Operation and Safety Manual

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

Boom Lift Models

450A
450AJ
S/N 0300201991,
S/N 1300007279,
S/N E300002833,
& S/N B300003516
to Present

ANSI ® AS/NZS 3121658

December 14, 2018 - Rev K
 WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
 FOREWORD

FOREWORD

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

3121658 a
 FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
GROUND. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

IMPORTANT
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
GROUND.

b 3121658
 FOREWORD

For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- Compliance Information
• Product Safety Publica-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions • Questions Regarding Special
THIS PRODUCT.
Product Applications
• Current Owner Updates
• Questions Regarding Prod-
IMPORTANT • Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
Contact:
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
Product Safety and Reliability Department
JLG Industries, Inc.
IMPORTANT 13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE Hagerstown, MD 21742
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY USA
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-
or Your Local JLG Office
SONAL PROPERTY OR THE JLG PRODUCT.
(See addresses on rear cover)

In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com

3121658 c
FOREWORD

REVISION LOG

Original Issue A - February 2, 2015

Revised B - April 2, 2015
Revised C - July 6, 2015
Revised D- January 19, 2016
Revised E - July 19, 2016
Revised F - January 23, 2017
Revised G - June 30, 2017
Revised H - September 20, 2017
Revised I - June 29, 2018 - Revised Covers, Prop 65
Revised J - November 5, 2018
Revised K - December 14, 2018

d 3121658
 TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.3 OSCILLATING AXLE LOCKOUT TEST . . . . . . . . . . . . . . . . . . 2-10
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-8
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Ground Control Console Display Gauge . . . . . . . . . . 3-12
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-20
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11 SECTION - 4 - MACHINE OPERATION
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.2 BOOM OPERATING CHARACTERISTICS AND
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
AND INSPECTION 4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-5
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

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

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 SECTION - 5 - EMERGENCY PROCEDURES
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-11 5.4 MANUAL SWING OVERRIDE . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12 5.5 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-3
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12 5.6 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-12 (CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 SECTION - 6 - ACCESSORIES
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
6.1 FALL ARREST PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
6.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Capacity Specifications (Australia Only) . . . . . . . . . . . . 6-4
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Shut Down and Park. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
6.3 SKYGLAZIER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

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

6.4 SKYPOWER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Wheel and Tire Replacement. . . . . . . . . . . . . . . . . . . . . 7-35
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35
6.5 SKYWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 7.5 PROPANE FUEL FILTER REPLACEMENT (GM ENGINE). . 7-37
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Welding Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 7.6 PROPANE FUEL FILTER REPLACEMENT (KUBOTA
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-38
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39
6.6 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 7.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-40
7.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-40
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTE-
NANCE SECTION - 8 - INSPECTION AND REPAIR LOG
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS AND PERFORMANCE
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

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iv 3121658
 LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 7-3. Engine Operating Temperature Specifications - GM - Sheet
3-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 1 of 27-11
3-2. Ground Control Console with MSSO (CE Only) . . . . . . . . 3-4 7-4. Engine Operating Temperature Specifications - GM - Sheet
3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-9 2 of 27-12
3-4. Ground Control Indicator Panel - Kubota Engine . . . . . 3-10 7-5. Engine Operating Temperature Specifications - Deutz
3-5. Splash Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12 2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
3-6. Diagnostic Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 7-6. Hydraulic Oil Operation Chart - Sheet 1 of 2. . . . . . . . . . 7-14
3-7. Engine Diagnostic Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13 7-7. Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . 7-15
3-8. Ground Control Console Display Gauge . . . . . . . . . . . . . 3-14 7-8. Engine Oil Operation Chart - Kubota. . . . . . . . . . . . . . . . . 7-16
3-9. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16 7-9. Operator Maintenance and Lubrication Diagram - Deutz
3-10. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-21 2.3L Engine7-17
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-6 7-10. Operator Maintenance and Lubrication Diagram - GM . . .
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-7 Engine7-18
4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 7-11. Operator Maintenance and Lubrication Diagram - Deutz
4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 2.9L Engine7-19
4-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 7-12. Operator Maintenance and Lubrication Diagram - Kubota
4-6. Decal Location Sheet 1 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 Engine7-20
4-7. Decal Location Sheet 2 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 7-13. GM Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37
4-8. Decal Location Sheet 3 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 7-14. Kubota Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . 7-39
4-9. Decal Location Sheet 4 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-10. Decal Location Sheet 5 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-11. Decal Location Sheet 6 of 6. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
7-1. Engine Operating Temperature Specifications - Deutz 2.3L
- Sheet 1 of 27-9
7-2. Engine Operating Temperature Specifications - Deutz 2.3L
- Sheet 2 of 27-10

3121658 v
 LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

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vi 3121658
 LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Decal Legend - Language Markets . . . . . . . . . . . . . . . . . . .4-23
4-2 Decal Legend - Kubota Engine-Powered Machines . . .4-26
6-1 Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Options/Accessories Relationship Table. . . . . . . . . . . . . . . 6-2
7-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Deutz D2011L03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-6 Deutz D2.9L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-8 Kubota WG 2503 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 DTE 10 Excel 15 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-12 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-15 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-16 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
7-17 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-36
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

3121658 vii
 LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

This Page Left Blank Intentionally

viii 3121658
 SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

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

3121658 1-1
 SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until Workplace Inspection

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

1-2 3121658
 SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection 1.3 OPERATION

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

3121658 1-3
 SECTION 1 - SAFETY PRECAUTIONS

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

1-4 3121658
 SECTION 1 - SAFETY PRECAUTIONS

• Before operating the machine, make sure all gates are closed Electrocution Hazards
and fastened in their proper position.
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.

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

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

3121658 1-5
 SECTION 1 - SAFETY PRECAUTIONS

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

Voltage Range MINIMUM APPROACH DISTANCE

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

1-6 3121658
 SECTION 1 - SAFETY PRECAUTIONS

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

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

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

ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-
ERWISE.

• Do not elevate platform or drive with platform elevated while

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

3121658 1-7
 SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions, including
platform. Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind
unless authorized by JLG. speed are; platform elevation, surrounding structures, local
weather events, and approaching storms. Refer to Table 1-2,
• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
Beaufort scale (For Reference Only) or use other means to
from holes, bumps, drop-offs, obstructions, debris, concealed
monitor wind conditions.
holes, and other potential hazards at the ground level.
• Wind speed can be significantly greater at height than at
• Do not push or pull any object with the boom.
ground level.
• Never attempt to use the machine as a crane. Do not tie-off
• Wind speed can change rapidly. Always consider approaching
machine to any adjacent structure. Never attach wire, cable, or
weather events, the time required to lower the platform, and
any similar items to platform.
methods to monitor current and potential wind conditions.
• If boom assembly or platform is in a position that one or more
• Do not increase surface area of the platform or the load.
wheels are off the ground, all persons must be removed before
Increased areas exposed to wind will decrease stability.
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine. • Do not increase the platform size with unauthorized modifica-
tions or attachments.

1-8 3121658
 SECTION 1 - SAFETY PRECAUTIONS

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

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

Beaufort Wind Speed

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

3121658 1-9
 SECTION 1 - SAFETY PRECAUTIONS

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

1-10 3121658
 SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

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

3121658 1-11
 SECTION 1 - SAFETY PRECAUTIONS

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

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

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

1-12 3121658
 SECTION 1 - SAFETY PRECAUTIONS

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

3121658 1-13
 SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 3121658
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

3121658 2-1
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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

2-2 3121658
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

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

3121658 2-3
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

 


1. Platform
 2. SkyGuard (If Equipped)
3. Cross Rail (If Equipped)

4. Platform Console
 5. Jib (If Equipped)
  6. Fly Boom Section
 7. Base Boom Section
8. Powertrack
9. Main Lift Cylinder
 10. Master Cylinder
 11. Upper Upright
OR 12. Lower Upright
13. Tower Lift Cylinder

 14. Tower Boom

15. Turntable
16. Front Drive/Steer Wheels
17. Rear Drive Wheels

18. Frame

0"$

Figure 2-1. Basic Nomenclature

2-4 3121658
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection 5. Daily Walk-Around Inspection – Perform as instructed.

The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required.

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7. Fuel (Combustion Engine Powered Machines) – Add the
tery fluid) or foreign objects. Report any leakage to the proper fuel as necessary.
proper maintenance personnel. 8. Engine Oil Supply – Ensure the engine oil level is at the Full
2. Structure – Inspect the machine structure for dents, dam- mark on the dipstick and the filler cap is secure.
age, weld or parent metal cracks or other discrepancies. 9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
10. Accessories/Attachments – Refer to the Accessories section
in this manual or the accessory installed upon the machine
for specific inspection, operation, and maintenance instruc-
tions.
11. Function Check – Once the “Walk-Around” Inspection is
Parent Metal Crack Weld Crack complete, perform a functional check of all systems in an
area free of overhead and ground level obstructions. Refer to
3. Decals and Placards – Check all for cleanliness and legibil- Section 4 for more specific operating instructions.
ity. Make sure none of the decals and placards are missing.
Make sure all illegible decals and placards are cleaned or
replaced.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
4. Operation and Safety Manuals – Make sure a copy of the ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
Operation and Safety Manual, AEM Safety Manual (ANSI OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
markets only), and ANSI Manual of Responsibilities (ANSI
markets only) is enclosed in the weather resistant storage
container.

3121658 2-5
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Daily Walk-Around Inspection

 
 

 





   




 




0"%


  

 


2-6 3121658
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Begin the "Walk-Around Inspection" at Item 1, as noted on the 6. Drive Motor, Brake, and Hub - No evidence of leakage.
diagram. Continue checking each item in sequence for the condi-
7. Hood Assemblies - See Inspection Note.
tions listed in the following checklist.
8. All Hydraulic Cylinders - No visible damage; pivot pins and
hydraulic hoses undamaged, not leaking.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF. 9. Turntable Bearing - Evidence of proper lubrication. No evi-
dence of loose bolts or looseness between bearing and
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
machine.
INSPECTION NOTE: On all components, make sure there are no 10. Tie Rod Ends and Steering Spindles - See Inspection Note.
loose or missing parts, that they are securely fastened, and no visible
damage, leaks or excessive wear exists in addition to any other crite- 11. Hydraulic Pump - See Inspection Note.
ria mentioned. 12. Fuel Tank - See Inspection Note.
1. Platform Assembly and Gate - Footswitch works properly, 13. Hydraulic Reservoir - See Inspection Note.
not modified, disabled or blocked. Latch and hinges in work-
ing condition. 14. Battery - Batteries have proper electrolyte level; cables
tight; see Inspection Note.
2. Platform & Ground Control Consoles - Switches and levers
return to neutral, decals/placards secure and legible, control 15. Platform Rotator - See Inspection Note.
markings legible. 16. SkyGuard (If Equipped) - See Inspection Note.
3. Boom Sections/Uprights/Turntable - See Inspection Note.
4. Swing Motor and Worm Gear - No evidence of damage.
5. Wheel/Tire Assemblies - Properly secured, no missing lug
nuts. Inspect for worn tread, cuts, tears or other discrepan-
cies. Inspect wheels for damage and corrosion.

