Operation and Safety Manual - JLG Industries Boom Lifts/1100SB... · Operation and Safety Manual ANSI Original Instructions - Keep this manual with the machine at all times. Boom

Operation and Safety Manual

ANSI

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

Boom Lift Models1100SB

3121264July 7, 2010

FOREWORD

a

l times.

lessors, and lessees with the precautions anderation for its intended purpose.

erves the right to make specification changesformation.

3121264 – JLG Lift –

FOREWORD

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

The purpose of this manual is to provide owners, users, operators,operating procedures essential for the safe and proper machine op

Due to continuous product improvements, JLG Industries, Inc. reswithout prior notification. Contact JLG Industries, Inc. for updated in

FOREWORD

b 3121264

SIGNAL WORDS

INDIAVOWIL

INDAVODEC

OTENTIALLY HAZARDOUS SITUATION. IF NOTRESULT IN MINOR OR MODERATE INJURY. IT MAYAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEGROUND.

RMATION OR A COMPANY POLICY THAT RELATESDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-PERTY.

the potential personalymbol to avoid possible

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALL HAVE A RED BACKGROUND.

ICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOTIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A PAVOIDED, MAY ALSO ALERT AGA YELLOW BACK

INDICATES INFODIRECTLY OR INTECTION OF PRO

This is the Safety Alert Symbol. It is used to alert you toinjury hazards. Obey all safety messages that follow this sinjury or death

FOREWORD

c

act:

duct Safety and Reliability Department Industries, Inc.24 Fountainhead Plazaerstown, MD 21742

our Local JLG Officee addresses on inside of manual cover)

A:

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

ide USA:

ne: 240-420-2661: 301-745-3713ail: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

tions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

3121264 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL ORWHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-ERTY OR THE JLG PRODUCT.

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ProJLG132Hag

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FOREWORD

d 3121264

O

– JLG Lift –

REVISION LOG

riginal Issue - July 7, 2010

TABLE OF CONTENTS

3121 i

SEC - PARAGRAPH, SUBJECT PAGE

SEC

SECRATI

Boom Control System Check Procedure . . . . . . 2-6General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

- 3 - MACHINE CONTROLS AND INDICATORS

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

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1Ground Control Indicator Panel . . . . . . . . . . . . . 3-5Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6Platform Control Indicator Panel . . . . . . . . . . . . 3-13

- 4 - MACHINE OPERATION

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

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Controlled Arc . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Envelope Tracking. . . . . . . . . . . . . . . . . . . . . . . . 4-3Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . 4-3Swing Speed Proportioning . . . . . . . . . . . . . . . . 4-3Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

264 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

TION - 1 - SAFETY PRECAUTIONS

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

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

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-81.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

TION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-ON, AND INSPECTION

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

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

2.3

SECTION

3.13.2

SECTION

4.14.2

TABLE OF CONTENTS

ii 3121264

SECTIO RAGRAPH, SUBJECT PAGE

4.34.4

4.5

4.64.74.8

4.9

4.104.114.124.13

WING THE JIB FOR TRANSPORT . . . . . . . . .4-14

EMERGENCY PROCEDURES

ERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1IDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1RGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1

perator Unable to Control Machine . . . . . . . . . 5-1atform or Boom Caught Overhead . . . . . . . . . 5-2oom Movement Prevented By Boom ontrol System . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2RGENCY TOWING PROCEDURES . . . . . . . . .5-2

GENERAL SPECIFICATIONS & OPERATOR E

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1RATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

imensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2hassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2apacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3gine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4ajor Component Weights. . . . . . . . . . . . . . . . . 6-7

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

CAPACITY SELECT . . . . . . . . . . . . . . . . . . . . . . . . . 4-4ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-6

Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . 4-6Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-7

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-7Traveling Forward and Reverse. . . . . . . . . . . . . 4-8

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . 4-8PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

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

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-11Raising and Lowering the Boom . . . . . . . . . . . 4-11Telescoping the Boom. . . . . . . . . . . . . . . . . . . 4-11Swinging the Jib. . . . . . . . . . . . . . . . . . . . . . . . 4-11

FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . 4-11EMERGENCY TOWING. . . . . . . . . . . . . . . . . . . . . 4-12SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-13LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-13

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4.14 STO

SECTION - 5 -

5.1 GEN5.2 INC5.3 EME

OPlBC

5.4 EME

SECTION - 6 - MAINTENANC

6.1 INTR6.2 OPE

DCCTiEnHM

TABLE OF CONTENTS

3121 iii

SEC - PARAGRAPH, SUBJECT PAGE

SEC

Lifting and Tie Down Chart - Sheet 1 of 2. . . . . . . 4-15Lifting and Tie Down Chart - Sheet 2 of 2. . . . . . . 4-16Decal Location Sheet 1 of 5 . . . . . . . . . . . . . . . . . 4-17Decal Location Sheet 2 of 5 . . . . . . . . . . . . . . . . . 4-18Decal Location Sheet 3 of 5 . . . . . . . . . . . . . . . . . 4-19Decal Location Sheet 4 of 5 . . . . . . . . . . . . . . . . . 4-20Decal Location Sheet 5 of 5 . . . . . . . . . . . . . . . . . 4-21Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

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

Lubrication and Maintenance Point Location. . . . 6-10

264 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-116.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-18

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-18Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-19Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-19

6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-20

TION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . .2-72-2. Daily Walk-Around Inspection - Sheet 1 of 3 . . . . . .2-82-3. Daily Walk-Around Inspection - Sheet 2 of 3 . . . . . .2-92-4. Daily Walk-Around Inspection - Sheet 3 of 3 . . . . .2-103-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-23-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . .3-53-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-83-4. Platform Control Indicator Panel . . . . . . . . . . . . . .3-144-1. Dual Capacity Decal. . . . . . . . . . . . . . . . . . . . . . . . .4-44-2. Position of Least Forward Stability . . . . . . . . . . . . .4-54-3. Position of Least Backward Stability . . . . . . . . . . . .4-64-4. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-94-5. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . .4-12

4-6.4-7.4-8.4-9.4-10.4-11.4-12.6-1.

6-2.

6-3.

TABLE OF CONTENTS

iv 3121264

SECTIO RAGRAPH, SUBJECT PAGE

1-11-22-16-16-26-36-46-56-66-76-86-96-106-116-126-136-146-157-1

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

LIST OF TABLES

Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10Inspection and Maintenance Table . . . . . . . . . . . . . 2-3Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-1Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Chassis Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-2Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Deutz TD2011L4 Specifications . . . . . . . . . . . . . . . 6-3Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . 6-4Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . 6-4Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-5UCon Hydrolube HP-5046. . . . . . . . . . . . . . . . . . . . 6-5Mobil EAL H 46 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-6Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . 6-6Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-7Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-11Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . 6-20Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

SECTION 1 - SAFETY PRECAUTIONS

1-1

CAUTIONS

E-OPERATION

Training and Knowledged and understand this manual before operating thehine.

not operate this machine until complete training is per-ed by authorized persons.

y authorized and qualified personnel can operate thehine.

3121264 – JLG Lift –

SECTION 1. SAFETY PRE

1.1 GENERALThis section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of this manual. A maintenanceprogram, using the information provided in this manual andthe Service and Maintenance Manual, must also be estab-lished by a qualified person and followed to ensure themachine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not operate the machine until this manual has beenread, training is accomplished, and operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.

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

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

1.2 PR

Operator• Rea

mac

• Do form

• Onlmac


1-2 3121264

Wo

chine can be operated in temperatures of 0o F to-20o C to 40o C). Consult JLG for operation out- range.

pection achine operation, perform inspections and func-

hecks. Refer to Section 2 of this manual for instructions.

perate this machine until it has been serviced anded according to requirements specified in theand Maintenance Manual.

the footswitch and all other safety devices areg properly. Modification of these devices is aolation.

R ALTERATION OF AN AERIAL WORK PLATFORMONLY WITH WRITTEN PERMISSION FROM THE MANU-

perate any machine on which safety or instruction or decals are missing or illegible.

ny buildup of debris on the platform floor. Keep, grease, and other slippery substances from foot-d platform floor.

– JLG Lift –

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

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

• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

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

rkplace Inspection• The operator is to take safety measures to avoid all haz-

ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail-ers, railway cars, floating vessels, scaffolds or other equip-ment unless approved in writing by JLG.

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

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

• This ma104o F (side this

Machine Ins• Before m

tional cdetailed

• Do not omaintainService

• Be sureoperatinsafety vi

MODIFICATION OSHALL BE MADE FACTURER

• Do not oplacards

• Avoid amud, oilwear an


1-3

plies or tools which extend outside the platform arehibited unless approved by JLG.

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

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

not place boom or platform against any structure tody the platform or to support the structure.

w boom and shut off all power before leaving machine.

Fall Hazards operation, occupants in the platform must wear a fullarness with a lanyard attached to an authorized lan-

nchorage point. Attach only one (1) lanyard per lan-nchorage point.

3121264 – JLG Lift –

1.3 OPERATION

General • Do not use the machine for any purpose other than posi-

tioning personnel, their tools, and equipment.

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

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

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

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

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

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Suppro

• Whwithfron

• Do pullfrom

• Do stea

• Sto

Trip and Duringbody hyard ayard a


1-4 3121264

reme caution when entering or leaving platform. that the boom is fully lowered. It may be neces-elescope out to position the platform closer to thefor entry/exit. Face the machine, maintain “threentact” with the machine, using two hands and one

o feet and one hand during entry and exit.

n Hazardschine is not insulated and does not provide pro-rom contact or proximity to electrical current.

– JLG Lift –

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

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

• Never use the boom assembly to enter or leave the plat-form.

• Use extBe suresary to tground point cofoot or tw

Electrocutio• This ma

tection f


1-5

in a clearance of at least 10 ft. (3m) between any part machine and its occupants, their tools, and their

ent from any electrical line or apparatus carrying up00 volts. One foot additional clearance is required for

additional 30,000 volts or less.

