JLG 1250AJP Operations Manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models

1250AJP
ANSI ®
3121170
January 5, 2015
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
3121170 – JLG Lift – a

FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
GROUND. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
GROUND.
b – JLG Lift – 3121170

FOREWORD
For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- Compliance Information
• Product Safety Publica-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions • Questions Regarding Special
THIS PRODUCT.
Product Applications
• Current Owner Updates
• Questions Regarding Prod-
• Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE Hagerstown, MD 21742
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY USA
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-
SONAL PROPERTY OR THE JLG PRODUCT. or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: [email protected]
3121170 – JLG Lift – c

FOREWORD
REVISION LOG
Original Issue - March 1, 2004

Revised - May 4, 2005
Revised - January 12, 2006
Revised - May 9, 2006
Revised - July 21, 2006
Revised - November 30, 2006
Revised - April 10, 2007
Revised - March 19, 2008
Revised - November 19, 2009
Revised - August 31, 2010
Revised - September 11, 2014
Revised - January 5, 2015
d – JLG Lift – 3121170

TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-11
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-7
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-15
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11 SECTION - 4 - MACHINE OPERATION
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.2 HYDRAULIC SYSTEM WARM UP . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 4.3 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
AND INSPECTION Envelope Control System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Tower Path Control System . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Automatic Main Boom Control System . . . . . . . . . . . . . 4-5
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Slow Down System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
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TABLE OF CONTENTS

4.4 AUXILIARY POWER OPERATION . . . . . . . . . . . . . . . . . . . . . 4-10 4.13 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
4.5 CAPACITY SELECT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 (CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.6 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.14 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.15 EMERGENCY TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.16 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . 4-13 4.17 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.7 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-16 Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.8 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.18 STOWING THE JIB FOR TRANSPORT. . . . . . . . . . . . . . . . . . 4-22
4.9 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.10 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 SECTION - 5 - EMERGENCY PROCEDURES
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.11 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-17 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-17 5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2
Tower Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 (CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
4.12 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-18
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TABLE OF CONTENTS

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS AND PERFORMANCE
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Data - Deutz 2011 Prior to S/N 0300127698 . 6-5
Engine Data - Deutz 2011 S/N 0300127698
to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Engine Data - Caterpillar . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 6-34
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-35
SECTION - 7 - INSPECTION AND REPAIR LOG
3121170 – JLG Lift – iii

TABLE OF CONTENTS
This Page Left Blank Intentionally.
iv – JLG Lift – 3121170

LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 6-2. Engine Operating Temperature Specifications - Deutz -
2-2. Daily Walk-Around Inspection - Sheet 1 of 2 . . . . . . . . . . 2-9 Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
2-3. Daily Walk-Around Inspection - Sheet 2 of 2 . . . . . . . . . 2-10 6-3. Engine Operating Temperature Specifications - Caterpillar
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
3-2. Ground Control Station with Machine Safety System 6-4. Engine Operating Temperature Specifications - Caterpillar
Override (MSSO) (CE Only). . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-8 6-5. Operator Maintenance and Lubrication Diagram - Deutz
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10 2011/CAT Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
3-5. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-16 6-6. Operator Maintenance and Lubrication Diagram - Deutz
3-6. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18 2.9 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
4-1. Tower Path vs. Main Boom Angle . . . . . . . . . . . . . . . . . . . . . 4-4 6-7. Hydraulic Return Filter Condition Indicator - Prior to S/N
4-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-7 139396 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
4-3. Position of Least Backward Stability - Sheet 1 of 2 . . . . . 4-8 6-8. Hydraulic Return Filter Condition Indicator - S/N 139396 to
4-4. Position of Least Backward Stability - Sheet 2 of 2 . . . . . 4-9 Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
4-5. Range Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 6-9. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
4-6. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-7. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-8. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-9. Decal Location Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
6-1. Engine Operating Temperature Specifications - Deutz -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
3121170 – JLG Lift – v

LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
vi – JLG Lift – 3121170

LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-2 Decal Legend - Prior to S/N 0300141446 . . . . . . . . . . . . .4-29
4-3 Decal Legend - S/N 0300141446 to Present . . . . . . . . . .4-33
6-1 Operating Specifications - Prior to S/N 0300141446 . . . 6-1
6-2 Operating Specifications - S/N 0300141446 to Present. 6-2
6-3 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Chassis Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Deutz BF4M2011 Specifications . . . . . . . . . . . . . . . . . . . . . . 6-5
6-8 Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Deutz TCD2.9L4 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-10 Caterpillar 3.4T. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-11 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-12 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-13 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-15 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-16 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-17 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-17
6-19 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-35
7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
3121170 – JLG Lift – vii

LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
viii – JLG Lift – 3121170

SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL
This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
safe machine usage and maintenance. It is mandatory that a daily COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
routine is established based on the content of this manual to pro- DEATH.
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
1.2 PRE-OPERATION
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate. Operator Training and Knowledge
The owner/user/operator/lessor/lessee of the machine must not • The Operation and Safety Manual must be read and under-
accept operating responsibility until this manual has been read, stood in its entirety before operating the machine. For clarifi-
training is accomplished, and operation of the machine has been cation, questions, or additional information regarding any
completed under the supervision of an experienced and quali- portions of this manual, contact JLG Industries, Inc.
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”).
3121170 – JLG Lift – 1-1

• An operator must not accept operating responsibilities until Workplace Inspection

adequate training has been given by competent and autho-
rized persons. • Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Allow only those authorized and qualified personnel to oper-
ate the machine who have demonstrated that they under- • Do not operate or raise the platform from a position on trucks,
stand the safe and proper operation and maintenance of the trailers, railway cars, floating vessels, scaffolds or other equip-
unit. ment unless the application is approved in writing by JLG.
• Read, understand, and obey all DANGERS, WARNINGS, CAU- • Before operation, check work area for overhead hazards such
TIONS, and operating instructions on the machine and in this as electric lines, bridge cranes, and other potential overhead
manual. obstructions.
• Ensure that the machine is to be used in a manner which is • Check operating surfaces for holes, bumps, drop-offs, obstruc-
within the scope of its intended application as determined by tions, debris, concealed holes, and other potential hazards.
JLG. • Check the work area for hazardous locations. Do not operate
• All operating personnel must be familiar with the emergency the machine in hazardous environments unless approved for
controls and emergency operation of the machine as specified that purpose by JLG.
in this manual. • Ensure that the ground conditions are adequate to support
• Read, understand, and obey all applicable employer, local, and the maximum tire load indicated on the tire load decals
governmental regulations as they pertain to your utilization located on the chassis adjacent to each wheel. Do not travel
and application of the machine. on unsupported surfaces.
1-2 – JLG Lift – 3121170

Machine Inspection 1.3 OPERATION

• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
General
been performed. • Machine operation requires your full attention. Bring the
• Do not operate this machine until it has been serviced and machine to a full stop before using any device, i.e. cell phones,
maintained according to the maintenance and inspection two-way radios, etc. that will distract your attention from
requirements as specified in the machine’s Service and Main- safely operating the machine.
tenance Manual. • Do not use the machine for any purpose other than position-
• Ensure all safety devices are operating properly. Modification ing personnel, their tools, and equipment.
of these devices is a safety violation. • Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE occurs, shut down the machine. Remove the unit from service
ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER. and notify the proper authorities.
• Do not operate any machine on which the safety or instruction • Do not remove, modify, or disable any safety devices.
placards or decals are missing or illegible.
• Never slam a control switch or lever through neutral to an
• Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop
Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con-
• Avoid accumulation of debris on platform floor. Keep mud, oil, trols with slow and even pressure.
grease, and other slippery substances from footwear and plat- • Do not allow personnel to tamper with or operate the
form floor. machine from the ground with personnel in the platform,
except in an emergency.
3121170 – JLG Lift – 1-3

• Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature,
approved by JLG. ambient air temperature, and boom and platform position.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
Trip and Fall Hazards
• Always ensure that power tools are properly stowed and never • During operation, occupants in the platform must wear a full
left hanging by their cord from the platform work area. body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard
• When driving, always position boom over rear axle in line with anchorage point..
the direction of travel. Remember, if boom is over the front
axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing or pull-
ing except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating • Enter and exit only through gate area. Use extreme caution
machine. Do not wear loose fitting clothing or long hair unre- when entering or leaving platform. Ensure that the platform
strained which may become caught or entangled in equip- assembly is fully lowered. Face the machine when entering or
ment. leaving the platform. Always maintain “three point contact”
• Persons under the influence of drugs or alcohol or who are with the machine, using two hands and one foot or two feet
subject to seizures, dizziness or loss of physical control must and one hand at all times during entry and exit.
not operate this machine.
• Hydraulic cylinders are subject to thermal expansion and con-
traction. This may result in changes to the boom and/or plat-
form position while the machine is stationary. Factors
affecting thermal movement can include the length of time
1-4 – JLG Lift – 3121170

• Before operating the machine, make sure all gates are closed Electrocution Hazards
and fastened in their proper position.
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
• Keep both feet firmly positioned on the platform floor at all

times. Never position ladders, boxes, steps, planks, or similar
items on unit to provide additional reach for any purpose.
• Keep oil, mud, and slippery substances cleaned from footwear
and the platform floor.
3121170 – JLG Lift – 1-5

Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range MINIMUM APPROACH DISTANCE

(Phase to Phase) in Feet (Meters)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.
• Maintain distance from electrical lines, apparatus, or any ener-
gized (exposed or insulated) parts according to the Minimum • Maintain a clearance of at least 10 ft. (3m) between any part of
Approach Distance (MAD) as shown in Table 1-1. the machine and its occupants, their tools, and their equip-
• Allow for machine movement and electrical line swaying. ment from any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
1-6 – JLG Lift – 3121170

• The minimum approach distance may be reduced if insulating Tipping Hazards

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

on or near a sloping, uneven, or soft surface. Ensure machine is
positioned on a firm, level and smooth surface before elevat-
ing platform or driving with the platform in the elevated posi-
tion.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
3121170 – JLG Lift – 1-7

• Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions exceed 28
platform. Keep all loads within the confines of the platform, mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Refer-
unless authorized by JLG. ence Only).
• Keep the chassis of the machine a minimum of 2 ft. (0.6m) • Do not increase the surface area of the platform or the load.
from holes, bumps, drop-offs, obstructions, debris, concealed Increase of the area exposed to the wind will decrease stabil-
holes, and other potential hazards at the ground level. ity.
• Do not push or pull any object with the boom. • Do not increase the platform size with unauthorized deck
extensions or attachments.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure. Never attach wire, cable, or • If boom assembly or platform is in a position that one or more
any similar items to platform. wheels are off the ground, all persons must be removed before
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine.
1-8 – JLG Lift – 3121170

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/
S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort Wind Speed

Description Land Conditions
Number mph m/s
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella use
becomes difficult.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
3121170 – JLG Lift – 1-9

Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Approved head gear must be worn by all operating and
• Under all travel conditions, the operator must limit travel
ground personnel.
speed according to conditions of ground surface, congestion,
• Check work area for clearances overhead, on sides, and bot- visibility, slope, location of personnel, and other factors which
tom of platform when lifting or lowering platform, and driving. may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driv-
ing in high speed, switch to low speed before stopping. Travel
grades in low speed only.
• Do not use high speed drive in restricted or close quarters or
when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Dis-
connect power to overhead cranes.
• During operation, keep all body parts inside platform railing.
• Warn personnel not to work, stand, or walk under a raised
• Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary.
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.
1-10 – JLG Lift – 3121170

