Professional Documents
Culture Documents
Operation 3120685 04-20-00 ANSI English
Operation 3120685 04-20-00 ANSI English
Model
120HX
3120685
April 20, 2000
ANSI
– JLG Lift –
FOREWORD
FOREWORD
The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.
REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER-
ATING PERSONNEL.
ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/OR
MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL FROM
JLG INDUSTRIES, PER OSHA REGULATIONS AND APPLICABLE ANSI STANDARDS.
THIS SAFETY ALERT SYMBOL IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS WHICH
MAY LEAD TO SERIOUS INJURY OR DEATH IF IGNORED.
Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAU-
TION, IMPORTANT, INSTRUCTIONS and NOTE are inserted throughout this manual to emphasize these
areas. They are defined as follows:
DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION
WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR WHICH, IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY
DEATH.] OR DEATH.
JLG INDUSTRIES MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUSTRIES INC.
OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLETINS WHICH MAY
HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED BULLETINS MUST BE COM-
PLETED ON THE AFFECTED JLG PRODUCT
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notifica-
tion. Contact JLG Industries, Inc. for updated information.
All procedures herein are based on the use of the 5. All personnel in the platform shall, at all times,
machine under proper operating conditions, with no wear approved fall protection devices and
deviations from original design intent... as per OSHA other safety gear as required.
regulations and applicable ANSI standards. 6. Load limits specified by the manufacturer shall
not be exceeded.
7. Instruction and warning placards must be legi-
ble.
READ & HEED! 8. Aerial lifts may be field modified for uses other
than those intended by the manufacturer only if
certified in writing by the manufacturer to be in
conformity to JLG requirements and to be at
The ownership, use, service, and/or maintenance of least as safe as it was prior to modification.
this machine is subject to various governmental and
local laws and regulations. It is the responsibility of 9. Aerial lifts shall not be used near electric power
the owner/user to be knowledgeable of these laws lines unless the lines have been de energized
and regulations and to comply with them. Owner/ or adequate clearance is maintained (See
OSHA 29 CFR 1910.67 and 1926.453).
user/operator/lessor and lessee must be familiar
with Sections 6,7,8,9, and 10 of ANSI A92.5-1992. 10. Employees using aerial lifts shall be instructed
These sections contain the responsibilities of the on how to recognize and avoid unsafe condi-
owner, users, operators, lessors, and lessees con- tions and hazards.
cerning safety, training, inspection, maintenance,
11. Ground controls shall not be operated unless
application and operation. The most prevalent regu- permission has been obtained from personnel
lations of this type in the United States are the Fed- in the platform, except in case of an emer-
eral OSHA Safety Regulations*. Listed below, in gency.
abbreviated form are some of the requirements of
Federal OSHA regulations in effect as of the date of 12. Regular inspection of the job site and aerial lift
publication of this handbook. shall be performed by competent persons.
13. Personnel shall always stand on the floor of the
The listing of these requirements shall not relieve platform, not on boxes, planks, railing or other
the owner/user of the responsibility and obligation devices, for a work position.
to determine all applicable laws and regulations and
*Applicable Federal OSHA regulations for the
their exact wording and requirements, and to com-
United States, as of the date of publication of this
ply with the requirements. Nor shall the listing of manual, include, but are not limited to, 29 CFR
these requirements constitute an assumption of
1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29 CFR
responsibility of liability on the part of JLG Indus-
1926.28, and 29 CFR 1926.453.
tries, Inc.
REVISON LOG
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION - FOREWORD
SECTION 1 - SAFETY PRECAUTIONS
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Driving/Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.3 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.4 Pre-Operational . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2
1.5 Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.6 Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1.7 Towing and Hauling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
SECTION 2 - PREPARATION AND INSPECTION
2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.3 Delivery and Frequent Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
2.4 Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9
2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12
2.7 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
SECTION 3 - USER RESPONSIBILITIES AND MACHINE CONTROL
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.3 Operating Characteristics and Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3.4 Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
3.5 Placards and Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
SECTION 4 - MACHINE OPERATION
4.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 Engine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.4 Traveling (Driving/Steering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4.5 Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.6 Parking and Stowing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.7 Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
4.8 Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.9 Shut Down and Park . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4.10 Tie Down and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4.11 Swing-Away Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
SECTION 5 - OPTIONAL EQUIPMENT
5.1 Cold Start Kit (Diesel Engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 Travel/motion Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.3 Tilt Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.4 Rotating Beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.5 Hostile Environment Package . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.6 110 Volt Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
SECTION 6 - EMERGENCY PROCEDURES
6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 Emergency Towing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
2-1. Machine Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
2-2. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
2-3. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10
2-4. Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14
3-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-3. Ground Control Station - Prior to May 1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Ground Control Station - May 1994 to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-5. Axle Extension/Axle Jacks Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-6. Remote Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10
3-7. Platform Station - Prior to May 1994 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-12
3-8. Platform Station - May 1994 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-9. Caution Decal Location - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-10. Caution Decal Location - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-11. Control Panel Symbols - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-20
3-12. Control Panel Symbols - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
4-1. Spindle Stop Pin Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-2. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
4-3. Machine Tie Down - Sheet 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
4-4. Machine Tie Down - Sheet 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
4-5. Machine Tie Down - Sheet 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4-6. Machine Tie Down - Sheet 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-7. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-12
4-8. Swing-Away Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
6-1. Disconnecting the Drive Hubs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
Table 1-1. Minimum Safe Approach Distances (M.S.A.D.) to energized (exposed or insulated) power lines and parts
1.4 PRE-OPERATIONAL
• AN OPERATOR MUST NOT ACCEPT OPERATING • NEVER DISABLE OR MODIFY THE FOOTSWITCH OR
RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS ANY OTHER SAFETY DEVICE. ANY UNAUTHORIZED
BEEN GIVEN BY COMPETENT AND AUTHORIZED MODIFICATION OF THE MACHINE IS A SAFETY VIO-
PERSONS. LATION AND IS A VIOLATION OF OSHA REGULA-
TIONS AND ANSI STANDARDS.