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

oltage Rangease to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

r 50KV to 200 KV 15 (5)

200 KV to 350 KV 20 (6)

350 KV to 500 KV 25 (8)

500 KV to 750 KV 35 (11)

50 KV to 1000 KV 45 (14)

This requirement shall apply except whereemployer, local or governmental regulationsare more stringent.

3121264 – JLG Lift –

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintaof theequipmto 50,0every

Table

V(Ph

Ove

Over

Over

Over

Over 7

NOTE:


1-6 3121264

•

DO ZONENE

ardsr must be familiar with the surface before driving.exceed the allowable sideslope and grade while

– JLG Lift –

The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Theminimum approach distance shall be reduced to a distancewithin the designed working dimensions of the insulatingbarrier. This determination shall be made by a qualified per-son in accordance with the employer, local, or governmentalrequirements for work practices near energized equipment

NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARERGIZED UNLESS KNOWN OTHERWISE.

Tipping Haz• The use

Do not driving.


1-7

oom assembly or platform is in a position that one ore wheels are off the ground, all persons must beoved before attempting to stabilize the machine. Usees, forklift trucks, or other appropriate equipment toilize machine.

and Collision Hazardsroved head gear must be worn by all operating and

und personnel.

ck work area for clearances overhead, on sides, andom of platform when lifting or lowering platform, anding.

ing operation, keep all body parts inside platform rail-

3121264 – JLG Lift –

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

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

• Never exceed the maximum platform capacity. Distributeloads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi-tion unless the machine is on firm, level (up to the rated 3degrees) and smooth surfaces.

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

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

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

• Do not operate the machine when wind conditions exceed28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (ForReference Only).

• Do not increase the surface area of the platform or theload. Increase of the area exposed to the wind willdecrease stability.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If bmorremcranstab

Crushing• App

gro

• Chebottdriv

• During.


1-8 3121264

G, LIFTING, AND HAULINGllow personnel in platform while towing, lifting, or

chine should not be towed, except in the event ofcy, malfunction, power failure, or loading/unload-

er to the Emergency Procedures section of thisfor emergency towing procedures.

boom is in the stowed position and the turntablerior to towing, lifting or hauling. The platform mustletely empty of tools.

ting machine, lift only at designated areas of the. Lift the unit with equipment of adequate capac-

the Machine Operation section of this manual forormation.

– JLG Lift –

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

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

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

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

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

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

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Be sure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedboom or platform. Position barricades on floor if neces-sary.

1.4 TOWIN• Never a

hauling.

• This maemergening. Refmanual

• Ensure locked pbe comp

• When lifmachineity.

• Refer tolifting inf


1-9

not refuel the machine with the engine running.

tery fluid is highly corrosive. Avoid contact with skin clothing at all times.

rge batteries only in a well ventilated area.

3121264 – JLG Lift –

1.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.

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

• Do

• Batand

• Cha


1-1 3121264

DO NMPH

Only)

Land Conditions

ertically

n smoke

skin. Leaves rustle

wigs in constant motion

r raised. Small branches begin to move.

tion. Whistling heard in overhead wires. es difficult.

n. Effort needed to walk against the wind.

ees. Cars veer on road.

ge.

0 – JLG Lift –

OT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 (12.5 M/S).

Table 1-2. Beaufort Scale (For Reference

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises v

1 1-3 0.3-1.5 Light air Wind motion visible i

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

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

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

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

6 25-31 10.8-13.8 Strong breeze Large branches in moUmbrella use becom

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

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

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

CHINE PREPARATION, AND INSPECTION

2-1

PREPARATION, AND INSPECTION

e safest means to operate the machine where over-ad obstructions, other moving equipment, and obsta-

es, depressions, holes, drop-offs, etc. exist.

eans to avoid the hazards of unprotected electricalnductors.

ecific job requirements or machine application.

Supervisiong must be done under the supervision of a qualified in an open area free of obstructions until the traineeveloped the ability to safely control and operate the

ne.

Responsibilityerator must be instructed that he/she has the respon-

and authority to shut down the machine in case of action or other unsafe condition of either the machinejob site.

SECTION 2 - USER RESPONSIBILITIES, MA

3121264 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

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

Operator TrainingOperator training must cover:

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

2. Control labels, instructions, and warnings on themachine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of themachine to recognize a malfunction or potential mal-function.

6. Thhecl

7. Mco

8. Sp

Training Traininpersonhas demachi

OperatorThe opsibilitymalfunor the

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121264

2.2, INC. RECOGNIZES A FACTORY-TRAINED SERVICEA PERSON WHO HAS SUCCESSFULLY COMPLETED TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for further requirements for aerial work plat-forms. The frequency of inspections and maintenance mustbe increased as necessary when the machine is used in aharsh or hostile environment, if the machine is used withincreased frequency, or if the machine is used in a severemanner.

JLG INDUSTRIESTECHNICIAN AS THE JLG SERVICEMODEL.


2-3

nce Table

y ility

Service Qualification

Reference

r User or Operator Operator and Safety Manual

r User Qualified JLG Mechanic

Service and Maintenance Manual and applicable JLG inspection form



r User Factory-TrainedService Technician(Recommended)



Service and Maintenance Manual

ance Manual to perform inspections.


3121264 – JLG Lift –

Table 2-1.Inspection and Maintena

Type FrequencyPrimar

Responsib

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

User or Operato

Pre-Delivery Inspection (See Note)

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

Frequent Inspection(See Note)

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

Owner, Dealer, o

Annual Machine Inspec-tion(See Note)

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

Owner, Dealer, o

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

Owner, Dealer, o

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


2-4 3121264

Pre NSI markets only) is enclosed in the weathernt storage container.

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

y – Charge as required.

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

e Oil Supply - Ensure the engine oil level is at theark on the dipstick and the filler cap is secure.

ulic Oil – Check the hydraulic oil level. Ensurelic oil is added as required.

sories/Attachments - Reference the Operatorafety Manual of each attachment or accessoryd upon the machine for specific inspection, oper-

and maintenance instructions.

on Check – Once the “Walk-Around” Inspectionplete, perform a functional check of all systems ina free of overhead and ground level obstructions.to Section 4 for more specific operating instruc-

Control System Check - Perform a check of thecontrol system as specified in this section.

– JLG Lift –

-Start InspectionThe Pre-Start Inspection should include each of the follow-ing:

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

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

3. Decals and Placards – Check all for cleanliness andlegibility. Make sure none of the decals and placards aremissing. Make sure all illegible decals and placards arecleaned or replaced.

4. Operators and Safety Manuals – Make sure a copy ofthe Operator and Safety Manual, AEM Safety Manual(ANSI markets only), and ANSI Manual of Responsibili-

ties (Aresista

5. “WalkFigure

6. Batter

7. Fuel (Cproper

8. EnginFull m

9. Hydrahydrau

10. Accesand Sinstalleation,

11. Functiis coman areRefer tions.

12. Boomboom

Parent Metal Crack Weld Crack


2-5

. Check that all guards protecting the switches orlocks are in place;

. Operate all functions and check all limiting and cut-out switches;

. Check that drive is disabled when the boom is ele-vated more than 15 degrees above horizontal ortelescoped out beyond transport mode;

. Ensure that all machine functions are disabledwhen the Emergency Stop Button is pushed in.

ith the platform in the (stowed) position:

. Drive the machine on a grade, not to exceed therated gradeability, and stop to ensure the brakeshold;

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

. Check that the boom telescope (beyond transportmode) and lift up (more than 15° above horizontal)functions are disabled with the axles retracted.

ing the boom over either of the rear tires and ensureat the Drive Orientation indicator illuminates and thate Drive Orientation Override switch must be used fore drive function to operate.


3121264 – JLG Lift –

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THEMACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPERMAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTILIT IS DECLARED SAFE FOR OPERATION.

Function CheckPerform the Function Check as follows:

1. From the ground control panel with no load in the plat-form:

a. Check that all guards protecting the switches orlocks are in place;

b. Operate all functions and check all limiting and cut-out switches;

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabledwhen the Emergency Stop Button is activated.

2. Check the Boom Control System. Refer to Boom ControlSystem Check Procedure below.

3. From the platform control console:

a. Ensure that the control console is firmly secured inthe proper location;

b

c

d

e

4. W

a

b

c

5. Swththth


2-6 3121264

Bo must stop on colored stripe matching the capac-icator. If the boom does not stop on the correct the system must be repaired by JLG authorizede Personnel before the machine can be used.

nd hold the gray Boom Control System Test But- the ground control panel. The lighting of theBoom Control System Calibrated indicator indi-the system is functioning properly. No indicatorr the lighting of the red Boom Control Systemg indicator indicates the system must be repairedG authorized Service Personnel before the

ne can be used.

– JLG Lift –

om Control System Check ProcedurePerform the following check with no load (personnel or mate-rial) in the platform from the ground control station.

1. Extend all axles fully.

2. With the boom fully retracted, raise the boom off theboom rest to horizontal.

3. Position the jib horizontal, jib straight, and platform level.

4. Extend the boom until it stops.

5. Boomity indstripe,Servic

6. Push aton ongreen cates light oWarninby JLmachi


2-7

Fig

ure

2-1.

Bas

ic N

om

encl

atur

e

1. F

ront

Ste

er W

heel

s2.

Rea

r Driv

e Whe

els

3. L

ift C

ylin

der

4. G

roun

d Co

ntro

l Con

sole

5. B

ase B

oom

Sec

tion

6. I

nner

Mid

Boo

m S

ectio

n7.

Out

er M

id B

oom

Sec

tion

8.

Fly B

oom

Sec

tion

9.

