP In Drive 2.56 Gal/Hr 9.72 L/Hr 5.64 kg/Hr

@ Idle 0.62 Gal/Hr 2.36 L/Hr 1.37 kg/Hr

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6-6 3121658

NOTTable 6-11. DTE 10 Excel 15 Specs

cosity Grade #15

Point, Max -65°F (-54°C)

Point, Min. 360°F (182°C)

Viscosity

t 40° C 15.8 cSt

100° C 4.1cSt

t 100° F 15.8 cSt

t 210° F 4.1 cSt

sity Index 168

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E: Aside from JLG recommendations, it is not advisable to mix oilsof different brands or types, as they may not contain the samerequired additives or be of comparable viscosities. If use ofhydraulic oil other than Mobil 424 is desired, contact JLG Indus-tries for proper recommendations.

Table 6-10. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

ISO Vis

Pour

Flash

a

at

a

a

Visco

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6-7

Table 6-13. Mobil EAL 224H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max -25°F (-32°C)

Flash Point, Min. 428°F (220°C)

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

Weight 7.64 lb. per gal.(0.9 kg per liter)

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

Must be stored above 32°F (14°C)

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Table 6-12. Quintolubric 888-46

Density 0.91 @ 15°C (59°F)

Pour Point <-20°C (<-4°F)

Flash Point 275°C (527°F)

Fire Point 325°C (617°F)

Autoignition Temperature 450°C (842°F)

Viscosity

at 0° C (32°F) 360 cSt

at 20° C (68°F) 102 cSt

at 40° C (104°F) 46 cSt

at 100° C (212°F) 10 cSt

Viscosity Index 220

NOTE:

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6-8 3121658

ent Weights

MS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHTFOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT WAY TO AFFECT STABILITY.

N

able 6-15. Critical Stability Weights

omponents LBS. KG.

1875 ± 75 850.5 ± 34

x9 Pneumatic 130 59

x9 Foam-Filled 220 99.8

x7 230 104.3

- 30x60 242.5 110

- 30x48 216 98

66 30

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– JLG Lift –

Major Compon

DO NOT REPLACE ITEOR SPECIFICATION (MODIFY UNIT IN ANY

Table 6-14. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

OTE: Mobil/Exxon recommends that this oil be checked on ayearly basis for viscosity.

T

C

Counterweight

Tire and Wheel - 20

Tire and Wheel - 20

Tire and Wheel - 18

Platform & Console

Platform & Console

Battery

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6-9

-40°F(-40°C)

-30F°(-34°C)

-20°F(-29°C)

-10°F(-23°C)

0°F(-18°C)

10°F(-12°C)

20°F(-7°C)

30°F(-1°C)

40°F(4°C)

50°F(10°C)

60°F(16°C)

70°F(21°C)

80°F(27°C)

90°F(32°C)

100°F(38°C)

110°F(43°C)

120°F(49°C)

AMBIENT AIRTEMPERATURE

- Deutz 2.3L - Sheet 1 of 2

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ENGINESPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATUREWITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHERPACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR

ENGINE WILL START AND OPERATE UNAIDED AT THISTEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

SUMMERGRADEFUEL

WINTERGRADEFUEL

WINTERGRADEFUELWITH

KEROSENEADDED

NO OPERATION BELOW THISAMBIENT TEMPERATURE

NO OPERATION ABOVE THISAMBIENT TEMPERATURE

Figure 6-1. Engine Operating Temperature Specifications

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6-1 3121658

CONDITIONSRECOMMENDS A HYDRAULICLT JLG SERVICE

ATION INERATURES ABOVE.

WITHK 180°F

424 TURE

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

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

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 10 20 30 40 50 60

% OF ADDED KEROSENE

AMBI

ENT T

EMPE

RATU

RE

SUMMER-GRADEFUEL

WINTER-GRADEFUEL

eutz 2.3L - Sheet 2 of 24150548-E

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0 – JLG Lift –

(HYD. OIL TANK TEMP.) IF EITHER OR BOTHEXIST JLG HIGHLY THE ADDITION OF

OIL COOLER (CONSU

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)


PROLONGED OPERAMBIENT AIR TEMPOF 100°F(38°C) OR

EXTENDED DRIVINGHYDRAULIC OIL TANTEMPERATURES OF(82°C) OR ABOVE.