3121658 2-7
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check 3. With the platform in the stowed position:

Perform the Function Check as follows: a. Drive the machine on a grade, not to exceed the rated
gradeability, and stop to ensure the brakes hold;
1. From the ground control console with no load in the plat- b. Check that the tilt indicator is illuminated to ensure
form: proper operation.
a. Check that all guards protecting the switches or locks 4. Swing the boom over either of the rear tires and ensure that
are in place; the Drive Orientation indicator illuminates and that the
b. Operate all functions and ensure proper operation; Drive Orientation Override switch must be used for the drive
c. Check auxiliary power and ensure proper operation; function to operate.
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure all boom functions stop when the function
enable switch is released.
2. From the platform control console:
a. Ensure that the control console is firmly secured in the
proper location;
b. Check that all guards protecting the switches or locks
are in place;
c. Operate all functions and ensure proper operation;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.
e. Ensure that all machine functions stop when the foot-
switch is released.

2-8 3121658
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test 4. Disengage the SkyGuard sensor, release controls, then recy-
cle the footswitch. Ensure normal operation is available.
NOTE: Refer to Section 4.10 for additional information on SkyGuard
NOTE: On machines equipped with SkyLine, reattach magnetic end of
operation.
the cable to the bracket.
From the Platform Console in an area free from obstructions:
If SkyGuard remains activated after function reversal or cutout,
1. Operate the telescope out function. depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the sensor is disengaged.
2. Activate the SkyGuard sensor:
a. SkyGuard - Apply approximately 50 lb (222 Nm) of
force to yellow bar.
b. SkyGuard - SkyLine - Press cable to break magnetic
connection between the cable and right bracket.
c. SkyGuard - SkyEye - Put arm or hand in path of sensor
beam.
3. Once the sensor has been activated, verify the following
conditions:
a. Telescope out function stops and telescope in function
operates for a short duration.
b. The horn sounds.
c. If equipped with a SkyGuard beacon, the beacon illumi-
nates.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 OSCILLATING AXLE LOCKOUT TEST 5. Place Drive control lever to Reverse and drive machine off of
block and ramp.
6. Have an assistant check to see that left front or right rear
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- wheel remains elevated in position off of ground.
PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. 7. Carefully return boom to stowed position (centered
between rear wheels if swung or fully lowered if raised).
NOTE: Ensure boom is fully retracted, lowered, and centered between When boom reaches stowed position, lockout cylinders
rear wheels prior to beginning lockout cylinder test. should release and allow wheel to rest on ground, it may be
necessary to activate Drive to release cylinders.
1. Place a 6 inches (15.2 cm) high block with ascension ramp in
front of left front wheel. 8. Place the 6 inches (15.2 cm) high block with ascension ramp
in front of right front wheel.
2. From platform control console, start engine.
9. Place Drive control lever to Forward and carefully drive
3. Place the Drive control lever to the forward position and machine up ascension ramp until right front wheel is on top
carefully drive machine up ascension ramp until left front of block.
wheel is on top of block.
10. Repeat steps 4 thru 7 to check the opposite side of the oscil-
4. Carefully activate Swing control lever and position boom lating axle.
over right side of machine or raise the main boom enough
to get it out of the transport position. 11. If lockout cylinders do not function properly, have qualified
personnel correct the malfunction prior to any further oper-
ation.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL NOTE: The indicator panels use different shaped symbols to alert the
operator to different types of operational situations that could
arise. The meaning of those symbols are explained below.
Indicates a potentially hazardous situation, which if
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.
OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH This indicator will be red.
GOOD SAFETY PRACTICES.
Indicates an abnormal operating condition, which if
This section provides the necessary information needed to not corrected, may result in machine interruption or
understand control functions. damage. This indicator will be yellow.

3.2 CONTROLS AND INDICATORS Indicates important information regarding the operat-
ing condition, i.e. procedures essential for safe opera-
NOTE: All machines are equipped with control consoles that use sym-
tion. This indicator will be green with the exception of
bols to indicate control functions. On ANSI machines refer to the capacity indicator which will be green or yellow
decal located on the control box guard in front of the control box depending upon platform position.
or by the ground controls for these symbols and the correspond-
ing functions.

3121658 3-1
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Display Gauge

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Registers the amount of time the machine
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE has been in use, with engine running. The
OFF POSITION WHEN RELEASED. hourmeter registers up to 16,500 hours and
cannot be reset.
Ground Control Console
(See Figure 3-1., Ground Control Console and Figure 3-2., Ground Con- WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE
trol Console with MSSO (CE Only).) POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.

1. Indicator Panel 3. Power/Emergency Stop Switch

The Indicator Panel contains indicator lights that signal A two-position red mushroom shaped switch
problem conditions or functions operating during machine supplies power to PLATFORM/GROUND
operation. SELECT switch when pulled out (on). When
NOTE: The Function Enable switch must be held down in pushed in (off ), power is shut off to the PLATFORM/GROUND
order to operate Main Boom Telescope, Tower Lift, SELECT switch.
Swing, Main Lift, Jib Lift, Platform Level Override,
and Platform Rotate functions.

3-2 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8
7
6
5
4
1. Indicator Panel
3 9 2. Display Gauge
3. Power/Emergency Stop
4. Platform/Ground Select
5. Platform Level
2 10 6. Platform Rotate
7. Jib Lift (If Equipped)
8. Telescope
9. Main Boom Lift
1 10. Tower Boom Lift
11. Swing
12. Engine Start/Auxiliary Power/
Function Enable

11

12

Figure 3-1. Ground Control Console

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8
7
6
5
4
1. Indicator Panel
3 9 2. Display Gauge
3. Power/Emergency Stop
4. Platform/Ground Select
5. Platform Level
2 10 6. Platform Rotate
7. Jib Lift (If Equipped)
8. Telescope
9. Main Boom Lift
1 10. Tower Boom Lift
11. Swing
12. Engine Start/Auxiliary Power/
Function Enable
13. Machine Safety System Override (MSSO)

11

13 12

Figure 3-2. Ground Control Console with MSSO (CE Only)

3-4 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When the Platform/Ground Select Switch is in the center posi-

tion, power is shut off to the controls at both operating consoles.
Remove the key to prevent the controls from being actuated. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
4. Platform/Ground Select Switch FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

The three position, key operated switch sup- 5. Platform Leveling Override
plies power to the platform control console
when positioned to PLATFORM. With the A three position switch allows the
switch key turned to the GROUND position operator to adjust the automatic self
only ground controls are operable. leveling system. This switch is used to
adjust platform level in situations
such as ascending/descending a
grade.
6. Platform Rotate

Provides rotation of the platform.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

7. Jib Lift (If Equipped) 9. Main Boom Lift

Provides raising and lowering of the Provides raising/lowering of the main

jib. boom when positioning up or down.

10. Tower Boom Lift

Provides raising and lowering of the

8. Telescope Control tower boom.

Provides extension and retraction of

the boom.

11. Swing

Provides 355 degrees non-continuous

turntable rotation.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

12. Engine Start/ Auxiliary Power /Function Enable 13. Machine Safety System Override (MSSO) (CE
Only)
To start the engine, the switch must be held
"UP" until the engine starts.
Provides override of function controls that
To use auxiliary power, the switch must be are locked out such as in the event of Load
held “DOWN” for duration of function use. Sense System activation.
When the engine is running, the switch must
be held "DOWN" to enable all boom controls.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel 5. Engine Malfunction/Check Engine Indicator

Indicates that engine oil pressure is below nor-

(See Figure 3-3., Ground Control Indicator Panel)
mal or engine coolant temperature is abnor-
1. Battery Malfunction Indicator mally high and service is required.
6. Low Fuel Level Indicator
Indicates a problem in the battery or charging
circuit, and service is required. Indicates the fuel level is low. The Fuel
2. Low Engine Oil Pressure Indicator Reserve/Cut-Out System will shut the engine
down (or allow it start and run for an addi-
Indicates that engine oil pressure is below nor- tional minute, depending upon machine setup) before the
mal and service is required. fuel tank is emptied.

3. High Engine Temperature Indicator 7. Glow Plug Indicator

Indicates that engine coolant temperature is Indicates the glow plugs are operating. After
abnormally high and service is required. turning on ignition, wait until light goes out
before cranking engine.
4. Engine Oil Temperature Indicator (Deutz)

Indicates that the temperature of the engine

oil, which also serves as engine coolant, is
abnormally high and service is required.

3-8 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1 2 3 4 5 6

1. Battery Malfunction
2. Low Engine Oil Pressure
3. High Engine Coolant Temperature
4. Engine Oil Temperature
5. Engine Malfunction/Check Engine
6. Low Fuel
7. Glow Plug
8. Platform Overload (If Equipped)
9. Drive and Steer Disable (If Equipped)

9 8 7

Figure 3-3. Ground Control Indicator Panel

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1 5 10 6

1. Battery Malfunction
2. Not Used
3. Not Used
4. Not Used
5. Engine Malfunction/Check Engine
6. Low Fuel
7. Glow Plug
8. Platform Overload (If Equipped)
9. Drive and Steer Disable (If Equipped)
10. System Distress
9 8 7

Figure 3-4. Ground Control Indicator Panel - Kubota Engine

3-10 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform Overload Indicator (If Equipped) 10. System Distress Indicator

Indicates the platform has been overloaded. The light indicates that the JLG Control System
has detected an abnormal condition and a
Diagnostic Trouble Code has been set in the
9. Drive and Steer Disable Indicator (If Equipped)
system memory. Refer to the Service Manual for instructions
concerning the trouble codes and trouble code retrieval.
Indicates the Drive and Steer Disable function
has been activated.
The system distress indicator light will illuminate for 2-3 sec-
onds when the key is positioned to the on position to act as
a self test.

3121658 3-11
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Console Display Gauge

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

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

Figure 3-5. Splash Screen

3-12 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter
the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count
played to show active faults. information. Engine SPN text is not scrollable. If there is more
than one engine trouble code, the operator must exit from the
Engine DTC Screen to see other SPN and FMI information.

Figure 3-6. Diagnostic Screen

Figure 3-7. Engine Diagnostic Screen

3121658 3-13
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

INDICATOR LAMP

ENGINE HOURS

NAVIGATE BACK ARROW NAVIGATE FORWARD ARROW

NAVIGATION BUTTONS

Figure 3-8. Ground Control Console Display Gauge

3-14 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Console
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
(See Figure 3-9., Platform Control Console)
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR 2. Platform Leveling Override
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
OFF OR NEUTRAL POSITION WHEN RELEASED. A three position switch allows the operator to
adjust the automatic self leveling system. This
1. Drive Speed Switch switch is used to adjust platform level in situa-
tions such as ascending/descending a grade.
The forward position gives maxi- 3. Fuel Select (Dual Fuel Engine Only) (If
mum drive speed. The back posi- Equipped)
tion gives maximum torque for
rough terrain and climbing Moving the switch to the appropriate position
grades. The center position selects gasoline or liquid propane fuel.
allows the machine to be driven
as quietly as possible. 4. Horn

A push-type HORN switch supplies electrical

power to an audible warning device when pressed.