Boom

Ass

embl

y10

. Pow

er Tr

ack

11. J

ib12

. Pla

tform

13. P

latfo

rm C

ontro

l Con

sole


3121264 – JLG Lift –


2-8 3121264

1

2

13

149

heet 1 of 3

– JLG Lift –

394

7

7

55

55 66

66

9

99

9 82

11

11

12

11

11

10

Figure 2-2. Daily Walk-Around Inspection - S


2-9

oom Sections/Uprights/Turntable - See Inspectionote.

wing Drive - No evidence of damage.

heel/Tire Assemblies - Properly secured, no missingg nuts. Inspect for worn tread, cuts, tears or other dis-epancies. Inspect wheels for damage and corrosion.

rive Motor, Brake, and Hub - No evidence of leak-e.

ood Assemblies - See Inspection Note.

uxiliary Hydraulic Pump - See Inspection Note.

ll Hydraulic Cylinders - No visible damage; pivotns and hydraulic hoses undamaged, not leaking.

rntable Bearing - Evidence of proper lubrication. Noidence of loose bolts or looseness between bearingd machine.

teering Spindles and Sensors - See Inspectionote.

n - Sheet 2 of 3


3121264 – JLG Lift –

GeneralBegin the "Walk-Around Inspection" at Item 1, as noted onthe diagram. Continue to the right (counterclockwise viewedfrom top) checking each item in sequence for the conditionslisted in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEENCORRECTED.

INSPECTION NOTE: On all components, make sure thereare no loose or missing parts, that they are securely fas-tened, and no visible damage, leaks or excessive wear existsin addition to any other criteria mentioned.

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

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

3. BN

4. S

5. Wlucr

6. Dag

7. H

8. A

9. Api

10. Tuevan

11. SN

Figure 2-3. Daily Walk-Around Inspectio


2-1 3121264

tator - See Description.

eet 3 of 3

0 – JLG Lift –

12. Main Hydraulic Pump - See Inspection Note.

13. Platform Rotator - See Inspection Note.

14. Jib Ro

Figure 2-4. Daily Walk-Around Inspection - Sh


2-11

ith boom in this position, place Drive control lever toverse and carefully drive machine off of block and

mp.

ave an assistant check to see that left front or right rearheel remains elevated in position off of the ground.

arefully return the boom to the transport position.hen boom reaches the transport position, carefullytivate Drive to release cylinders. The lockout cylindersould release and allow the wheel to rest on ground.

peat the procedure for the right oscillation cylinderecking to see that the right front or left rear wheelmains elevated in position off of the ground.

lockout cylinders do not function properly, have quali-d personnel correct the malfunction prior to any fur-er operation.


3121264 – JLG Lift –

2.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

The front axles will oscillate when the boom is in the transportposition (i.e. when the boom is less than 15° above horizontaland not extended beyond 12" (30.4 cm).

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIMEA SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEMOPERATION IS SUSPECTED.

NOTE: Ensure the axles are extended and the boom is fullyretracted, lowered, and centered between the rearwheels prior to beginning lockout cylinder test.

1. Place a 6 inch (15.2 cm) high block with ascension rampin front of left front wheel.

2. From platform control station, start engine.

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

4. Carefully extend the boom just enough to get it out ofthe transport position.

5. WRera

6. Hw

7. CWacsh

8. Rechre

9. If fieth


2-1 3121264
2 – JLG Lift –
NOTES:

MACHINE CONTROLS AND INDICATORS

3-1

AND INDICATORS

ontrol Station

e Function Enable switch must be heldwn in order to operate Telescope, Swing,in Lift, Jib Lift, Platform Level Override,

d Platform Rotate functions.

re 3-1., Ground Control Station)

dicator Panel

e LED Indicator Panel contains indicator lights thatgnal problem conditions or functions operating duringachine operation.

om Control System Test Button

e push button is used to test the boom control systemd confirm that it is working properly.

lescope Control

ovides extension and retraction of the boom whensitioned to IN or OUT.

SECTION 3 -

3121264 – JLG Lift –

SECTION 3. MACHINE CONTROLS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machine is equipped with control panels that usesymbols to indicate control functions. Refer to decallocated on the control box guard in front of the controlbox or by the ground controls for these symbols and thecorresponding functions.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMMOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

Ground C

NOTE: ThdoMaan

(See Figu

1. In

Thsim

2. Bo

Than

3. Te

Prpo

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121264

on

1. Indicator Panel2. Boom Control System Test Button3. Telescope4. Swing5. Lift6. Platform/Ground Select Switch7. Hourmeter8. Power/Emergency Stop9. Engine Start/Auxiliary Power/Function Enable10. Articulating Jib11. Platform Leveling Override12. Platform Rotate13. Jib Swing

– JLG Lift –

1706911 A

1 13

3

2

4 5 6

7

8

9

10

11

12

Figure 3-1. Ground Control Stati


3-3

en Power/Emergency Stop switch is in the “ON” posi- and engine is not running, an alarm will sound, indi-

ting Ignition is “ON”.

ACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOPST BE POSITIONED TO THE “OFF” POSITION TO PREVENTE BATTERY.

wer/Emergency Stop Switch

two-position red mushroom shaped switch furnisheswer to PLATFORM/GROUND SELECT switch whenlled out (on). When pushed in (off), power is shut off

the PLATFORM/GROUND SELECT switch.

SECTION 3 -

3121264 – JLG Lift –

4. Swing Control

Provides 360 degrees continuous turntable rotation.

5. Lift Control

Provides raising and lowering of the main boom.

NOTE: With PLATFORM/GROUND SELECT switch in the centerposition, power is shut off to controls at both operatingstations.

6. Platform/Ground Select Switch

A three position, key operated switch supplies power tothe platform control console when positioned to PLAT-FORM. With the switch key held in the GROUND posi-tion, power is shut off to platform and only groundcontrols are operable.

7. Hourmeter

Registers the amount of time the machine has been inuse, with engine running. By connecting into the oilpressure circuit of the engine, only engine run hours arerecorded. The hourmeter registers up to 9,999.9 hoursand cannot be reset.

NOTE: Whtionca

WHEN THE MSWITCH MUDRAINING TH

8. Po

A poputo


3-4 3121264

NOT

WHEFUNTHE

ating Jib

itch provides raising and lowering of the jib.

PLATFORM LEVELING OVERRIDE FUNCTION FOR OF THE PLATFORM. INCORRECT USE COULD CAUSEANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD OR SERIOUS INJURY.

m Leveling Override

witch allows the operator to adjust the automaticveling system. This switch is used to adjust plat-vel in situations such as ascending/descending a

m Rotate

itch permits rotation of the platform.

ing

itch allows the operator to swing the jib to the leftht.

– JLG Lift –

E: Auxiliary power only works if there is no engine oil pres-sure, and is disabled if engine is running.

Functions will operate at a slower than normal ratebecause of the lesser flow of hydraulic fluid delivered.

N USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONECTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD AUXILIARY PUMP.

9. 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 beheld “DOWN” for duration of auxiliary pumpuse. Aux power can only be used if the engineis not running.

The enable switch must be held "DOWN" toenable all boom controls when the engine isrunning.

10. Articul

This sw

ONLY USE THE SLIGHT LEVELINGTHE LOAD/OCCUPRESULT IN DEATH

11. Platfor

This sself leform legrade.

12. Platfor

This sw

13. Jib Sw

This swand rig


3-5

w Engine Oil Pressure Indicator

dicates that engine oil pressure is below normal andrvice is required.

igh Engine Temperature Indicator

dicates that engine coolant temperature is abnormallygh and service is required.

gine Oil Temperature Indicator

dicates the temperature of the engine oil, which alsorves as engine coolant, is abnormally high and ser-

ce is required.

les Set Indicator

dicates that the axles are fully extended. The indicatorill flash as the axles are extending or retracting and be solid when fully extended. The light will go out when

e axles are fully retracted.

atform Capacity Indicator

dicates which capacity range is selected. This capac- can only be selected at the platform control console.

SECTION 3 -

3121264 – JLG Lift –

Ground Control Indicator Panel

(See Figure 3-2., Ground Control Indicator Panel)

1. Battery Charging Indicator

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

2. Lo

Inse

3. H

Inhi

4. En

Insevi

5. Ax

Inwonth

6. Pl

Inity

1. Battery Charging2. Low Engine Oil Pressure3. High Engine Coolant Temp.4. High Engine Oil Temp.5. Axles Set

6. Platform Capacity7. Platform Overload 8. Boom Control System Warning9. Boom Control System Calibrated

Figure 3-2. Ground Control Indicator Panel


3-6 3121264

tion

3., Platform Control Console)

S INJURY, DO NOT OPERATE MACHINE IF ANY CON-R TOGGLE SWITCHES CONTROLLING PLATFORM

NOT RETURN TO THE OFF OR NEUTRAL POSITION.

/Emergency Stop

position red mushroom shaped switch furnishes to PLATFORM Controls when pulled out (on).pushed in (off), power is shut off to the platformns.

about 2 seconds of pulling the switch out, thene will perform a diagnostic check of the variouscal circuits, and if everything is OK, the platformwill beep once. During this time the lights on thetor panel will also blink once as a bulb check.

– JLG Lift –

7. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

8. Boom Control System Warning Indicator

Indicates the platform is outside the operating area andoperation of certain boom functions may be disabled(i.e. lift, telescope). Attempts to use the disabled func-tions cause the indicator to flash and an alarm to sound.Immediately return the platform to the ground. If the indi-cator remains lit, a boom control system fault or failurehas been detected. If a fault or failure is discovered, thesystem must be repaired by JLG authorized service per-sonnel before the machine can be used.

9. Boom Control System Calibrated Indicator

When the Boom Control System Test Button is pushed,illuminates to indicate that the Boom Control System iscalibrated properly.