• BEFORE OPERATION, CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES, MACHINE TRAFFIC
SUCH AS BRIDGE CRANES, HIGHWAY, RAILWAY AND
CONSTRUCTION EQUIPMENT.
1.6 OPERATION.
.
FERING WITH OPERATING CONTROLS AND PER-
SONS IN PLATFORM.
• ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR MACHINES ARE AWARE OF THE AERIAL
PLATFORMS PRESENCE. DISCONNECT POWER TO
OVERHEAD CRANES. POSITION BARRICADES ON
FLOOR IF NECESSARY.
• NEVER "SLAM" A CONTROL SWITCH OR LEVER
THROUGH NEUTRAL TO THE OPPOSITE DIRECTION.
ALWAYS RETURN SWITCH TO NEUTRAL AND STOP;
THEN MOVE SWITCH TO THE DESIRED POSITION.
OPERATE LEVERS WITH SLOW, EVEN PRESSURE.
• DO NOT CARRY MATERIALS ON PLATFORM RAILING
UNLESS APPROVED BY JLG INDUSTRIES INC.
• NEVER PUSH OR PULL THE MACHINE OR OTHER
OBJECTS BY TELESCOPING THE BOOM.
• NEVER USE BOOM FOR ANY PURPOSE OTHER
THAN POSITIONING PERSONNEL, THEIR TOOLS
AND EQUIPMENT.
• NEVER EXCEED MANUFACTURERS RATED PLAT-
• ENSURE MACHINE IS POSITIONED ON A FIRM,
FORM CAPACITY - REFER TO CAPACITY DECAL ON
LEVEL AND UNIFORM SUPPORTING SURFACE
MACHINE. DISTRIBUTE LOADS EVENLY ON PLAT-
BEFORE RAISING OR EXTENDING BOOM.
FORM FLOOR.
• NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS , SHUT DOWN THE
MACHINE , RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.
• DO NOT REMOVE, MODIFY, OR DISABLE FOOT-
SWITCH BY BLOCKING OR ANY OTHER MEANS.
• DO NOT ASSIST A STUCK OR DISABLED MACHINE
BY PUSHING OR PULLING EXCEPT BY PULLING AT
CHASSIS TIE-DOWN LUGS.
• NEVER ATTEMPT USING BOOM AS A CRANE.
• CHECK CLEARANCES ABOVE, ON SIDES AND BOT-
STRUCTURAL DAMAGE OR TIPPING MAY OCCUR.
TOM OF PLATFORM WHEN RAISING, LOWERING,
SWINGING, AND TELESCOPING BOOM. • STOW BOOM AND SHUT OFF ALL POWER BEFORE
LEAVING MACHINE.
• EXERCISE EXTREME CAUTION AT ALL TIMES TO
PREVENT OBSTACLES FROM STRIKING OR INTER- • NO STUNT DRIVING OR HORSEPLAY IS PERMITTED.
• NEVER ATTEMPT TO FREE A MACHINE STUCK IN • MACHINE MUST ALWAYS BE SHUT DOWN WHEN
SOFT GROUND OR ASSIST A MACHINE UP A STEEP REFUELING. NO SMOKING IS MANDATORY. NEVER
HILL OR RAMP BY USING BOOM "LIFT", "TELE- REFUEL DURING AN ELECTRICAL STORM. ENSURE
SCOPE", OR "SWING" FUNCTIONS. THAT FUEL CAP IS CLOSED AND SECURE AT ALL
OTHER TIMES.
• NEVER ATTACH WIRE, CABLE, OR ANY SIMILAR
ITEMS TO PLATFORM.
• DO NOT PLACE BOOM OR PLATFORM AGAINST ANY 1.7 TOWING AND HAULING
STRUCTURE TO STEADY PLATFORM OR SUPPORT
STRUCTURES. • DO NOT TOW A MACHINE EXCEPT IN AN EMER-
GENCY. SEE SECTION 6 FOR EMERGENCY TOWING
• DO NOT USE THE LIFT, SWING, OR TELESCOPE PROCEDURES.