3121658 3-15
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Drive Speed/Torque Select 6. Start/Auxiliary Power 10. Lights (If Equipped) 14. Tower Boom Lift
2. Platform Leveling Override 7. Drive Orientation Override 11. Jib Lift (If Equipped) 15. Platform Rotate
3. Fuel Select 8. Drive/Steer 12. Soft Touch/SkyGuard Override (If Equipped) 16. Function Speed Control
4. Horn 9. Telescope 13. Soft Touch/SkyGuard Indicator (If Equipped) 17. Main Lift/Swing Controller
5. Power/Emergency Stop
Figure 3-9. Platform Control Console

3-16 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Power/Emergency Stop Switch 7. Drive Orientation Override

A two-position red mushroom shaped switch When the boom is swung over the rear tires
furnishes power to PLATFORM Controls when or further in either direction, the Drive Orien-
pulled out (on). When pushed in (off ), power is tation indicator will illuminate when the drive
shut off to the platform functions. function is selected. Push and release the
switch, and within 3 seconds move the Drive/Steer control
6. Start/Auxiliary Power
to activate drive or steer. Before driving, locate the black/
white orientation arrows on both the chassis and the plat-
When pushed forward, the switch energizes
form controls. Move the drive controls in a direction match-
the starter motor to start the engine.
ing the directional arrows for the intended direction of
The Auxiliary Power control switch energizes travel.
the electrically operated hydraulic pump.
NOTE: To operate the Drive joystick, pull up on the lock-
(Switch must be held ON for duration of auxil-
ing ring below the handle.
iary pump use.)
The auxiliary pump functions to provide sufficient oil flow to NOTE: The Drive joystick is spring loaded and will auto-
operate the basic machine functions should the main pump matically return to neutral (off) position when
or engine fail. The auxiliary pump will operate tower boom released.
lift, tower telescope, main boom lift, main telescope and
swing.
8. Drive/Steer

Push forward to drive forward,

pull back to drive in reverse.
Steering is accomplished via a
thumb-activated rocker switch on
the end of the steer handle.

3121658 3-17
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Telescope If equipped with SkyGuard, the switch

enables functions cut out by the Sky-
Provides extension and retraction of the main guard system to be operated again,
boom. allowing the operator to resume use of
machine functions.
10. Lights (If Equipped) If equipped with both Soft Touch and
SkyGuard, the switch operates like
This switch operates the chassis lights if described above and allows the opera-
the machine is so equipped. tor to override the system that has
experienced a cutout situation.
11. Jib Lift (If Equipped)
13. Soft Touch/SkyGuard Indicator (If Equipped)
Provides for raising or lowering of the jib by
positioning up/down. Indicates the Soft Touch bumper is against an object or the
SkyGuard sensor has been activated. All controls are cut out
until the override button is pushed. For Soft Touch, controls
12. Soft Touch/SkyGuard Override Switch (If Equipped)
are then active in the Creep Mode or for SkyGuard, controls
will work normally.
The machine can be equipped with one of three options. It
may have Soft Touch, SkyGuard, or both Soft Touch and Sky-
When Soft Touch is active, the indicator will be on continu-
Guard.
ously and the alarm will sound. When SkyGuard is active, the
If equipped with Soft Touch, the switch indicator will flash, and the horn will sound continuously.
enables the functions that were cut out
by the Soft Touch system to operate
again at creep speed, allowing the
operator to move the platform away from the obstacle that
caused the shutdown situation.

3-18 3121658
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

14. Tower Boom Lift NOTE: To operate the Main Boom Lift/Swing joystick,
pull up on the locking ring below the handle.
Provides for raising and lowering of tower
boom when positioned up or down.
NOTE: The Main Boom Lift/Swing joystick is spring
loaded and will automatically return to neutral
15. Platform Rotate
(off) position when released.
Provides rotation of the platform when posi-
17. Main Lift/Swing Controller
tioned to the right or left.
Provides main lift and swing. Push for-
16. Function Speed Control ward to lift up, pull backward to boom
down. Move right to swing right, move
This control affects the speed of telescope, left to swing left. Moving the joystick
tower lift and jib lift. Turning the knob all activates switches to provide the func-
the way counterclockwise until it clicks puts tions selected.
drive, main lift and swing into creep mode.

3121658 3-19
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel 3. Tilt Alarm Warning Light and Alarm

This red illuminator indicates that the chassis is

(See Figure 3-10., Platform Control Indicator Panel)
on a slope. An alarm will also sound when the
NOTE: The indicator lights will illuminate for approximately 1 second chassis is on an excessive slope and the boom
when the key is positioned to the on position to act as a self test. is out of transport position. If lit when boom is out of trans-
port position, lower to below horizontal then reposition
1. AC Generator (If Equipped) machine so that it is level before continuing operation. If the
boom is above horizontal and the machine is on a slope, the
Indicates the generator is in operation. tilt alarm warning light will illuminate and an alarm will
sound and CREEP is automatically activated.

2. Platform Overload Indicator (If Equipped) Tilt Angle Market

Indicates the platform has been overloaded. 5° All Markets

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED,

RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT
IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. AC Generator (If Equipped)

2. Platform Overload (If Equipped)
3. Tilt
4. Glow Plug/Wait to Start
5. Enable/Footswitch
6. Fuel Level
7. Creep
8. System Distress
9. Drive Orientation

Figure 3-10. Platform Control Indicator Panel

3121658 3-21
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

4. Glow Plug/Wait to Start Indicator 6. Fuel Level Indicator

Indicates the glow plugs are operating. After
Indicates a low fuel condition in the tank.
turning on ignition, wait until light goes out
before starting engine.
7. Creep Speed Indicator
5. Enable Indicator/Footswitch
When the Function Speed Control is turned to
To operate any function, the footswitch must the creep position, the indicator acts as a
be depressed and the function selected within reminder that all functions are set to the slow-
seven seconds. The enable indicator shows est speed. The light will be on continuously if the operator
that the controls are enabled. If a function is not selected selects creep speed or if the control system puts the
within seven seconds, or if a seven second lapse between machine into creep speed. In addition, if the control system
ending one function and beginning the next function, the puts one or more individual functions in creep speed, the
enable light will go out and the footswitch must be released indicator flashes when that function is selected.
and depressed again to enable the controls.

Releasing the footswitch removes power from all controls

and applies the drive brakes.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH

BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY

OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

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 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. System Distress Indicator 9. Drive Orientation Indicator

The light indicates that the JLG Control System When the boom is swung beyond the rear
has detected an abnormal condition and a drive tires or further in either direction, the
Diagnostic Trouble Code has been set in the Drive Orientation indicator will illuminate
system memory. Refer to the Service Manual for instructions when the drive function is selected. This is a signal for the
concerning the trouble codes and trouble code retrieval. operator to verify that the drive control is being operated in
the proper direction (i.e. controls reversed situations).

3121658 3-23
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-24 3121658
 SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION The primary operator control console is in the platform. From this
control console, the operator can drive and steer the machine in
This machine is a mobile elevating work platform used to posi- both forward and reverse directions. The operator can raise or
tion personnel, along with their necessary tools and materials at lower the boom or swing the boom to the left or right. Standard
work locations. boom swing is 355 degree non-continuous. The machine has a
Ground Control Console which will override the Platform Control
Console. Ground Controls operate all functions except drive and
steer and are to be used in an emergency to lower the platform to
the ground should the operator in the platform be unable to do
so.

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 SECTION 4 - MACHINE OPERATION

4.2 BOOM OPERATING CHARACTERISTICS AND Stability

LIMITATIONS Machine stability is based on two (2) conditions which are called
FORWARD and BACKWARD stability. The machine’s position of
Capacities least FORWARD stability is shown in Figure 4-1., and its position
of least BACKWARD stability is shown in Figure 4-2.
Raising boom above horizontal with or without any load in plat-
form, is based on the following criteria:
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER-
1. Machine is positioned on a smooth, firm and level surface. ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.
2. Load is within manufacturers rated design capacity.
3. All machine systems are functioning properly.
4. Machine is as originally equipped from JLG.

4-2 3121658
 SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION 2. Pull the Power/Emergency Stop switch to On.

NOTE: Initial starting must always be

performed from the Ground Con-
trol station.
3. Push the Engine Start switch until engine starts.

Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING
ANY LOAD.

4. After engine has had sufficient time to warm

up, push in the Power/Emergency Stop switch
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD
and shut engine off.
ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF
ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.
5. Turn Platform/Ground Select switch to Plat-
NOTE: Diesel engines only: After turning on ignition, form.
operator must wait until glow plug indicator light
goes out before cranking engine.

1. Turn key of Platform/Ground Select switch to

Ground.

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 SECTION 4 - MACHINE OPERATION

6. Pull out the Ground Console Power/Emer- Shutdown Procedure

gency Stop switch to provide power to the
platform controls.

7. From Platform, pull Power/Emergency Stop IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE
switch out. THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.

1. Remove all load and allow engine to operate at low speed

for 3-5 minutes; this allows further reduction of internal
8. Push the Engine Start switch until engine starts. engine temperature.
2. Push Power/Emergency Stop switch in.

NOTE: Footswitch must be in released (up) position before starter will

operate. If starter operates with footswitch in the depressed posi-
tion, DO NOT OPERATE MACHINE.
3. Turn Platform/Ground Select switch to Off.
Refer to Engine Manufacturer’s manual for detailed
information.

4-4 3121658
 SECTION 4 - MACHINE OPERATION

Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera-
tor will be permitted to cycle power and restart the engine
NOTE: Reference the Service and Maintenance Manual along with a for approximately 2 minutes of run time. After the 2 min-
qualified JLG Mechanic to verify your machine setup. utes of run time is complete, the operator may cycle power
and restart the engine for an additional 2 minutes of run
The Fuel Shutoff System monitors the fuel in the time. The operator can repeat this process until there is no
tank and senses when the fuel level is getting more fuel available.
low. The JLG Control System automatically shuts • Engine Stop - When the engine shuts down, no restarts
the engine down before the fuel tank is emptied will be permitted until fuel is added to the tank.
unless the machine is set up for Engine Restart.
If fuel level reaches the Empty range, the Low Fuel light will begin
to flash once a second and there will be approximately 60 min-
utes of engine run time left. If the system is in this condition and
automatically shuts down the engine or if the operator manually
shuts down the engine before the 60 minute run time is com-
plete, the Low Fuel light will flash 10 times a second and the
engine will react according to machine setup. Setup options are
as follows:
• Engine One Restart - When the engine shuts down, the
operator will be permitted to cycle power and restart the
engine once with approximately 2 minutes of run time.
After the 2 minute run time is complete or if the engine is
shut down by the operator prior to the completion of the 2
minute run time, it cannot be restarted until fuel is added
to the tank.