Platform Sta

(See Figure 3-

TO AVOID SERIOUTROL LEVERS OMOVEMENT DO WHEN RELEASED

1. Power

A two-powerWhen functio

Withinmachielectrialarm indica


3-7

rive Orientation Override

hen the boom is swung over the rear tires or further inther direction, the Drive Orientation indicator will illumi-te when the drive function is selected. Push andlease the switch, and within 3 seconds move therive/Steer control to activate drive or steer. Before driv-g, locate the black/white orientation arrows on bothe chassis and the platform controls and match thentrol direction arrow to the intended chassis direction.

operate the Drive Joystick, pull up on the locking ringlow the handle.

e DRIVE control levers are spring-loaded and will auto-tically return to neutral (OFF) position when released.

rive/Steer

e DRIVE joystick provides for driving either forward orckward. The controller is ‘ramped’ to allow variableive speed.

eering is controlled by a thumb operated switch onp of the joystick.

SECTION 3 -

3121264 – JLG Lift –

2. Start/Auxiliary Power

When pushed forward, the switch energizes the startermotor to start the engine.

When pushed back, it energizes the electrically oper-ated hydraulic pump. (Switch must be held ON for dura-tion of auxiliary pump use.)

The auxiliary pump functions to provide sufficient oil flowto operate the basic machine functions should the mainpump or engine fail. The auxiliary pump will operateplatform rotate, jib lift, jib swing, platform level override,main boom lift, main telescope and swing.

3. Capacity Select

This switch allows the operator to select between anoperating envelope with a 500 lb. (230 kg) capacityrestriction or a 1000 lb. (450 kg) capacity restriction.

4. D

WeinareDinthco

NOTE: To be

NOTE: Thma

5. D

Thbadr

Stto


3-8 3121264

n Speed Controlift / Swingpeed / Torque Selectelect

19. Platform Level Override20. Horn21. Indicator Panel22. Boom Control Select

e

– JLG Lift –

1. Power/Emergency Stop2. Engine Start / Aux Power3. Capacity Select4. Drive Orientation Override5. Drive/Steer

6. Telescope7. Lights8. Jib Lift9. Soft Touch Override10. Jib Swing

11. Axle Extend/Retract12. Soft Touch Indicator13. Platform Rotate14. Jib Stow Override

15. Functio16. Main L17. Drive S18. Steer S

Figure 3-3. Platform Control Consol


3-9

e Jib Swing function is not operable when the Capacitylect control is in the 1000 lb. (450 kg) position.

b Swing

is switch allows the operator to swing the jib to the left right.

le Extend/Retract

is switch allows the operator to extend or retract theles. The axles can only be extended or retracted whilee machine is being driven forward or reverse.

ft Touch Indicator (If Equipped)

dicates the Soft Touch bumper is against an object. Allntrols are cut out until the override button is pushed,

which time controls are active in the Creep Mode.

atform Rotate

is switch allows the operator to rotate the basket toe left or right.

SECTION 3 -

3121264 – JLG Lift –

6. Main Telescope

This control allows extension and retraction of the mainboom.

7. Lights (If Equipped)

This switch operates accessory light packages if themachine is so equipped.

8. Jib Lift

Provides for raising or lowering of the jib by positioningup/down.

9. Soft Touch Override Switch (If equipped)

This switch enables the functions that were cut out bythe Soft Touch system to operate again at creep speed,allowing the operator to move the platform away fromthe obstacle that caused the shutdown situation.

NOTE: ThSe

10. Ji

Thor

11. Ax

Thaxth

12. So

Incoat

13. Pl

Thth


3-1 3121264

NOT

NOT

oom is positioned above transport position or tele- out and any of the following switches, DRIVE/TORQUE SELECT or FUNCTION SPEED, are posi-to HIGH, high function speeds are automatically and the machine continues to operate at a lower

E MACHINE IF DRIVE SPEED /TORQUE SELECT or SWITCHES OPERATE WHEN BOOM IS MORE THANONTAL.

peed/Torque Select

rward position gives maximum drive speed by the drive motors to minimum displacement and

high engine when drive controller is moved. Theosition gives maximum torque for rough terrain

limbing grades by shifting the wheel motors toum displacement and giving high engine speeddrive controller is moved. The center position the machine to be driven as quietly as possibleving the engine at mid speed and the drive motorsimum displacement.

0 – JLG Lift –

14. Jib Stow Override

This switch allows the operator to rotate the jib to theright past the electronic stop to stow the jib under theboom for transport.

15. Function Speed Control

This control affects the speed of telescope, main lift andjib lift. Turning the knob all the way counterclockwiseuntil it clicks puts drive, main lift and swing into creepmode.

E: To operate the Main Lift/Swing Joystick, pull up on thelocking ring below the handle.

E: The MAIN LIFT/SWING control lever is spring-loaded andwill automatically return to neutral (OFF) position whenreleased.

16. Main Lift/Swing Controller

An infinitely proportional dual axis joystick is providedfor main lift and swing. Push forward to lift up, pull back-ward to lift down. Move right to swing right, move left toswing left.

NOTE: When bscopedSPEEDtioned cut outspeed.

DO NOT OPERATFUNCTION SPEED15° ABOVE HORIZ

17. Drive S

The foshiftinggivingback pand cmaximwhen allowsby leain max


3-11

THE PLATFORM LEVELING OVERRIDE FUNCTION FORLING OF THE PLATFORM. INCORRECT USE COULD CAUSE

CCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULDEATH OR SERIOUS INJURY.

atform Leveling Override

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

orn

pressed, this switch supplies power to the horn.

SECTION 3 -

3121264 – JLG Lift –

18. Steer Select

The action of the steering system is operator selectable.The center switch position gives conventional frontwheel steering with the rear wheels unaffected. This isfor normal driving at maximum speeds. The forwardposition is for “crab” steering. When in this mode bothfront and rear axles steer in the same direction, whichallows the chassis to move sideways as it goes forward.This can be used for positioning the machine in aisleways or against buildings. The back switch position isfor “coordinated” steering. In this mode the front andrear axles steer in the opposite directions to produce thetightest turning circle for maneuvering in confined areas.

To re-synchronize the front and rear axles, position therear drive wheels to the forward drive position by select-ing either crab or compound steer, then select frontsteer (center switch position) to operate the normalsteering function.

ONLY USE SLIGHT LEVETHE LOAD/ORESULT IN D

19. Pl

A auadde

20. H

If


3-1 3121264

NOT

l Mode:

the boom control is positioned tol, lift and telescope movements arelled separately by the operator andtomatic platform leveling feature isonly during lift functions.

positioned to Manual, boom functions will be when the envelope limits are reached. When this

operate a different function or select the auto-osition.

ing upon the angle of the chassis and the angle ofm, swing left or swing right may be disallowed the Manual mode. The BCS light will illuminate

ther attempts to swing in the disallowed directionse the BCS to flash. When this occurs the only are to swing in the opposite direction or switch totic mode.

2 – JLG Lift –

21. Indicator Panel

The LED Indicator Panel contains indicator lights thatsignal problem conditions or functions operating duringmachine operation.

22. Boom Control Select

Automatic Mode:

When the Boom Control is positioned toAutomatic, lift and telescope movements arecoordinated by the JLG control system andthe automatic platform leveling feature isactive during lift, telescope, swing, and drive move-ments.

E: • While operating lift up, the boom may also telescopeout. • While operating lift down, the boom may also telescopein. • While operating swing or drive, the boom may lift up orlift down.• While operating telescope in, the boom may lift downwhen at high boom angles and the creep light is flashing.

Manua

WhenManuacontrothe auactive

NOTE: When stoppedoccurs,matic p

NOTE: Dependthe boowhile inand furwill cauchoicesautoma


3-13

nsport mode (12 inches [30.5 cm]) or elevated morean 15° above horizontal.

EL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUTACHINE, RECYCLE THE EMERGENCY STOP, AND RESTARTE. IF THE FAULT PERSISTS, RETURN THE PLATFORM TO

D POSITION, USING MANUAL LEVELING AS REQUIRED,EVELING SYSTEM REPAIRED.

Generator

dicates the generator is in operation.

atform Overload Indicator (If Equipped)

dicates the platform has been overloaded.

atform Capacity Indicator

dicates the maximum platform capacity selected fore platform.

ne of the capacity lights should be on at all times. Bothhts will flash and an alarm will sound if the platform ist of the operating envelope for the selected capacity.

SECTION 3 -

3121264 – JLG Lift –

Platform Control Indicator Panel

(See Figure 3-4., Platform Control Indicator Panel)

NOTE: The platform control indicator panel uses different shapedsymbols to alert the operator to different types of opera-tional situations that could arise. The meaning of thosesymbols are explained below.

1. Level System Fault Indicator

Indicates a fault in the electronic leveling system. Thefault indicator will flash and an alarm sound. All func-tions will default to creep if the boom is extended past

trath

IF THE LEVDOWN THE MTHE MACHINTHE STOWEAND HAVE L

2. AC

In

3. Pl

In

4. Pl

Inth

Oligou

Indicates a potentially hazardous situation, which ifnot corrected, could result in serious injury ordeath. This indicator will be red.

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

Indicates important information regarding the oper-ating condition, i.e. procedures essential for safeoperation. This indicator will be green with theexception of the capacity indicator which will begreen or yellow depending upon platform position.


3-1 3121264

ceation

rol System Warning

anel

4 – JLG Lift –

1. Level System2. AC Generator3. Platform Overload4. Platform Capacity5. Tilt Alarm Warning

6. Glow Plug7. Enable8. Fuel Level9. Creep Speed10. System Distress

11. Cable Servi12. Drive Orient13. Axles Set14. Boom Cont

Figure 3-4. Platform Control Indicator P


3-15

otswitch/Enable Indicator

operate any function, the footswitch must bepressed and the function selected within seven sec-ds. The enable indicator shows that the controls areabled. If a function is not selected within seven sec-ds, or if a seven second lapse between ending one

nction and beginning the next function, the enableht will go out and the footswitch must be released andpressed again to enable the controls.

leasing the footswitch removes power from all con-ls and applies the drive brakes.

ERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLEITCH BY BLOCKING OR ANY OTHER MEANS.

MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHENY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT-

SECTION 3 -

3121264 – JLG Lift –

5. Tilt Alarm Warning Light and Alarm

Indicates that the chassis is on a slope. An alarm willalso sound when the chassis is on a slope and theboom is above transport position. If lit when the boom israised or extended, retract and lower to below horizontalthen re-position machine so that it is level (within therated 3 degrees) before continuous operation. If theboom is above transport position or telescoped, out andthe machine is on a slope, the tilt alarm warning light willilluminate and an alarm will sound and CREEP is auto-matically activated.

IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT ANDLOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THATIT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM MORETHAN 15 DEGREES ABOVE HORIZONTAL.

6. Glow Plug Indicator

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

7. Fo

Todeonenonfuligde

Retro

TO AVOID STHE FOOTSW

FOOTSWITCHSWITCH ONLTOM.


3-1 3121264

Service Indicator

illuminated, the light indicates the boom cablesse or broken and must be repaired or adjustediately.

rientation Indicator

the boom is swung beyond the rear drive tires or in either direction, the Drive Orientation indicatorminate when the drive function is selected. This isal for the operator to verify that the drive control isoperated in the proper direction (i.e. controls

ed situations).

et Indicator

tes that the axles are fully extended. The indicatorsh as the axles are extending or retracting and beid when fully extended. The light will go out whenles are fully retracted.

6 – JLG Lift –

8. Fuel Level Indicator

Indicates the level of fuel in the fuel tank.

9. Creep Speed Indicator

When the Function Speed Control is turned to the creepposition, the indicator acts as a reminder that all func-tions are set to the slowest speed. The light flashes if thecontrol system puts the machine into creep speed andwill be on continuously if the operator selects creepspeed.

10. System Distress Indicator

The light indicates that the JLG Control System hasdetected an abnormal condition and a Diagnostic Trou-ble Code has been set in the system memory. Refer tothe Service Manual for instructions concerning the trou-ble codes and trouble code retrieval.

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

11. Cable

When are looimmed

12. Drive O

When furtherwill illua signbeing revers

13. Axles S

Indicawill flaon solthe ax


3-17

SECTION 3 -

3121264 – JLG Lift –

14. Boom Control System Warning Indicator

Indicates the platform is outside the operating area andoperation of certain boom functions may be disabled(i.e. lift, telescope). Attempts to use the disabled func-tions cause the indicator to flash and an alarm to sound.Immediately return the platform to the ground. If the indi-cator remains lit, a boom control system fault or failurehas been detected. If a failure is discovered, the systemmust be repaired by JLG authorized service personnelbefore the machine can be used.


3-1 3121264
8 – JLG Lift –
NOTES:

SECTION 4 - MACHINE OPERATION

4-1

PERATION

OM OPERATING CHARACTERISTICS AND ITATIONS

esom can be raised more than 15° above horizontal without any load in platform, if:

achine is positioned on a smooth, firm and level (up to e rated 3 degrees) surface.

les are extended.

ad is within manufacturer’s rated capacity.

l machine systems are functioning properly.

oper tire pressure.

achine is as originally equipped from JLG.

3121264 – JLG Lift –

SECTION 4. MACHINE O

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. Fromthis control station, the operator can drive and steer themachine in both forward and reverse directions. The opera-tor can raise or lower the upper or lower boom or swing theboom to the left or right. Standard boom swing is 360 degreecontinuous left and right of the stowed position. The machinehas a Ground Control Station which will override the PlatformControl Station. Ground Controls operate Boom Lift andSwing, and are to be used in an emergency to lower the plat-form to the ground should the operator in the platform beunable to do so.

4.2 BOLIM

CapacitiThe boor with

1. Mth

2. Ax

3. Lo

4. Al

5. Pr

6. M


4-2 3121264

Co , telescope in will function automatically, or whenlescope out will function automatically.

Boom Control Switch is in the manual mode, liftope functions are independent functions con-

he operator.

– JLG Lift –

ntrolled Arc

When the Boom Control Select switch is in the automaticmode, the boom control system automatically controls liftand telescope when the lift function is selected to move theplatform through a predetermined arc, equivalent to the per-centage of extension. (i.e. If you start at 70% boom exten-sion, you will end up at approximately 70% boom extensionno matter where you stop in the arc). This means that when

lifting downlifting up, te

When the and telesctrolled by t


4-3

om Control System in Automatic Mode: When theom is completely elevated along the edge of the back-rd stability region and the telescope in function is acti-ed, lift down will automatically function until the boomway from the edge of the backward stability region.

om Control System in Manual Mode: The boom willp when the end of the envelope is reached and theerator must activate lift and/or telescope, in the properection, to bring the boom back into the envelope.

d Anglentrol system automatically maintains a constant ele-

boom angle when swinging the turntable. If the boomis at 30 degrees, swing engaged by itself shall add liftntain the relative boom angle at 30 degrees.

eed Proportioningoom control system sensors sense the distance therm is extended from the turntable, allowing higherspeeds with the boom retracted and gradually slowerspeeds as the boom is extended.

3121264 – JLG Lift –

Envelope Tracking

When the platform approaches the edges of the operatingenvelope all machine functions are slowed down automati-cally by the boom control system to reduce machinemotions.

NOTE: Bobowavatis a

Bostoopdir

ControlleThe covated angle to mai

Swing SpThe bplatfoswing swing

BUFFER LINE

ENVELOPE

SLOWDOWN LINE

BUFFERZONE

SLOWDOWNZONE


4-4 3121264

Sta

TO MACMOR

ITY SELECT

ntrol System allows the operator to select opera-ound (230 kg) capacity restriction envelope or a

450 kg) capacity restriction envelope. The opera-e desired capacity restriction by positioning thect switch on the platform console. The Capacitys the capacity selected, and both capacity lights an alarm sound if the platform is out of thecity range.

on in the 1000 pound (450 kg) envelope requireso be fixed in the centered position.

– JLG Lift –

bilityMachine stability is based on two (2) conditions which arecalled FORWARD and BACKWARD stability. The machine’sposition of least FORWARD stability is shown in (See Figure4-2.), and its position of least BACKWARD stability is shownin (See Figure 4-3.)

AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOADHINE OR OPERATE THE MACHINE ON A SURFACE OUT-OF-LEVELE THAN THE RATED 3 DEGEES.

4.3 CAPAC

The Boom Cotion in a 500 p1000 pound (tor selects thCapacity SeleIndicator showwill flash andselected capa

NOTE: Operatithe jib t

Figure 4-1. Dual Capacity Decal


4-5

rd Stability

3121264 – JLG Lift –

Figure 4-2. Position of Least Forwa


4-6 3121264

. E OPERATION

tarting should always be performed from the Control station.

cedure

TO START PROMPTLY, DO NOT CRANK FOR AN. SHOULD ENGINE FAIL TO START AGAIN, ALLOWOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER

PTS, REFER TO ENGINE MAINTENANCE MANUAL.

engines only: After turning on ignition, operatorait until glow plug indicator light goes out beforeg engine.

key of SELECT switch to GROUND. PositionR/EMERGENCY STOP switch to ON, then pushGINE START switch until engine starts.

TO WARM-UP FOR A FEW MINUTES AT LOW SPEEDG ANY LOAD.

ngine has had sufficient time to warm up, shut off.

– JLG Lift –

4.4 ENGIN

NOTE: Initial sGround

Starting Pro

IF ENGINE FAILSEXTENDED TIMESTARTER TO “COSEVERAL ATTEM

NOTE: Diesel must wcrankin

1. Turn POWEthe EN

ALLOW ENGINE BEFORE APPLYIN

2. After eengineFigure 4-3. Position of Least Backward Stability


4-7

AVELING (DRIVING)

en the boom is raised approximately 15 degreesove horizontal, all drive functions will be disabled.

IVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON AM AND LEVEL (UP TO THE RATED 3 DEGREES) SURFACE.

SS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE GRADES EXCEEDING THOSE SPECIFIED IN THE OPERAT-

CATIONS SECTION OF THIS MANUAL.

E ON SIDESLOPES WHICH EXCEED 5 DEGREES.

E CAUTION WHEN DRIVING IN REVERSE AND AT ALL THE PLATFORM IS ELEVATED.

3121264 – JLG Lift –

3. Turn SELECT switch to PLATFORM.

4. From Platform, pull POWER/EMERGENCY STOP switch out, then push the ENGINE START switch until engine starts.

NOTE: Footswitch must be in released (up) position beforestarter will operate. If starter operates with footswitch inthe depressed position, DO NOT OPERATE MACHINE.

Shutdown Procedure

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUT-DOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTART-ING THE ENGINE.

1. Remove all load and allow engine to operate at lowspeed for 3-5 minutes; this allows further reduction ofinternal engine temperature.

2. Push POWER/EMERGENCY STOP switch in.

3. Turn MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed informa-tion.

4.5 TR

NOTE: Whab

DO NOT DRSMOOTH, FIR

TO AVOID LOMACHINE ONING SPECIFI

DO NOT DRIV

USE EXTREMTIMES WHEN


4-8 3121264

BEFON DRIVARR

Tra

the black and white direction arrows on both plat-ontrol panel and the chassis to determine the on the machine will travel.

nd release the Drive Orientation Override switch. 3 seconds, slowly move the Drive control toward ow matching the intended direction of machine The indicator light will flash during the 3 second l until the drive function is selected.

INGumb switch on Drive/Steer controller to RIGHT forht, or to LEFT for steering left.

DING THE AXLES

erator must be driving the machine (forward or) in order to extend the axles.

e Axle Extend switch to extend the axles or totract the axles.

– JLG Lift –

ORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWSBOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THEE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONALOWS.

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

start engine, and activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as desired.