FUNCTIONS FOR THE BOOM, TO MOVE EITHER THE
MACHINE OR OTHER OBJECTS. • LOCK TURNTABLE BEFORE TRAVELING LONG DIS-
TANCES OR BEFORE HAULING MACHINE ON A
• HYDRAULIC CYLINDERS SHOULD NEVER BE LEFT TRUCK OR TRAILER.
FU L LY E X T E N D E D O R R E T RA C T E D F O R A N Y
LENGTH OF TIME. ALWAYS "BUMP" CONTROL IN
OPPOSITE DIRECTION SLIGHTLY WHEN FUNCTION
BEING USED REACHES END OF TRAVEL. THIS
APPLIES TO MACHINES IN OPERATION OR IN
STOWED MODE.
• DO NOT OPERATE ANY MACHINE ON WHICH DAN-
GER, WARNING, CAUTION OR INSTRUCTION PLAC-
ARDS OR DECALS ARE MISSING OR ILLEGIBLE.
PLATFORM
CONTROL PLATFORM
BOX
EXTEND-A-REACH
BASE BOOM
TELESCOPE
CYLINDER
(inside)
LIFT
CYLINDER
GROUND SWING
CONTROL BEARING
BOX
TURNTABLE
DRIVE/STEER
WHEELS
DRIVE/STEER
WHEELS
FRAME
5. Start each day with a full fuel tank. minimum of two complete cycles and recheck oil
level in reservoir.
NOTE: On new machines, those recently overhauled, or 8. Assure that all items requiring lubrication are ser-
after changing hydraulic oil, operate all systems a viced. Refer to Lubrication Chart, Figure 2-3., for
specific requirements.
23
22
24
25 21
20
17, 18, 19
16
15
26
14
27
13
28
4
12
29
5
30
31 11
10
32 3
34 8
33 35 7
6
36
2
37
5. Extend-A-Reach Pivot - No loose, damaged, or 22. Ground Controls - Switches operable, no visible
missing parts, evidence of proper lubrication. damage, decals secure and legible.
6. Hose and Cable Guards/Clamps - Properly 23. Engine Air Filter - No loose or missing parts, no vis-
secured, no visible damage. ible damage, element clean.
7. Power Track - No loose, damaged or missing parts, 24. Tie Rod and Steering Linkage - No loose or miss-
no visible damage. ing parts, no visible damage. Tie rod end studs
locked.
8. Drive Motor and Brake, Right Rear - No visible
damage, no evidence of leakage. 25. Wheel/Tire Assembly, Left Front - Properly
secured, no loose or missing lug nuts, no visible
damage.
26. Engine Oil Supply - Full mark on dipstick; filler cap 32. Drive Hub, Left Rear - No visible damage, no evi-
secure. dence of leakage.
27. Muffler and Exhaust System - Properly secured, no 33. Wheel/Tire Assembly, Left Rear - Properly
evidence of leakage. secured, no loose or missing lug nuts, no visible
damage.
28. Cowling and Latches, Right Side - All cowling and
latches in working condition, properly secured, no 34. Drive Motor and Brake, Left Rear - No visible dam-
loose or missing part. age, no evidence of leakage.
29. Turntable Bearing and Pinion - No loose or missing 35. Boom Sections - No visible damage; wear pads
hardware; no visible damage, evidence of proper secure. All cylinders - rod end shafts and barrel-end
lubrication. No evidence of loose bolts or looseness shafts properly secured.
between bearing and structure.
36. Rotator and Motor - Properly secured, no visible
30. Battery - Proper electrolyte levels; cables tight, no damage, no evidence of leakage.
visible damage or corrosion.
37. Platform Pivot and Slave Cylinder Attach Pins -
31. Frame - No visible damage, no loose or missing Properly secured; evidence of proper lubrication
hardware (top and underside). where applicable.
18 14
17 10
24 9
SECTION 2 - PREPARATION AND INSPECTION
23
25
12
33 19 15 13 11
– JLG Lift –
34 20 16 32
1 6
21
5 5 8
Note: Items 27 and 29 are on opposite side
2 2 Items 33 and 34 are on both sides of T/T
3 3
4 4 9
3120685
SECTION 2 - PREPARATION AND INSPECTION
1 Wheel Drive Hubs Fill/Drain Plugs EPGL (SAE 90) 150/1200 Check Every 150 Hours
Change Every 1200 Hours
2 Steer Cylinders - Rod End 2 Grease Fitting MPG - Pressure Gun 150
3 Steer Cylinders - Barrel End 2 Grease Fittings MPG - Pressure Gun 150
4 King Pins 4 Grease Fittings MPG - Pressure Gun 150
5 Tie Rods 4 Grease Fitting MPG - Pressure Gun 150
6 Rotary Platform Stand 2 Grease Fittings MPG - Pressure Gun 150
Rotary Worm Gear N/A MPG - Brush 150 Remove Cover to Grease
7 Platform Level cylinder 3 Grease Fittings MPG - Pressure Gun 150
8 Platform Pivot Pin 1 Grease Fitting MPG - Pressure Gun 150
9 Link Level Pin 2 Grease Fittings MPG - Pressure Gun 150
10 E-A-R Pivot Pin 1 Grease Fitting MPG - Pressure Gun 150
11 E-A-R Lift Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
12 E-A-R Lift Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150
13 Sheave Pin - Fly Extend 1 Grease Fitting MPG - Pressure Gun 150
14 Sheave Pin - Upper Aux. 1 Grease Fitting MPG - Pressure Gun 150
15 Tele Cyl. Sheave Pin 1 Grease Fitting MPG - Pressure Gun 150 Extend boom until grease fitting
is accessible thru hole in fly sec.