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

• Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must
hauling. be observed during maintenance of this machine. Additional pre-
cautions to be observed during machine maintenance are
• This machine should not be towed, except in the event of
inserted at the appropriate points in this manual and in the Ser-
emergency, malfunction, power failure, or loading/unloading.
vice and Maintenance Manual. It is of utmost importance that
Refer to the Emergency Procedures section of this manual for
maintenance personnel pay strict attention to these precautions
emergency towing procedures.
to avoid possible injury to personnel or damage to the machine
• Ensure boom is in the stowed position and the turntable or property. A maintenance program must be established by a
locked prior to towing, lifting or hauling. The platform must be qualified person and must be followed to ensure that the
completely empty of tools. machine is safe.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity. Maintenance Hazards
• Refer to the Machine Operation section of this manual for lift- • Shut off power to all controls and ensure that all moving parts
ing information. are secured from inadvertent motion prior to performing any
adjustments or repairs.
• Never work under an elevated platform until it has been fully
lowered to the full down position, if possible, or otherwise
supported and restrained from movement with appropriate
safety props, blocking, or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic hoses or fit-
tings while the machine is powered on or when the hydraulic
system is under pressure.
• Always relieve hydraulic pressure from all hydraulic circuits
before loosening or removing hydraulic components.
3121170 – JLG Lift – 1-11

• DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding.
board or paper to search for leaks. Wear gloves to help protect
• When performing welding or metal cutting operations, pre-
hands from spraying fluid.
cautions must be taken to protect the chassis from direct
exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Use only approved non-flammable cleaning solvents.
• Do not replace items critical to stability, such as batteries or
solid tires, with items of different weight or specification. Do
not modify unit in any way to affect stability.
• Refer to the Service and Maintenance Manual for the weights
of critical stability items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

• Ensure replacement parts or components are identical or ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
equivalent to original parts or components.
• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in an
unstable position. Ensure adequate support is provided when
raising components of the machine.
1-12 – JLG Lift – 3121170

Battery Hazards
• Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
• Do not allow smoking, open flame, or sparks near battery dur- CLEAN WATER AND SEEK MEDICAL ATTENTION.
ing charging or servicing. • Charge batteries only in a well ventilated area.
• Do not contact tools or other metal objects across the battery • Avoid overfilling the battery fluid level. Add distilled water to
terminals. batteries only after the batteries are fully charged.
• Always wear hand, eye, and face protection when servicing
batteries. Ensure that battery acid does not come in contact
with skin or clothing.
3121170 – JLG Lift – 1-13

NOTES:
1-14 – JLG Lift – 3121170

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

2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
The aerial platform is a personnel handling device; so it is neces- depressions, holes, drop-offs.
sary that it be operated and maintained only by trained person-
7. Means to avoid the hazards of unprotected electrical con-
nel.
ductors.
Persons under the influence of drugs or alcohol or who are sub-
8. Specific job requirements or machine application.
ject to seizures, dizziness or loss of physical control must not
operate this machine.
Training Supervision
Operator Training Training must be done under the supervision of a qualified per-
son in an open area free of obstructions until the trainee has
Operator training must cover:
developed the ability to safely control and operate the machine.
1. Use and limitations of the controls in the platform and at the
ground, emergency controls and safety systems. Operator Responsibility
2. Control labels, instructions, and warnings on the machine. The operator must be instructed that he/she has the responsibil-
ity and authority to shut down the machine in case of a malfunc-
3. Rules of the employer and government regulations.
tion or other unsafe condition of either the machine or the job
4. Use of approved fall protection device. site.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunc-
tion.
3121170 – JLG Lift – 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A
maintenance required by JLG Industries, Inc. Consult local regula- PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL
tions for further requirements for aerial work platforms. The fre- FOR THE SPECIFIC JLG PRODUCT MODEL.
quency of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile environ-
ment, if the machine is used with increased frequency, or if the
machine is used in a severe manner.
2-2 – JLG Lift – 3121170

Table 2-1. Inspection and Maintenance Table
Type Frequency Primary Service Reference

Responsibility Qualification
Pre-Start Inspection Before using each day; or User or Operator User or Operator Operator and Safety Manual
whenever there’s an Operator change.
Pre-Delivery Inspection (See Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Note) and applicable JLG inspection form
Frequent Inspection In service for 3 months or 150 hours, whichever comes first; Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
(See Note) or and applicable JLG inspection form
Out of service for a period of more than 3 months; or
Purchased used.
Annual Machine Inspection Annually, no later than 13 months from the date of prior Owner, Dealer, or User Factory Trained Service and Maintenance Manual
(See Note) inspection. Service Technician and applicable JLG inspection form
(Recommended)
Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Manual.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
3121170 – JLG Lift – 2-3

Pre-Start Inspection 4. Operation and Safety Manuals – Make sure a copy of the
Operator and Safety Manual, AEM Safety Manual (ANSI mar-
The Pre-Start Inspection should include each of the following: kets only), and ANSI Manual of Responsibilities (ANSI mar-
kets only) is enclosed in the weather resistant storage
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-
container.
tery fluid) or foreign objects. Report any leakage to the
proper maintenance personnel. 5. “Walk-Around” Inspection – Refer to Figure 2-2.
2. Structure - Inspect the machine structure for dents, dam- 6. Battery – Charge as required.
age, weld or parent metal cracks or other discrepancies.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Engine Oil Supply - Ensure the engine oil level is at the Full
mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
Parent Metal Crack Weld Crack 10. Accessories/Attachments - Reference the Operator and
Safety Manual of each attachment or accessory installed
3. Decals and Placards – Check all for cleanliness and legibil- upon the machine for specific inspection, operation, and
ity. Make sure none of the decals and placards are missing. maintenance instructions.
Make sure all illegible decals and placards are cleaned or
replaced.
2-4 – JLG Lift – 3121170

11. Function Check – Once the “Walk-Around” Inspection is Function Check

complete, perform a functional check of all systems in an
area free of overhead and ground level obstructions. Refer to Perform the Function Check as follows:
Section 4 for more specific operating instructions.
1. From the ground control console with no load in the plat-
form:
a. Check that all guards protecting the switches or locks
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
are in place;
ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. b. Operate all functions and make sure the Boom Control
System warning light does not come on;
c. Check auxiliary power;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure all boom functions stop when the function
enable switch is released.
3121170 – JLG Lift – 2-5

2. From the platform control console: 4. Swing the boom over either of the rear tires and ensure that
the Drive Orientation indicator illuminates and that the
a. Ensure that the control console is firmly secured in the
Drive Orientation Override switch must be used for the drive
proper location;
function to operate.
b. Check that all guards protecting the switches or locks
are in place;
c. Operate all functions and make sure the Boom Control
System warning light does not come on;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
3. With the platform in the stowed position:

a. Drive the machine on a grade, not to exceed the rated
gradeability, and stop to ensure the brakes hold;
b. Check the tilt sensor alarm to ensure proper operation.
c. Check that all boom functions are disabled with the
axles retracted and the boom out of transport mode.
NOTE: The machine is in transport mode until one of the following

three factors are exceeded:
Main boom extended more than 4 ft. (1.2 m) OR
Main boom 6° above horizontal (w/tower stowed) OR
Tower above horizontal.
2-6 – JLG Lift – 3121170

SkyGuard Function Test NOTE: If the machine is equipped with both SkyGuard and Soft Touch,
functions will not reverse, only stop.
From the Platform Console:
NOTE: If equipped, ensure the blue beacon illuminates when SkyGuard
Test the SkyGuard feature by operating the telescope out func-
is activated.
tions and then activating the SkyGuard sensor. The telescope out
function will stop and the telescope in function will operate for a
Disengage the SkyGuard sensor, release controls, recycle the foot
short duration and the horn will sound until the SkyGuard sensor
switch, make sure normal operation is available.
and footswitch are disengaged.
If SkyGuard remains activated after function reversal or cutout,
depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the SkyGuard sensor is disen-
gaged.
3121170 – JLG Lift – 2-7

1. Front Drive\Steer Wheels

2. Rear Drive\Steer Wheels
3. Tower Lift Cylinder
4. Ground Console
5. Tower Base Boom Section
6. Tower Mid Boom Section
7. Tower Fly Boom Section
8. Tower Boom Assembly
9. Main Lift Cylinder
10. Main Base Boom Section
11. Main Boom Fly Section
12. Main Boom Assembly
13. Jib
14. Platform
15. Platform Console
16. SkyGuard (If Equipped)
Figure 2-1. Basic Nomenclature
2-8 – JLG Lift – 3121170

Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 2
3121170 – JLG Lift – 2-9

General 4. Swing Drive - No evidence of damage.
Begin the "Walk-Around Inspection" at Item 1, as noted on the 5. Wheel/Tire Assemblies - Properly secured, no missing
diagram. Continue checking each item in sequence for the lug nuts. Inspect for worn tread, cuts, tears or other dis-
conditions listed in the following checklist. crepancies. Inspect wheels for damage and corrosion.
6. Drive Motor, Brake, and Hub - No evidence of leakage.
7. Hood Assemblies - See Inspection Note.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.
8. Auxiliary Hydraulic Pump - See Inspection Note.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
9. All Hydraulic Cylinders - No visible damage; pivot pins
INSPECTION NOTE: On all components, make sure there are no and hydraulic hoses undamaged, not leaking.
loose or missing parts, that they are securely fastened, and no vis- 10. Turntable Bearing - Evidence of proper lubrication. No
ible damage, leaks or excessive wear exists in addition to any evidence of loose bolts or looseness between bearing
other criteria mentioned. and machine.
1. Platform Assembly and Gate - Footswitch works prop- 11. Steering Spindles and Sensors - See Inspection Note.
erly, not modified, disabled or blocked. Latch and hinges
in working condition. 12. Main Hydraulic Pump - See Inspection Note.
2. Platform & Ground Control Consoles - Switches and 13. Platform Rotator - See Inspection Note.
levers return to neutral, decals/placards secure and legi- 14. Jib Rotator - See Inspection Note.
ble, control markings legible.
15. SkyGuard - See Inspection Note.
3. Boom Sections/Turntable - See Inspection Note.
Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 2
2-10 – JLG Lift – 3121170

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 6. Have an assistant check to see that left front or right rear
wheel remains elevated in position off of the ground.
The front axles will oscillate when the boom is in the transport posi- 7. Carefully return the boom to the transport position. When
tion. boom reaches the transport position, carefully activate Drive
to release cylinders. The lockout cylinders should release
and allow the wheel to rest on ground.
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- 8. Repeat the procedure for the right oscillation cylinder check-
PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. ing to see that the right front or left rear wheel remains ele-
vated in position off of the ground.
NOTE: Ensure the axles are extended and the boom is fully retracted,
lowered, and centered between the rear wheels prior to begin- 9. If lockout cylinders do not function properly, have qualified
ning lockout cylinder test. personnel correct the malfunction prior to any further oper-
ation.
1. Place a 6 inches (15.2 cm) high block with ascension ramp in
front of left front wheel.
2. From platform control station, start engine.
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front
wheel is on top of block.
4. Carefully extend the boom just enough to get it out of the
transport position.
5. With boom in this position, place Drive control lever to
Reverse and carefully drive machine off of block and ramp.
3121170 – JLG Lift – 2-11

NOTES:
2-12 – JLG Lift – 3121170

SECTION 3 - MACHINE CONTROLS AND INDICATORS
SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL NOTE: The indicator panels use different shaped symbols to alert the
operator to different types of operational situations that could
arise. The meaning of those symbols are explained below.
Indicates a potentially hazardous situation, which if
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.
OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH This indicator will be red.
GOOD SAFETY PRACTICES.
Indicates an abnormal operating condition, which if
This section provides the necessary information needed to not corrected, may result in machine interruption or
understand control functions. damage. This indicator will be yellow.
3.2 CONTROLS AND INDICATORS Indicates important information regarding the operat-
ing condition, i.e. procedures essential for safe opera-
NOTE: All machines are equipped with control panels that use symbols
tion. This indicator will be green with the exception of
to indicate control functions. On ANSI machines refer to decal the capacity indicator which will be green or yellow
located on the control box guard in front of the control box or by depending upon platform position.
the ground controls for these symbols and the corresponding
functions.
3121170 – JLG Lift – 3-1