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 SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

4-6 3121658
 SECTION 4 - MACHINE OPERATION
.
4.4 TRAVELING (DRIVING)
See Figure 4-3., Grade and Side Slopes

NOTE: Refer to the Operating Specifications table for Gradeability and

Sideslope ratings.

All ratings for Gradeability and Sideslope are based upon the
machine’s boom being in the stowed position, fully lowered, and
retracted.

Traveling is limited by two factors:

1. Gradeability, which is the percent of grade of the incline the
machine can climb.
2. Sideslope, which is the angle of the slope the machine can
be driven across.

Figure 4-2. Position of Least Backward Stability

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 SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

4-8 3121658
 SECTION 4 - MACHINE OPERATION

2. Position Drive controller to Forward

or Reverse as desired.
DO NOT DRIVE WITH BOOM OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRM
AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON

GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION
OF THIS MANUAL.
This machine is equipped with a Drive Orientation Indicator. The
yellow light on the platform control console indicates that the
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
boom is swung beyond the rear drive tires and the machine may
Drive/Steer in the opposite direction from the movement of the
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE
controls. If the indicator is illuminated, operate the Drive function
PLATFORM IS ELEVATED.
in the following manner:
BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE 1. Match the black and
CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC- white direction arrows
TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF on both platform con-
TRAVEL. trol console and the
chassis to determine
Traveling Forward and Reverse the direction the
machine will travel.
1. At Platform Controls, pull out Emergency Stop
switch, start the engine, and activate foot- 2. Push and release the Drive Orientation Over-
switch. ride switch. Within 3 seconds, slowly move the
Drive control toward the arrow matching the
intended direction of machine travel. The indi-
cator light will flash during the 3 second inter-
val until the drive function is selected.

3121658 4-9
 SECTION 4 - MACHINE OPERATION

Traveling on a Grade 4.5 STEERING

When traveling a grade, maximum braking and traction are obtained Position thumb switch on Drive/Steer controller to
with the boom stowed, in position over the rear (drive) axle, and in Right for steering right, or to Left for steering left.
line with the direction of travel. Drive the machine forward when
climbing a grade, and in reverse when descending a grade. Do not
exceed the machine's maximum rated gradability.
4.6 PLATFORM
Platform Level Adjustment

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

To Level Up or Down - Position the Platform/Level

control switch Up or Down and hold until the plat-
form is level.

Figure 4-4. Traveling on a Grade

Platform Rotation
To rotate the platform to the left or right, use the
Platform Rotate control switch to select the direc-
IF THE BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE tion and hold until desired position is reached.
MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS.

4-10 3121658
 SECTION 4 - MACHINE OPERATION

4.7 BOOM
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL
SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-
A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS GENCY STOP SWITCH TO STOP THE MACHINE.
WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM
ABOVE HORIZONTAL WHEN LIGHT IS LIT. Swinging the Boom
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT
To swing boom, use Swing control switch to select
ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREES OR GREATER).
Right or Left direction.
CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL
OR DRIVING WITH THE BOOM ELEVATED.
Raising and Lowering the Tower Boom
TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED
ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION To raise or lower the Tower Boom, position Tower
MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM. Boom Lift switch to Up or Down until desired height is
reached.
TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE
SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVER OR

TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE
‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

3121658 4-11
 SECTION 4 - MACHINE OPERATION

Raising and Lowering the Main Boom 4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
ONLY)
To raise or lower the Main Boom, use Main Boom Lift
controller to select UP or DOWN movement. The Machine Safety System Override (MSSO) is
used to override function controls for Emergency
Platform Retrieval only. Refer to Section 5.5,
Telescoping the Main Boom Machine Safety System Override (MSSO)(CE
Only)for operating procedures.
To extend or retract the main boom, use the Main
Telescope Control Switch to select IN or OUT move-
ment.

4.8 FUNCTION SPEED CONTROL

This control affects the speed of telescope, tower
boom lift and jib lift. Turning the knob all the
way counterclockwise until it clicks puts drive,
main lift, platform rotate, and swing into creep
mode.

4-12 3121658
 SECTION 4 - MACHINE OPERATION

4.10 SKYGUARD OPERATION SkyGuard

SkyGuard provides enhanced control panel protection. When the
SkyGuard sensor is activated, functions in use at the time of actu-
ation will reverse or cutout. The SkyGuard Function Table pro-
vides more details on these functions.
During activation, the horn will sound and, if equipped with a
SkyGuard beacon, the beacon will illuminate until sensor and
footswitch are disengaged.
If the SkyGuard sensor remains activated after function reversal
0"$
or cutout, depress and hold the SkyGuard Override Switch to
allow normal functions until the sensor is disengaged. Approximately 50 lb (222 Nm) of force is applied to yellow bar.
Consult the following illustrations to determine which type of
SkyGuard the machine has. Regardless of type, SkyGuard func- SkyGuard - SkyLine
tion according to the SkyGuard Function Table does not change.

0"%

Cable is pressed, breaking the magnetic connection between the

cable and right bracket.

3121658 4-13
 SECTION 4 - MACHINE OPERATION

SkyGuard - SkyEye

0"$
0"$
Reattach magnetic end of cable to bracket if it becomes discon-
nected. Operator passes through path of sensor beam.

SkyGuard Function Table

Tower Boom
Drive Drive Tower Boom Boom Boom Basket Basket
Steer Swing Lift Lift Jib Lift
Forward Reverse Lift Up Lift Up Tele Out Tele In Level Rotate
Down Down
R * / C ** R C R R C R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active

4-14 3121658
 SECTION 4 - MACHINE OPERATION

4.11 SHUT DOWN AND PARK 4.12 LIFTING AND TIE DOWN
(See Figure 4-5.)
Shut Down and Park
The procedures to shut down and park the machine are as fol- Lifting
lows:
1. Refer to the Serial Number Plate, refer to the Specifications
1. Drive machine to a reasonably well protected area. section of this manual, or weigh the individual unit to find
out the Gross Vehicle Weight.
2. Ensure boom is lowered over rear drive axle.
2. Place the boom in the stowed position.
3. Shut down Emergency Stop at Platform Controls.
3. Remove all loose items from the machine.
4. Shut down Emergency Stop at Ground Controls. Position
Platform/Ground Select switch to center OFF. 4. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level.
5. If necessary, cover Platform Controls to protect instruction
placards, warning decals, and operating controls from hos- Tie Down
tile environment.

WHEN TRANSPORTING THE MACHINE IN THE STOWED POSITION, THE BOOM MUST BE
FULLY LOWERED INTO THE BOOM REST.

1. Place the boom in the stowed position or storage position.

2. Remove all loose items from the machine.
3. Secure the chassis and the platform using straps or chains of
adequate strength.

3121658 4-15
 SECTION 4 - MACHINE OPERATION

520AJ 450AJ
53.7 in 57.9 in
A (1366 mm) (1471 mm)
49.6 in 45.5 in
B (1261 mm) (1156 mm)
1702300

1701500

1702300

1701500
A
1001172217B

Figure 4-5. Lifting and Tie Down Chart

4-16 3121658
 SECTION 4 - MACHINE OPERATION

38

36

47

44

12

21 20 42 29 48 16 18 27 17
42 20

Figure 4-6. Decal Location Sheet 1 of 6

3121658 4-17
 SECTION 4 - MACHINE OPERATION

49

12 39

46
33

14 3

47
2

6 44 51 50 32

Figure 4-7. Decal Location Sheet 2 of 6

4-18 3121658
 SECTION 4 - MACHINE OPERATION

14
3
14 43

33

37

23

20 21 20
20 20

Figure 4-8. Decal Location Sheet 3 of 6

3121658 4-19
 SECTION 4 - MACHINE OPERATION

10

12

5
41
30 11
33 34
33 4

10

28

33
33 8 37 33
33
Figure 4-9. Decal Location Sheet 4 of 6

4-20 3121658
 SECTION 4 - MACHINE OPERATION

26 25 40

19

24
1

12

12

Figure 4-10. Decal Location Sheet 5 of 6

3121658 4-21
 SECTION 4 - MACHINE OPERATION

15 35

22

22

Figure 4-11. Decal Location Sheet 6 of 6

4-22 3121658
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Language Markets

Item # ANSI Australia Japan Korea French Chinese Portuguese CE Spanish

1001162521-G 1001162522-E 1001162523-C 1001162524-C 1001162525-D 1001162526-D 1001162527-F 1001162528-G 1001162529-F
1 1703797 1001162429 1703926 1703927 1703924 1703925 1703928 1001162429 1703923
2 1705336 1705822 1705344 1705345 1705347 1001116849 1705349 1705822 1705917
3 1703805 1705961 1703938 1703939 1703936 1703937 1703940 1705961 1703935
4 1703804 -- 1703950 1703951 1703848 1703949 1703952 -- 1703947
5 1001173262 -- -- -- 1001173262 -- -- -- 1001173262
6 1001174313 -- -- -- 1001174313 -- -- -- 1001174313
7 -- -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- 1702773 --
10 1702868 -- -- 1705969 1704000 1705968 1704002 -- 1704001
11 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
12 1001162416 1001190913 1001162418 1001162420 1001162422 1001162416 1001162426 1001190913 1001162415
13 -- -- -- -- -- -- -- -- --
14 1703953 1701518 1703944 1703945 1703942 1703953 1705903 1701518 1703941
15 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504
16 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
17 1001131269 -- -- -- 1001131269 -- -- -- --
18 -- -- -- -- -- -- -- -- --

3121658 4-23
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Language Markets

Item # ANSI Australia Japan Korea French Chinese Portuguese CE Spanish

1001162521-G 1001162522-E 1001162523-C 1001162524-C 1001162525-D 1001162526-D 1001162527-F 1001162528-G 1001162529-F
19 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
20 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300
21 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500
22 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687
23 3251243 -- -- -- 3251243 -- 3251243 -- 3251243
24 -- -- -- -- -- -- -- -- --
25 -- -- -- -- -- -- -- -- --
26 -- -- -- -- -- -- -- -- --
27 -- -- -- -- -- -- -- -- --
28 -- -- 1703980 1703981 1703984 1703982 1703985 1705828 1703983
29 -- -- -- -- -- -- -- -- --
30 1705514 -- -- -- 1705514 -- -- -- --
31 -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- --
33 -- -- -- -- -- -- -- -- --
34 -- -- -- -- -- -- -- -- --
35 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
36 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217 1001172217

4-24 3121658
 SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - Language Markets

Item # ANSI Australia Japan Korea French Chinese Portuguese CE Spanish

1001162521-G 1001162522-E 1001162523-C 1001162524-C 1001162525-D 1001162526-D 1001162527-F 1001162528-G 1001162529-F
37 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
38 -- -- -- -- -- -- -- -- --
39 -- -- -- -- -- -- -- -- --
40 -- -- -- -- -- -- -- -- --
41 1705351 -- 1705426 1705427 1705351 1705430 1705905 -- 1705910
42 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
43 3251813 -- -- -- 3251813 -- 3251813 1001204510 3251813
44 -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- --
46 -- 1001112551 -- -- -- -- -- 1001189882 --
47 -- -- -- -- -- -- -- --
48 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 1001223055 -- 1001224053 1001224048 1001223971 1001224050 1001224052 -- 1001224049

3121658 4-25
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - Kubota Engine-Powered Machines Table 4-2. Decal Legend - Kubota Engine-Powered Machines

ANSI ANSI
CSA CSA
Item # ANSI Export Item # ANSI Export
French French
China China
1001218928-B 1001218928-B
1001218927-B 1001218927-B
1 1703797 1703924 18 -- --
2 1705336 1705347 19 1701509 1701509
3 1703805 1703936 20 1702300 1702300
4 1703804 1703848 21 1701500 1701500
5 1001173262 1001173262 22 1703687 1703687
6 1001216408 1001216408 23 3251243 3251243
7 -- -- 24 -- --
8 -- -- 25 -- --
9 -- -- 26 -- --
10 1702868 1704000 27 -- --
11 1704277 1704277 28 -- 1703984
12 1001162416 1001162422 29 -- --
13 -- -- 30 1705514 1705514
14 1703953 1703942 31 -- --
15 1701504 1701504 32 -- --
16 1702631 1702631 33 -- --
17 1001131269 1001131269 34 -- --

4-26 3121658
 SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - Kubota Engine-Powered Machines

ANSI
CSA
Item # ANSI Export
French
China
1001218928-B
1001218927-B
35 1704412 1704412
36 1001172217 1001172217
37 1704885 1704885
38 -- --
39 -- --
40 -- --
41 1705351 1705429
42 1701499 1701499
43 3251813 3251813
44 -- --
45 -- --
46 -- --
47 -- --
48 1701529 1701529
49 -- --
50 -- --
51 1001223055 1001223971

3121658 4-27
 SECTION 4 - MACHINE OPERATION

NOTES:

4-28 3121658
 SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL
This section explains the steps to be taken in case of an emer- FOLLOWING ANY INCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
5.2 INCIDENT NOTIFICATION BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-
RECTLY.
JLG Industries, Inc. must be notified immediately of any incident
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro-
5.3 EMERGENCY OPERATION
vided with all necessary details.
Operator Unable to Control Machine
• USA: 877-JLG-SAFE (554-7233)
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
• EUROPE: (32) 0 89 84 82 20 OPERATE OR CONTROL MACHINE:
• AUSTRALIA: (61) 2 65 811111 1. Other personnel should operate the machine from ground
• E-mail: ProductSafety@JLG.com controls only as required.
Failure to notify the manufacturer of an incident involving a JLG 2. Other qualified personnel on the platform may use the plat-
Industries product within 48 hours of such an occurrence may form controls. DO NOT CONTINUE OPERATION IF CONTROLS
void any warranty consideration on that particular machine. DO NOT FUNCTION PROPERLY.
3. Cranes, forklift trucks or other equipment can be used to sta-
bilize motion of the machine.

3121658 5-1
 SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead 5.4 MANUAL SWING OVERRIDE

If the platform or boom becomes jammed or snagged in over- The manual swing override is used to manually swing the boom and
head structures or equipment, do the following: turntable assembly in the event of a total power failure when the
1. Shut off the machine. platform is positioned over a structure or obstacle. To operate the
manual swing override, proceed as follows:
2. Rescue all people in the platform before freeing the
machine. Personnel must be out of the platform before 1. Using a 7/8 inch socket and ratchet wrench, locate nut on
operating any controls on the machine. swing worm gear on left side of machine.
3. Use cranes, forklifts, or other equipment to stabilize motion 2. Install wrench on nut and ratchet in the direction desired.
of the machine to prevent a tip over as required.
4. From the ground controls, use the Auxiliary Power System (if
equipped) to carefully free the platform or boom from the
object.
5. Once clear, restart the machine and return the platform to a
safe position.
6. Inspect the machine for damage. If the machine is damaged
or does not operate properly, turn off the machine immedi-
ately. Report the problem to the proper maintenance per-
sonnel. Do not operate the machine until it is declared safe
for operation.

5-2 3121658
 SECTION 5 - EMERGENCY PROCEDURES

5.5 EMERGENCY TOWING PROCEDURES After moving machine, complete the following procedure:
1. Position machine on a firm level surface.
Towing this machine is prohibited. However, provisions for moving
the machine have been incorporated. The following procedures are 2. Chock wheels securely.
to be used ONLY for emergency movement to a suitable mainte-
3. Disengage the mechanical release on both drive hubs by
nance area.
loosening, completely reversing, and tightening the two
bolts on each hub.
4. Remove chocks from wheels as desired.
THE ALLOWABLE TOWING SPEED IS 1.9 MPH (3 KPH). THE MAXIMUM ALLOWABLE
TOWING DISTANCE IS 0.6 MILES (1 KM).

1. Chock wheels securely.

2. Engage the mechanical release on both drive hubs by loos-
ening, completely reversing, and tightening the two bolts on
each hub.
3. Connect suitable equipment, remove chocks, and move
machine.

3121658 5-3
 SECTION 5 - EMERGENCY PROCEDURES

5.6 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE To operate the MSSO:

ONLY) 1. From the ground control console, place the Platform/

Ground Select switch in the Ground position.
The Machine Safety System Override (MSSO) is
only to be used to retrieve an operator that is 2. Pull out the Power/Emergency Stop control.
pinned, trapped, or unable to operate the 3. Start the engine or MSSO will function through the Auxiliary
machine. The MSSO will override function con- Power system.
trols that are locked out from the platform and
ground consoles. An example of this would be in the case of Load 4. Press and hold the MSSO switch and the control switch for
Sense System activation. the desired function.

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

NOTE: No functional checks of the MSSO system are necessary. The JLG
Control system will set a Diagnostic Trouble Code if the control
switch is faulty.

5-4 3121658
 SECTION 6 - ACCESSORIES

SECTION 6. ACCESSORIES

Table 6-1. Available Accessories

Market
Accessory ANSI
ANSI CSA CE AUS China
(USA Only)
Fall Arrest Platform (30" x 60") √ √
Pipe Racks √ √ √ √ √ √
SkyGlazier™ √ √ √
SkyPower™ √ √ √ √ √ √
SkyWelder™ √ √ √ √
Soft Touch™ √ √ √

3121658 6-1
 SECTION 6 - ACCESSORIES

Table 6-2. Options/Accessories Relationship Table

COMPATIBLE WITH
ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2)
(Note 1)
Platform MMR**, Platform MTR*,
Pipe Racks SkyPower™ SkyGlazier™, SkyWelder™
Soft Touch
4’ Platform, Pipe Racks, Platform
SkyGlazier™ SkyPower™ SkyWelder™
MTR*, Soft Touch
SkyPower™ SkyGlazier™, SkyWelder™
4’ Platform, Pipe Racks, Platform
SkyWelder™ SkyPower™ SkyGlazier™
MTR*, Soft Touch
Pipe Racks, SkyGlazier™,
Soft Touch SkyPower™
SkyWelder™
Note 1: Any non-"Sky" accessory not listed under "INCOMPATIBLE WITH" is assumed to be compatible.
Note 2: Can be used on same unit but not simultaneously.
* Platform MTR = Platform Mesh to Top Rail; ** Platform MMR = Platform Mesh to Mid Rail
4150459 M

6-2 3121658
 SECTION 6 - ACCESSORIES

6.1 FALL ARREST PLATFORM 6.2 PIPE RACKS

NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for
more information.

The external fall arrest system is designed to provide a lanyard

attach point while allowing the operator to access areas outside
the platform. Exit/enter the platform through the gate area only.
The system is designed for use by one person.
Personnel must use fall protection at all times. A full body harness
is required with lanyard not to exceed 6 ft (1.8 m) in length, that
limits the maximum arrest force to 900 lbs (408 kg) for the trans-
fastener type and 1350 lbs (612 kg) for the shuttle type fall arrest
system.

Safety Precautions

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM. USE
CAUTION WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.

Pipe Racks provide a way to store pipe or conduit inside the plat-
form in order to prevent rail damage and optimize platform util-
ity. This accessory consists of two racks with adjustable straps to
secure the load in place.

3121658 6-3
 SECTION 6 - ACCESSORIES

Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform.
• Do not exit platform over rails or stand on rails.
Max. Platform Capacity
Max. Capacity in Racks • Do not drive machine without material secured
(With Max. Weight in Racks)
80 kg 184 kg • Return racks to the stowed position when not in use.
Max. Length of Material in Racks: 6.0 m • Use this option only on approved models.
Min. Length of Material in Racks: 2.4 m
Preparation and Inspection
Safety Precautions • Ensure racks are secured to the platform rails.
• Replace torn or frayed tie-down straps.

REDUCE PLATFORM CAPACITY BY 100 LBS (45.5 KG) WHEN INSTALLED.

Operation
1. To prepare racks for loading, remove locking pins, rotate
each rack 90 degrees from stowed to working position, then
secure with locking pins.
WEIGHT IN RACKS PLUS WEIGHT IN PLATFORM MUST NOT EXCEED RATED CAPACITY.
2. Loosen and remove tie-down straps. Place material on racks
with weight evenly distributed between both racks.
3. Route the tie-down straps at each end across loaded mate-
THE MAXIMUM LOAD IN THE RACKS IS 180 LBS (80 KG) EVENLY DISTRIBUTED rial and tighten.
BETWEEN THE TWO RACKS.
4. To remove material, loosen and remove tie-down straps,
then carefully remove material from racks.

THE MAXIMUM LENGTH OF MATERIAL IN RACKS IS 20 FT (6.1 M). NOTE: Reinstall tie-down straps across any remaining material before
continuing machine operations.

6-4 3121658
 SECTION 6 - ACCESSORIES

6.3 SKYGLAZIER™ Capacity Specifications

Max. Platform Capacity
Capacity Zone * Max. Tray Capacity
(With Max. Weight in Tray)

500 lbs 150 lbs 250 lbs

(227 kg) (68 kg) (113 kg)
550 lbs 150 lbs 250 lbs
(250 kg) (68 kg) (113 kg)
600 lbs 150 lbs 250 lbs
(272 kg) (68 kg) (113 kg)
750 lbs 150 lbs 440 lbs
(340 kg) (68 kg) (200 kg)
1000 lbs 250 lbs 500 lbs
(454 kg) (113 kg) (227 kg)
* Refer to the capacity decals installed on the machine for capac-
ity zone information.

Required Platform Type: Side-Entry

Max. Dimensions of Panel: 32 sq ft (3 sq m)

SkyGlazier™ allows glaziers to position panels efficiently. The gla-
zier package consists of a tray that attaches the bottom of the
platform. The panel rests on the tray and against top-rail of the
platform, which is padded to prevent damage. SkyGlazier™
includes a strap to secure the panel to the platform rail.

3121658 6-5
 SECTION 6 - ACCESSORIES

Safety Precautions Preparation and Inspection

• Check for cracked welds and damage to tray.
• Ensure tray is properly secured to platform.
ENSURE PANEL IS SECURED WITH STRAP.
• Ensure strap is not torn or frayed.

Operation
DO NOT OVERLOAD TRAY OR PLATFORM. TOTAL MACHINE CAPACITY IS REDUCED
1. Load SkyGlazier™ tray with panel.
WHEN TRAY IS INSTALLED.
2. Route the adjustable strap around the panel and tighten
until secure.
3. Position panel to its desired location.
WITH SKYGLAZIER™ INSTALLED, THE ORIGINAL PLATFORM CAPACITY RATINGS ARE
REDUCED AS SPECIFIED IN THE SPECIFICATIONS TABLE ABOVE. DO NOT EXCEED THE
NEW PLATFORM CAPACITY RATING. REFER TO CAPACITY DECAL LOCATED ON TRAY.

AN INCREASE OF THE AREA EXPOSED TO THE WIND WILL DECREASE STABILITY. LIMIT
PANEL AREA TO 32 SQ FT (3 SQ M).

• Ensure no personnel are beneath platform.

• Do not exit platform over rails or stand on rails.
• Remove tray when not in use.
• Use this option only on approved models.

6-6 3121658
 SECTION 6 - ACCESSORIES

6.4 SKYPOWER™ All power regulation components are located in a watertight box
connected by cable to the generator. The generator supplies
power when running at the specified speed with the power
switch on (switch is located on platform). A three-pole, 30 Amp
circuit breaker protects the generator from overload.

Generator Output
ANSI Specifications:
• 3-phase: 240 V, 60 Hz, 7.5 kW
• 1-phase: 240 V/120 V, 60 Hz, 6 kW
CE Specifications:
• 3-phase: 240 V, 7.5 kW, 18.3 A, 1.0-pf
• 1-phase: 240 V, 6.0 kW, 26 A, 1.0-pf
• 1-phase: 120 V, 6.0 kW, 50 A, 1.0-pf
Peak:
• 3-phase: 8.5 kW
• 1-phase: 6.0 kW

Accessory Ratings
The SkyPower™ system supplies AC power to the platform • 3000 rpm (50 Hz)
through an AC receptacle to run tools, lights, cutting, and weld- • 3600 rpm (60 Hz)
ing equipment.

3121658 6-7
 SECTION 6 - ACCESSORIES

Safety Precautions 6.5 SKYWELDER™

DO NOT OVERLOAD PLATFORM.

• Ensure no personnel are beneath platform.

• This factory-installed option is available only on specified
models.
• Keep lanyard attached at all times.
• Do not use electrical tools in water.
• Use correct voltage for tool being used.
• Do not overload circuit.

Preparation and Inspection

• Ensure generator is secure.
• Check condition of belt and wiring.

Operation
Start the engine, then turn on the generator. SkyWelder™ is capable of TIG and Stick welding, producing 200
Amps at 100% duty cycle or 250 Amps at 50% duty cycle. It
See the Miller Generator Technical Manual (PN 3121677) for more receives power from the SkyPower™ system.
information.

6-8 3121658
 SECTION 6 - ACCESSORIES

Accessory Ratings
Welding Amps Input At Rated Load Output (50/60 Hz)
Maximum Open
Welding Mode Input Power Rated Output Amperage
Circuit Voltage 230 V 460 V 575 V kVa kW
Range
280 Amp at 31.2 V,
32 17 13 15.7 10
35% Duty Cycle
3- phase 5-250 A 79 VDC
200 Amp at 28 V,
20 11 8 10.3 6.4
Stick (SMAW) 100% Duty Cycle
TIG (GTAW) 200 Amp at 28 V,
35 ------ ------ 9.8 6.5
50% Duty Cycle
1 -phase 5-200 A 79 VDC
150 Amp at 28 V,
34 ------ ------ 6.9 4.4
100% Duty Cycle

Generator Output Welding Accessories

Engine Speed of 1800 rpm +/- 10%. • 12 ft welding leads with clamp and stinger (stored in the
platform)
ANSI Specifications:
• Fire extinguisher
• 3-phase: 240 V, 60 Hz, 7.5 kW
• 1-phase: 240 V/120 V, 60 Hz, 6 kW

3121658 6-9
 SECTION 6 - ACCESSORIES

Safety Precautions • Use correct rod size and current settings.

• Do not use electrical cords without ground.
• Do not use electrical tools in water.
DO NOT OVERLOAD PLATFORM.
• Do not weld to the platform.
• Do not ground through the platform.
• Do not use a high frequency arc starter with TIG welder.
DE-RATE THE PLATFORM BY 70 LBS (32 KG) WHEN WELDER IS IN THE PLATFORM.
Preparation and Inspection
• Check for cracked welds and damage to welder supports.
• Connect ground clamp to metal being welded.
• Check for proper and secure installation of welder and
bracket. • Ensure there is a good ground connection and observe
proper polarity.
• Ensure no personnel are beneath platform.
• Do not exit platform over rails or stand on rails. Operation
• Use this option only on approved models. Start the engine, turn on the generator, then turn on the welder.
• Keep lanyard attached at all times. See the Miller Welder Owner’s Manual (PN 3128957) for more
• Ensure correct polarity of leads. information.
• Wear proper welding apparel.

6-10 3121658
 SECTION 6 - ACCESSORIES

6.6 SOFT TOUCH

A padding kit is mounted to the platform rails and a frame sus-
pended below the platform. Limit switches deactivate platform
functions when the padded framework contacts an adjacent
structure. A button on the platform console allows override of the
system.

OVERRIDE BUTTON
OVERRIDE INDICATOR
LIGHT RAIL BUMPER

LIMIT
SWITCH

LIMIT
SWITCH
SUSPENDED FRAME AND RAIL BUMPER

3121658 6-11
 SECTION 6 - ACCESSORIES

NOTES:

6-12 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.1 INTRODUCTION 7.2 OPERATING SPECIFICATIONS AND PERFORMANCE
This section of the manual provides additional necessary infor-
DATA
mation to the operator for proper operation and maintenance of Operating Specifications
this machine.
Table 7-1. Operating Specifications
The maintenance portion of this section is intended as informa-
tion to assist the machine operator to perform daily maintenance Capacity: Unrestricted: 550 lbs. (249.5 kg)
tasks only, and does not replace the more thorough Preventive
Maximum Travel Grade, stowed 45%
Maintenance and Inspection Schedule included in the Service
Position (Gradeability)
and Maintenance Manual.
Maximum Travel Grade, stowed 5°
Other Publications Available:
Position (Side Slope)
Service and Maintenance Manual .............................................3121659
Drive Speed - Stowed 4.25 mph (6.8 kph)
Illustrated Parts Manual ................................................................3121660
Gross Machine Weight - Approximate 13,250 lbs. (6010 kg)

Maximum Ground Bearing Pressure 65 psi (4.6 kg/cm2)

Max. Tire Load 7200 lbs. (3266 kg)

System Voltage 12V DC

Maximum Main Relief Hyd. Pressure 4060 psi (280 Bar)

Average Fuel Consumption 0.85 gph (3.2 lph)

3121658 7-1
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Dimensional Data Capacities

Table 7-2. Dimensional Data Table 7-3. Capacities

Turning Radius (Inside) 6’ 9" (2.06 m) Hydraulic System 38 gal. (143.8 L)

Turning Radius (Outside) 15’ 8" (4.78 m) Hydraulic Oil Tank (to Full Level) 31.7 Gal. (119.9 L)

Machine Height (stowed) 89.3" (2269 mm) Drive Hub 24 oz. (0.7 L)

Machine Length (stowed) 258.9" (6576mm) Drive Brake 27 oz. (0.8 L)

Up and Over Platform Height 24’ (7.3 m) Engine Coolant
Horizontal Reach 25’ (7.62 m) Deutz 2.9L 2.9 gal. (11.3L)
GM 3.0L 2.4 gal. (9.1L)
Machine Width 92.6" (2353 m) Kubota 2.25 gal. (8.5 L)

Wheel Base 93.0" (2362 mm)

Platform Height 45’ 9" (13.72 m)

Ground Clearance 16.4" (417 mm)

7-2 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tires Engine Data

Table 7-4. Tires
Table 7-5. Deutz D2011L03
Size Type Pressure Weight Fuel Diesel
33/1550x16.5 Pneumatic 90 psi (6 Bar) 135 lbs. (61 kg) No. of Cylinders 3
Foam-Filled N/A 395 lbs. (179 kg) Bore 3.7 in (94 mm)
12 x 16.5 Foam-Filled N/A 328 lbs. (149 kg) Stroke 4.4 in (112 mm)
33/16LL x 16.1 Pneumatic 40 psi (3 Bar) 155 lbs. (70 kg) Displacement 142 cu. in (2331 cm³)
315/55 D20 Foam-Filled N/A 286 lbs. (130 kg) Oil Capacity
Solid N/A 286 lbs. (130 kg) crankcase 6.3 qt (6 L)
33x12-20 Solid N/A 285lbs. (129 kg) cooler 3.7 qt (3.5 L)
total capacity 10 qt (9.5 L)
Low RPM 1200
Mid RPM
Tower Lift, Upper Lift, Tele
Swing, Basket Level, Basket 1800
Rotate, Jib Lift 1500
High RPM 2800

3121658 7-3
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-6. Deutz D2.9L4 Table 7-7. GM 3.0L

Type Liquid Cooled Fuel Gasoline or Gasoline/LP Gas

Number of Cylinders 4 No. of Cylinders 4
Bore 3.6 in (92 mm) BHP
Stroke 4.3 in (110 mm) Gasoline 82 hp @ 3000 rpm
LP 75 hp @ 3000 rpm
Total Displacement 178 cu. in (2925 cm³)
Bore 4.0 in (101.6 mm)
Firing Order 1-3-4-2
Stroke 3.6 in (91.44 mm)
Output 49 hp (36.5 kW)
Displacement 181 cu.in(3.0 L, 2966 cc)
Oil Capacity 2.4 gal (8.9 L)
Oil Capacity w/filter 4.5 qt (4.25 L)
Coolant Capacity (System) 3.2 gal (12.1 L)
Minimum Oil Pressure
Average Fuel Consumption 1.2 gph (4.1 Lph)
at idle 6 psi (0.4 bar) @ 1000 rpm
Min. Low Engine RPM 1200 Hot 18 psi (1.2 bar) @ 2000 rpm
Mid Engine RPM 1800 Compression Ratio 9.2:1
Max. High Engine RPM 2500 Firing Order 1-3-4-2
Max. RPM 2800