16 Boom Chains N/A Chain Lube/Hot Oil Dip 1200 Extend and Retract Chains
17 Sheave Pin - Fly Retract 2 Grease Fittings MPG - Pressure Gun 150 Extend boom until fitting is
accessible thru hole in fly
18 Sheave Pin - Outer-Mid Retract 2 Grease Fittings MPG - Pressure Gun 150 Extend boom until fitting is
accessible thru hole in fly
19 Lift Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150 Remote Access
20 Master Cylinder - Barrel End 1 Grease Fitting MPG - Pressure Gun 150 Remote Access
21 Swing Bearing 1 Grease Fitting MPG - Pressure Gun 150 Remote Access. Lube, rotate
180°, lube again.
22 Swing Bearing Gear N/A MPG - Brush 150
23 Master Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
24 Boom Pivot Bearings 2 Grease Fittings MPG - Pressure Gun 150
25 Lift Cylinder - Rod End 1 Grease Fitting MPG - Pressure Gun 150
26 Load Moment Pivot Pins 1 Grease Fitting MPG - Pressure Gun 150 Position boom over side for
access under turntable
27 Hydraulic Filter - Function Pump N/A N/A 50/300 Replace after first 50 hrs. of
operation, then every
300 hrs. thereafter
28 Hydraulic Filter - Drive Pump N/A N/A 50/300 Replace after first 50 hrs. of
operation, then every
300 hrs. thereafter
29 Hydraulic Fluid Fill Cap HO 10/1200 Check oil daily.
Change oil every 1200 hrs
30 Engine Crankcase Fill Cap/Drain Plug EO - SAE30 10/300 Check oil daily.
Change oil every 300 hrs.
31 Engine Oil Filter N/A Replaceable Cartridge 300
32 Platform Door Hinges 2 Grease Fittings MPG - Pressure Gun 150
33 Access Door Hinges N/A SAE10 - Oil Can 150 As Needed
34 Access Door Latches N/A SAE10 - Oil Can 150 As Needed
35 Axle Beams N/A MPG - Brush 600 As Needed
Key to Lubricants: MPG - Multipurpose Grease
EPGL - Extreme Pressure Gear Lubricant
HO - Hydraulic Fluid
EO - Engine Oil
Figure 2-3. Lubrication Chart (Sheet 2 of 2)
6. Check platform rotator for smooth operation and a. Activate hydraulic system by depressing foot-
assure platform will rotate 90 degrees in both direc- switch. Operate TELESCOPE and hold control.
tions from centerline of boom.Raise, lower, and Remove foot from footswitch, motion should
swing boom to LEFT and RIGHT a minimum of 45 stop. If it does not, shut down machine and con-
degrees (Cycle function several times.) Check for tact a certified JLG service technician.
smooth elevation and swing motion. b. With footswitch depressed, operate LIFT and
7. Raise and lower Extend-A-Reach (Cycle functions hold control. Remove foot from footswitch,
several times). Check for smooth elevation and motion should stop. If it does not, shut down
swing motion. machine and contact a certified JLG service
technician.
8. Telescope boom in and out several cycles at various
c. With engine power shut down, depress the foot-
degrees of elevation lengths. Check for smooth tele-
switch. Attempt to start engine. Engine should
scope operation.
not attempt to start when footswitch is
9. Check that platform automatic self-leveling system depressed. If starter engages or engine turns
functions properly during raising and lowering of the over, shut down machine and contact a certified
boom. JLG service technician.
10. Check platform level adjustment system for proper 14. Auxiliary Power.
operation.
Operate each function control switch (e.g. TELE,
NOTE: Turntable lock is on turntable facing platform. To dis- LIFT and SWING) to assure that they function in
engage lock, pull snap pin from lock pin, lift lock pin both directions using auxiliary power instead of
up to unlock turntable. Return snap pin to lock pin to engine power.
hold lock pin in the disengaged position. Reverse
procedure to engage turntable lock. 15. Ground Controls.
11. Swing turntable to LEFT and RIGHT a minimum of Place GROUND/PLATFORM SELECT switch to
45 degrees. Check for smooth motion. GROUND. Start engine. Platform controls should not
operate.