3. Tower Lift Control
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Provides raising and lowering of the tower boom.
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
4. Swing Control
OFF POSITION WHEN RELEASED.
Provides 360 degrees continuous turntable rotation.
Ground Control Station
5. Main Lift Control
(See Figure 3-1., Ground Control Station) and Section 3-2., Ground Con-
trol Station with Machine Safety System Override (MSSO) (CE Only). Provides raising and lowering of the main boom.
6. Jib Lift
1. Indicator Panel
Provides raising and lowering of the jib.
The Indicator Panel contains indicator lights that signal
problem conditions or functions operating during machine
operation.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
NOTE: The Function Enable switch must be held down in THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
order to operate Main Boom Telescope, Tower Lift, FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
Swing, Main Lift, Jib Lift, Platform Level Override,
Platform Rotate, and Jib Swing functions. 7. Platform Leveling Override
2. Main Boom Telescope Control A three position switch allows the operator to adjust the
automatic self leveling system. This switch is used to adjust
Provides extension and retraction of the main boom. platform level in situations such as ascending/descending a
grade.
3-2 – JLG Lift – 3121170

1 9
1. Indicator Panel
2. Main Boom Telescope
8
3. Tower Boom Lift
4. Swing
2 5. Main Boom Lift
6. Jib Lift
7 7. Platform Leveling Override
8. Platform Rotate
9. Jib Swing
10. Platform/Ground Select Switch
6
11. Hourmeter
12. Power/Emergency Stop
13 13. Engine Start/Auxiliary Power/Function Enable
3
12
11
4 5 10
Figure 3-1. Ground Control Station
3121170 – JLG Lift – 3-3

1. Indicator Panel
2. Main Boom Telescope
3. Tower Boom Lift
4. Swing
5. Main Boom Lift
6. Jib Lift
7. Platform Leveling Override
8. Platform Rotate
9. Jib Swing
11. Hourmeter
13. Engine Start/Auxiliary Power/Function Enable
14. Machine Safety System Override (MSSO)
Figure 3-2. Ground Control Station with Machine Safety System Override (MSSO) (CE Only)
3-4 – JLG Lift – 3121170

8. Platform Rotate 11. Hourmeter
Allows rotation of the platform. Registers the amount of time the machine has been in use,
with engine running. By connecting into the oil pressure cir-
9. Jib Swing
cuit of the engine, only engine run hours are recorded. The
hourmeter registers up to 9,999.9 hours and cannot be reset.
Allows swinging of the jib.
NOTE: When Power/Emergency Stop switch is in the “ON” position and
NOTE: With PLATFORM/GROUND SELECT switch in the center position,
engine is not running, an alarm will sound, indicating Ignition is
power is shut off to controls at both operating stations.
“ON”.
A three position, key operated switch supplies power to the WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST
platform control console when positioned to PLATFORM. BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.
With the switch key held in the GROUND position, power is
shut off to platform and only ground controls are operable. 12. Power/Emergency Stop Switch
A two-position red mushroom shaped switch supplies

power to PLATFORM/GROUND SELECT switch when pulled
out (on). When pushed in (off ), power is shut off to the PLAT-
FORM/GROUND SELECT switch.
3121170 – JLG Lift – 3-5

NOTE: Auxiliary power only works if there is no engine oil pressure, and 14. Machine Safety System Override (MSSO) (CE
is disabled if engine is running. Only)
Functions will operate at a slower than normal rate because of Provides emergency override of function
the reduced hydraulic flow. controls that are locked out in the event of
Load Sense System activation.
WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A
TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.
13. Engine Start/ Auxiliary Power Switch /Function Enable
To start the engine, the switch must be held "UP"

until the engine starts.
To use auxiliary power, the switch must be held

“DOWN” for duration of auxiliary pump use.
When the engine is running, the switch must be

held "DOWN" to enable all boom controls.
3-6 – JLG Lift – 3121170

Ground Control Indicator Panel 4. Engine Oil Temperature Indicator
Indicates the temperature of the engine oil, which also

(See Figure 3-3., Ground Control Indicator Panel)
serves as engine coolant, is abnormally high and service is
1. Battery Charging Indicator required.
5. Glow Plug Indicator
Indicates a problem in the battery or charging circuit, and
service is required. Indicates the glow plugs are operating. After turning on igni-
2. Low Engine Oil Pressure Indicator tion, wait until light goes out before cranking engine.
Indicates that engine oil pressure is below normal and ser-

vice is required.
3. High Engine Temperature Indicator
Indicates that engine coolant temperature is abnormally

high and service is required.
3121170 – JLG Lift – 3-7

1. Battery Charging 4. High Engine Oil Temp. 7. Platform Capacity

2. Low Engine Oil Pressure 5. Glow Plug Indicator 8. Platform Overload
3. High Engine Coolant Temp. 6. Axles Set 9. Boom Control System Warning
Figure 3-3. Ground Control Indicator Panel
3-8 – JLG Lift – 3121170

6. Axles Set Indicator Platform Station

Indicates that the axles are fully extended. The indicator will
(See Figure 3-4., Platform Control Console)
flash as the axles are extending or retracting and be on solid
when fully extended. The light will go out when the axles are
fully retracted.
7. Platform Capacity Indicator TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
Indicates which capacity range is selected. This capacity can OFF OR NEUTRAL POSITION WHEN RELEASED.
only be selected at the platform control console.
8. Platform Overload Indicator (If Equipped)
A two-position red mushroom shaped switch supplies
Indicates the platform has been overloaded. power to PLATFORM Controls when pulled out (on). When
pushed in (off ), power is shut off to the platform controls.
9. Boom Control System Warning Indicator
Within about 2 seconds of pulling the switch out, the
Indicates the platform is outside the operating area and
machine will perform a diagnostic check of the various elec-
operation of certain boom functions may be disabled (i.e.
trical circuits, and if everything is OK, the platform alarm will
lift, telescope). Attempts to use the disabled functions cause
beep once. During this time the lights on the indicator panel
the indicator to flash and an alarm to sound. Immediately
will also blink once as a bulb check.
return the platform to the ground. If the indicator remains lit,
a boom control system fault or failure has been detected. If a
failure is discovered, the system must be repaired by JLG
authorized service personnel before the machine can be
used.
3121170 – JLG Lift – 3-9

1. Power/Emergency Stop 7. Lights 13. Platform Rotate 19. Platform Level Override
2. Engine Start / Aux Power 8. Jib Lift 14. Jib Stow Override 20. Axle Extend/Retract
3. Capacity Select 9. Soft Touch/SkyGuard Override 15. Function Speed Control 21. Horn
4. Drive Orientation Override 10. Jib Swing 16. Main Lift / Swing 22. Indicator Panel
5. Drive/Steer 11. Tower Boom Lift 17. Drive Speed / Torque Select
6. Main Boom Telescope 12. Soft Touch/SkyGuard Indicator 18. Steer Select
Figure 3-4. Platform Control Console
3-10 – JLG Lift – 3121170

2. Start/Auxiliary Power 4. Drive Orientation Override
When pushed forward, the switch energizes the starter When the boom is swung over the rear tires or further in
motor to start the engine. either direction, the Drive Orientation indicator will illumi-
nate when the drive function is selected. Push and release
When pushed back, it energizes the electrically operated the switch, and within 3 seconds move the Drive/Steer con-
hydraulic pump, when actuated. (Switch must be held ON trol to activate drive or steer. Before driving, locate the black/
for duration of auxiliary pump use.) white orientation arrows on both the chassis and the plat-
3. Capacity Select form controls. Move the drive controls in a direction match-
ing the directional arrows.
This switch allows the operator to select between an operat- NOTE: To operate the Drive Joystick, pull up on the locking ring below
ing envelope with a 500 lb. (227 kg for ANSI markets and 230 the handle.
kg for CE and Australia markets) capacity restriction or a
1000 lb. (454 kg for ANSI markets and 450 kg for CE and Aus- NOTE: The DRIVE control levers are spring-loaded and will automati-
tralia markets) capacity restriction. cally return to neutral (OFF) position when released.
5. Drive/Steer
Provides for driving either forward or backward. The control-

ler is infinitely proportional to allow variable drive speed.
Steering is controlled by a thumb operated switch on top of

the joystick.
3121170 – JLG Lift – 3-11

6. Main Telescope If equipped with SkyGuard, the switch

enables functions cut out by the Sky-
Allows extension and retraction of the main boom. guard system to be operated again,
allowing the operator to resume use of
7. Lights (If Equipped)
machine functions.
Operates accessory light packages if the machine is so If equipped with both Soft Touch and
equipped. SkyGuard, the switch operates like
described above and allows the opera-
8. Jib Lift
tor to override the system that has
experienced a cutout situation.
Push forward to lift up, pull back to lift down. Variable lift
speed is accomplished by using the Function Speed Control. NOTE: The Jib Swing function is not operable when the Capacity Select
control is in the 1000 lb. (454 kg for ANSI markets and 450 kg
9. Soft Touch/SkyGuard Override Switch (If equipped)
for CE and Australia markets) position.
The machine can be equipped with one of three options. It
10. Jib Swing
may have Soft Touch, SkyGuard, or both Soft Touch and Sky-
Guard.
Allows the operator to swing the jib to the left or right.
If equipped with Soft Touch, the switch
11. Tower Boom Lift
enables the functions that were cut out
by the Soft Touch system to operate
Allows raising and lowering of the tower boom by activating
again at creep speed, allowing the
the tower lift and telescope cylinders as dictated by the
operator to move the platform away from the obstacle that
Boom Control System.
caused the shutdown situation.
3-12 – JLG Lift – 3121170

12. Soft Touch/SkyGuard Indicator (If Equipped) NOTE: To operate the Main Lift/Swing Joystick, pull up on the locking
ring below the handle.
Indicates the Soft Touch bumper is against an object or the
SkyGuard sensor has been activated. All controls are cut out NOTE: The MAIN LIFT/SWING control lever is spring-loaded and will
until the override button is pushed. For Soft Touch, controls automatically return to neutral (OFF) position when released.
are then active in the Creep Mode or for SkyGuard, controls
will work normally. 16. Main Boom Lift/Swing Controller
13. Platform Rotate
An infinitely proportional dual axis joystick is provided for
main lift and swing. Push forward to lift up, pull backward to
Allows the operator to rotate the platform to the left or right.
lift down. Move right to swing right, move left to swing left.
14. Jib Stow Override
Allows the operator to swing the jib to the right past the
electronic stop to stow the jib beside the boom for trans-
port.
15. Function Speed Control
Controls the speed of Boom and Swing Functions. Rotate

CCW for slower speed and CW for faster speed. To adjust to
creep, turn knob fully CCW until it clicks.
3121170 – JLG Lift – 3-13

NOTE: When boom is positioned above transport position or telescoped 18. Steer Select
out and any of the following switches, DRIVE SPEED/TORQUE
SELECT or FUNCTION SPEED, are positioned to HIGH, high func- The action of the steering system is operator selectable. The
tion speeds are automatically cut out and the machine contin- center switch position gives conventional front wheel steer-
ues to operate at a lower speed. ing with the rear wheels unaffected. This is for normal driv-
ing at maximum speeds. The forward position is for “crab”
steering. When in this mode both front and rear axles steer
in the same direction, which allows the chassis to move side-
DO NOT OPERATE MACHINE IF DRIVE SPEED/TORQUE SELECT OR FUNCTION SPEED ways as it goes forward. This can be used for positioning the
SWITCHES OPERATE WHEN BOOM IS OUT OF TRANSPORT POSITION. machine in aisle ways or close to buildings. The back switch
position is for “coordinated” steering. In this mode the front
17. Drive Speed/Torque Select and rear axles steer in the opposite directions to produce the
tightest turning circle for maneuvering in confined areas.
The forward position gives maximum drive speed. The back
position gives maximum torque for rough terrain and climb-
ing grades. The center position allows the machine to be
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
driven as quietly as possible.
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
19. Platform Leveling Override
A three position switch allows the operator to adjust the

automatic self leveling system. This switch is used to adjust
platform level in situations such as ascending/descending a
grade.
3-14 – JLG Lift – 3121170

20. Axle Extend/Retract Platform Control Indicator Panel

Allows the operator to extend or retract the axles. The axles
(See Figure 3-5., Platform Control Indicator Panel)
can only be extended or retracted while the machine is
being driven forward or reverse. 1. Level System Fault Indicator
21. Horn
Indicates a fault in the electronic leveling system. The fault
If pressed, this switch supplies power to the horn. indicator will flash and an alarm sound. All functions will
default to creep if the boom is out of transport mode.
22. Indicator Panel
The LED Indicator Panel contains indicator lights that signal

problem conditions or functions operating during machine IF THE LEVEL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUT DOWN THE
operation. MACHINE, RESET THE EMERGENCY STOP, AND RESTART THE MACHINE. IF THE FAULT
PERSISTS, RETURN THE PLATFORM TO THE STOWED POSITION, USING MANUAL LEV-
ELING AS REQUIRED, AND HAVE LEVELING SYSTEM REPAIRED.
2. AC Generator (If Equipped)
Indicates the generator is in operation.