MO

BIL

424

10W

-30

HYDRAULICSPECIFICATIONS


DO NOT START UP HYDRAULIC SYSTEMWITHOUT HEATING AIDS WITH MOBILE HYDRAULIC OIL BELOW THIS TEMPERA

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

EXXO

N U

NIV

IS H

VI 2

6

MO

BIL

DTE

13

Figure 6-2. Engine Operating Temperature Specifications - D

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6-11

-40 F(-40 C)

-30 F(-34 C)

-20 F(-29 C)

-10 F(-23 C)

0 F(-18 C)

10 F(-12 C)

20 F(-7 C)

30 F(-1 C)

40 F(4 C)

50 F(10 C)

60 F(16 C)

70 F(21 C)

80 F(27 C)

90 F(32 C)

100 F(38 C)

110 F(43 C)

120 F(49 C)

TURE

ON LPG.

ERATURE

LUIDS,


tions - GM - Sheet 1 of 2

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3121658 – JLG Lift –

ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERAWITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.

NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE

ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPWITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED F A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

ENGINESPECIFICATIONS



Figure 6-3. Engine Operating Temperature Specifica

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6-1 3121658

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTENTLY WITHIN SHOWN LIMITS

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

T

s - GM - Sheet 2 of 24150548-E

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2 – JLG Lift –

(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHLY RECOMMENDSTHE ADDITION OF A HYDRAULICOIL COOLER (CONSULT JLG SERVICE

180° F(82° C)

PROLONGED OPERATION INAMBIENT AIR TEMPERATURESOF 100° F(38° C) OR ABOVE.

EXTENDED DRIVING WITHHYDRAULIC OIL TANKTEMPERATURES OF 180°F(82° C) OR ABOVE.


MO

BIL

424

10W

-30

HYDRAULICSPECIFICATIONS


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

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

EXXO

N U

NIV

IS H

VI 2

6

MO

BIL

DTE

13

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIREMPERATURE

Figure 6-4. Engine Operating Temperature Specification

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6-13

cations - Deutz 2.9L

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Figure 6-5. Engine Operating Temperature Specifi

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6-1 3121658

1001206353 A

t 1 of 2

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Figure 6-6. Hydraulic Oil Operation Chart - Shee

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6-15

t - Sheet 2 of 2

se Classi?cation

Syn

thet

ic

Syn

thet

icP

olyo

l Est

ers

Rea

dilly

Bio

degr

adea

ble*

Virtu

ally

Non

-toxi

c**

Fire

Res

ista

nt**

*

X XX X X

X X X X

RATION USING NON-JLG APPROVEDUIDS OR OPERATION OUTSIDE OFTURE BOUNDARIES OUTLINED INIC FLUID OPERATION CHART" MAYMATURE WEAR OR DAMAGE TO

OF THE HYDRAULIC SYSTEM.1001206353 A

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3121658 – JLG Lift –

Figure 6-7. Hydraulic Oil Operation Char

Fluid Properties Ba

Des

crip

tion

Visc

osity

@ 4

0° C

(CsT

, Typ

ical

)

Visc

Inde

x

Min

eral

Oils

Vege

tabl

e O

ils

Mobilfluid 424 55 145 XMobil DTE 10 Excel 32 32 141 XUNIVIS HVI 26 26 376 XMobil EAL 224 H 36 212 XMobil Envirosyn H 46 49 145Quintolubric 888-46 50 185

NOTICE:MACHINE OPEHYDRAULIC FLTHE TEMPERATHE "HYDRAULRESULT IN PRECOMPONENTS

* Readily biodegradable classi?cation indicates one of the following: CO2 Conversion>60% per EPA 560/6-82-003 CO2 Conversion>80% per CEC-L-33-A-93** Virtually Non-toxic classi?cation indicates an LC50>5000 ppm per OECD 203*** Fire Resistant classi?cation indicates Factory Mutual Research Corp. (FMRC) Approval

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6-1 3121658

1001120075-A

E:

INE OPERATION USING NON-JLG APPROVEDE OIL OR OPERATION OUTSIDE OF

EMPERATURE BOUNDARIES OUTLINED INENGINE OIL OPERATION CHART" MAYLT IN PREMATURE WEAR OR DAMAGE TOONENTS OF THE ENGINE.