12. With the aid of an assistant to monitor the CHASSIS
OUT OF LEVEL indicator light on the platform con-
trol console, manually activate the indicator light by 2.6 TORQUE REQUIREMENTS
compressing any one of the three tilt indicator
mounting springs. If the light does not illuminate, The Torque Chart (Figure 2-4.) consists of standard torque
shut down machine and contact a qualified service values based on bolt diameter and grade, also specifying
technician before continuing operation. dry and wet torque values in accordance with recom-
mended shop practices. This chart is provided as an aid
13. Footswitch. to the operator in the event a condition is noticed that
requires prompt attention during the walk-around inspec-
tion or during operation until the proper service personnel
FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL can be notified. The Service and Maintenance manual
OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF provides specific torque values and periodic maintenance
TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, procedures with a listing of individual components. Utiliz-
TOP OR BOTTOM, IT SHOULD BE ADJUSTED. ing this Torque Chart in conjunction with the preventive
maintenance section in the Service and Maintenance
manual, will enhance safety, reliability and performance of
the machine.
Capacities
3.3 OPERATING CHARACTERISTICS AND
LIMITATIONS Raising boom above horizontal and/or extension of boom
beyond retracted position with or without any load in plat-
General form, is based on the following criteria:
A thorough knowledge of the operating characteristics 1. Machine is positioned on a smooth, firm and level
and limitations of the machine is always the first require- surface.
ment for any user, regardless of the user’s experience with 2. Load is within manufacturer’s rated design capacity.
similar types of equipment.
3. All machine systems are functioning properly.
Placards 4. Proper tire pressure exists in the tires.
Important points to remember during operation are pro-
5. Machine is as originally equipped from JLG.
vided at the control stations by DANGER, WARNING,
CAUTION, IMPORTANT and INSTRUCTION placards. This
Stability
information is placed at various locations for the express
purpose of alerting personnel of potential hazards consti- This machine as originally manufactured by JLG Indus-
tuted by the operating characteristics and load limitations tries Inc., when operated within its rated capacity on a
of the machine. See FOREWORD for definitions of the smooth, firm and level supporting surface, and in accor-
above placards. dance with the instructions provided on the machine and
this manual, provides a stable machine for all platform
positions.
Machine stability is based on two positions which are
called FORWARD STABILITY and BACKWARD STABILITY.
The machines position of least forward stability is shown
in Figure 3-1., and its position of least backward stability is
shown in Figure 3-2.
76°
A three-position EXTEND-A-REACH lift control An hourmeter, installed in the ground control box,
switch provides raising/lowering of the Extend-A- registers the amount of time the machine has been
Reach when positioned up or down. in use, with the engine running. The hourmeter reg-
isters up to 9,999.9 hours and cannot be reset.
7. Telescope Control.
12. Voltmeter.
The three-position TELESCOPE control switch pro-
vides extension and retraction of the boom, when An voltmeter, installed in the ground control box,
positioned to in or out. indicates battery condition (i.e. charging or dis-
charging).
8. Swing Control.
13. Oil Pressure Gauge.
The three-position SWING control switch provides
360 degrees continuous turntable rotation when An oil pressure gauge, installed in the ground con-
positioned to right or left. trol box, provides an indication of the engine lubri-
cating oil pressure. Normal operating pressure at
2000 rpm is 40 to 60 psi.
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE 14. Axles Set Indicator.
MORE THEN ONE FUNCTION AT THE SAME TIME. SIMULTA-
NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP The AXLES SET indicator provides a visual indica-
MOTOR. tion that the extendable axles are properly set. It
consists of a green indicator that lights up when the
9. Auxiliary Power Control. axles are extended and the retaining pins are prop-
erly installed.
A toggle type AUXILIARY POWER control switch
energizes the electrically operated auxiliary hydrau-
lic pump, when actuated. The switch must be held in
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY
the ON position for the duration of auxiliary pump
CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING
use.
PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION
WHEN RELEASED.
The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine functions should
15. Rotate (If equipped).
the main hydraulic pumps or engine fail. The auxil-
iary pump enables the telescope, lift, and swing,
The three position platform ROTATE control switch
functions to be operated.
permits rotation of the platform when positioned to
left or right.
It should be noted that the functions will operate at a
slower than normal rate due to the lower amount of 16. Level.
hydraulic flow provided.
The three position platform LEVEL control switch
10. Circuit Breaker.
allows the operator to compensate for any differ-
ence in the automatic self leveling system by posi-
The 3 amp circuit breaker return control power to the
tioning the control switch to up or down.
High Engine circuit when depressed.
NOTE: The boom must be fully retracted in the stowed posi- NOTE: To operate the remote control box, set the SELECT
tion when axles are being extended. Also, the SWITCH to GROUND and start the engine.
SELECT SWITCH must be in the GROUND mode,
with the engine running. 1. Power/Emergency Stop Switch.
1. Axle Jack Control Switch. Position the Power/Emergency Stop switch to the on
position.