3. Platform Overload Indicator (If Equipped)
Indicates the platform has been overloaded.
3121170 – JLG Lift – 3-15

1. Level System 6. Glow Plug 11. Drive Orientation

2. AC Generator 7. Enable 12. Axles Set
3. Platform Overload 8. Fuel Level 13. Boom Control System Warning
4. Platform Capacity 9. Creep Speed
5. Tilt Alarm Warning 10. System Distress
Figure 3-5. Platform Control Indicator Panel
3-16 – JLG Lift – 3121170

4. Platform Capacity Indicator 6. Glow Plug/Wait to Start Indicator
Indicates the maximum platform capacity selected for the NOTE: If the engine fails to start due to cold temperatures or excessive
platform. amounts of smoke are produced on startup, wait for the glow
plug/wait to start indicator to go out before starting the engine.
One of the capacity lights should be on at all times. Both
lights will flash and an alarm will sound if the platform is out Indicates the glow plugs are operating. After turning on igni-
of the operating envelope for the selected capacity. tion, wait until light goes out before starting engine.
5. Tilt Alarm Warning Light
IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO

BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE
EXTENDING BOOM OR RAISING BOOM FROM THE TRANSPORT POSITION.
Indicates that the chassis is on a slope (over 3 to 5 degrees,

depending upon boom angle). If the boom is out of trans-
port position and the machine is on a slope, an alarm will
sound and CREEP is automatically activated.
3121170 – JLG Lift – 3-17

7. Footswitch/Enable Indicator NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more
detailed information concerning the Low Fuel Indicator.
8. Fuel Level Indicator

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH
BY BLOCKING OR ANY OTHER MEANS.
Indicates the level of fuel in the fuel tank.
FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY

OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.
To operate any function, the footswitch must be depressed

and the function selected within seven seconds. The enable
indicator shows that the controls are enabled. If a function is FULL TANK 3/4 TANK ½ TANK
not selected within seven seconds, or if a seven second lapse
between ending one function and beginning the next func-
tion, the enable light will go out and the footswitch must be
released and depressed again to enable the controls.
Releasing the footswitch removes power from all controls

and applies the drive brakes.
1/4 TANK LOW FUEL EMPTY
(FLASHES ONCE (FLASHES TEN
PER SECOND) TIMES
PER SECOND)
Figure 3-6. Fuel Level Indicator
3-18 – JLG Lift – 3121170

9. Creep Speed Indicator 12. Axles Set Indicator
When the Function Speed Control is turned to the creep Indicates that the axles are fully extended. The indicator will
position, the indicator acts as a reminder that all functions flash as the axles are extending or retracting and be on solid
are set to the slowest speed. The light flashes if the control when fully extended. The light will go out when the axles are
system puts the machine into creep speed and will be on fully retracted.
continuously if the operator selects creep speed.
13. Boom Control System Warning Indicator
10. System Distress Indicator
Indicates the platform is outside the operating area and
The light indicates that the JLG Control System has detected operation of certain boom functions may be disabled (i.e.
a malfunction and a Diagnostic Trouble Code has been set in lift, telescope). Attempts to use the disabled functions cause
the system memory. Refer to the Service Manual for instruc- the indicator to flash and an alarm to sound. Immediately
tions concerning the trouble codes and trouble code return the platform to the ground. If the indicator remains lit,
retrieval. a boom control system fault or failure has been detected. If a
failure is discovered, the system must be repaired by JLG
The malfunction indicator light will illuminate for 2-3 sec- authorized service personnel before the machine can be
onds when the key is positioned to the on position to act as used.
a self test.
11. Drive Orientation Indicator
When the boom is swung beyond the rear drive tires or fur-
ther in either direction, the Drive Orientation indicator will
illuminate when the drive function is selected. This is a signal
for the operator to verify that the drive control is being oper-
ated in the proper direction (i.e. controls reversed situa-
tions).
3121170 – JLG Lift – 3-19

NOTES:
3-20 – JLG Lift – 3121170

SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION The primary operator control station is in the platform. From this
control station, the operator can drive and steer the machine in
This machine is a self-propelled hydraulic personnel lift equipped both forward and reverse directions. The operator can raise or
with a work platform on the end of an elevating and rotating lower the main or tower boom or swing the boom to the left or
boom. right. Standard boom swing is 360 degree continuous left and
right of the stowed position. The machine has a Ground Control
Station which will override the Platform Control Station. Ground
Controls operate Boom Lift and Swing, and are to be used in an
emergency to lower the platform to the ground should the oper-
ator in the platform be unable to do so.
3121170 – JLG Lift – 4-1

4.2 HYDRAULIC SYSTEM WARM UP 4.3 BOOM OPERATING CHARACTERISTICS AND

The control system monitors the hydraulic system in extremely LIMITATIONS
cold temperatures and provides optimal performance by auto-
matically limiting the function speeds of the high demand func- Capacities
tions. The warm up mode automatically shuts off when system oil
The boom can be raised from the transport position with or with-
reaches allowable temperatures.
out any load in platform, if:
While the system is cold and in the warm up mode, the tower lift,
1. Machine is positioned on a smooth, firm and level surface.
main lift, and main telescope functions are limited to creep
speeds and is indicated to the operator by flashing the creep light 2. Axles are extended.
on the platform control panel.
3. Load is within manufacturer’s rated capacity.
Functions being operated when the warm up mode turns off will
4. All machine systems are functioning properly.
remain in the creep speed until the function is re-initiated.
5. Proper tire pressure.
6. Machine is as originally equipped from JLG.
4-2 – JLG Lift – 3121170

Envelope Control System scope out without auto tower lift up) or the tower lift down
switch (tower lift down without auto tower telescope in). A back-
The Envelope Control System is the primary means of controlling ward tower path violation can be resolved by operating the tower
the working positions of the tower and main boom within the lift up switch (tower lift up without auto tower telescope out) or
stability and structural requirements of the machine. the tower lift down switch (tower telescope in without auto
The main boom must be controlled in maximum angle and mini- tower lift down).
mum angle to avoid entering a position that could compromise The restricted functions due to backward tower envelope viola-
backward stability and avoid main boom to tower boom interfer- tions are disallowing automatic tower lift down, automatic tower
ence. The tower boom must be controlled by permitting only telescope out, main lift up and down, main telescope in, jib,
specific combinations of tower length and tower angle to avoid swing, drive and steer.
entering a position that could compromise forward and back-
ward stability (see Tower Path Control System). The restricted functions due to forward tower envelope viola-
tions are disallowing automatic tower lift up, automatic tower
Recognized failures within this system will result in control by the telescope in, main lift up and down, main telescope out, jib,
Electrical Retrieval System (refer to the Service Manual), reduced swing, drive and steer.
function speeds, and BCS warning light illumination. After
retrieval the boom will be restricted from leaving the transport The restricted functions due to maximum main boom envelope
position until the failure is resolved. violations are disallowing tower lift up and down, main lift up,
main telescope in, jib, swing and drive.
Boom position violations outside of the allowable envelope will
result in reduced function speeds, BCS warning light illumination, The restricted functions due to minimum main boom envelope
and restriction of functions. Attempts to operate restricted func- violations are disallowing main lift down, swing and drive.
tions will cause the BCS warning light to flash and the platform
alarm to sound.
Violations of the tower path (with a healthy control system) will
cause the automatic combined operation of tower lift and tower
telescope to be suspended. A forward tower path violation can
be resolved by operating the tower lift up switch (tower tele-
3121170 – JLG Lift – 4-3

Tower Path Control System

The Tower Path Control System uses the envelope control sensors
to enhance the control of the tower boom for increased user effi-
ciency and is used as an integral part of the envelope control sys-
tem.
Both the ground and platform control panels use one function
switch to control the tower. User commands for tower lift up or
tower lift down causes the control system to automatically intro-
duce the correct combination of tower telescope and tower lift TOWER PATH FOR MAIN
BOOM ANGLES BELOW
for the tower boom to follow a pre-described path or trajectory of 15 DEGREES
the tower nose.
TOWER PATH FOR MAIN

BOOM ANGLES ABOVE 55
DEGREES
4-4 – JLG Lift – 3121170

Automatic Main Boom Control System TOWER LIFT UP - MAIN BOOM ABOVE 60°
During tower lift up with the main boom already above 60°, the
During combined tower lift and main lift functions, the control
control system will delay automatic compensation of the main
system will maintain the tower lift speed and automatically vary
boom angle during tower lift until the main boom reaches
the maximum main lift command as needed to compensate for
approximately 60°. The control system will then control the main
the movement of the tower.
boom to 60° until the tower boom has reached its maximum
The interaction of the main boom and the tower boom is slightly height. Continuing to operate the tower lift up when the tower
different when the main boom is above or below 60° relative to reaches its maximum height will cause the control system to
gravity. automatically raise the main boom to its original angle.
TOWER LIFT UP/DOWN - MAIN BOOM BELOW 60°
Slow Down System
During tower lift up or down with the main boom below 60°, the
The control system uses the envelope control sensors to auto-
control system will maintain the angle of the main boom read at
matically slow down the tower lift up and tower lift down at the
the start of the tower lift command or as read at the conclusion of
top of the tower path and to automatically slow down main lift
main lift during combined tower and main lift commands.
up and main lift down as the minimum and maximum angles of
TOWER LIFT DOWN - MAIN BOOM ABOVE 60° the working envelope are approached. The control system indi-
During tower lift down with the main boom initially above 60°, cates to the operator this slow down by flashing the creep light
the control system will lower the main boom to approximately on the platform display. This applies to both platform and ground
60° before starting tower movement. The control system will then controls, however, no indication is made on the ground control
control the main boom to 60° for the remainder of the tower lift panel.
down command.
3121170 – JLG Lift – 4-5

Controlled Angle Swing Speed Proportioning

The Controlled Boom Angle System minimizes the interaction of The boom control system sensors sense the distance the platform
swing and drive functions with the envelope edges. This interac- is extended from the centerline of rotation, allowing higher
tion is due to two factors. First, the envelope is controlled relative swing speeds with the platform nearest to the centerline of rota-
to gravity regardless of ground slope and second, the turntable/ tion and gradually slower swing speeds the further the platform
boom mounting is effected by swing and drive functions when gets from the centerline of rotation.
the ground slope varies. This can cause the boom position to vary
within the envelope or even violate the envelope edges when Stability
swinging or driving without intentionally moving the boom. The
Machine stability is based on two (2) conditions which are called
controlled boom angle system automatically activates either the
FORWARD and BACKWARD stability. The machine’s position of
tower or main boom lift up or down during swing and drive com-
least FORWARD stability is shown in (See Figure 4-2.), and its posi-
mands to maintain a constant boom angle relative to gravity.
tion of least BACKWARD stability is shown in (See Figure 4-4.)
Controlled boom angle is disabled with any envelope violation or
failure.
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER-
ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.
4-6 – JLG Lift – 3121170

MAIN BOOM
FULLY EXTENDED
MACHINE WILL TIP OVER IN

DIRECTION OF ARROWS IF OVERLOADED
OR OPERATED
ON AN OUT-OF-LEVEL SURFACE
TOWER BOOM
FULLY LOWERED TO
FULLY RAISED
TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-2. Position of Least Forward Stability
3121170 – JLG Lift – 4-7

.
4-8
JIB ELEVATED

DIRECTION OF ARROW IF OVERLOADED
OR OPERATED
– JLG Lift –
MAIN BOOM
FULLY ELEVATED
TOWER BOOM
FULLY LOWERED
TO FULLY RAISED TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-3. Position of Least Backward Stability - Sheet 1 of 2