This machine is equipped with a Drive Orientation Indicator.The yellow light on the platform control console indicatesthat the boom is swung beyond the rear drive tires and themachine may Drive/Steer in the opposite direction from themovement of the controls. If the indicator is illuminated,operate the Drive function in the following manner:

1. Matchform cdirecti

2. Push aWithinthe arrtravel.interva

4.6 STEERPosition thsteering rig

4.7 EXTEN

NOTE: The opreverse

Position thretract to re


4-9

SIDESLOPE

lopes

3121264 – JLG Lift –

GRADE

LEVEL

Figure 4-4. Grade and Side S


4-1 3121264

4.8

Pla

ONLSLIGTHERES

NOT

tationhe platform to the left or right, use the Platformtrol switch to select the direction and hold until

sition is reached.

OR RAISE BOOM ABOVE HORIZONTAL WHENOF LEVEL MORE THAN THE RATED 3 DEGREES.

ON TILT ALARM AS A LEVEL INDICATOR FOR THE

ER, LOWER PLATFORM TO GROUND LEVEL. THEN TO A LEVEL SURFACE (WITHIN THE RATED 3E RAISING BOOM.

S INJURY, DO NOT OPERATE MACHINE IF ANY CON- TOGGLE SWITCH CONTROLLING PLATFORM MOVE-RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN

M DOES NOT STOP WHEN A CONTROL SWITCH ORSED, REMOVE FOOT FROM FOOTSWITCH OR USEP SWITCH TO STOP THE MACHINE.

0 – JLG Lift –

PLATFORM

tform Level Adjustment

Y USE THE PLATFORM LEVELING OVERRIDE FUNCTION FORHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE

LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULDULT IN DEATH OR SERIOUS INJURY.

E: When the Boom Control Select Switch is in the Manualmode, Platform leveling only functions during Main Liftoperation. When the Boom Control Select Switch is in theAutomatic mode, Platform Leveling is active during allfunctions except during telescope operation. Also, whenin the Manual mode, the Controlled Angle system is notactive.

During normal operation of the machine, the platform willautomatically maintain it’s position. To manually Level Up orDown - Position the Platform/Level control switch Up orDown and hold until the desired platform position isobtained.

Platform RoTo rotate tRotate condesired po

4.9 BOOM

DO NOT SWINGMACHINE IS OUT

DO NOT DEPENDCHASSIS.

TO AVOID TIP OVDRIVE MACHINEDEGREES) BEFOR

TO AVOID SERIOUTROL LEVER ORMENT DOES NOT RELEASED.

IF THE PLATFORLEVER IS RELEAEMERGENCY STO


4-11

the Jib

r 1000 lb. (450 kg) mode operation, the jib must bentered and the Jib Swing function is not operable. If theis out of the centered position when in this mode, theswing function will allow the operator to center the jibain.

ng the jib, use the Jib Swing control to select Right orrection.

NCTION SPEED CONTROLontrol affects the speed of telescope, main lift and jibrning the knob all the way counterclockwise until itputs drive, main lift and swing into creep mode.

3121264 – JLG Lift –

Swinging the BoomTo swing boom, use Swing control to select Right or Leftdirection.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FORTHE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIP-MENT.

Raising and Lowering the Boom

NOTE: The lift function is not operable above 15 degrees abovehorizontal if the axles are not fully extended.

To raise or lower the Boom, use Boom Lift control to selectUp or Down movement.

Telescoping the Boom

NOTE: The telescope function is not operable beyond the trans-port position if the axles are not fully extended.

To extend or retract the main boom, use the Telescope ControlSwitch to select In or Out movement.

Swinging

NOTE: Focejib jib ag

To swiLeft di

4.10 FUThis clift. Tuclicks


4-1 3121264

4.1

RUNBRAALLLOW

MAX

MAX

DO ENG

nect drive hubs by inverting disconnect cap.

nect the drive hubs by inverting the disconnect en towing is complete.

igure 4-5. Drive Disconnect Hub

2 – JLG Lift –

1 EMERGENCY TOWING

AWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL- INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

IMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)

IMUM TOWING GRADE 25%.

NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBSAGED.

1. Retract, lower and position boom in travel position; lockturntable.

2. Discon

3. Reconcap wh

F


4-13

TING AND TIE DOWN

e 4-6. and Figure 4-7.

fer to the Serial Number Plate, Specifications section this manual, or weigh the individual unit to find out theross Vehicle Weight.

ace the boom in the stowed position with the turntable cked.

move all loose items from the machine.

tach lifting device and equipment only to the desig-ted lifting points.

operly adjust the rigging to prevent damage to the achine and so the machine remains level.

3121264 – JLG Lift –

4.12 SHUT DOWN AND PARKTo shut down and park the machine, the procedures are asfollows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Posi-tion Platform/Ground Select switch to center OFF.

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

4.13 LIF

See Figur

Lifting1. Re

ofG

2. Pllo

3. Re

4. Atna

5. Prm


4-1 3121264

Tie

WHELOW

NOT

ING THE JIB FOR TRANSPORTthe boom in the stowed position with the axlesed.

he Jib Swing control switch to the right until the m will no longer swing.

Swing function is not operable when the Capacityontrol is in the 1000 lb. (450 kg) position.

tic platform leveling is disabled when stowing the

nd hold the Jib Stow control switch until the jib atform are in the stowed position under the boom.

4 – JLG Lift –

Down

N TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLYERED INTO THE BOOM REST.

E: When loading the machine onto a trailer, it will be neces-sary to rotate the turntable 180 degrees to provide betterweight distribution.

1. Place the boom in the stowed position with the turntablelocked.

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or chains of adequate strength and attached to the desig-nated tie down points.

4.14 STOW1. Place

retract

2. Hold tplatfor

NOTE: The JibSelect c

NOTE: Automajib.

3. Push aand pl


4-15

Sheet 1 of 2

3121264 – JLG Lift –

Figure 4-6. Lifting and Tie Down Chart -


4-1 3121264

11’2”/3.40 m

R

et 2 of 2

6 – JLG Lift –

38’11”/11.86 m

27’9"/8.46 m

Figure 4-7. Lifting and Tie Down Chart - She


4-17

of 5

3121264 – JLG Lift –

Figure 4-8. Decal Location Sheet 1


4-1 3121264

5

8 – JLG Lift –

Figure 4-9. Decal Location Sheet 2 of


4-19

eet 3 of 5

3121264 – JLG Lift –

Figure 4-10. Decal Location Sh


4-2 3121264

of 5

0 – JLG Lift –

Figure 4-11. Decal Location Sheet 4


4-21

5 of 5

3121264 – JLG Lift –

Figure 4-12. Decal Location Sheet


4-2 3121264

19 1702868

20 1703797

21 1001120457

22 1703804

23 1703805

24 - -

25 3251813

26 1705492

27 1702631

28 1705168

29 1705181

30 1700584

31 1706751

32 1705868

33 1705351

34 1701505

35 1704972

36 1705511

37 1701501

38 - -

Item # ANSI1001120455-1

2 – JLG Lift –

Item # ANSI1001120455-1

1 - -

2 1701499

3 - -

4 - -

5 1701509

6 1701529

7 1703811

8 1703814

9 1704277

10 1704412

11 - -

12 - -

13 3251243

14 - -

15 1705337

16 - -

17 - -

18 1703953


4-23

59 - -

60 - -

Item # ANSI1001120455-1

3121264 – JLG Lift –

39 - -

40 - -

41 - -

42 - -

43 - -

44 - -

45 - -

46 - -

47 - -

48 - -

49 - -

50 - -

51 - -

52 - -

53 - -

54 - -

55 - -

56 - -

57 - -

58 - -

Item # ANSI1001120455-1


4-2 3121264
4 – JLG Lift –
NOTES:

SECTION 5 - EMERGENCY PROCEDURES

5-1

ROCEDURES

ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINELL FUNCTIONS FIRST FROM THE GROUND CONTROLS,THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10OU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IFND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

ERGENCY OPERATION

Unable to Control Machine PLATFORM OPERATOR IS PINNED, TRAPPED OR

LE TO OPERATE OR CONTROL MACHINE:

ther personnel should operate the machine from ound controls only as required.

ther qualified personnel on the platform may use the atform controls. DO NOT CONTINUE OPERATION IF ONTROLS DO NOT FUNCTION PROPERLY.

ranes, forklift trucks or other equipment can be used to move platform occupants and stabilize motion of the achine.

3121264 – JLG Lift –

SECTION 5. EMERGENCY P

5.1 GENERALThis section explains the steps to be taken in case of anemergency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any inci-dent involving a JLG product. Even if no injury or propertydamage is evident, the factory should be contacted by tele-phone and provided with all necessary details.

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

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving aJLG Industries product within 48 hours of such an occur-rence may void any warranty consideration on that particularmachine.

FOLLOWINGAND TEST ATHEN FROM FT.) UNTIL YREQUIRED, A

5.3 EM

OperatorIF THEUNAB

1. Ogr

2. OplC

3. Crem

SECTION 5 - EMERGENCY PROCEDURES

5-2 3121264

Pla

BoSys

GENCY TOWING PROCEDURES machine is prohibited, unless properly equipped.provisions for moving the machine have beend. For specific procedures, refer to Section 4.

– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged inoverhead structures or equipment, rescue platform occu-pants prior to freeing the machine.

om Movement Prevented By Boom Control temLowering the boom onto an object or structure, with theboom at high angles, may cause the boom control system toprevent movement of the machine. This can include move-ment necessary to lift the boom off the object. Movement ofthe boom can be regained by observing the following:

1. Shut off the engine.

2. Rescue platform occupants prior to freeing machine.

3. Use cranes, forklifts or other equipment to stabilize motion of the machine as required.

4. From the ground control position, use the Auxiliary Power System to carefully raise the boom off the object.

5. Once clear, restart the engine and return the platform to the ground.

6. Inspect the machine for damage before continued use of the machine.

5.4 EMERTowing thisHowever, incorporate

FICATIONS & OPERATOR MAINTENANCE

6-1

OPERATOR MAINTENANCE

ERATING SPECIFICATIONS

Table 6-1. Operating Specifications

ork Load (Capacity)d 500 lb (230 kg)

1000 lb. (450 kg)

Platform Height (Unrestricted) 110 ft. (33.5 m)

Platform Height (Restricted) 110 ft. (33.5 m)

tal Platform Reach (Unrestricted) 76 ft. (23.1 m)

tal Platform Reach (Restricted) 68 ft. (20.7 m)

ind Speed 28 mph (12.5 m/s)

anual Force 100 lb (450 N)

Motiontion

8ft. (2.44m)180° working, 244° stowed130° (+75/-55)

SECTION 6 - GENERAL SPECI

3121264 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS &

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machine.

The maintenance portion of this section is intended as infor-mation to assist the machine operator to perform daily main-tenance tasks only, and does not replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual ............................ 3121265

Illustrated Parts Manual ............................................ 3121266

6.2 OP

Maximum W Unrestricte Restricted

Max.Vertical

Max.Vertical

Max.Horizon

Max.Horizon

Maximum W

Maximum M

JibPLUS Length Horizontal Vertical Mo

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121264

Dim

Ove A A

Sto

Sto

Sto

Wh

Tail

Gro

Gro

able 6-3. Chassis Specifications

rade With boom in radeability)

45%

rade With boom in ide Slope)

5°

Operating Slope 3°

les Retracted)22 ft. 6 in. (6.8 m)14 ft. 5 in. (4.4 m)

les Extended)8 ft. (2.4 m)

19 ft. 4 in. (5.9 m)

26,250 lbs. (11,907 kg)

g Pressure 105 psi (7.38 kg/cm2)

eed 3.25 mph (5.2 kph)

tem Pressure 4600 psi (317 Bar)

oltage 12 Volts

ight (Platform Empty) 44,750 lb. (20,298 kg)

– JLG Lift –

ensional Data Chassis

Table 6-2. Dimensional Data

rall Widthxles Retractedxles Extended

8ft. 2in. (2.49 m)12ft. 6in. (3.8 m)

wed Height 10ft. (3.04 m)

wed Length (Transport Mode) 38ft. 11in. (11.86 m)

wed Length (Working Mode) 48ft. 11in. (14.91 m)

eelbase 12ft. 6in. (3.81 m)

swing 5ft. 6 in. (1.6 m)

und Clearance (Axle) 12 in. (30.4 cm)

und Clearance (Chassis) 25.5 in. (64.7 cm)

T

Maximum Travel Gstowed position (G

Maximum Travel Gstowed position (S

Maximum Elevated

Turning Radius (Ax Outside Inside

Turning Radius (Ax Inside Outside

Max Tire Load

Max Ground Bearin

Maximum Drive Sp

Max. Hydraulic Sys

Electrical System V

Gross Machine We


6-3

ata able 6-6. Deutz TD2011L4 Specifications

Liquid Cooled

ylinders 4

3.7 in. (94 mm)

4.4 in. (112 mm)

ement 190 cu. in. (3108 cm³)

n Ratio 17.5

1-3-4-2

75hp (56 kW)

stem

city

5 Quarts (4.5 L) 11 Quarts (10.5 L) 16 Quarts (15 L)

Consumption 1.1 gph (4.1 lph)

PM 1200

PM 1800

RPM 2475


3121264 – JLG Lift –

Capacities

Tires

Engine DTable 6-4. Capacities

Hydraulic Tank 55 gallons (208 liters)

Fuel Tank 31 gallons (117 liters)

Hydraulic System 66 gallons (250 liters)

Table 6-5. Tire Specifications

Size 445/50D710

Load Range J

Ply Rating 18

Load Rating 26,500 lbs. @ 100 psi (12020 kg @ 6.9 Bar)

Foam Fill Poly urethane HD (55 Durometer) Foam

Max Tire Load 26,250 lbs. (11,907 kg)

T

Type

Number of C

Bore

Stroke

Total Displac

Compressio

Firing Order

Output

Oil Capacity Cooling Sy w/Filter Total Capa

Average Fuel

Idle Engine R

Mid Engine R

High Engine


6-4 3121264

Hy

NOT

NOT

AofrehyIn

Table 6-8. Mobilfluid 424 Specs

Grade 10W30

vity, API 29.0

Lb/Gal. 60°F 7.35

oint, Max -46°F (-43°C)

oint, Min. 442°F (228°C)

Viscosity

d, cP at -18°C 2700

40° C 55 cSt

100° C 9.3 cSt

sity Index 152

– JLG Lift –

draulic Oil

E: Hydraulic oils must have anti-wear qualities at least to APIService Classification GL-3, and sufficient chemical stabil-ity for mobile hydraulic system service. JLG Industriesrecommends Mobilfluid 424 hydraulic oil, which has anSAE viscosity index of 152.

E: When temperatures remain consistently below 20degrees F. (-7 degrees C.), JLG Industries recommendsthe use of Mobil DTE13.

side from JLG recommendations, it is not advisable to mix oils different brands or types, as they may not contain the samequired additives or be of comparable viscosities. If use ofdraulic oil other than Mobilfluid 424 is desired, contact JLGdustries for proper recommendations.

Table 6-7. Hydraulic Oil Specifications

Hydraulic System OperatingTemperature Range

S.A.E. ViscosityGrade

+0° to + 180° F(-18° to +83° C)

10W

+0° to + 210° F(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F(+10° to +99° C

20W-20

SAE

Gra

Density,

Pour P

Flash P

Brookfiel

at

at

Visco


6-5

Table 6-10. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

Specific Gravity 1.082

Pour Point, Max -58°F (-50°C)

pH 9.1

Viscosity

at 0° C (32° F) 340 cSt (1600SUS)

t 40° C (104° F) 46 cSt (215SUS)

t 65° C (150° F) 22 cSt (106SUS)

Viscosity Index 170


3121264 – JLG Lift –

Table 6-9. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40°F (-40°C)

Flash Point, Min. 330°F (166°C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

a

a


6-6 3121264

le 6-12. Exxon Univis HVI 26 Specs

ic Gravity 32.1

r Point -76°F (-60°C)

h Point 217°F (103°C)

Viscosity

40° C 25.8 cSt

00° C 9.3 cSt

sity Index 376

il/Exxon recommends that this oil be checked yearly basis for viscosity.

– JLG Lift –

Table 6-11. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

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

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

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

Tab

Specif

Pou

Flas

at

at 1

Visco

NOTE: Mobon a


6-7


3121264 – JLG Lift –

Major Component Weights

Table 6-13. Component Weights

Component Pounds Kilograms

Tire & Wheel 867 393

Drive Hub & Motor 275.5 123

Swing Drive 290 132

Engine Assembly 1275 579

Boom (Complete) 11850 5375

Lift Cylinder 787 357

Tele Cylinder 1322 600

Jib Cylinder 69 31

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 8500 3856

T/T Assy. (less Cwt) 9450 4286


6-8 3121264

-40° F(-40° C)

-30° F(-34° C)

-20° F(-29° C)

-10° F(-23° C)

0° F(-18° C)

10° F(-12° C)

20° F(-7° C)

30° F(-1° C)

40° F(4° C)

50° F(10° C)

60° F(16° C)

70° F(21° C)

80° F(27° C)

90° F(32° C)

100° F(38° C)

110° F(43° C)

120° F(49° C)

WA

G

AMBIENT AIRTEMPERATURE

- Deutz - Sheet 1 of 2

– JLG Lift –

ENGINESPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATUREITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERYND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHERPACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR

LOW PLUGS, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

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

FULLY CHARGED BATTERY.

SUMMERGRADEFUEL

WINTERGRADEFUEL

WINTERGRADEFUELWITH

KEROSENEADDED

NO OPERATION BELOW THISAMBIENT TEMPERATURE

NO OPERATION ABOVE THISAMBIENT TEMPERATURE

Figure 6-1. Engine Operating Temperature Specifications


6-9

TH CONDITIONS RECOMMENDS

F A HYDRAULICULT JLG SERVICE

RATION INPERATURESR ABOVE.

G WITHNKF 180°F

M E 424 ATURE

R

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

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

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 10 20 30 40 50 60

% OF ADDED KEROSENE

AMBI

ENT T

EMPE

RATU

RE

SUMMER-GRADEFUEL

WINTER-GRADEFUEL

ions - Deutz - Sheet 2 of 24150548-D


3121264 – JLG Lift –

(HYD. OIL TANK TEMP.) IF EITHER OR BOEXIST JLG HIGHLYTHE ADDITION O

OIL COOLER (CONS

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIRTEMPERATURE

PROLONGED OPEAMBIENT AIR TEMOF 100°F(38°C) O

EXTENDED DRIVINHYDRAULIC OIL TATEMPERATURES O(82°C) OR ABOVE.

NO OPERATION BELOW THISAMBIENT TEMPERATURE

MO

BIL

424

10W

-30

HYDRAULICSPECIFICATIONS

NO OPERATION ABOVE THISAMBIENT TEMPERATURE

DO NOT START UP HYDRAULIC SYSTEWITHOUT HEATING AIDS WITH MOBILHYDRAULIC OIL BELOW THIS TEMPER

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

EXXO

N U

NIV

IS H

VI 2

6

MO

BIL

DTE

13

Figure 6-2. Engine Operating Temperature Specificat


6-1 3121264

oint Location

0 – JLG Lift –

Figure 6-3. Lubrication and Maintenance P


6-11

recommended as a good practice to replace all filtersthe same time.

ing Bearing - Remote Lube

e Point(s) - 2 Grease Fittingacity - A/Re - MPGrval - Every 3 months or 150 hours of operation


3121264 – JLG Lift –

6.3 OPERATOR MAINTENANCENOTE: The following numbers correspond to those in Figure 6-

3., Lubrication and Maintenance Point Location.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATIONUNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFTOPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON-DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD-INGLY.

NOTE: It isat

1. Sw

LubCapLubInte

Table 6-14. Lubrication Specifications

KEY SPECIFICATIONS

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

EPGL Extreme Pressure Gear Lube (oil) meeting API service classifica-tion GL-5 or MIL-Spec MIL-L-2105

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

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.


6-1 3121264

Brake

int(s) - Fill Plug - 2.7 ounces (80 ml)TE24 Check level every 150 hrs/Change every 1200 of operation.

2 – JLG Lift –

2. Swing Gearbox

Lube Point(s) - Fill PlugCapacity - 79 ounces (2.3 L)Lube - GL-5Interval - Check level every 150 hrs/Change every 1200 hours of operation. Fill to cover ring gear.

3. Swing

Lube PoCapacityLube - DInterval - hours


6-13

el Drive Hub - Reggiana Riduttori

e Point(s) - Level/Fill Plugacity - 0.5 quarts (0.5 liters) ± 10%e - EPGLrval - Change after first 150 hours then every 1200hours of operation

ments - Place Fill port at 12 o’clock position andCheck port at 3 o’clock position. Pour lubricant into fillport until it just starts to flow out of check port.


3121264 – JLG Lift –

4. Wheel Drive Hub - Bonfiglioli

Lube Point(s) - Level/Fill PlugCapacity - 2.1 quarts (2 liters) ± 10%Lube - EPGLInterval - Change after first 150 hours then every 1200

hours of operationComments - Place Fill port at 12 o’clock position and

Check port at 8 o’clock position. Pour lubricant into fillport until it just starts to flow out of check port.

Whe

LubCapLubInte

Com


6-1 3121264

ulic Oil

int(s) - Fill Cap - 55 gallons (208 liters) TankO Check level daily. Change every 2 years or 1200 of operation.

FULL LEVEL (HOT OIL)

FULL LEVEL (COLD OIL)

4 – JLG Lift –

5. Hydraulic Return Filter

Lube Point(s) - Replaceable ElementInterval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator

6. Hydraulic Charge Filter

Lube Point(s) - Replaceable ElementInterval - Change after first 50 hours and every 300 hours thereafter or as indicated by condition indicator.

7. Hydra

Lube PoCapacityLube - HInterval - hours


6-15

il Change w/Filter - Deutz

e Point(s) - Fill Cap/Spin-on Elementacity - Quarts (4.5 L) Cooling System1 Quarts (10.5 L) w/Filter6 Quarts (15 L) Total Capacitye - EOrval - Check level daily; change every 500 hours or sixonths, whichever comes first. Adjust final oil level byark on dipstick.


3121264 – JLG Lift –

8. Suction Strainers (In Tank)

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

9. O

LubCap 5 1 1LubInte

mm


6-1 3121264

trainer

int(s) - Replaceable Element Every year or 600 hours of operation

6 – JLG Lift –

10. Fuel Filter - Deutz

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

11. Fuel S

Lube PoInterval -


6-17

atform Filter

e Point(s) - Replaceable Elementrval - Change after first 50 hours and then every yearor 600 hours of operation thereafter


3121264 – JLG Lift –

12. Air Filter - Deutz

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

13. Pl

LubInte


6-1 3121264

6.4

Tir

Tir

FanarJLm

Fmmattir

damage to the bead area cords of the tire

aged but is within the above noted criteria, the tirected on a daily basis to insure the damage hasd beyond the allowable criteria.

ment

nds a replacement tire be the same size, ply andnally installed on the machine. Please refer to theual for the part number of the approved tires for ahine model. If not using a JLG approved replace-ecommend that replacement tires have the follow-stics:

l or greater ply/load rating and size of original

tread contact width equal or greater than original

el diameter, width, and offset dimensions equal toriginal

oved for the application by the tire manufactureruding inflation pressure and maximum tire load)

ically approved by JLG Industries Inc. do not filled or ballast filled tire assembly with a pneu-en selecting and installing a replacement tire,

l tires are inflated to the pressure recommended

8 – JLG Lift –

TIRES & WHEELS

e InflationThe air pressure for pneumatic tires must be equal to the airpressure that is stenciled on the side of the JLG product orrim decal for safe and proper operational characteristics.

e Damage

or pneumatic tires, JLG Industries, Inc. recommends that wheny cut, rip, or tear is discovered that exposes sidewall or treadea cords in the tire, measures must be taken to remove theG product from service immediately. Arrangements must beade for replacement of the tire or tire assembly.

or polyurethane foam filled tires, JLG Industries, Inc. recom-ends that when any of the following are discovered, measuresust be taken to remove the JLG product from service immedi-ely and arrangements must be made for replacement of thee or tire assembly.

• a smooth, even cut through the cord plies whichexceeds 3 inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plieswhich exceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

• any

If a tire is dammust be inspenot propagate

Tire Replace

JLG recommebrand as origiJLG Parts Manparticular macment tire, we ring characteri

• Equa

• Tire

• Whethe o

• Appr(incl

Unless specifreplace a foammatic tire. Whensure that al


6-19

h, then immediately have a service garage or dealere lug nuts to the proper torque. Over-tightening willbreaking the studs or permanently deforming the stud holes in the wheels. The proper procedure for wheels is as follows:

art all nuts by hand to prevent cross threading. DO OT use a lubricant on threads or nuts.

ghten nuts in the following sequence:


3121264 – JLG Lift –

by JLG. Due to size variations between tire brands, both tireson the same axle should be the same.

Wheel Replacement

The rims installed on each product model have been designedfor stability requirements which consist of track width, tire pres-sure, and load capacity. Size changes such as rim width, centerpiece location, larger or smaller diameter, etc., without writtenfactory recommendations, may result in an unsafe conditionregarding stability.

Wheel InstallationIt is extremely important to apply and maintain proper wheelmounting torque.

WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPERTORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI-BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURETO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THEWHEEL.

Tighten the lug nuts to the proper torque to prevent wheels fromcoming loose. Use a torque wrench to tighten the fasteners. Ifyou do not have a torque wrench, tighten the fasteners with a

lug wrenctighten thresult in mountingattaching

1. StN

2. Ti


6-2 3121264

EMENTAL INFORMATIONng information is provided in accordance with thets of the European Machinery Directive 2006/42/nly applicable to CE machines.

powered machines, the equivalent continuous A-ound pressure level at the work platform is lessA)

ustion engine powered machines, guaranteeder Level (LWA) per European Directive 2000/14/

Emission in the Environment by Equipment forors) based on test methods in accordance withart B, Method 1 and 0 of the directive, is 106 dB.

ion total value to which the hand-arm system isdoes not exceed 2,5 m/s2. The highest root meanue of weighted acceleration to which the wholejected does not exceed 0,5 m/s2.

0 – JLG Lift –

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

4. Wheel nuts should be torqued before first road use and after each wheel removal. Check and torque every 3 months or 150 hours of operation.

6.5 SUPPLThe followirequiremenEC and is o

For electricWeighted sthan 70dB(

For combSound PowEC (NoiseUse OutdoAnnex III, P

The vibratsubjected square valbody is sub

Table 6-15. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

45 ft. lbs.(60 Nm)

100 ft. lbs.(140 Nm)

180 ft. lbs.(252 Nm)

TION 7 - INSPECTION AND REPAIR LOG

7-1

D REPAIR LOG

ir Log

nts

SEC

3121264 – JLG Lift –

SECTION 7. INSPECTION ANMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121264

g

– JLG Lift –

Table 7-1. Inspection and Repair Lo

Date Comments

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Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

(717) 485-5161

(717) 485-6417

JLG Worldwide LocationsJLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia

+61 2 65 811111

+61 2 65 810122

JLG Latino Americana Ltda.Rua Eng. Carlos Stevenson,80-Suite 7113092-310 Campinas-SPBrazil

+55 19 3295 0407

+55 19 3295 1025

JLG Industries (UK) LtdBentley HouseBentley AvenueMiddletonGreater ManchesterM24 2GP - England

+44 (0)161 654 1000

+44 (0)161 654 1001

JLG France SASZ.I. de Baulieu47400 FauilletFrance

+33 (0)5 53 88 31 70

+33 (0)5 53 88 31 79

JLG Deutschland GmbHMax-Planck-Str. 21D - 27721 Ritterhude - IhlpohlGermany

+49 (0)421 69 350 20

+49 (0)421 69 350 45

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

(852) 2639 5783

(852) 2639 5797

JLG Industries (Italia) s.r.l.Via Po. 2220010 Pregnana Milanese - MIItaly

+39 029 359 5210

+39 029 359 5845

Oshkosh-JLG Singapore Technology Equipment Pte Ltd29 Tuas Ave 4,Jurong Industrial EstateSingapore, 639379

+65-6591 9030

+65-6591 9031

JLG PolskaUI. Krolewska00-060 WarsawaPoland

+48 (0)914 320 245

+48 (0)914 358 200

JLG Industries (Scotland)Wright Business Centre1 Lonmay RoadQueenslie, Glasgow G33 4ELScotland

+44 (0)141 781 6700

+44 (0)141 773 1907

Plataformas Elevadoras JLG Iberica, S.L.Trapadella, 2P.I. Castellbisbal Sur08755 Castellbisbal, BarcelonaSpain

+34 93 772 4700

+34 93 771 1762

JLG Sverige ABEnkopingsvagen 150Box 704SE - 176 27 JarfallaSweden

+46 (0)850 659 500

+46 (0)850 659 534

www.jlg.com

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Documents

Operation and Safety Manual - JLG Industries Boom Lifts/1100SB... · Operation and Safety Manual ANSI Original Instructions - Keep this manual with the machine at all times. Boom