The axle jack control switch allows the operator to
2. Steer Switch (Front).
raise the axle so it can be extended before operating
the boom. Place the switch in the down position to
This switch allows the operator to steer the front
raise the axle, or to the up position to lower the axle.
wheels as desired. The Speed Control switch does
2. Axle Extension Switch not affect the steer function.
3. Drive Switch.
The axle extension switch allows the operator to
extend the axle after it has been raised by the axle
Position the Drive switch to forward or reverse as
jack. Place the switch to the left to extend the axle or
desired.
to the right to retract the axle.
4. Speed Control.
CAUTION
PLATFORM SHALL NOT BE
OCCUPIED WHILE USING
THIS CONTROL. KEEP
CLEAR OF MACHINE WHILE 4
DRIVING.
4
FWD
DRIVE DRIVE
REV
3
3
STEER STEER
LEFT RIGHT
2
2
ON
P
O
W
E
R 1
EMERG. STOP 1
PUSH DOWN
4 4
3 3
2 2
5 5
1 1
Platform Station. NOTE: LIFT, SWING, and DRIVE control levers or switches
are spring-loaded and will automatically return to the
NOTE: For engine starting, the footswitch must be in the neutral (OFF) position when released.
released (up) position. Footswitch must be actuated
in order for controls to function.
6. Lift.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DIS- The LIFT control lever provides raising and lowering
ABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS. of the boom when positioned to up or down and
automatically returns to off when released.
7. Telescope.
THE FOOTSWITCH MUST BE ADJUSTED SO FUNCTIONS WILL
OPERATE WHEN THE PEDAL IS APPROXIMATELY AT ITS CEN- The TELESCOPE switch provides extension and
TER OF TRAVEL. IF THE SWITCH OPERATES WITHIN LAST 6.35 retraction or the boom when positioned to in or out,
MM OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED. and automatically returns to off when released.
8. Swing.
2. Power/Emergency Stop.
The SWING control lever provides continuous swing
An on-off POWER/EMERGENCY STOP switch and a
when positioned to left or right.
separate START push button on the platform con-
sole supply electrical power to the starter solenoid, 9. Function Speed.
when the power switch is pulled out to the “on” posi-
tion and the START button is depressed. The FUNCTION SPEED switch controls the speed of
Extend-A-Reach, Telescope, Basket Rotate, and
3. Start Button.
Basket Level functions. Turning the knob to the left
slows the speed and turning the knob to the right
The START button is a momentary contact, push-
increases the speed.rols is dependent upon the
button switch. With the POWER /EMERGENCY
position of the STEER/AXLES selector valve.
STOP switch pulled up and the START button
depressed, electrical power is supplied to the start 10. Creep.
solenoid.
The CREEP switch allows the operator to select a
4. Warning Horn.
lower speed for DRIVE, LIFT, or SWING.
A push-type HORN switch, when pressed, supplies NOTE: When the boom is above horizontal, the DRIVE func-
electrical power to activate the horn. tion automatically goes into CREEP speed.
5. Chassis Out of Level Warning Light.
11. Drive/Steer Controller.
This red indicator lights to indicate that the chassis is
on a slope (over 3 degrees). If illuminated when The Drive/Steer controller allows the operator to
boom is raised or extended, retract and lower to select either forward or reverse when positioning the
below horizontal then reposition the machine so that controller to the desired position. The controller is
it is level before extending the boom or raising the electrically ramped to allow infinitely variable driving
boom above horizontal. speed between fast and slow. Also, a thumb oper-
ated switch on top of the lever controls steer for the
rear wheels.
The PLATFORM LEVEL control switch allows the The AUXILIARY POWER control switch energizes the
operator to compensate for any difference in the electrically operated hydraulic pump, when actu-
automatic self-leveling system by positioning the ated. The switch must be held on for duration of aux-
switch up or down. iliary pump use.
13. Platform Rotate.
The auxiliary pump functions to provide sufficient oil
flow to operate the basic machine system should the
The platform ROTATE control switch allows operator
main pump or engine fail. The auxiliary pump will
to rotate the basket to the left or right when posi-
operator boom lift, telescope and swing.
tioned to the desired direction.
14. Extend-A-Reach. It should be noted that the functions will operate at a
slower than normal rate because of lower hydraulic
The EXTEND-A-REACH LIFT control switch allows flow.
operator to raise or lower the snoot, as required.
15. Steer.
WHEN OPERATING ON AUXILIARY POWER, DO NOTOPERATE
Controls operation of the front steer wheels. When MORE THAN ONE FUNCTION AT THE SAME TIME. SIMULTA-
the steer switch is positioned right or left, the NEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
machine will steer in the corresponding direction. MOTOR.
16. Axles Set Indicator (If equipped). NOTE: The main function of the auxiliary power is to lower
the platform in the event of primary power failure.
The green AXLES SET indicator lights to inform the Determine the reason for primary power failure and
operator that the axles are set in position. have the problem corrected by a qualified service
technician.