7-4 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-8. Kubota WG 2503 Hydraulic Oil

Table 7-9. Hydraulic Oil
Fuel Gasoline or Gasoline/LP Gas
BHP Hydraulic System
S.A.E. Viscosity
Gasoline 45.5 kW @ 2700 rpm Operating
Grade
LP 46 Kw @ 2700 rpm Temperature Range
Bore 3.46 in (88 mm) +0° to + 180° F 10W
Stroke 4.03 in (102.4 mm) (-18° to +83° C)
Displacement 153 cu.in(2.5 L) +0° to + 210° F 10W-20, 10W30
Oil Capacity w/filter 2.5 gal (9.5 L) (-18° to +99° C)

Coolant Capacity (engine only) 1.4 gal (5.4 L) +50° to + 210° F 20W-20
(+10° to +99° C
Max. RPM 2700
Fuel Consumption - Gasoline In Drive 2.35 Gal/Hr 8.92 L/Hr -- NOTE: Hydraulic oils require anti-wear qualities at least API Service
@ Idle 0.48 Gal/Hr 1.83 L/Hr -- Classification GL-3, and sufficient chemical stability for mobile
Fuel Consumption - LP In Drive 2.56 Gal/Hr 9.72 L/Hr 5.64 kg/Hr hydraulic system service.
@ Idle 0.62 Gal/Hr 2.36 L/Hr 1.37 kg/Hr NOTE: Machines may be equipped with Mobil EAL biodegradable and
non-toxic hydraulic oil. This is a fully synthetic hydraulic oil that
possesses the same anti-wear and rust protection characteristics
as mineral oils, but will not adversely affect the ground water or
the environment when spilled or leaked in small amounts.

3121658 7-5
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

NOTE: Aside from JLG recommendations, it is not advisable to mix oils

of different brands or types, as they may not contain the same Table 7-11. DTE 10 Excel 15 Specs
required additives or be of comparable viscosities. If use of
hydraulic oil other than Mobil 424 is desired, contact JLG Indus- ISO Viscosity Grade #15
tries for proper recommendations. Pour Point, Max -65°F (-54°C)
Table 7-10. Mobilfluid 424 Specs Flash Point, Min. 360°F (182°C)
Viscosity
SAE Grade 10W30
at 40° C 15.8 cSt
Gravity, API 29.0
at 100° C 4.1cSt
Density, Lb/Gal. 60°F 7.35
at 100° F 15.8 cSt
Pour Point, Max -46°F (-43°C)
at 210° F 4.1 cSt
Flash Point, Min. 442°F (228°C)
Viscosity Index 168
Viscosity
Brookfield, cP at -18°C 2700
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152

7-6 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-12. Quintolubric 888-46 Table 7-13. Mobil EAL 224H Specs
Density 0.91 @ 15°C (59°F) Type Synthetic Biodegradable
Pour Point <-20°C (<-4°F) ISO Viscosity Grade 32/46
Flash Point 275°C (527°F) Specific Gravity .922
Fire Point 325°C (617°F) Pour Point, Max -25°F (-32°C)
Flash Point, Min. 428°F (220°C)
Autoignition Temperature 450°C (842°F)
Operating Temp. 0 to 180°F (-17 to 162°C)
Viscosity
Weight 7.64 lb. per gal.
at 0° C (32°F) 360 cSt (0.9 kg per liter)
at 20° C (68°F) 102 cSt Viscosity
at 40° C (104°F) 46 cSt at 40° C 37 cSt
at 100° C (212°F) 10 cSt at 100° C 8.4 cSt
Viscosity Index 220 Viscosity Index 213
NOTE: Must be stored above 32°F (14°C)

3121658 7-7
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Major Component Weights

Table 7-14. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C) DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT
Flash Point 217°F (103°C) OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT
Viscosity MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.

at 40° C 25.8 cSt Table 7-15. Critical Stability Weights

at 100° C 9.3 cSt
Viscosity Index 376 Components LBS. KG.

NOTE: Mobil/Exxon recommends that this oil be checked on a Counterweight 1875 ± 75 850.5 ± 34
yearly basis for viscosity.
Tire and Wheel - 20x9 Pneumatic 130 59

Tire and Wheel - 20x9 Foam-Filled 220 99.8

Tire and Wheel - 18x7 230 104.3

Platform & Console - 30x60 242.5 110

Platform & Console - 30x48 216 98

Battery 66 30

7-8 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

AMBIENT AIR
TEMPERATURE

120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30°F(-1°C)
WINTER 20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
ADDED
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 7-1. Engine Operating Temperature Specifications - Deutz 2.3L - Sheet 1 of 2

3121658 7-9
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

EXTENDED DRIVING WITH

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

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. 1) RECOMMENDATIONSAREFORAMBIENTTEMPERATURES
100° F (38° C) CONSISTANTLYWITHIN SHOWN LIMITS

MOBIL 424 10W-30

90° F (32° C)
2) ALLVALUESAREASSUMED TO BEATSEA LEVEL.
80° F (27° C)

EXXON UNIVIS HVI 26

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

SPECIFICATIONS FUEL FUEL

40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM

AMBIENTTEMPERATURE
WITHOUT HEATING AIDS WITH MOBILE 424 +14 -10
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE -13 -25

-22 -30
0 10 20 30 40 50 60

% OFADDED KEROSENE
4150548-E
Figure 7-2. Engine Operating Temperature Specifications - Deutz 2.3L - Sheet 2 of 2

7-10 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

AMBIENT AIR
TEMPERATURE

120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 7-3. Engine Operating Temperature Specifications - GM - Sheet 1 of 2

3121658 7-11
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

EXTENDED DRIVING WITH

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

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30

90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13

SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE:
-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C)
NO OPERATION BELOW THIS 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
AMBIENT TEMPERATURE

4150548-E
Figure 7-4. Engine Operating Temperature Specifications - GM - Sheet 2 of 2

7-12 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 7-5. Engine Operating Temperature Specifications - Deutz 2.9L

3121658 7-13
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1001206353 A

Figure 7-6. Hydraulic Oil Operation Chart - Sheet 1 of 2

7-14 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Fluid Properties Base Classi?cation

Fire Resistant***
Biodegradeable*
Viscosity @ 40° C
(CsT, Typical)

Vegetable Oils

Polyol Esters

Readilly
Mineral Oils

Synthetic

Non-toxic**
Description

Virtually
Visc Index

Synthetic
Mobilfluid 424 55 145 X
Mobil DTE 10 Excel 32 32 141 X
UNIVIS HVI 26 26 376 X
Mobil EAL 224 H 36 212 X X X
Mobil Envirosyn H 46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classi?cation indicates
NOTICE:
one of the following:
MACHINE OPERATION USING NON-JLG APPROVED
CO2 Conversion>60% per EPA 560/6-82-003
HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF
CO2 Conversion>80% per CEC-L-33-A-93
THE TEMPERATURE BOUNDARIES OUTLINED IN
** Virtually Non-toxic classi?cation indicates
THE "HYDRAULIC FLUID OPERATION CHART" MAY
an LC50>5000 ppm per OECD 203
RESULT IN PREMATURE WEAR OR DAMAGE TO
*** Fire Resistant classi?cation indicates
COMPONENTS OF THE HYDRAULIC SYSTEM.
Factory Mutual Research Corp. (FMRC) Approval
1001206353 A

Figure 7-7. Hydraulic Oil Operation Chart - Sheet 2 of 2

3121658 7-15
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

NOTICE:

MACHINE OPERATION USING NON-JLG APPROVED

ENGINE OIL OR OPERATION OUTSIDE OF
THE TEMPERATURE BOUNDARIES OUTLINED IN
THE "ENGINE OIL OPERATION CHART" MAY
RESULT IN PREMATURE WEAR OR DAMAGE TO
COMPONENTS OF THE ENGINE.

1001120075-A

Figure 7-8. Engine Oil Operation Chart - Kubota

7-16 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6 6
4 3 5 1
5 3 4

S/N 0300220579
& S/N E300003513
to Present

19
2WD Only 17 11 8
6 16 6
Figure 7-9. Operator Maintenance and Lubrication Diagram - Deutz 2.3L Engine

3121658 7-17
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6 6
4 3 5 1
5 3 4

7 14

S/N 0300220579
& S/N E300003513
to Present

19
2WD Only
18 10 15
17 16
6 6

Figure 7-10. Operator Maintenance and Lubrication Diagram - GM Engine

7-18 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6 6
4 3 5 1
5 3 4

S/N 0300220579
& S/N E300003513
to Present

19
2WD Only 13
17 18 9
6 16 12 6

Figure 7-11. Operator Maintenance and Lubrication Diagram - Deutz 2.9L Engine

3121658 7-19
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6 6
4 3 5 21 1
5 3 4

S/N 0300220579
& S/N E300003513
to Present

19
2WD Only 20
17 18
6 16 6

Figure 7-12. Operator Maintenance and Lubrication Diagram - Kubota Engine

7-20 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.3 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 7-9., Oper- LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL
ator Maintenance and Lubrication Diagram - Deutz 2.3L Engine. CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED
TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
Table 7-16. Lubrication Specifications.

KEY SPECIFICATIONS 1. Swing Bearing

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460.
HO Hydraulic Oil. API service classification GL-4, e.g. Mobilfluid 424.
EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or
Mil-Spec Mil-L-2105.
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C).
Excellent water resistance and adhesive qualities, and being of extreme
pressure type.
(Timken OK 40 pounds minimum.)
EO Engine (crankcase). Gas (5W30)- API SN, -Arctic ACEA AI/BI, A5/B5 - API
SM, SL, SJ, EC, CF, CD - ILSAC GF-4. Diesel (15W40, 5W30 Arctic) - API CJ-4.
*MPG may be substituted for these lubricants, if necessary, but service intervals will be
Lube Point(s) - Fitting
reduced.
Capacity - A/R
Lube - BG
Interval - Every 3 months or 150 hrs of operation
Comments - Apply grease and rotate in 90 degree intervals
until bearing is completely lubricated

3121658 7-21
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Swing Bearing/Worm Gear Teeth

Lube Point(s) - Grease Fitting

Lube Point(s) - Grease Fitting Capacity - A/R
Capacity - A/R Lube - Mobil SHC 007
Lube - Lubriplate 930-AAA Interval - A/R
Interval - A/R

DO NOT OVERGREASE BEARINGS. OVERGREASING BEARINGS WILL RESULT IN DAM-

AGE TO OUTER SEAL IN HOUSING.

7-22 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

Lube Point(s) - Fill Cap

Capacity - 36 Gal. (136.3 L), 31.7 Gal. (119.9 L) to Full Level; 28.8
Gal (109.0 L) to Low Level Lube Point(s) - Fill Cap
Lube - HO Capacity - 15 Gal. (57 L) to Full Level
Interval - Check Level daily; Change every 2 years or 1200 Lube - HO
hours of operation. Interval - Check Level daily; Change every 2 years or 1200
Comments - On new machines, those recently overhauled, or hours of operation.
after changing hydraulic oil, operate all systems a minimum Comments - On new machines, those recently overhauled, or
of two complete cycles and recheck oil level in reservoir. after changing hydraulic oil, operate all systems a minimum
of two complete cycles and recheck oil level in reservoir.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Hydraulic Return Filter 5. Hydraulic Tank Breather

Lube Point(s) - Replaceable Element Interval - Change after first 50 hrs. and every 6 months or 300
Interval - Change after first 50 hours and every 6 months or hrs. thereafter.
300 hours thereafter. Comments - Remove wing nut and cover to replace. Under cer-
tain conditions, it may be necessary to replace on a more
frequent basis.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6. Wheel Drive Hub 7. Drive Brake

OIL LEVEL CHECK

ANDFILL

Lube Point(s) - Level/Fill Plug

Capacity - 24 oz. (0.8 L)(1/2 Full)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of opera-
Lube Point(s) - Fill Plug
tion; change every 2 years or 1200 hours of operation
Capacity - 2.7 oz. (89 mL)
Lube - DTE-10 Excel 32
Interval - Change as necessary

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. Oil Change with Filter - Deutz 2.3 L3 9. Oil Change w/Filter - Deutz 2.9 L4

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.4 gal (8.9 L)
Lube Point(s) - Fill Cap/Spin-on Element Lube - EO
Capacity - 10 Quarts (9.5 L) w/Filter Interval - Every Year or 600 hours of operation
Lube - EO Comments - Check level daily/Change in accordance with
Interval - Check level daily; change every 500 hours or six engine manual
months, whichever comes first. Adjust final oil level by mark
on dipstick.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

10. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 4.5 qt (4.25 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

11. Fuel Filter/Water Separator - Deutz 2.3 L3 12. Fuel Pre-Filter - Deutz D2.9

Lube Point(s) - Replaceable Element

Interval - Drain water daily; Every year or 600 hours of opera-
Lube Point(s) - Replaceable Element tion
Interval - Every year or 500 hours of operation

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

13. Fuel Filter - Deutz D2.9 14. Fuel Filter (Gasoline) - GM

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

Interval - Every year or 600 hours of operation Interval - Every 6 months or 300 hours of operation

3121658 7-29
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

15. Fuel Filter (Propane) - GM Engine 16. Charge Filter

Interval - 3 Months or 150 hours of operation

Comments - Replace filter. Refer to Section 7.5, Propane Fuel
Filter Replacement (GM Engine)

Interval - Change after first 50 hrs. and every 6 months or 300

hrs. thereafter.
Comments - Remove the engine tray retaining bolt and pull
out engine tray to gain access.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

17. Air Filter 18. Engine Coolant

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

Interval - Every 6 months or 300 hours of operation or as Capacity (Deutz 2.9L)- 2.9 gal. (11.3L)
indicated by the condition indicator Capacity (GM 3.0L)- 2.4 gal. (9.1L)
Comments - Check Dust Valve daily Capacity (Kubota) - 2.25 gal. (8.5 L)
Lube - Anti-Freeze
Interval - Check level daily; change every 1000 hours or two
years, whichever comes first.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

19. Wheel Bearings 20. Oil Change w/Filter - Kubota

Lube Point(s) - Repack

Capacity - A/R
Lube - MPG
Interval - Every 2 years or 1200 hours of operation

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

21. Fuel Filter - Kubota

Lube Point(s) - Replaceable Component

Interval - Every year or 600 hours of operation

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 2.5 gal. (9.5 L) w/filter
Lube - EO
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance with
engine manual

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

22. Fuel Filter (Propane) - Kubota

Interval - Every year or 1000 hours of operation

Comments - Replace filter. Refer to Section 7.6, Propane
Fuel Filter Replacement (Kubota Engine)

7-34 3121658
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.4 TIRES & WHEELS Wheel and Tire Replacement

Tire Replacement The rims installed on each product model have been designed for
stability requirements which consist of track width, tire pressure, and
JLG recommends a replacement tire be the same size, ply and brand load capacity. Size changes such as rim width, center piece location,
as originally installed on the machine. Please refer to the JLG Parts larger or smaller diameter, etc., without written factory recommen-
Manual for the part number of the approved tires for a particular dations, may result in an unsafe condition regarding stability.
machine model. If not using a JLG approved replacement tire, we
recommend that replacement tires have the following characteris- Wheel Installation
tics:
It is extremely important to apply and maintain proper wheel
• Equal or greater ply/load rating and size of original mounting torque.

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal to the
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO
original PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION
• Approved for the application by the tire manufacturer OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
(including inflation pressure and maximum tire load) ANGLE OF THE WHEEL.

Unless specifically approved by JLG Industries Inc. do not replace a Tighten the lug nuts to the proper torque to prevent wheels from
foam filled or ballast filled tire assembly with a pneumatic tire. When coming loose. Use a torque wrench to tighten the fasteners. If you do
selecting and installing a replacement tire, ensure that all tires are not have a torque wrench, tighten the fasteners with a lug wrench,
inflated to the pressure recommended by JLG. Due to size variations then immediately have a service garage or dealer tighten the lug
between tire brands, both tires on the same axle should be the same. nuts to the proper torque. Over-tightening will result in breaking the
studs or permanently deforming the mounting stud holes in the
wheels. The proper procedure for attaching wheels is as follows:

3121658 7-35
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1. Start all nuts by hand to prevent cross threading. DO NOT Table 7-17. Wheel Torque Chart
use a lubricant on threads or nuts.
TORQUE SEQUENCE
2. Tighten nuts in the following sequence.
1st Stage 2nd Stage 3rd Stage
40 ft lbs (55 Nm) 95 ft lbs (130 Nm) 170 ft lbs (230 Nm)

3. The tightening of the nuts should be done in stages. Follow-

ing the recommended sequence, tighten nuts per wheel
torque.
4. Wheel nuts should be torqued after first 50 hours of opera-
tion and after each wheel removal. Check and torque every 3
months or 150 hours of operation.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.5 PROPANE FUEL FILTER REPLACEMENT (GM ENGINE)

Removal 1
1. Relieve the propane fuel system pressure. Refer to Propane 6
Fuel System Pressure Relief. 10 7 5
2. Disconnect the negative battery cable. 2
3. Slowly loosen the Filter housing and remove it. 8
4. Pull the filter housing from the Electric lock off assembly. 3

5. Remove the filter from the housing. 4

6. Locate Filter magnet and remove it.
7. Remove and discard the housing seal. 9

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

1. Electric Lock Off Solenoid 6. Fuel Outlet
9. Remove and discard mounting plate to lock off O-ring seal. 2. Housing Seal 7. O-ring
3. Filter Magnet 8. Filter
4. Filter Housing 9. Fuel Inlet
5. Electrical Connector 10. Ring
Figure 7-13. GM Filter Lock Assembly

3121658 7-37
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Installation 7.6 PROPANE FUEL FILTER REPLACEMENT (KUBOTA

ENGINE)
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING Removal
NEW SEAL
1. Relieve the propane fuel system pressure. Refer to Propane
1. Install the mounting plate to lock off O-ring seal. Fuel System Pressure Relief.
2. If equipped, install the retaining bolt seal. 2. Disconnect the negative battery cable.
3. Install the housing seal. 3. Slowly loosen the bowl retaining nut and remove the nut
and filter housing from the Electric lock off assembly.
4. Drop the magnet into the bottom of the filter housing.
4. Remove the filter from the housing.
5. Install the filter into the housing.
5. Remove and discard the housing seal.
6. If equipped, install the retaining bolt into the filter housing.
6. Remove and discard the retaining nut seal.
7. Install the filter up to the bottom of the electric lock off.
8. Tighten the filter bowl retainer to 106 in-lb (12 Nm).
9. Open manual shut-off valve. Start the vehicle and leak check
the propane fuel system at each serviced fitting.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Installation
1. If equipped, install the filter bowl gasket.
2. Install the filter into the housing.

OUTLET
3. Install the filter bowl up to the bottom of the electric lock off.
FILTER BOWL 4. Tighten the filter bowl retainer nut.
GASKET
5. Open manual shut-off valve. Start the vehicle and leak check
FILTER the propane fuel system at each serviced fitting.

BOWL
RETAINING NUT SEAL

Figure 7-14. Kubota Filter Lock Assembly

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.7 PROPANE FUEL SYSTEM PRESSURE RELIEF 7.8 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/EC
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MIN- and is only applicable to CE machines.
IMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM
For electric powered machines, the equivalent continuous A-
PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COM-
Weighted sound pressure level at the work platform is less than
PONENTS.
70dB(A)
To relieve propane fuel system pressure: For combustion engine powered machines, guaranteed Sound
Power Level (LWA) per European Directive 2000/14/EC (Noise
1. Close the manual shut-off valve on the propane fuel tank.
Emission in the Environment by Equipment for Use Outdoors)
2. Start and run the vehicle until the engine stalls. based on test methods in accordance with Annex III, Part B,
Method 1 and 0 of the directive, is 102 dB.
3. Turn the ignition switch OFF.
The vibration total value to which the hand-arm system is sub-
jected does not exceed 2,5 m/s2. The highest root mean square
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE WORK value of weighted acceleration to which the whole body is sub-
AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. jected does not exceed 0,5 m/s2.

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 SECTION 8 - INSPECTION AND REPAIR LOG

SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 8-1. Inspection and Repair Log

Date Comments

3121658 8-1
 SECTION 8 - INSPECTION AND REPAIR LOG

Table 8-1. Inspection and Repair Log

Date Comments

8-2 3121658
 TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company

To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this manual,
we would like to know who you are. For the purpose of receiving safety-related bulletins, it is
very important to keep JLG Industries, Inc. updated with the current ownership of all JLG
products. JLG maintains owner information for each JLG product and uses this information in
cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current
ownership of JLG products. Please return completed form to the JLG Product Safety &
Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713

NOTE: Leased or rented units should not be included on this form.

Mfg. Model: ______________________________________________________________________

Serial Number: ____________________________________________________________________

Previous Owner: __________________________________________________________________

Address: _________________________________________________________________________

_________________________________________________________________________________

Country: _____________________________ Telephone: (_______) ________________________

Date of Transfer: ______________________________________

Current Owner: ___________________________________________________________________

Address: _________________________________________________________________________

_________________________________________________________________________________

Country: _____________________________ Telephone: (_______) ________________________

Who in your organization should we notify?

Name: ___________________________________________________________________________

Title:____________________________________________________________________
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417

Visit our website for JLG Worldwide Locations.

www.jlg.com