3121170
3121170
JIB ELEVATED

DIRECTION OF ARROW IF OVERLOADED
OR OPERATED
MAIN BOOM
FULLY ELEVATED
– JLG Lift – TOWER BOOM

FULLY LOWERED TO
FULLY RAISED
TURNTABLE ROTATED
90 DEGREES FROM
STOWED POSITION
Figure 4-4. Position of Least Backward Stability - Sheet 2 of 2

4-9
4.4 AUXILIARY POWER OPERATION 4.5 CAPACITY SELECT

The Auxiliary Power System provides a means of moving the plat- The Boom Control System allows the operator to select operation
form in the event of an engine malfunction. This system uses an in a 500 lb. (227 kg for ANSI markets and 230 kg for CE and Austra-
electric motor/pump unit capable of operating all boom func- lia markets) capacity restriction envelope or a 1000 lb. (454 kg for
tions needed to allow the platform to be lowered to ground level. ANSI markets and 450 kg for CE and Australia markets) capacity
restriction envelope. The operator selects the desired capacity
With auxiliary power activated, the control system will attempt to
restriction by positioning the Capacity Select switch on the plat-
use the force of gravity to operate main lift down, tower lift down,
form console. The Capacity Indicator shows the capacity selected,
and tower telescope in. If appropriate movement is not detected
and both capacity lights will flash and an alarm sound if the plat-
by the boom sensors, the auxiliary power system will supply
form is out of the selected capacity range.
hydraulic flow to power boom movement. Allow sufficient oper-
ating time for system to respond. NOTE: Operation in the 1000 lb. (454 kg for ANSI markets and 450 kg for
CE and Australia markets) envelope requires the jib to be fixed in
NOTE: To ensure sufficient battery life, where possible, use the Main Lift
the centered position.
and Main Telescope functions to lower the platform to ground
level before using Tower Lift. Movements of the boom using aux-
iliary power will be SLOW and the movements will momentarily
stop and alternate between other functions as needed. When
operating Tower Lift, the movements will alternate between
tower lift, tower telescope, and main lift. When operating Main
Lift, the movements will alternate between main lift, tower lift,
and platform level.
4-10 – JLG Lift – 3121170

Figure 4-5. Range Diagram

3121170 – JLG Lift – 4-11
4.6 ENGINE OPERATION 2. After engine has had sufficient time to warm up, shut engine
off.
NOTE: Initial starting should always be performed from the Ground
3. Turn SELECT switch to PLATFORM.
Control console.
4. From Platform, pull POWER/EMERGENCY STOP switch out,
Starting Procedure then push the ENGINE START switch until engine starts.
NOTE: Footswitch must be in released (up) position before starter will

operate. If starter operates with footswitch in the depressed posi-
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. tion, DO NOT OPERATE MACHINE.
SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN-
UTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE Shutdown Procedure
MANUAL.
NOTE: If the engine fails to start due to cold temperatures or excessive

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE
amounts of smoke are produced on startup, wait for the glow
THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.
plug/wait to start indicator to go out before starting the engine.
1. Remove all load and allow engine to operate at low speed
1. Turn key of SELECT switch to GROUND. Position POWER/ for 3-5 minutes; this allows further reduction of internal
EMERGENCY STOP switch to ON, then push the ENGINE engine temperature.
START switch until engine starts.
2. Push POWER/EMERGENCY STOP switch in.
3. Turn MASTER switch to Off.
ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING Refer to Engine Manufacturer’s manual for detailed information.
ANY LOAD.
4-12 – JLG Lift – 3121170

Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera-
tor will be permitted to cycle power and restart the engine
NOTE: Reference the Service and Maintenance Manual along with a for approximately 2 minutes of run time. After the 2 min-
qualified JLG Mechanic to verify your machine setup. utes of run time is complete, the operator may cycle power
and restart the engine for an additional 2 minutes of run
The Fuel Shutoff System monitors the fuel in the tank and senses time. The operator can repeat this process until there is no
when the fuel level is getting low. The JLG Control System auto- more fuel available.
matically shuts the engine down before the fuel tank is emptied
unless the machine is set up for Engine Restart.
If fuel level reaches the Low Fuel range the ¼ tank CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO
indicator will flash once a second and there will be MORE FUEL IS AVAILABLE.
approximately 5 minutes of engine run time left. If
the system is in this condition and automatically • Engine Stop - The engine will shut down. No restarts will
shuts down the engine, or the engine is manually be permitted until fuel is added to the tank.
shut down before the 5 minute run time is com-
plete, the ¼ tank indicator will flash 10 times a sec-
ond and the engine will react according to
machine setup. Setup options are as follows:
• Engine One Restart - When the engine shuts down, the
operator will be permitted to cycle power and restart the
engine once with approximately 2 minutes of run time.
After the 2 minute run time is complete or if the engine is
shut down by the operator prior to the completion of the 2
minute run time, it cannot be restarted until fuel is added
to the tank.
3121170 – JLG Lift – 4-13

4.7 TRAVELING (DRIVING)

See Figure 4-6., Grade and Side Slopes
NOTE: Refer to the Operating Specifications table for Gradeability and

Sideslope ratings.
All ratings for Gradeability and Sideslope are based upon the
machine’s boom being in the stowed position, fully lowered, and
retracted. Traveling is limited by two factors:
1. Gradeability, which is the percent of grade of the incline the
machine can climb.
DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRM 2. Sideslope, which is the angle of the slope the machine can
AND LEVEL SURFACE. be driven across.
When the boom is raised or extended, the machine must not be
TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON operated on grades or sideslopes that are greater than that
GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE. detected by the tilt alarm. The tilt alarm will sound to alert the
operator when the machine is on an unsafe slope. The machines
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES. high drive function will also be cut back to low drive.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE
PLATFORM IS ELEVATED.
BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE

CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC-
TION MATCHING THE DIRECTIONAL ARROWS.
4-14 – JLG Lift – 3121170

Figure 4-6. Grade and Side Slopes
3121170 – JLG Lift – 4-15

Traveling Forward and Reverse 4.9 EXTENDING THE AXLES

1. At Platform Controls, pull out Emergency Stop switch, start NOTE: The operator must be driving the machine (forward or reverse) in
engine, and activate footswitch. order to extend the axles.
2. Position Drive controller to FORWARD or REVERSE as desired.
Position the Axle Extend switch to extend the axles or to retract
This machine is equipped with a Drive Orientation Indicator. The to retract the axles.
yellow light on the platform control console indicates that the
boom is swung beyond the rear drive tires and the machine may 4.10 PLATFORM
Drive/Steer in the opposite direction from the movement of the
controls. If the indicator is illuminated, operate the Drive function Platform Level Adjustment
in the following manner:
1. Match the black and white direction arrows on both plat-
form control panel and the chassis to determine the direc- ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
tion the machine will travel. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
2. Push and release the Drive Orientation Override switch. FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
Within 3 seconds, slowly move the Drive control toward the
arrow matching the intended direction of machine travel. NOTE: Platform Leveling is active during all functions except during
The indicator light will flash during the 3 second interval main boom telescope operations.
until the drive function is selected.
During normal operation of the machine, the platform will auto-
4.8 STEERING matically maintain it’s position. To manually Level Up or Down -
Position the Platform/Level control switch Up or Down and hold
Position thumb switch on Drive/Steer controller to RIGHT for until the desired platform position is obtained.
steering right, or to LEFT for steering left.
4-16 – JLG Lift – 3121170

Platform Rotation Swinging the Boom

To rotate the platform to the left or right, use the Platform Rotate To swing boom, use Swing control to select Right or Left direc-
control switch to select the direction and hold until desired position.
tion is reached.
4.11 BOOM WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO
CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.
DO NOT SWING OR RAISE BOOM OUT OF TRANSPORT MODE WHEN MACHINE IS OUT Raising and Lowering the Main Boom
OF LEVEL.
NOTE: The main lift function is not operable with the boom out of the
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. transport mode if the axles are not fully extended.
TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TO To raise or lower the Main Boom, use Boom Lift control to select
A LEVEL SURFACE BEFORE RAISING BOOM. Up or Down movement.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR Telescoping the Main Boom
TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE
‘OFF’ OR NEUTRAL POSITION WHEN RELEASED. NOTE: The telescope function is not operable beyond the transport
position if the axles are not fully extended.
IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED,
REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE To extend or retract the main boom, use the Telescope Control
MACHINE. Switch to select In or Out movement.
3121170 – JLG Lift – 4-17

Tower Lift 4.12 FUNCTION SPEED CONTROL

NOTE: The control system automatically uses a combination of tower This control affects the speed of all boom functions and Platform
telescope and tower lift for the tower boom to follow a pre- Rotate. When in the CCW maximum position, Drive is placed in
described path. creep speed.
To raise or lower the tower boom, use the Tower Boom Lift con- 4.13 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
trol to select Up or Down movement. ONLY)
Swinging the Jib The Machine Safety System Override (MSSO) is
used to override function controls for Emergency
NOTE: For 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Platform Retrieval only. Refer to Section 5.5,
Australia markets) mode operation, the jib must be centered Machine Safety System Override (MSSO)(CE Only)
and the Jib Swing function is not operable. If the jib is out of the for operating procedures.
centered position when in this mode, the jib swing function will
allow the operator to center the jib again.
To swing the jib, use the Jib Swing control to select Right or Left
direction.
4-18 – JLG Lift – 3121170

4.14 SKYGUARD OPERATION

Skyguard is used to provide enhanced control panel protection.
When the SkyGuard sensor is activated, functions that were in
use at the time of actuation will reverse or cutout. The table
below outlines these functions.
Table 4-1. Skyguard Function Table
Main Main Drive Drive Tower Tower Platform Platform Jib Jib Jib
Swing
Lift Tele Forward Reverse Lift Tele Level Rotate Lift Rotate Tele
R C/R* R R I R R C/R** C C C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
I = Input is Ignored
Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.
* Reversal only applies to Main Tele Out. Main Tele In would be cut out
** Reversal only applies to Tower Lift Up. Tower Lift Down would be cut out.
3121170 – JLG Lift – 4-19

4.15 EMERGENCY TOWING
RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING

VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING
NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY
OR DEATH.
MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)
MAXIMUM TOWING GRADE 25%.
DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.
1. Retract, lower and position boom in travel position; lock

turntable.
2. Disconnect drive hubs by inverting disconnect cap.
Figure 4-7. Drive Disconnect Hub
4-20 – JLG Lift – 3121170

3. Reconnect the drive hubs by inverting the disconnect cap 4.17 LIFTING AND TIE DOWN
when towing is complete.
(See Figure 4-8.)
4.16 SHUT DOWN AND PARK
Lifting
To shut down and park the machine, the procedures are as fol-
lows: 1. The weight of the machine is stamped on the serial number
plate. If the plate is missing or illegible, call JLG Industries or
1. Drive machine to a reasonably well protected area.
weigh the individual unit to find out the Gross Vehicle
2. Ensure boom is lowered over rear drive axle. Weight.
3. Push in the Emergency Stop at Platform Controls. 2. Place the boom in the stowed position with the turntable
locked.
4. Push in the Emergency Stop at Ground Controls. Position
Platform/Ground Select switch to center OFF. 3. Remove all loose items from the machine.
5. If necessary, cover Platform Controls to protect instruction 4. Attach lifting device and equipment only to the designated
placards, warning decals and operating controls from hostile lifting points.
environment.
5. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level.
3121170 – JLG Lift – 4-21

Tie Down 4.18 STOWING THE JIB FOR TRANSPORT

1. Place the boom in the stowed position with the axles
retracted.
WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO
THE BOOM REST. 2. Hold the Jib Swing control switch to the right until the plat-
form will no longer swing.
1. Place the boom in the stowed position with the turntable NOTE: The Jib Swing function is not operable when the Capacity Select
locked. control is in the 1000 lb. (454 kg for ANSI markets and 450 kg
2. Remove all loose items from the machine. for CE and Australia markets) position.
3. Secure the chassis and the platform using straps or chains of NOTE: Automatic platform leveling is disabled when stowing the jib.
adequate strength and attached to the designated tie down
points. 3. Push and hold the Jib Stow Override control switch until the
jib and platform are in the stowed position under the boom.
4-22 – JLG Lift – 3121170