NOTE: One of the capacity indicator lights should be illumi-
nated at all times during operation. If no capacity
NOTE: Auxiliary power is primarily intended for platform low-
lights are on, a bulb is probably burned out. Opera-
ering in the event of primary power failure. However,
tion of the machine must be halted until the lights are
auxiliary power may be used for platform positioning
working properly.
when operating in close quarters in the following
sequence:
17. Capacity Indicator.
a. Position PLATFORM/GROUND switch to PLAT-
The capacity indicator displays to the operator the
FORM.
maximum rated platform capacity and the maximum
radius for that capacity using colored lights and a b. Pull the POWER/EMERGENCYSTOP switch out
reach diagram. The operator must not exceed the to the on position.
rated capacity or the rated radius for the load (per- c. Depress and hold footswitch.
sonnel, tools, and supplies) shown on the indicator. d. Operate appropriate control switch or lever for
desired function and hold.
The blue light indicates operating within 500 lb.
range. A steady red light indicates you have e. Position AUXILIARY POWER switch on and hold.
exceeded the machines operating radius. You must f. Release AUXILIARY POWER switch, selected
immediately stop and ‘’LIFT UP’’ or ‘’TELE IN’’ until control switch or lever, and footswitch.
the red light goes out. A blinking red light and a g. Push the POWER/EMERGENCY STOP switch to
buzzer sounding indicates you have exceeded the the off position.
platform load capacity (personnel, tools, and sup-
plies). You must immediately stop and ‘’LIFT UP’’ or 19. Torque Switch.
‘’TELE IN’’ until the red light goes out and the buzzer
stops. Check to make sure the load in the platform With the Torque Switch in the upper position, the
does not exceed the rated capacity. operator will have maximum drive motor speed and
minimum torque. With the switch in the lower posi-
tion, you have minimum drive motor speed and
maximum torque. Use maximum torque for driving
on slopes or rough terrain.
AUXILIARY
or FUEL
POWER
PLATFORM
AXLE JACK
CONTROL
CREEP HORN
SLOW EXTEND-A-REACH
FAST LIFT
DRIVE TELESCOPE
MAXIMUM SPEED
SWING
MINIMUM TORQUE
PLATFORM
OFF
ROTATE
START STEER
IGNITION/
BROKEN
EMERGENCY or CHAIN
STOP
Updated 4-20-00
3120685 – JLG Lift – 4-1
SECTION 4 - MACHINE OPERATION
5. Repeat steps 1 thru 3 for the for the rear axle. The
4.5 AXLES machine is now ready for boom operations.
NOTE: To extend or retract jacks or to extend or retract the
axles, the boom must be below horizontal and not To Retract the Axles
extended more than 10 feet (3 meters). The machine
must also be on a flat, level surface. 1. Remove the pins from the front steer cylinder and tie
rod. Be sure the SELECT SWITCH is set to
GROUND. On machines after S/N 47227, place the
To Extend the Axles
spindle stop pin in the Axle Extend/Retract position.
1. Remove the pins from the front steer cylinder and tie
rod. Be sure the SELECT SWITCH is set to
GROUND.
2. Machines after S/N 47227 have spindle stop pins to
keep the spindles centered while extending the axle.
Place the stop pin in the hole closest to the spindle
as shown.
A RED TILT ALARM WARNING LIGHT, LOCATED ON THE CON- ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE
TROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE STARTING ANY SWING OPERATION.
SLOPE (5 DEGREES OR GREATER). DO NOT SWING, EXTEND OR
RAISE BOOM ABOVE HORIZONTAL WHEN LIT. Depress footswitch to swing boom, position SWING con-
trol switch or controller to RIGHT or LEFT for direction
desired.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR
THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A NOTE: When boom functions are being operated there is an
SEVERE SLOPE (5 DEGREES OR GREATER). CHASSIS MUST BE interlock that prevents the use of DRIVE and STEER
LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM functions.
ABOVE HORIZONTAL.
Raising and Lowering the Main Boom
TO AVOID UPSET, IF RED TILT ALARM WARNING LIGHT LIGHTS
WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZON- To raise and lower Boom, position LIFT control switch or
TAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND controller to UP OR DOWN and hold until desired height is
LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS reached.
LEVEL BEFORE EXTENDING OR RAISING BOOM.
Telescoping the Main Boom
TRAVELING WITH BOOM RETRACTED AND BELOW HORIZONTAL To extend or retract Boom, position TELESCOPE control
IS PERMITTED ON GRADES SPECIFIED ON SERIAL NUMBER switch to IN or OUT and hold until platform reaches
PLATE. desired position.
GRADE
SIDESLOP
E
LEVEL
DO NOT DRIVE MACHINE ON GRADES AND SIDESLOPES
EXCEEDING THOSE SPECIFIED ON SERIAL NUMBER PLATE
4. Remove all load and allow engine to operate 3-5 engaged and machine securely tied down to truck or
minutes at LOW setting to permit reduction of trailer deck. Four tie down eyes are provided in the frame
engine internal temperatures. slab, one at each corner of the machine.