ubota

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NOTIC

MACHENGINTHE TTHE "RESUCOMP

Figure 6-8. Engine Oil Operation Chart - K

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6-17

6

7

2

7

616

iagram - Deutz 2.3L Engine

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3121658 – JLG Lift –

6 34 5 1

811176

3 45

19

S/N 0300220579& S/N E300003513

to Present

2WD Only

Figure 6-9. Operator Maintenance and Lubrication D

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6-1 3121658

6

7 14

2

7

616

iagram - GM Engine

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6 34 5 1

151017 186

3 45

19

S/N 0300220579& S/N E300003513

to Present

2WD Only

Figure 6-10. Operator Maintenance and Lubrication D

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6-19

6

7

2

7

616 1213

Diagram - Deutz 2.9L Engine

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6 33

44

55

1

917 186

19

S/N 0300220579& S/N E300003513

to Present

2WD Only

Figure 6-11. Operator Maintenance and Lubrication

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6-2 3121658

6

7

2

7

616

gram - Kubota Engine

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0 – JLG Lift –

6 34 5 121

2017 186

3 45

19

S/N 0300220579& S/N E300003513

to Present

2WD Only

Figure 6-12. Operator Maintenance and Lubrication Dia

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6-21

INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMALOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSEDVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BEORDINGLY.

ing Bearing

e Point(s) - Fittingacity - A/Re - BGrval - Every 3 months or 150 hrs of operationments - Apply grease and rotate in 90 degree intervalsntil bearing is completely lubricated

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3121658 – JLG Lift –

6.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-9., Oper-ator Maintenance and Lubrication Diagram - Deutz 2.3L Engine.

LUBRICATION CONDITIONS. FTO HOSTILE ENINCREASED ACC

1. Sw

LubCapLubInteCom

u

Table 6-16. Lubrication Specifications.

KEY SPECIFICATIONS

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

HO Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424.

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L-2105.

MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API SM, SL, SJ, EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4.

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

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6-2 3121658

nt(s) - Grease Fitting - A/Robil SHC 007 A/R

E BEARINGS. OVERGREASING BEARINGS WILL RESULT IN DAM-N HOUSING.

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2 – JLG Lift –

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - Grease FittingCapacity - A/RLube - Lubriplate 930-AAAInterval - A/R

Lube PoiCapacityLube - MInterval -

DO NOT OVERGREASAGE TO OUTER SEAL I

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6-23

raulic Tank - S/N 0300220579 & S/N E300003513 to Present

e Point(s) - Fill Capacity - 15 Gal. (57 L) to Full Levele - HOrval - Check Level daily; Change every 2 years or 1200ours of operation.ments - On new machines, those recently overhauled, orfter changing hydraulic oil, operate all systems a minimumf two complete cycles and recheck oil level in reservoir.

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3121658 – JLG Lift –

3. Hydraulic Tank -Prior to S/N 0300220579 & S/N E300003513

Lube Point(s) - Fill CapCapacity - 36 Gal. (136.3 L), 31.7 Gal. (119.9 L) to Full Level; 28.8

Gal (109.0 L) to Low LevelLube - HOInterval - Check Level daily; Change every 2 years or 1200

hours of operation.Comments - On new machines, those recently overhauled, or

after changing hydraulic oil, operate all systems a minimumof two complete cycles and recheck oil level in reservoir.

Hyd

LubCapLubInte

hCom

ao

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6-2 3121658

lic Tank Breather

Change after first 50 hrs. and every 6 months or 300ereafter.ts - Remove wing nut and cover to replace. Under cer-

onditions, it may be necessary to replace on a morent basis.

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4 – JLG Lift –

4. Hydraulic Return Filter

Lube Point(s) - Replaceable ElementInterval - Change after first 50 hours and every 6 months or

300 hours thereafter.

5. Hydrau

Interval -hrs. th

Commentain cfreque

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6-25

ive Brake

e Point(s) - Fill Plugacity - 2.7 oz. (89 mL)e - DTE-10 Excel 32rval - Change as necessary

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3121658 – JLG Lift –

6. Wheel Drive Hub

Lube Point(s) - Level/Fill PlugCapacity - 24 oz. (0.8 L)(1/2 Full)Lube - EPGL

Interval - Check level every 3 months or 150 hrs of opera-tion; change every 2 years or 1200 hours of operation

7. Dr

LubCapLubInte

OIL LEVEL CHECKAND FILL

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6-2 3121658

nge w/Filter - Deutz 2.9 L4

nt(s) - Fill Cap/Spin-on Element - 2.4 gal (8.9 L)

Every Year or 600 hours of operationts - Check level daily/Change in accordance withe manual

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8. Oil Change with Filter - Deutz 2.3 L3

Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 10 Quarts (9.5 L) w/FilterLube - EOInterval - Check level daily; change every 500 hours or six

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

9. Oil Cha

Lube PoiCapacityLube - EOInterval -Commen

engin

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6-27

be Point(s) - Fill Cap/Spin-on Elementpacity - 4.5 qt (4.25 L) w/filterbe - EOterval - 3 Months or 150 hours of operationmments - Check level daily/Change in accordance with

engine manual

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10. Oil Change w/Filter - GM

LuCaLuInCo

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6-2 3121658

e-Filter - Deutz D2.9

oint(s) - Replaceable Elementl - Drain water daily; Every year or 600 hours of opera-

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8 – JLG Lift –

11. Fuel Filter/Water Separator - Deutz 2.3 L3

Lube Point(s) - Replaceable ElementInterval - Every year or 500 hours of operation

12. Fuel Pr

Lube PInterva

tion

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6-29

el Filter (Gasoline) - GM

be Point(s) - Replaceable Elementterval - Every 6 months or 300 hours of operation

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3121658 – JLG Lift –

13. Fuel Filter - Deutz D2.9

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

14. Fu

LuIn

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6-3 3121658

Filter

Change after first 50 hrs. and every 6 months or 300ereafter.ts - Remove the engine tray retaining bolt and pullgine tray to gain access.

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15. Fuel Filter (Propane) - GM Engine

Interval - 3 Months or 150 hours of operationComments - Replace filter. Refer to Section 6.5, Propane Fuel

Filter Replacement (GM Engine)

16. Charge

Interval -hrs. th

Commenout en

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6-31

gine Coolant

e Point(s) - Fill Capacity (Deutz 2.9L)- 2.9 gal. (11.3L)acity (GM 3.0L)- 2.4 gal. (9.1L)acity (Kubota) - 2.25 gal. (8.5 L)e - Anti-Freezerval - Check level daily; change every 1000 hours or twoears, whichever comes first.

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17. Air Filter

Lube Point(s) - Replaceable ElementInterval - Every 6 months or 300 hours of operation or as

indicated by the condition indicatorComments - Check Dust Valve daily

18. En

LubCapCapCapLubInte

y

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nge w/Filter - Kubota

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19. Wheel Bearings

Lube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hours of operation

20. Oil Cha

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6-33

el Filter - Kubota

be Point(s) - Replaceable Componentterval - Every year or 600 hours of operation

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Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 2.5 gal. (9.5 L) w/filterLube - EOInterval - 3 Months or 150 hours of operationComments - Check level daily/Change in accordance with

engine manual

21. Fu

LuIn

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22. Fuel Filter (Propane) - Kubota

Interval - Every year or 1000 hours of operationComments - Replace filter. Refer to Section 6.6, PropaneFuel Filter Replacement (Kubota Engine)

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Tire Replacement

nstalled on each product model have been designed forquirements which consist of track width, tire pressure, andity. Size changes such as rim width, center piece location,maller diameter, etc., without written factory recommen-ay result in an unsafe condition regarding stability.

tallationmely important to apply and maintain proper wheel

torque.

UST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TOE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATIONM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONEWHEEL.

e lug nuts to the proper torque to prevent wheels fromose. Use a torque wrench to tighten the fasteners. If you do torque wrench, tighten the fasteners with a lug wrench,

ediately have a service garage or dealer tighten the lug proper torque. Over-tightening will result in breaking theermanently deforming the mounting stud holes in thee proper procedure for attaching wheels is as follows:

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6.4 TIRES & WHEELS

Tire Replacement

JLG recommends a replacement tire be the same size, ply and brandas originally installed on the machine. Please refer to the JLG PartsManual for the part number of the approved tires for a particularmachine model. If not using a JLG approved replacement tire, werecommend that replacement tires have the following characteris-tics:

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

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to theoriginal

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

Unless specifically approved by JLG Industries Inc. do not replace afoam filled or ballast filled tire assembly with a pneumatic tire. Whenselecting and installing a replacement tire, ensure that all tires areinflated to the pressure recommended by JLG. Due to size variationsbetween tire brands, both tires on the same axle should be the same.