Figure 4-8. Lifting and Tie Down Chart
3121170 – JLG Lift – 4-23

Figure 4-9. Decal Location Sheet 1 of 5
4-24 – JLG Lift – 3121170

3121170 – JLG Lift – 4-25

4-26 – JLG Lift – 3121170

3121170 – JLG Lift – 4-27

4-28 – JLG Lift – 3121170

Table 4-2. Decal Legend - Prior to S/N 0300141446
English/
Item # ANSI Korean Chinese Portuguese French/English CE/Australian Japan
Spanish
0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7
0274726-8
1 -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
11 -- -- -- -- -- -- 17055515 --
12 -- -- -- -- -- 1705514 -- --
13 3251243 3251243 3251243 3251243 3251243 3251243 -- 3251243
14 -- -- -- -- -- -- -- --
15 1705337 1705337 1705342 1705904 1705337 1705341 -- 1705338
16 -- -- 1705507 1705906 1705916 1705505 -- 1705493
3121170 – JLG Lift – 4-29

English/
Spanish
0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7
0274726-8
17 -- 1702153 -- 1705901 1704007 1704006 -- --
18 1703953 1703953 1703943 1705903 1703941 1703942 -- 1703944
19 1702868 1702868 1705968 1705967 1704001 1704000 -- --
20 1703797 1703797 1703925 1705895 1703923 1703924 1705921 1703926
21 1705336 1705336 1705348 1705896 1705917 1705347 1705822 1705344
22 1703804 1703804 1703949 1705898 1703947 1703948 1701518 1703950
23 1703805 1703805 1703937 1705897 1703935 1703936 1705961 1703938
24 3252347 -- 1703982 1705902 1703983 1703984 1705828 1703980
25 3251813 3251813 3251813 3251813 3251813 3251813 -- 3251813
26 1705492 1705492 1705508 1705907 1705915 1705506 -- 1705494
27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
28 1705168 1705168 1705334 1705899 1705908 1705333 1706770 1705330
29 1705181 1705181 1705478 1705900 1705919 1705477 1705468 1705480
30 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584
31 1706751 1706751 1706751 1706751 1706751 1706751 -- 1706751
32 1705868 1705868 1705868 1705868 1705868 1705868 -- 1705868
33 1705351 1705351 1705430 1705905 1705910 1705429 -- 1705426
34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505
4-30 – JLG Lift – 3121170

English/
Spanish
0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7
0274726-8
35 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972
36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511
37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501
38 -- -- -- -- -- -- -- --
39 -- -- -- -- -- -- -- --
40 -- -- -- -- -- -- -- --
41 -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- --
3121170 – JLG Lift – 4-31

English/
Spanish
0274722-7 0274723-7 0274724-7 0274725-7 0274727-7 0274728-8 0274729-7
0274726-8
53 -- -- -- -- -- -- -- --
54 -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- --
4-32 – JLG Lift – 3121170

Table 4-3. Decal Legend - S/N 0300141446 to Present
English/
Spanish
0274722-B 0274723-B 0274724-B 0274725-B 0274727-B 0274728-B 0274729-B
0274726-B
1 -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
11 -- -- -- -- -- -- 17055515 --
12 -- -- -- -- -- 1705514 -- --
13 3251243 3251243 3251243 3251243 3251243 3251243 -- 3251243
14 -- -- -- -- -- -- -- --
15 1705337 1705337 1705342 1705904 1705337 1705341 -- 1705338
16 -- -- 1001117035 1705906 1705916 1705505 -- 1705493
3121170 – JLG Lift – 4-33

English/
Spanish
0274722-B 0274723-B 0274724-B 0274725-B 0274727-B 0274728-B 0274729-B
0274726-B
17 -- 1702153 -- -- -- -- -- --
18 1703953 1703953 1703943 1705903 1703941 1703942 -- 1703944
19 1702868 1702868 1001116846 1705967 1704001 1704000 -- --
20 1703797 1703797 1703925 1705895 1703923 1703924 1705921 1703926
21 1705336 1705336 1001116849 1705896 1705917 1705347 1705822 1705344
22 1703804 1703804 1703949 1705898 1703947 1703948 1701518 1703950
23 1703805 1703805 1001116851 1705897 1703935 1703936 1705961 1703938
24 3252347 -- 1703982 1705902 1703983 1703984 1705828 1703980
25 -- -- -- -- -- -- -- --
26 1705492 1705492 1705508 1705907 1705915 1705506 -- 1705494
27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
28 1001122369 1001122370 1001122371 1001122372 1001122373 1001122374 1706770 1001122375
29 1001122376 1001122377 1001122378 1001122379 1001122380 1001122381 1705468 1001122382
30 1001131269 -- -- -- -- 1700584 -- --
31 1706751 1706751 1706751 1706751 1706751 1706751 -- 1706751
32 1705868 1705868 1705868 1705868 1705868 1705868 -- 1705868
33 1705351 1705351 1705430 1705905 1705910 1705429 -- 1705426
34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505
4-34 – JLG Lift – 3121170

English/
Spanish
0274722-B 0274723-B 0274724-B 0274725-B 0274727-B 0274728-B 0274729-B
0274726-B
35 1704972 1704972 1706060 1706059 1706063 1706064 1706098 1704972
36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511
37 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501
38 -- -- -- -- -- -- -- --
39 -- -- -- -- -- -- -- --
40 -- -- -- -- -- -- -- --
41 -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- --
3121170 – JLG Lift – 4-35

English/
Spanish
0274722-B 0274723-B 0274724-B 0274725-B 0274727-B 0274728-B 0274729-B
0274726-B
53 -- -- -- -- -- -- -- --
54 -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- --
4-36 – JLG Lift – 3121170

SECTION 5 - EMERGENCY PROCEDURES
SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL
This section explains the steps to be taken in case of an emer- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
5.2 INCIDENT NOTIFICATION BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-
RECTLY.
JLG Industries, Inc. must be notified immediately of any incident
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro-
5.3 EMERGENCY OPERATION
vided with all necessary details.
Operator Unable to Control Machine
In USA:
JLG Phone: 877-JLG-SAFE (554-7233) IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
(8am till 4:45pm EST) OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from ground
Outside USA: controls only as required.
240-420-2661
2. Other qualified personnel on the platform may use the plat-
E-mail: form controls. DO NOT CONTINUE OPERATION IF CONTROLS
DO NOT FUNCTION PROPERLY.
[email protected]
3. Cranes, forklift trucks or other equipment can be used to
Failure to notify the manufacturer of an incident involving a JLG remove platform occupants and stabilize motion of the
Industries product within 48 hours of such an occurrence may machine.
void any warranty consideration on that particular machine.
3121170 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES
Platform or Boom Caught Overhead 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
If the platform or boom becomes jammed or snagged in over- ONLY)
head structures or equipment, rescue platform occupants prior to
The Machine Safety System Override (MSSO) is
freeing the machine.
only to be used to retrieve an operator that is
pinned, trapped, or unable to operate the
5.4 EMERGENCY TOWING PROCEDURES machine and function controls are locked out
Towing this machine is prohibited, unless properly equipped. from the platform due to a platform overload sit-
However, provisions for moving the machine have been incorpo- uation.
rated. For specific procedures, refer to Section 4.
NOTE: If the MSSO functionality is used, the fault indicator will flash
and a fault code is set in the JLG Control System which must be
reset by a qualified JLG Service Technician.
NOTE: No functional checks of the MSSO system are necessary. The JLG
Control system will set a Diagnostic Trouble Code if the control
switch is faulty.
To operate the MSSO:

1. From the ground control console, place the Platform/
Ground Select switch in the Ground position.
2. Pull out the Power/Emergency Stop control.
3. Start the engine.
4. Press and hold the MSSO switch and the control switch for
the desired function.
5-2 – JLG Lift – 3121170

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION 6.2 OPERATING SPECIFICATIONS AND PERFORMANCE
This section of the manual provides additional necessary infor- DATA
mation to the operator for proper operation and maintenance of
this machine. Table 6-1. Operating Specifications - Prior to S/N 0300141446
The maintenance portion of this section is intended as informa- Maximum Work Load (Capacity)
tion to assist the machine operator to perform daily maintenance Unrestricted 500 lb (230 kg)
tasks only, and does not replace the more thorough Preventive Restricted 1000 lb. (450 kg)
Maintenance and Inspection Schedule included in the Service Max.Vertical Platform Height (Unrestricted) 125 ft. (38.1 m)
and Maintenance Manual.
Max.Vertical Platform Height (Restricted) 125 ft. (38.1 m)
Other Publications Available: Max.Horizontal Platform Reach (Unrestricted) 63 ft. 2 in. (19.3 m)
Service and Maintenance Manual .............................................3121171 Max.Horizontal Platform Reach (Restricted) 53 ft. 2 in. (16.2 m)
Illustrated Parts Manual ................................................................3121172 Up and Over Height 60 ft. 7 in. (18.5 m)
Main Boom Range (At Maximum Up & Over) +75° / -55°
Troubleshooting Guide .................................................................3128411
Maximum Boom Swing 360° Continuous
Troubleshooting CD .......................................................................3128444 JibPLUS
Length 8ft. (2.44m)
Horizontal Motion 125° working, 210° stowed
Vertical Motion 130° (+75/-55)
Max. Hydraulic System Pressure 4600 psi (317 Bar)
3121170 – JLG Lift – 6-1

Table 6-1. Operating Specifications - Prior to S/N 0300141446 Table 6-2. Operating Specifications - S/N 0300141446 to Present
Maximum Wind Speed 28 mph (12.5 m/s) JibPLUS

Maximum Manual Force 400 N Length 8ft. (2.44m)
Horizontal Motion 125° working, 210° stowed
Electrical System Voltage 12 Volts
Vertical Motion 130° (+75/-55)
Max Tire Load 23,700 lbs. (10750 kg)
Max. Hydraulic System Pressure 4600 psi (317 Bar)
Maximum Platform Rotation ±90°
Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Manual Force 400 N
Table 6-2. Operating Specifications - S/N 0300141446 to Present
Electrical System Voltage 12 Volts
Maximum Work Load (Capacity) - ANSI Max Tire Load 23,700 lbs. (10750 kg)
Unrestricted 500 lb (227 kg)
Maximum Platform Rotation ±90°
Restricted 1000 lb. (454 kg)
Maximum Work Load (Capacity)-
CE & Australia
Unrestricted 500 lb (230 kg)
Restricted 1000 lb. (450 kg)
Max.Vertical Platform Height (Unrestricted) 125 ft. (38.1 m)
Max.Vertical Platform Height (Restricted) 125 ft. (38.1 m)
Max.Horizontal Platform Reach (Unrestricted) 63 ft. 2 in. (19.3 m)
Max.Horizontal Platform Reach (Restricted) 53 ft. 2 in. (16.2 m)
Up and Over Height 60 ft. 7 in. (18.5 m)
Main Boom Range (At Maximum Up & Over) +75° / -55°
Maximum Boom Swing 360° Continuous
6-2 – JLG Lift – 3121170

Dimensional Data Chassis

Table 6-3. Dimensional Data Table 6-4. Chassis Specifications
Overall Width Maximum Travel Grade With boom in stowed 45%

Axles Retracted 8ft. 2in. (2.49 m) position (Gradeability)
Axles Extended 12ft. 6in. (3.8 m) Maximum Travel Grade With boom in stowed 5°
Stowed Height 10ft. (3.05 m) position (Side Slope)
Stowed Length (Transport Mode) 37 ft. 7 in. (11.46 m) Turning Radius (Axles Retracted)
Stowed Length (Working Mode) 47 ft. 6 in. (14.48 m) Outside 22 ft. 6 in. (6.8 m)
Inside 14 ft. 5 in. (4.4 m)
Wheelbase 12ft. 6in. (3.81 m)
Turning Radius (Axles Extended)
Tailswing
Inside 8 ft. (2.4 m)
Tower Up 7 ft. (2.13 m)
Outside 19 ft. 4 in. (5.9 m)
Tower Down 11 ft. 3 in. (3.43 m)
Max Tire Load 23700 lbs. (10750 kg)
Oscillating Axle ±6 in. (0.15 m)
Max Ground Bearing Pressure 100 psi (7.03 kg/cm2)
Ground Clearance (Axle) 12 in. (30.4 cm)
Ground Clearance (Chassis) 25.5 in. (64.7 cm) Maximum Drive Speed
Stowed 3.25 mph (5.2 kph)
Elevated 0.75 mph (1.2 kph)
Gross Machine Weight
Platform Empty 44,000 lbs. (19,958 kg)
Platform Empty w/ Skypower 44,215 lbs. (20,056 kg)
3121170 – JLG Lift – 6-3