5. At Ground Controls, turn MASTER SWITCH to (cen- If it becomes necessary to lift the machine using an over-
ter) OFF. Position, the IGNITION switch (down) to head or mobile crane, it is very important that the lifting
OFF. devices are attached only to the designated lifting eyes,
and that the turntable lock pin is engaged. See Figure 4-3,
6. Cover the Platform Control Console to protect
Lifting Chart.
instruction placards, warning decals and operating
controls from hostile environment. NOTE: Lifting eyes are provided at the front and rear in the
frame slab. Each of the four chains or slings used for
lifting machine must be adjusted individually so
4.10 TIE DOWN AND LIFTING machine remains level when elevated.
When transporting machine, boom and extend-a-reach
must be in the stowed mode with turntable lock pin
– JLG Lift –
Figure 4-3. Machine Tie Down - Sheet 1
3120685
SECTION 4 - MACHINE OPERATION
LIFT HERE
CENTER
OF
GRAVITY
A
L ROTATION
C
5.1 COLD START KIT (DIESEL ENGINE) 5.5 HOSTILE ENVIRONMENT PACKAGE
A cold weather start system for the diesel engine functions The hostile environment package provides additional pro-
automatically to provide starting fluid, as necessary, to the tection against the entry of dust, dirt, sand and other abra-
engine during starting. A sensor switch mounted on the sive materials into the hydraulic system, control handles
engine will permit ether injection into the air intake when and switches, cylinders, boom wire ropes and wear pads,
the engine is cold. A temperature sensor will not permit and the air inlet of the engine. The package is intended for
ether injection into a cold engine. machines that will be exposed to painting, sandblasting or
other similar hostile conditions. The hostile environment
package includes boom wipers, cylinder bellows, heavy
5.2 TRAVEL/MOTION ALARM duty reservoir breather, an engine air cleaner and control
console cover, as required.
A 12-volt alarm horn, mounted on the turntable, provides
an audible warning when the machine is in the travel
(DRIVE) mode. It will function in FORWARD or REVERSE
to warn jobsite personnel the machine is traveling.
5.6 110 VOLT GENERATOR
A 110 volt generator, mounted beside the engine, is belt
driven from the output shaft of the engine. This application
5.3 TILT ALARM provides for a 110 volt receptacle at the ground control
and also at the platform. The lead from the ground control
Senses when the machine is out of level in any direction
and also at the platform. The lead from the ground control
approximately 5 degrees and illuminates a warning light at
to the platform is routed along the boom power track thus
the platform control station and sounds the machine’s
eliminating the use of extension cords hanging freely from
horn, signaling the operator. A second switch mounted on
the platform.
the machine senses when the machine is out of level 5
degrees and will cut out two speed drive when activated.
6.1 GENERAL
This section provides information on the procedures to be
followed and on the systems and controls to be used in
the event an emergency situation is encountered during
machine operation. Prior to operation of the machine and
periodically thereafter, the entire operating manual, includ- DISCONNECT
ing this section, should be reviewed by all personnel CAP
whose responsibilities include any work or contact with
the machine.
Ground Control Station 2. To steer, push the steer switch to the left or to the
right.
The Ground Control Station is located on the right front
side of the turntable. The controls on this panel provide 3. To drive, push the drive switch to forward or reverse.
the means for overriding the platform controls, and for
4. The speed control switch controls the speed of the
controlling the platform level, boom and swing functions
drive function. Rotate the switch to increase or
from the ground. Place the SELECT switch to GROUND
decrease the drive speed.
position and operate the proper switch to lift, swing, or
telescope the boom, or level the platform.
4. Position the AUXILIARY POWER switch to ON and 3. Cranes, forklift trucks or other equipment which may
hold. be available are to be used to remove platform
occupants and stabilize motion of the machine in
5. Release the AUXILIARY POWER switch, and appro- case machine controls are inadequate or malfunc-
priate control switch or controller. tion when used.
6. Position the EMERGENCY STOP switch to OFF.
Platform or Boom Caught Overhead
Remote Control Box If the platform or boom becomes jammed or snagged in
The remote control box is located behind the left rear overhead structures or equipment, do not continue opera-
access door on the turntable. To use these controls, the tion of the machine from either the platform or the ground
engine must be running and the SELECT SWITCH must until the operator and all personnel are safely moved to a
be in the ground position. secure location. Only then should an attempt be made to
free the platform using any necessary equipment and per-
1. Pull the POWER/EMERGENCY STOP out. sonnel. Do not operate controls to cause one or more
wheels to leave the ground.
Date Comments
Date Comments
TRANSFER OF OWNERSHIP
To: JLG, Gradall, Lull and Sky Trak 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 (717) 485-
6573 or mail to address as specified on the back of this form.
Thank you,
Product Safety & Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533
Telephone: (717) 485-5161
Fax: (717) 485-6573
Mfg. Model:
Serial Number:
Previous Owner:
Address:
Please cut on the dotted line and fax to 717-485-6573
City: State:
Zip: Telephone: ( )
Date Of Transfer:
Current Owner:
Address:
City: State:
Zip: Telephone: ( )
Name:
Title:
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
Phone: (717) 485-5161
Fax: (717) 485-6417
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762