Wheel and

The rims istability reload capaclarger or sdations, m

Wheel InsIt is extremounting

WHEEL NUTS MPREVENT LOOSOF WHEEL FROANGLE OF THE

Tighten thcoming lonot have athen immnuts to thestuds or pwheels. Th

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Table 6-17. Wheel Torque Chart

TORQUE SEQUENCE

2nd Stage 3rd Stage

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

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1. Start all nuts by hand to prevent cross threading. DO NOTuse a lubricant on threads or nuts.

2. Tighten nuts in the following sequence.

3. The tightening of the nuts should be done in stages. Follow-ing the recommended sequence, tighten nuts per wheel torque.

4. Wheel nuts should be torqued after first 50 hours of opera-tion and after each wheel removal. Check and torque every 3 months or 150 hours of operation.

1st Stage

40 ft lbs (55 Nm)

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6-37

1

10

2

3

4

5

6

7

8

9

1. Electric Lock Off Solenoid2. Housing Seal3. Filter Magnet4. Filter Housing5. Electrical Connector

6. Fuel Outlet7. O-ring8. Filter9. Fuel Inlet

10. Ring

Figure 6-13. GM Filter Lock Assembly

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6.5 PROPANE FUEL FILTER REPLACEMENT (GM ENGINE)

Removal1. Relieve the propane fuel system pressure. Refer to Propane

Fuel System Pressure Relief.

2. Disconnect the negative battery cable.

3. Slowly loosen the Filter housing and remove it.

4. Pull the filter housing from the Electric lock off assembly.

5. Remove the filter from the housing.

6. Locate Filter magnet and remove it.

7. Remove and discard the housing seal.

8. If equipped, remove and discard the retaining bolt seal.

9. Remove and discard mounting plate to lock off O-ring seal.

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Ins

BE SUNEW

NE FUEL FILTER REPLACEMENT (KUBOTA )

the propane fuel system pressure. Refer to Propanestem Pressure Relief.

nect the negative battery cable.

loosen the bowl retaining nut and remove the nuter housing from the Electric lock off assembly.

e the filter from the housing.

e and discard the housing seal.

e and discard the retaining nut seal. an

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tallation

RE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING SEAL

1. Install the mounting plate to lock off O-ring seal.

2. If equipped, install the retaining bolt seal.

3. Install the housing seal.

4. Drop the magnet into the bottom of the filter housing.

5. Install the filter into the housing.

6. If equipped, install the retaining bolt into the filter housing.

7. Install the filter up to the bottom of the electric lock off.

8. Tighten the filter bowl retainer to 106 in-lb (12 Nm).

9. Open manual shut-off valve. Start the vehicle and leak checkthe propane fuel system at each serviced fitting.

6.6 PROPAENGINE

Removal1. Relieve

Fuel Sy

2. Discon

3. Slowlyand filt

4. Remov

5. Remov

6. Remov

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6-39

nequipped, install the filter bowl gasket.

stall the filter into the housing.

stall the filter bowl up to the bottom of the electric lock off.

ghten the filter bowl retainer nut.

pen manual shut-off valve. Start the vehicle and leak checke propane fuel system at each serviced fitting. an

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3121658 – JLG Lift –

Installatio1. If

2. In

3. In

4. Ti

5. Oth

OUTLETFILTER BOWLGASKET

FILTER

SEALBOWLRETAINING NUT

Figure 6-14. Kubota Filter Lock Assembly

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6.7

THE PIMIZPRESPONE

To

RESIDAREA

MENTAL INFORMATIONng information is provided in accordance with thets of the European Machinery Directive 2006/42/EC

applicable to CE machines.

powered machines, the equivalent continuous A-ound pressure level at the work platform is less than

tion engine powered machines, guaranteed Soundl (LWA) per European Directive 2000/14/EC (Noise the Environment by Equipment for Use Outdoors)est methods in accordance with Annex III, Part B,nd 0 of the directive, is 102 dB.

n total value to which the hand-arm system is sub- not exceed 2,5 m/s2. The highest root mean squareighted acceleration to which the whole body is sub- not exceed 0,5 m/s2.

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PROPANE FUEL SYSTEM PRESSURE RELIEF

ROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MIN-E THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEMSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COM-NTS.

relieve propane fuel system pressure:

1. Close the manual shut-off valve on the propane fuel tank.

2. Start and run the vehicle until the engine stalls.

3. Turn the ignition switch OFF.

UAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE WORK IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.

6.8 SUPPLEThe followirequiremenand is only

For electricWeighted s70dB(A)

For combusPower LeveEmission inbased on tMethod 1 a

The vibratiojected doesvalue of wejected does

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SECTION 7 - INSPECTION AND REPAIR LOG

7-1

REPAIR LOG

ir Log

nts

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SECTION 7. INSPECTION ANDMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

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SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121658

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Table 7-1. Inspection and Repair Log

Date Comments

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JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA

(717) 485-5161 (Corporate) (800) 544-5438 (Service) (717) 485-6417

www.jlg.com

JLG Worldwide LocationsJLG Industries 358 Park RoadRegents ParkNSW 2143Sydney 2143Australia

+6 (12) 87186300 +6 (12) 65813058

Email: [email protected]

JLG Ground Support OudeBunders 1034Breitwaterstraat 12A3630 MaasmechelenBelgium

+32 (0) 89 84 82 26Email: [email protected]

JLG Latino Americana LTDARua Antonia Martins Luiz, 580Distrito Industrial Joao NarezziIndiaatuba-SP 13347-404Brasil

+55 (19) 3936 7664 (Parts) +55(19)3936 9049 (Service)

Email: [email protected]: [email protected]

Oshkosh-JLG (Tianjin) Equipment Technology LTDShanghai BranchNo 465 Xiao Nan RoadFeng Xian DistrictShanghai 201204China

+86 (21) 800 819 0050

JLG Industries DubaiJafza ViewPO Box 262728, LB 1920th Floor, Office 05Jebel Ali, Dubai

+971 (0) 4 884 1131 +971 (0) 4 884 7683


JLG France SASZ.I. Guillaume Mon Amy30204 Fauillet47400 TonniensFrance

+33 (0) 553 84 85 86 +33 (0) 553 84 85 74


JLG Deutschland GmbHMax Planck Str. 2127721 Ritterhude - IhlpohlGermany

+49 (0) 421 69350-0 +49 (0) 421 69350-45

Email:[email protected]

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

+(852) 2639 5783 +(852) 2639 5797

JLG Industries (Italia) S.R.L.Via Po. 2220010 Pregnana Milanese (MI)Italy

+39 (0) 2 9359 5210 +39 (0) 2 9359 5211


JLG EMEA B.V. Polaris Avenue 632132 JH HoofdorfThe Netherlands

+31 (0) 23 565 5665Email: [email protected]

JLG NZ Access Equipment & Services2B Fisher CresentMt Wellington 1060Auckland, New Zealand

+6 (12) 87186300 +6 (12) 65813058


JLG IndustriesVahutinskoe shosse 24b.KhimkiMoscow Region 141400Russia Federation

+7 (499) 922 06 99 +7 (499) 922 06 99

Oshkosh-JLG Singapore Technology Equipment Pte Ltd.35 Tuas Avenue 2Jurong Industrial Estate Singapore 639454

+65 6591 9030 +65 6591 9045


JLG Iberica S.L.Trapadella, 2Pol. Ind. Castellbisbal Sur08755 Castellbisbal BarcelonaSpain

+34 (0) 93 772 47 00 +34 (0) 93 771 1762


JLG Sverige ABEnkopingsvagen 150176 27 JarfallaSweden

+46 (0) 8 506 595 00 +46 (0) 8 506 595 27


JLG Industries (UK) Ltd.Bentley HouseBentley AvenueMiddleton, Greater ManchesterM24 2GPUnited Kingdom

+44 (0) 161 654 1000 +44 (0) 161 654 1003


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