Capacities Tires
Table 6-6. Tire Specifications
Table 6-5. Capacities
Size 445/50D710
Hydraulic Tank 53.3 gallons (201.7 liters) Load Range J
Fuel Tank 31 gallons (117 liters) Ply Rating 18
Hydraulic System 65.4 gallons (247.5 liters) Foam Fill Polyurethane HD (55 Durometer) Foam
Drive Hub Diameter 46.45 in. (117.9 cm)
Bonfiglioli 2.1 quarts (2 liters) ± 10%
Width 18 in. (45.7 cm)
Reggiana Riduttori 0.5 quarts (0.5 liters) ± 10%
Rim Size 15x28
Tire & Wheel Weight 867 lbs. (393 kg)
Size 445/65-24
Type Solid
Diameter 45.3 in. (115.1 cm)
Width 17.3 in. (43.9 cm)
Rim Size 12.00-24
Tire & Wheel Weight 960 lbs. (435.4 kg)
6-4 – JLG Lift – 3121170

Engine Data - Deutz 2011 Prior to S/N 0300127698 Engine Data - Deutz 2011 S/N 0300127698 to Present
Table 6-7. Deutz BF4M2011 Specifications Table 6-8. Deutz TD2011L4 Specifications
Type Liquid Cooled Type Liquid Cooled

Number of Cylinders 4 Number of Cylinders 4
Bore 3.7 in. (94 mm) Bore 3.7 in. (94 mm)
Stroke 4.4 in. (112 mm) Stroke 4.4 in. (112 mm)
Total Displacement 190 cu. in. (3108 cm3) Total Displacement 190 cu. in. (3108 cm3)
Compression Ratio 17.5 Compression Ratio 17.5
Firing Order 1-3-4-2 Firing Order 1-3-4-2
Output 87hp (65 kW) Output 75hp (56 kW)
Oil Capacity Oil Capacity
Cooling System 5 Quarts (4.5 L) Cooling System 5 Quarts (4.5 L)
w/Filter 11 Quarts (10.5 L) w/Filter 11 Quarts (10.5 L)
Total Capacity 16 Quarts (15 L) Total Capacity 16 Quarts (15 L)
Average Fuel Consumption 1.1 gph (4.1 lph) Average Fuel Consumption 1.1 gph (4.1 lph)
Idle Engine RPM 1200 Idle Engine RPM 1200
Mid Engine RPM 1800 Mid Engine RPM 1800
High Engine RPM 2475 High Engine RPM 2475
3121170 – JLG Lift – 6-5

Engine Data - Deutz TCD2.9L4 Engine Data - Caterpillar

Table 6-9. Deutz TCD2.9L4 Specifications Table 6-10. Caterpillar 3.4T
Type Liquid Cooled Type Liquid Cooled, Antifreeze

Number of Cylinders 4 Number of Cylinders 4
Bore 3.6 in. (92 mm) Bore 3.7 in. (94 mm)
Stroke 4.3 in. (110 mm) Stroke 4.7 in. (120 mm)
Total Displacement 178 cu. in. (2925 cm3) Total Displacement 201 cu. in. (3294 cm3)
Firing Order 1-3-4-2 Compression Ratio 19.5:1
Output 74.2hp (55.4 kW) Firing Order 1-3-4-2
Oil Capacity 2.4 Gallon (8.9 L) Output 73.7hp (55 kW)
Coolant Capacity (System) 3.2Gallon (12.1 L) Oil Capacity 10.5 Quarts (10 L)
Average Fuel Consumption 1.2 gph (4.1 lph) Average Fuel Consumption 1.36 gph (5.14 lph)
Min. Low Engine RPM 1200 Idle Engine RPM 1200
Mid Engine RPM 1800 Mid Engine RPM 1800
Max. High Engine RPM 2500 High Engine RPM 2475
6-6 – JLG Lift – 3121170

Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of differ-
ent brands or types, as they may not contain the same required addi-
Table 6-11. Hydraulic Oil Specifications tives or be of comparable viscosities. If use of hydraulic oil other than
Hydraulic System Mobilfluid 424 is desired, contact JLG Industries for proper recommenda-
S.A.E. Viscosity tions.
Operating
Grade
Temperature Range
+0° to + 180° F 10W Table 6-12. Mobilfluid 424 Specs
(-18° to +83° C)
SAE Grade 10W30
+0° to + 210° F 10W-20, 10W30
Gravity, API 29.0
(-18° to +99° C)
Density, Lb/Gal. 60°F 7.35
+50° to + 210° F 20W-20
(+10° to +99° C Pour Point, Max -46°F (-43°C)
Flash Point, Min. 442°F (228°C)
NOTE: Hydraulic oils must have anti-wear qualities at least to API Ser- Viscosity
vice Classification GL-3, and sufficient chemical stability for Brookfield, cP at -18°C 2700
mobile hydraulic system service. JLG Industries recommends at 40° C 55 cSt
Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of
152. at 100° C 9.3 cSt
Viscosity Index 152
NOTE: When temperatures remain consistently below 20 degrees F. (-7
degrees C.), JLG Industries recommends the use of Mobil DTE13.
3121170 – JLG Lift – 6-7

Table 6-14. UCon Hydrolube HP-5046

Table 6-13. Mobil DTE 13M Specs
Type Synthetic Biodegradable
ISO Viscosity Grade #32
Specific Gravity 0.877 Specific Gravity 1.082
Pour Point, Max Pour Point, Max -58°F (-50°C)
-40°F (-40°C)
pH 9.1
Flash Point, Min. 330°F (166°C)
Viscosity
Viscosity
at 0° C (32° F) 340 cSt (1600SUS)
at 40° C 33cSt
at 40° C (104° F) 46 cSt (215SUS)
at 100° C 6.6 cSt
at 65° C (150° F) 22 cSt (106SUS)
at 100° F 169 SUS
Viscosity Index 170
at 210° F 48 SUS
cp at -20° F 6,200
Viscosity Index 140
6-8 – JLG Lift – 3121170

Table 6-16. Mobil EAL H 46 Specs

Table 6-15. Exxon Univis HVI 26 Specs
Type Synthetic Biodegradable
Specific Gravity 32.1
ISO Viscosity Grade 46
Pour Point -76°F (-60°C)
Specific Gravity .910
Flash Point 217°F (103°C)
Pour Point -44°F (-42°C)
Viscosity
Flash Point 500°F (260°C)
at 40° C 25.8 cSt
at 100° C 9.3 cSt Operating Temp. 0 to 180°F (-17 to 162°C)
Viscosity Index 376 Weight 7.64 lb. per gal.
NOTE: Mobil/Exxon recommends that this oil be checked on a (0.9 kg per liter)
yearly basis for viscosity. Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121170 – JLG Lift – 6-9

Major Component Weights

Table 6-17. Component Weights
Component Pounds Kilograms

Tire & Wheel 867 393
Drive Hub & Motor 275.5 123
Engine Assembly 1275 579
Main Boom 5186 2357
Tower Boom 6990 3173
Tower Telescope Cylinder 915 415
Axle Oscillation Cylinder 74 34
Axle Extend Cylinder 92 42
Level Cylinder 89 40
Platform 36 x 96 245 111
Platform 36 x 72 195 89
Counterweight * 3320 1506
* For actual weight, see stamping on counterweight
6-10 – JLG Lift – 3121170

AMBIENT AIR
TEMPERATURE
120° F(49° C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110° F(43° C)
100° F(38° C)
90° F(32° C)
80° F(27° C)
SUMMER
GRADE 70° F(21° C)
ENGINE FUEL
60° F(16° C)
SPECIFICATIONS 50° F(10° C)
40° F(4° C)
30° F(-1° C)
WINTER 20° F(-7° C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10° F(-12° C)
FULLY CHARGED BATTERY.
0° F(-18° C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10° F(-23° C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20° F(-29° C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE
GLOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER) -30° F(-34° C)
ADDED
-40° F(-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
Figure 6-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2
3121170 – JLG Lift – 6-11

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. 1) RECOMMENDATIONSAREFORAMBIENTTEMPERATURES
100° F (38° C) MOBIL 424 10W-30 CONSISTANTLYWITHIN SHOWN LIMITS
90° F (32° C)
2) ALLVALUESAREASSUMED TO BEATSEA LEVEL.
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC SUMMER-GRADE WINTER-GRADE
MOBIL DTE 13
SPECIFICATIONS FUEL FUEL

40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
AMBIENTTEMPERATURE
WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
AMBIENT TEMPERATURE -13 -25
-22 -30
0 10 20 30 40 50 60
% OFADDED KEROSENE
4150548-E
Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2
6-12 – JLG Lift – 3121170

AMBIENT AIR
TEMPERATURE
120 F(49 C)
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
30 F(-1 C)
20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
Figure 6-3. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2
3121170 – JLG Lift – 6-13

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F (38° C) OR ABOVE.
100° F (38° C)
90° F (32° C)
MOBIL 424 10W-30
80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26
60° F (16° C)
50° F (10° C)
HYDRAULIC
SPECIFICATIONS
MOBIL DTE 13
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C)
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C) NOTE:
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
AMBIENT TEMPERATURE
CONSISTENTLY WITHIN SHOWN LIMITS
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
4150548-E
Figure 6-4. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2
6-14 – JLG Lift – 3121170

Figure 6-5. Operator Maintenance and Lubrication Diagram - Deutz 2011/CAT Engines
3121170 – JLG Lift – 6-15

Figure 6-6. Operator Maintenance and Lubrication Diagram - Deutz 2.9 Engine
6-16 – JLG Lift – 3121170

6.3 OPERATOR MAINTENANCE 1. Swing Bearing - Remote Lube
NOTE: The following numbers correspond to those in Figure 6-5., Oper-

ator Maintenance and Lubrication Diagram - Deutz 2011/CAT
Engines.
Table 6-18. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel-
lent water resistance and adhesive qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-
Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424. Lube Point(s) - 2 Grease Fitting
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD Capacity - A/R
class, MIL-L-2104B/MIL-L-2104C. Lube - MPG
Interval - Every 3 months or 150 hours of operation
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL

CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED
TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
NOTE: It is recommended as a good practice to replace all filters at the

same time.
3121170 – JLG Lift – 6-17

2. Swing Gearbox 3. Swing Brake
Lube Point(s) - Fill Plug Lube Point(s) - Fill Plug

Capacity - 79 ounces (2.3 L) Capacity - 2.7 ounces (80 ml)
Lube - GL-5 Lube - DTE24
Interval - Check level every 150 hrs/Change every 1200 Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear. hours of operation.
6-18 – JLG Lift – 3121170

4. A. Wheel Drive Hub (Prior to S/N 100128) B: Wheel Drive Hub - Bonfiglioli (S/N 100128 to Present)
Lube Point(s) - Level/Fill Plug

Capacity - 0.5 liters (1/2 full) Lube Point(s) - Level/Fill Plug
Lube - EPGL Capacity - 2.1 quarts (2 liters) ± 10%
Interval - Change after first 150 hours then every 1200 Lube - EPGL
hours of operation Interval - Change after first 150 hours then every 1200 hours
Comments - Place Fill port at 12 o’clock position and Check of operation
port at 3 o’clock position. Pour lubricant into fill port until it Comments - Place Fill port at 12 o’clock position and Check
just starts to flow out of check port. port at 8 o’clock position. Pour lubricant into fill port until it
just starts to flow out of check port.
NOTE: After S/N 0300134389 machines may be built with either Bonfigli-
oli or Reggiana Riduttori wheel drive hubs.
3121170 – JLG Lift – 6-19

C: Wheel Drive Hub - Reggiana Riduttori (S/N 134389 to Pres- 5. Hydraulic Return Filter
ent) (See Figure 6-7., Hydraulic Return Filter Condition Indicator - Prior to S/N
139396 and Figure 6-8., Hydraulic Return Filter Condition Indicator - S/N
139396 to Present)
Lube Point(s) - Replaceable Element

Interval - Change after first 50 hours and every 300 hours
thereafter or as indicated by condition indicator.
Lube Point(s) - Level/Fill Plug

Capacity - 0.5 quarts (0.5 liters) ± 10%
Lube - EPGL
Interval - Change after first 150 hours then every 1200 hours of
operation
Comments - Place Fill port at 12 o’clock position and Check
port at 3 o’clock position. Pour lubricant into fill port until it
just starts to flow out of check port.
6-20 – JLG Lift – 3121170

A - Red = Filter Restricted; Filter Bypassed

B - Green = Filter Good; Not Restricted
Figure 6-7. Hydraulic Return Filter Condition Indicator - Prior to S/N 139396
3121170 – JLG Lift – 6-21

Red = Filter Restricted; Filter Bypassed

Green = Filter Good; Not Restricted
Figure 6-8. Hydraulic Return Filter Condition Indicator - S/N 139396 to Present
6-22 – JLG Lift – 3121170

6. Hydraulic Charge Filter or

thereafter or as indicated by condition indicator
(if equipped)
3121170 – JLG Lift – 6-23

7. Main Valve Filter 8. Hydraulic Oil
FULL LEVEL (HOT OIL)
FULL LEVEL (COLD OIL)

thereafter
1705511 B
Lube Point(s) - Fill Cap

Capacity - 55 gallons (208 liters) Tank
Lube - HO
Interval - Check level daily. Change every 2 years or 1200
hours of operation.
6-24 – JLG Lift – 3121170

9. Suction Strainers (In Tank) 10. A. Oil Change w/Filter - Deutz 2011
Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 11 Quarts (10.5 L) w/Filter
Lube - EO
Interval - Check level daily; change every 500 hours or six
Lube Point(s) - 2 months, whichever comes first. Adjust final oil level by mark
Interval - Every 2 years or 1200 hours of operation. on dipstick.
Remove and clean at time of hydraulic oil change.
3121170 – JLG Lift – 6-25

B. Oil Change w/Filter - Deutz TCD2.9
Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.4 Gallon (8.9 L)
Lube - EO
Interval - Check level daily; change every 500 hours or six
months, whichever comes first. Adjust final oil level by
mark on dipstick.
6-26 – JLG Lift – 3121170

MINIMUM OIL MINIMUM LEVEL OIL

LEVEL HOT
MAXIMUM LEVEL OIL
HOT
MAXIMUM OIL MINIMUM LEVEL OIL

LEVEL COLD MAXIMUM LEVEL OIL
COLD
NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down.
Figure 6-9. Deutz 2011 Engine Dipstick
3121170 – JLG Lift – 6-27

11. A. Fuel Filter - Deutz 2011 B. Fuel Filter - Deutz TCD2.9
Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every year or 600 hours of operation Interval - Every year or 500 hours of operation
6-28 – JLG Lift – 3121170

12. Fuel Strainer - Deutz 2011 13. Fuel Pre-Filter TCD2.9

Interval - Drain water daily; Change every year or 500 hours of
operation

Interval - Every year or 600 hours of operation
3121170 – JLG Lift – 6-29

14. Oil Change w/Filter - CAT 15. Fuel Filter/Water Separator - CAT
Lube Point(s) - Fill Cap/Spin-on Element (element can be Lube Point(s) - Replaceable Element
accessed from below engine tray) Interval - Drain water daily; Replace element every year or 600
Capacity - 10.5 Quarts (10 L) hours of operation
Lube - EO
Interval - Check level daily; change every 150 hours or three
months, whichever comes first. Adjust final oil level by mark
on dipstick.
6-30 – JLG Lift – 3121170

16. Radiator Coolant TCD2.9 17. A. Air Filter -Deutz 2011/CAT
DEUTZ 2011
Lube Point(s) - Fill Cap
Capacity - 3.2Gallon (12.1 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or 2 years,
whichever comes first.
CAT
3121170 – JLG Lift – 6-31

Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or as Interval - Every 6 months or 300 hours of operation or as indi-
indicated by the condition indicator cated by the condition indicator
Comments - Check Dust Valve daily
B. Air Filter - Deutz TCD2.9
18. Platform Filter

Interval - Change after first 50 hours and then every year or
600 hours of operation thereafter
6-32 – JLG Lift – 3121170

6.4 TIRES & WHEELS • any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the tire
Tire Inflation must be inspected on a daily basis to insure the damage has not
The air pressure for pneumatic tires must be equal to the air pres- propagated beyond the allowable criteria.
sure that is stenciled on the side of the JLG product or rim decal
for safe and proper operational characteristics. Tire Replacement
JLG recommends a replacement tire be the same size, ply and brand
Tire Damage as originally installed on the machine. Please refer to the JLG Parts
For pneumatic tires, JLG Industries, Inc. recommends that when any Manual for the part number of the approved tires for a particular
cut, rip, or tear is discovered that exposes sidewall or tread area cords machine model. If not using a JLG approved replacement tire, we
in the tire, measures must be taken to remove the JLG product from recommend that replacement tires have the following characteris-
service immediately. Arrangements must be made for replacement tics:
of the tire or tire assembly. • Equal or greater ply/load rating and size of original
For polyurethane foam filled tires, JLG Industries, Inc. recommends • Tire tread contact width equal or greater than original
that when any of the following are discovered, measures must be
• Wheel diameter, width, and offset dimensions equal to the
taken to remove the JLG product from service immediately and
original
arrangements must be made for replacement of the tire or tire
assembly. • Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
• a smooth, even cut through the cord plies which exceeds 3
inches (7.5 cm) in total length Unless specifically approved by JLG Industries Inc. do not replace a
foam filled or ballast filled tire assembly with a pneumatic tire. When
• any tears or rips (ragged edges) in the cord plies which
selecting and installing a replacement tire, ensure that all tires are
exceeds 1 inch (2.5 cm) in any direction
inflated to the pressure recommended by JLG. Due to size variations
• any punctures which exceed 1 inch in diameter between tire brands, both tires on the same axle should be the same.
3121170 – JLG Lift – 6-33

Wheel and Tire Replacement 1. Start all nuts by hand to prevent cross threading. DO NOT
use a lubricant on threads or nuts.
The rims installed on each product model have been designed for 2. Tighten nuts in the following sequence:
stability requirements which consist of track width, tire pressure, and
load capacity. Size changes such as rim width, center piece location,
larger or smaller diameter, etc., without written factory recommen-
dations, may result in an unsafe condition regarding stability.
Wheel Installation
It is extremely important to apply and maintain proper wheel
mounting torque.
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO

PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION
OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
ANGLE OF THE WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten the fasteners. If you do
not have a torque wrench, tighten the fasteners with a lug wrench,
then immediately have a service garage or dealer tighten the lug
nuts to the proper torque. Over-tightening will result in breaking the
studs or permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is as follows:
6-34 – JLG Lift – 3121170

3. The tightening of the nuts should be done in stages. Follow- 6.5 SUPPLEMENTAL INFORMATION
ing the recommended sequence, tighten nuts per wheel
torque chart. The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/EC
and is only applicable to CE machines.
Table 6-19. Wheel Torque Chart
For electric powered machines, the equivalent continuous A-
TORQUE SEQUENCE Weighted sound pressure level at the work platform is less than
70dB(A)
1st Stage 2nd Stage 3rd Stage
45 ft. lbs. 100 ft. lbs. 180 ft. lbs. For combustion engine powered machines, guaranteed Sound
(60 Nm) (140 Nm) (252 Nm) Power Level (LWA) per European Directive 2000/14/EC (Noise
Emission in the Environment by Equipment for Use Outdoors)
based on test methods in accordance with Annex III, Part B,
4. Wheel nuts should be torqued before first road use and after
Method 1 and 0 of the directive, is 109 dB.
each wheel removal. Check and torque every 3 months or
150 hours of operation. The vibration total value to which the hand-arm system is sub-
jected does not exceed 2,5 m/s2. The highest root mean square
value of weighted acceleration to which the whole body is sub-
jected does not exceed 0,5 m/s2.
3121170 – JLG Lift – 6-35

NOTES:
6-36 – JLG Lift – 3121170

SECTION 7 - INSPECTION AND REPAIR LOG
SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________
Table 7-1. Inspection and Repair Log
Date Comments
3121170 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG
Table 7-1. Inspection and Repair Log
Date Comments
7-2 – JLG Lift – 3121170

TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this manual,
we would like to know who you are. For the purpose of receiving safety-related bulletins, it is
very important to keep JLG Industries, Inc. updated with the current ownership of all JLG
products. JLG maintains owner information for each JLG product and uses this information in
cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current
ownership of JLG products. Please return completed form to the JLG Product Safety &
Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: ______________________________________________________________________
Serial Number: ____________________________________________________________________
Previous Owner: __________________________________________________________________
Address: _________________________________________________________________________
_________________________________________________________________________________
Country: _____________________________ Telephone: (_______) ________________________
Date of Transfer: ______________________________________
Current Owner: ___________________________________________________________________
Address: _________________________________________________________________________
_________________________________________________________________________________
Country: _____________________________ Telephone: (_______) ________________________
Who in your organization should we notify?
Name: ___________________________________________________________________________
Title:____________________________________________________________________
Corporate Office
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
3121170
JLG Worldwide Locations

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P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65813058 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore Technology
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Equipment Pte Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
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Technology., Ltd JLG Iberica, S.L. Enkopingsvagen 150
Pudong Kerry Parkside Trapadella, 2 Box 704
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Pudong, Shanghai 201204 Spain +46 (0)850 659 500
+0086 21 60311575 +34 93 772 4700 +46 (0)850 659 534
+0086 21 60311599 +34 93 771 1762
www.jlg.com

JLG 1250AJP Operations Manual

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What safety symbols are used in the manual?

What safety symbols are used in the manual?

What should be done if an accident occurs involving the equipment?

What should be done if an accident occurs involving the equipment?

Operation and Safety Manual

Boom Lift Models

3121170 – JLG Lift – a

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

b – JLG Lift – 3121170

3121170 – JLG Lift – c

Original Issue - March 1, 2004

d – JLG Lift – 3121170

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

3121170 – JLG Lift – i

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

ii – JLG Lift – 3121170

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

SECTION - 7 - INSPECTION AND REPAIR LOG

3121170 – JLG Lift – iii

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

This Page Left Blank Intentionally.

iv – JLG Lift – 3121170

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

3121170 – JLG Lift – v

This Page Left Blank Intentionally.

vi – JLG Lift – 3121170

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

3121170 – JLG Lift – vii

This Page Left Blank Intentionally.

viii – JLG Lift – 3121170

SECTION 1. SAFETY PRECAUTIONS

3121170 – JLG Lift – 1-1

• An operator must not accept operating responsibilities until Workplace Inspection

1-2 – JLG Lift – 3121170

Machine Inspection 1.3 OPERATION

3121170 – JLG Lift – 1-3

1-4 – JLG Lift – 3121170

• Keep both feet firmly positioned on the platform floor at all

3121170 – JLG Lift – 1-5

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

Voltage Range MINIMUM APPROACH DISTANCE

1-6 – JLG Lift – 3121170

• The minimum approach distance may be reduced if insulating Tipping Hazards

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).

• Do not elevate platform or drive with platform elevated while

3121170 – JLG Lift – 1-7

1-8 – JLG Lift – 3121170

Table 1-2. Beaufort Scale (For Reference Only)

Beaufort Wind Speed

3121170 – JLG Lift – 1-9

1-10 – JLG Lift – 3121170

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

3121170 – JLG Lift – 1-11

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

1-12 – JLG Lift – 3121170

3121170 – JLG Lift – 1-13

1-14 – JLG Lift – 3121170

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121170 – JLG Lift – 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE