JLG 1850 Operation and Safety Manual

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

1850SJ
ANSI ®
3121618
May 14, 2015
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
3121618 – JLG Lift – a

FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
GROUND. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
GROUND.
b – JLG Lift – 3121618

FOREWORD
For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- Compliance Information
• Product Safety Publica-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions • Questions Regarding Special
THIS PRODUCT.
Product Applications
• Current Owner Updates
• Questions Regarding Prod-
• Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE Hagerstown, MD 21742
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY USA
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-
or Your Local JLG Office
SONAL PROPERTY OR THE JLG PRODUCT.
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: [email protected]
3121618 – JLG Lift – c

FOREWORD
REVISION LOG
Original Issue - March 24, 2014

Revised -September 5, 2014
Revised -January 5, 2015
Revised -May 14, 2015
d – JLG Lift – 3121618

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

SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Boom Control System Check Procedure . . . . . . . . . . . . 2-8
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-7
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-18
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, Controlled Arc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
AND INSPECTION Envelope Tracking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Controlled Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Swing Speed Proportioning. . . . . . . . . . . . . . . . . . . . . . . . 4-3
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.3 CAPACITY SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 4.4 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
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TABLE OF CONTENTS

Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-9 4.16 STOWING THE JIB FOR TRANSPORT. . . . . . . . . . . . . . . . . . 4-19
4.5 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-13 SECTION - 5 - LCD DISPLAY PANEL
4.6 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 5.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.7 EXTENDING THE AXLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 5.2 BOOT UP SPLASH SCREEN. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
4.8 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 5.3 MACHINE OPERATING SCREEN . . . . . . . . . . . . . . . . . . . . . . . 5-4
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-14 Diagnostic Trouble Code (DTC) Tray . . . . . . . . . . . . . . . 5-5
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Console Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
4.9 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Icons Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Machine Status Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Raising and Lowering the Boom . . . . . . . . . . . . . . . . . . 4-15 5.4 KEYSWITCH IN GROUND MODE: . . . . . . . . . . . . . . . . . . . . . . 5-6
Telescoping the Boom. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.5 FUNCTION SPEED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Telescoping the Jib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.6 CAN BUS LOST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Stowing/Swinging the Jib . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.7 TAKE FOOT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
4.10 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.8 PUT FOOT IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) 5.9 BCS LAMP ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.10 BROKEN CABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
4.12 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 5.11 PLATFORM LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
4.13 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 5.12 PLATFORM OVERLOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
4.14 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 5.13 CAPACITY MODE ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
4.15 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.14 SWING DTCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.15 JIB UNLOCKED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.16 JIB LOCKED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
5.17 CHASSIS STATUS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Axles Retracted In Transport Position . . . . . . . . . . . . . 5-21
Axles Extended. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
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TABLE OF CONTENTS

Axles Retracted In Out of Transport Position . . . . . . 5-23 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Axles In Transient State . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
5.18 MACHINE TILTED MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 7-4
5.19 ENVELOPE STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
5.20 MACHINE MODEL UNKNOWN . . . . . . . . . . . . . . . . . . . . . . . 5-29 7.3 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . 7-12
7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
SECTION - 6 - EMERGENCY PROCEDURES Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
6.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
6.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
6.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Operator Unable to Control Machine . . . . . . . . . . . . . . . 6-1 Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Platform or Boom Caught Overhead. . . . . . . . . . . . . . . . 6-2 7.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-22
Boom Movement Prevented By Boom
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 SECTION - 8 - INSPECTION AND REPAIR LOG
6.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . 6-2
6.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE
7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS AND PERFORMANCE
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
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This Page Left Blank Intentionally.
iv – JLG Lift – 3121618

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

2-1. Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-9 4-12. Decal Location Sheet 6 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
2-2. Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . 2-10 4-13. Decal Location Sheet 7 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
2-3. Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . 2-11 4-14. Decal Location Sheet 8 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
2-4. Daily Walk-Around Inspection - Sheet 1 of 5 . . . . . . . . . 2-12 4-15. Decal Location Sheet 9 of 9 . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
2-5. Daily Walk-Around Inspection - Sheet 2 of 5 . . . . . . . . . 2-13 5-1. LCD Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
2-6. Daily Walk-Around Inspection - Sheet 3 of 5 . . . . . . . . . 2-14 5-2. Boot Up Splash Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
2-7. Daily Walk-Around Inspection - Sheet 4 of 5 . . . . . . . . . 2-15 5-3. Manual Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
2-8. Daily Walk-Around Inspection - Sheet 5 of 5 . . . . . . . . . 2-16 5-4. Lanyard Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
3-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 5-5. Select Capacity Zone Screen . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
3-2. Ground Control Console with Machine Safety System 5-6. Machine Operating Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Override (MSSO) (CE Only). . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 5-7. Keyswitch In Ground Mode Screen . . . . . . . . . . . . . . . . . . . 5-6
3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-8 5-8. Function Speed Icons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11 5-9. CAN Bus Lost Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
3-5. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-19 5-10. Take Foot Out Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
3-6. Fuel Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21 5-11. Put Foot In Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-5 5-12. BCS Lamp Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
4-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-6 5-13. Broken Cable Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
4-3. Grade and Side Slopes - Sheet 1 of 2 . . . . . . . . . . . . . . . . . 4-11 5-14. Level System DTC Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
4-4. Grade and Side Slopes - Sheet 2 of 2 . . . . . . . . . . . . . . . . . 4-12 5-15. Overload DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
4-5. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 5-16. Capacity Mode Error Screen . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
4-6. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 5-17. Swing DTC Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-18
4-7. Decal Location Sheet 1 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 5-18. Jib Unlocked Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
4-8. Decal Location Sheet 2 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 5-19. Jib Locked Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
4-9. Decal Location Sheet 3 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 5-20. Axles Retracted Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
4-10. Decal Location Sheet 4 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 5-21. Axles Extended Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
4-11. Decal Location Sheet 5 of 9. . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 5-22. Axles In Transient State Screen . . . . . . . . . . . . . . . . . . . . . . 5-23
3121618 – JLG Lift – v

LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
5-23. Machine Tilted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . 5-24
5-24. Unrestricted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
5-25. Restricted Mode Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5-26. Machine Model Unknown Screen . . . . . . . . . . . . . . . . . . . 5-29
7-1. Engine Operating Temperature Specifications . . . . . . . . 7-8
7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2. . . . . . . . . . . 7-9
7-3. Hydraulic Oil Operation Chart - Sheet 2 of 2. . . . . . . . . . 7-10
7-4. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . 7-11
vi – JLG Lift – 3121618

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

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
4-2 Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
7-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Engine Data - Deutz TD 3.6L . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-10 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .7-12
7-14 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-21
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
3121618 – JLG Lift – vii

LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
This Page Left Blank Intentionally.
viii – JLG Lift – 3121618

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”).
3121618 – JLG Lift – 1-1

• An operator must not accept operating responsibilities until Workplace Inspection

adequate training has been given by competent and autho-
rized persons. • Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Allow only those authorized and qualified personnel to oper-
ate the machine who have demonstrated that they under- • Do not operate or raise the platform from a position on trucks,
stand the safe and proper operation and maintenance of the trailers, railway cars, floating vessels, scaffolds or other equip-
unit. ment unless the application is approved in writing by JLG.
• Read, understand, and obey all DANGERS, WARNINGS, CAU- • Before operation, check work area for overhead hazards such
TIONS, and operating instructions on the machine and in this as electric lines, bridge cranes, and other potential overhead
manual. obstructions.
• Ensure that the machine is to be used in a manner which is • Check operating surfaces for holes, bumps, drop-offs, obstruc-
within the scope of its intended application as determined by tions, debris, concealed holes, and other potential hazards.
JLG. • Check the work area for hazardous locations. Do not operate
• All operating personnel must be familiar with the emergency the machine in hazardous environments unless approved for
controls and emergency operation of the machine as specified that purpose by JLG.
in this manual. • Ensure that the ground conditions are adequate to support
• Read, understand, and obey all applicable employer, local, and the maximum tire load indicated on the tire load decals
governmental regulations as they pertain to your utilization located on the chassis adjacent to each wheel. Do not travel
and application of the machine. on unsupported surfaces.
1-2 – JLG Lift – 3121618

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.
3121618 – JLG Lift – 1-3

• Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature,
approved by JLG. ambient air temperature, and boom and platform position.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
Trip and Fall Hazards
• Always ensure that power tools are properly stowed and never • During operation, occupants in the platform must wear a full
left hanging by their cord from the platform work area. body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard
• When driving, always position boom over rear axle in line with anchorage point.
the direction of travel. Remember, if boom is over the front
axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing or pull-
ing except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating • Enter and exit only through gate area. Use extreme caution
machine. Do not wear loose fitting clothing or long hair unre- when entering or leaving platform. Ensure that the platform
strained which may become caught or entangled in equip- assembly is fully lowered. Face the machine when entering or
ment. leaving the platform. Always maintain “three point contact”
• Persons under the influence of drugs or alcohol or who are with the machine, using two hands and one foot or two feet
subject to seizures, dizziness or loss of physical control must and one hand at all times during entry and exit.
not operate this machine.
• Hydraulic cylinders are subject to thermal expansion and con-
traction. This may result in changes to the boom and/or plat-
form position while the machine is stationary. Factors
affecting thermal movement can include the length of time
1-4 – JLG Lift – 3121618

• 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.
3121618 – JLG Lift – 1-5

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

(Phase to Phase) in Feet (Meters)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.
• Maintain distance from electrical lines, apparatus, or any ener-
gized (exposed or insulated) parts according to the Minimum • Maintain a clearance of at least 10 ft. (3m) between any part of
Approach Distance (MAD) as shown in Table 1-1. the machine and its occupants, their tools, and their equip-
• Allow for machine movement and electrical line swaying. ment from any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
1-6 – JLG Lift – 3121618

• 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.
3121618 – JLG Lift – 1-7

• Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions exceed 28
platform. Keep all loads within the confines of the platform, mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Refer-
unless authorized by JLG. ence Only).
• Keep the chassis of the machine a minimum of 2 ft. (0.6m) • Do not increase the surface area of the platform or the load.
from holes, bumps, drop-offs, obstructions, debris, concealed Increase of the area exposed to the wind will decrease stabil-
holes, and other potential hazards at the ground level. ity.
• Do not push or pull any object with the boom. • Do not increase the platform size with unauthorized deck
extensions or attachments.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure. Never attach wire, cable, or • If boom assembly or platform is in a position that one or more
any similar items to platform. wheels are off the ground, all persons must be removed before
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine.
1-8 – JLG Lift – 3121618

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.
3121618 – JLG Lift – 1-9

Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Approved head gear must be worn by all operating and
• Under all travel conditions, the operator must limit travel
ground personnel.
speed according to conditions of ground surface, congestion,
• Check work area for clearances overhead, on sides, and bot- visibility, slope, location of personnel, and other factors which
tom of platform when lifting or lowering platform, and driving. may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driv-
ing in high speed, switch to low speed before stopping. Travel
grades in low speed only.
• Do not use high speed drive in restricted or close quarters or
when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Dis-
connect power to overhead cranes.
• During operation, keep all body parts inside platform railing.
• Warn personnel not to work, stand, or walk under a raised
• Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary.
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.
1-10 – JLG Lift – 3121618

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

• Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must
hauling. be observed during maintenance of this machine. Additional pre-
cautions to be observed during machine maintenance are
• This machine should not be towed, except in the event of
inserted at the appropriate points in this manual and in the Ser-
emergency, malfunction, power failure, or loading/unloading.
vice and Maintenance Manual. It is of utmost importance that
Refer to the Emergency Procedures section of this manual for
maintenance personnel pay strict attention to these precautions
emergency towing procedures.
to avoid possible injury to personnel or damage to the machine
• Ensure boom is in the stowed position and the turntable or property. A maintenance program must be established by a
locked prior to towing, lifting or hauling. The platform must be qualified person and must be followed to ensure that the
completely empty of tools. machine is safe.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity. Maintenance Hazards
• Refer to the Machine Operation section of this manual for lift- • Shut off power to all controls and ensure that all moving parts
ing information. are secured from inadvertent motion prior to performing any
adjustments or repairs.
• Never work under an elevated platform until it has been fully
lowered to the full down position, if possible, or otherwise
supported and restrained from movement with appropriate
safety props, blocking, or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic hoses or fit-
tings while the machine is powered on or when the hydraulic
system is under pressure.
• Always relieve hydraulic pressure from all hydraulic circuits
before loosening or removing hydraulic components.
3121618 – JLG Lift – 1-11

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

• Ensure replacement parts or components are identical or ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
equivalent to original parts or components.
• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in an
unstable position. Ensure adequate support is provided when
raising components of the machine.
1-12 – JLG Lift – 3121618

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.
3121618 – JLG Lift – 1-13

NOTES:
1-14 – JLG Lift – 3121618

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.
3121618 – JLG Lift – 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A
maintenance required by JLG Industries, Inc. Consult local regula- PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL
tions for further requirements for aerial work platforms. The fre- FOR THE SPECIFIC JLG PRODUCT MODEL.
quency of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile environ-
ment, if the machine is used with increased frequency, or if the
machine is used in a severe manner.
2-2 – JLG Lift – 3121618

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 Operation 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.
3121618 – JLG Lift – 2-3

Pre-Start Inspection 4. Operation and Safety Manuals – Make sure a copy of the
Operation and Safety Manual, AEM Safety Manual (ANSI
The Pre-Start Inspection should include each of the following: markets only), and ANSI Manual of Responsibilities (ANSI
markets only) is enclosed in the weather resistant storage
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-
container.
tery fluid) or foreign objects. Report any leakage to the
proper maintenance personnel. 5. “Walk-Around” Inspection – Refer to Figure 2-4.
2. Structure - Inspect the machine structure for dents, dam- 6. Battery – Charge as required.
age, weld or parent metal cracks or other discrepancies.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Engine Oil Supply - Ensure the engine oil level is at the Full
mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
Parent Metal Crack Weld Crack 10. Accessories/Attachments - Reference the Operation and
Safety Manual of each attachment or accessory installed
3. Decals and Placards – Check all for cleanliness and legibil- upon the machine for specific inspection, operation, and
ity. Make sure none of the decals and placards are missing. maintenance instructions.
Make sure all illegible decals and placards are cleaned or
replaced.
2-4 – JLG Lift – 3121618

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

complete, perform a functional check of all systems in an
area free of overhead and ground level obstructions. Refer to Perform the Function Check as follows:
Section 4 for more specific operating instructions.
1. From the ground control console with no load in the plat-
12. Boom Control System Check - Perform a check of the form:
boom control system as specified in this section.
a. Check that all guards protecting the switches or locks
are in place.
b. Operate all functions and ensure proper operation.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
c. Check auxiliary power and ensure proper operation.
ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. 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. Check the Boom Control System. Refer to Boom Control Sys-
tem Check Procedure later in this section.
3121618 – JLG Lift – 2-5

3. From the platform control console: 5. With the jib inline with the boom and locked, make sure the
jib will not unlock unless:
a. Ensure that the control console is firmly secured in the
proper location. a. The machine is in transport position (booms retracted;
b. Check that all guards protecting the switches or locks main boom below elevation [5 degrees]).
are in place. b. Jib boom retracted; axles retracted.
c. Operate all functions and ensure proper operation. c. The boom capacity select switch is in 500# mode.
d. Ensure that all machine functions are disabled when 6. With the jib in the stowed position, make sure the jib will not
the Emergency Stop Button is pushed in. swing unless:
e. Ensure that all machine functions stop when the foot-
a. The jib is fully retracted.
switch is released.
b. The machine is in transport position (booms retracted;
4. With the platform in the stowed position: main boom below elevation [5 degrees]; axles
a. Drive the machine on a grade, not to exceed the rated retracted).
gradeability, and stop to ensure the brakes hold. c. The boom capacity select switch is in 500# mode.
b. Check that the tilt indicator is illuminated to ensure 7. Extend the axles and swing the boom over either of the rear
proper operation. tires and ensure that the Drive Orientation indicator illumi-
c. Check that the boom telescope (beyond transport nates and that the Drive Orientation Override switch must
mode), lift up (more than 5° above horizontal), and be used for the drive function to operate.
swing (beyond 35° from center) functions are disabled
with the axles retracted.
2-6 – JLG Lift – 3121618

SkyGuard Function Test NOTE: If the machine is equipped with both SkyGuard and Soft Touch,
functions will not reverse, only stop.
From the Platform Console:
NOTE: If equipped, ensure the blue beacon illuminates when SkyGuard
Test the SkyGuard feature by operating the telescope out func-
is activated.
tions and then activating the SkyGuard sensor. The telescope out
function will stop and the telescope in function will operate for a
Disengage the SkyGuard sensor, release controls, recycle the foot
short duration and the horn will sound until the SkyGuard sensor
switch, make sure normal operation is available.
and footswitch are disengaged.
If SkyGuard remains activated after function reversal or cutout,
depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the SkyGuard sensor is disen-
gaged.
3121618 – JLG Lift – 2-7

Boom Control System Check Procedure 5. Boom must stop on colored stripe matching the capacity
indicator. If the boom does not stop on the correct stripe,
Perform the following check with no load (personnel or material) the system must be repaired by JLG authorized Service Per-
in the platform from the ground control console. sonnel before the machine can be used.
1. Extend all axles fully. 6. Push and hold the gray Boom Control System Test Button on
the ground control console. The lighting of the green Boom
2. With the boom fully retracted, raise the boom off the boom
Control System Calibrated indicator indicates the system is
rest to horizontal.
functioning properly. No indicator light or the lighting of the
3. Position the jib horizontal and fully retracted, jib straight and red Boom Control System Warning indicator indicates the
locked, and platform level. system must be repaired by JLG authorized Service Person-
nel before the machine can be used.
4. Extend the boom until it stops.
2-8 – JLG Lift – 3121618

1. Platform Control Console

2. Jib
3. Main Boom
4. Powertrack
5. Turntable
6. Ground Control Console
7. Chassis
8. Platform Level Cylinder
9. Platform Rotator
10. Platform
11. SkyGuard (If Equipped)
Figure 2-1. Basic Nomenclature - Sheet 1 of 3
3121618 – JLG Lift – 2-9

12. Boom Section 1

13. Boom Section 2
14. Boom Section 3
15. Boom Section 4
16. Boom Section 5
17. Jib Rotator
18. Jib Lift Cylinder
2-10 – JLG Lift – 3121618

19. Tire and Wheel

20. Axle
21. Frame
22. Drive Hub
23. Swing Bearing
24. Axle Extend Cylinder
25. Drive Motor
3121618 – JLG Lift – 2-11

Figure 2-4. Daily Walk-Around Inspection - Sheet 1 of 5
2-12 – JLG Lift – 3121618

3121618 – JLG Lift – 2-13

2-14 – JLG Lift – 3121618

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

levers return to neutral, decals/placards secure and legible,
control markings legible.
3121618 – JLG Lift – 2-15

12. Hydraulic Pump - See Inspection Note. 15. Axles - See Inspection Note.
13. Platform Rotator - See Inspection Note. 16. SkyGuard - See Inspection Note.
14. Jib Rotator and Jib Lock Cylinder - See Inspection Note.
2-16 – JLG Lift – 3121618

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.
3121618 – JLG Lift – 3-1

2. Jib Telescope
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR Provides extension and retraction of
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE the jib.
OFF POSITION WHEN RELEASED.
Ground Control Console

3. Platform Rotate
See Figure 3-1., Ground Control Console and Figure 3-2., Ground Control
Provides rotation of the platform.
Console with Machine Safety System Override (MSSO) (CE Only).
NOTE: The Function Enable switch must be held down in

order to operate Main Boom Telescope, Swing,
Main Lift, Jib Lift, Platform Level Override, Plat-
form Rotate, and Jib Telescope functions.
1. Indicator Panel
The Indicator Panel contains indicator lights that signal

problem conditions or functions operating during machine
operation.
3-2 – JLG Lift – 3121618

1. Indicator Panel
2. Jib Telescope
3. Platform Rotate
4. Platform Leveling Override
5. Jib Lift
6. Engine Start/Auxiliary Power Switch/Function Enable
7. Power/Emergency Stop
8. Hourmeter
9. Platform/Ground Select
10. Main Lift
11. Not Used
12. Swing
13. Telescope
14. Boom Control System Test
Figure 3-1. Ground Control Console
3121618 – JLG Lift – 3-3

1. Indicator Panel
2. Jib Telescope
3. Platform Rotate
5. Jib Lift
6. Engine Start/Auxiliary Power Switch/Function Enable
8. Hourmeter
9. Platform/Ground Select
10. Main Lift
11. Machine Safety System Override (MSSO)
12. Swing
13. Telescope
14. Boom Control System Test
Figure 3-2. Ground Control Console with Machine Safety System Override (MSSO) (CE Only)
3-4 – JLG Lift – 3121618

NOTE: Auxiliary power only works if there is no engine oil pressure, and
is disabled if engine is running.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR Functions will operate at a slower than normal rate because of
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. the reduced hydraulic flow.
A three position switch allows WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A
the operator to adjust the TIME. SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.
automatic self leveling sys-
tem. This switch is used to 6. Engine Start/ Auxiliary Power Switch /Function Enable
adjust platform level in situa- To start the engine, the switch must be held
tions such as ascending/ "UP" until the engine starts.
descending a grade.
To use auxiliary power, the switch must be
5. Jib Lift held “DOWN” for duration of auxiliary pump
use.
Provides raising and lowering of
the jib. When the engine is running, the switch must
be held "DOWN" to enable all boom controls.
WHEN THE MACHINE IS SHUT DOWN THE POWER/EMERGENCY STOP SWITCH MUST BE
POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERIES.
3121618 – JLG Lift – 3-5

7. Power/Emergency Stop Switch NOTE: With Platform/Ground Select switch in the center position,
power is shut off to controls at both operating consoles.
A two-position red mushroom shaped switch
supplies power to Platform/Ground Select 9. Platform/Ground Select Switch
switch when pulled out (on). When pushed in
(off ), power is shut off to the Platform/Ground Select switch. A three position, key operated switch sup-
plies power to the platform control console
8. Hourmeter
when positioned to Platform. With the switch
key positioned in the Ground position, power
Registers the amount of time the machine
is shut off to platform and only ground controls are opera-
has been in use, with engine running. In the
ble.
event of a fault, the hourmeter also displays
the three digit fault code. Refer to the Service 10. Main Lift
Manual for a listing of fault codes. Additionally, there is a
small, red indicator light that will blink when there is a fault Provides raising and lowering of
on the machine to draw operator attention to the display. the main boom.
11. Machine Safety System Override (MSSO) (CE

Only)
Provides emergency override of function

controls that are locked out as in the event
of Load Sense System activation.
3-6 – JLG Lift – 3121618

12. Swing Ground Control Indicator Panel

Provides 360 degrees continuous
(See Figure 3-3., Ground Control Indicator Panel)
turntable rotation.
1. No Alternator Output Indicator
Indicates a problem in the charging circuit,

and service is required.
13. Main Telescope
2. Low Engine Oil Pressure Indicator
Provides extension and retraction
of the main boom. Indicates that engine oil pressure is below
normal and service is required.
3. High Engine Temperature Indicator
Indicates that engine coolant temperature

14. Boom Control System Test Button is abnormally high and service is required.
The push button is used to test the

boom control system and confirm
that it is working properly.
3121618 – JLG Lift – 3-7

1. No Alternator Output 4. Glow Plug Indicator 7. Platform Overload

2. Low Engine Oil Pressure 5. Axles Set 8. Boom Control System Warning
3. High Engine Coolant Temperature 6. Platform Capacity 9. Boom Control System Calibrated
Figure 3-3. Ground Control Indicator Panel
3-8 – JLG Lift – 3121618

4. Glow Plug Indicator 7. Platform Overload Indicator (If Equipped)
Indicates the glow plugs are operating. Indicates the platform has been over-
After turning on ignition, wait until light loaded.
goes out before cranking engine.
8. Boom Control System Warning Indicator
5. Axles Set Indicator
Indicates the platform is outside the oper-
Indicates that the axles are fully extended. ating area and operation of certain boom
The indicator will flash as the axles are functions may be disabled (i.e. lift, tele-
extending or retracting and be on solid scope). Attempts to use the disabled
when fully extended. The light will go out functions cause the indicator to flash and
when the axles are fully retracted. an alarm to sound. Immediately return the platform to the
ground. If the indicator remains lit, a boom control system
6. Platform Capacity Indicator
fault or failure has been detected. If a failure is discovered,
the system must be repaired by JLG authorized service per-
Indicates which capacity range is selected.
sonnel before the machine can be used.
This capacity can only be selected at the plat-
form control console. 9. Boom Control System Calibrated Indicator
When the Boom Control System Test But-

ton is pushed, illuminates to indicate that
the Boom Control System is calibrated
properly.
3121618 – JLG Lift – 3-9

Platform Console 2. Steer Select
The action of the steering system is opera-

(See Figure 3-4., Platform Control Console)
tor selectable. The center switch position
gives conventional front wheel steering
with the rear wheels unaffected. This is for
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR normal driving at maximum speeds. The
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE forward position is for “crab” steering. When in this mode
OFF OR NEUTRAL POSITION WHEN RELEASED. both front and rear axles steer in the same direction, which
allows the chassis to move sideways as it goes forward. This
1. Drive Speed/Torque Select can be used for positioning the machine in aisle ways or
close to buildings. The back switch position is for “coordi-
The forward position gives maximum drive nated” steering. In this mode the front and rear axles steer in
speed. The back position gives maximum the opposite directions to produce the tightest turning cir-
torque for rough terrain and climbing cle for maneuvering in confined areas.
grades. The center position allows the machine to be driven
as quietly as possible.
3-10 – JLG Lift – 3121618

1. Drive Speed/Torque Select 7. Boom Control Select 13. Main Telescope 19. Soft Touch/SkyGuard Indicator
2. Steer Select 8. Power/Emergency Stop 14. Lights 20. Platform Rotate
3. Platform Leveling Override 9. Start/Auxiliary Power 15. Jib Lift 21. Lock Pin Indicator
4. Axle Extend/Retract 10. Capacity Select 16. Soft Touch/SkyGuard Override 22. Function Speed Control
5. Horn 11. Drive Orientation Override 17. Jib Stow 23. Main Lift/Swing
6. Indicator Panel 12. Drive/Steer 18. Jib Telescope
Figure 3-4. Platform Control Console
3121618 – JLG Lift – 3-11

5. Horn
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF A push-type HORN switch supplies electrical
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR power to an audible warning device when pressed.
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
6. Indicator Panel
The LED Indicator Panel contains indicator lights that signal
problem conditions or functions operating during machine
A three position switch allows the operator to
operation.
adjust the automatic self leveling system. This
switch is used to adjust platform level in situa-
Within about 2 seconds of pulling the Power/Emergency
tions such as ascending/descending a grade.
Stop switch out, the machine will perform a diagnostic
check of the various electrical circuits, and if everything is
4. Axle Extend/Retract OK, the platform alarm will beep once. During this time the
lights on the indicator panel will also blink once as a bulb
Allows the operator to extend or retract check.
the axles. The axles can only be extended
or retracted while the machine is being
driven forward or reverse.
3-12 – JLG Lift – 3121618

7. Boom Control Select NOTE: Depending upon the angle of the chassis and the angle of the
boom, swing left or swing right may be disallowed while in the
Automatic Mode:
Manual mode. The BCS light will illuminate and further attempts
to swing in the disallowed direction will cause the BCS to flash.
When the Boom Control is positioned to Auto-
When this occurs the only choices are to swing in the opposite
matic, lift and telescope movements are coordi-
direction or switch to automatic mode.
nated by the JLG control system and the
automatic platform leveling feature is active
during lift, telescope, swing, and drive movements.
NOTE: • While operating lift up, the boom may also telescope out. A two-position red mushroom shaped switch
• While operating lift down, the boom may also telescope in. supplies power to Platform Controls when
• While operating swing or drive, the boom may lift up or lift pulled out (on). When pushed in (off ), power is
down. shut off to the platform controls.
• While operating telescope in, the boom may lift down when at
high boom angles and the creep light is flashing.
Manual Mode:
When the boom control is positioned to Man-

ual, lift and telescope movements are con-
trolled separately by the operator and the
automatic platform leveling feature is active
only during lift functions.
NOTE: When positioned to Manual, boom functions will be stopped

when the envelope limits are reached. When this occurs, operate
a different function or select the automatic position.
3121618 – JLG Lift – 3-13

9. Start/Auxiliary Power 11.Drive Orientation Override
When pushed forward, the switch energizes the When the boom is swung over the rear tires
starter motor to start the engine. or further in either direction, the Drive Orien-
tation indicator will illuminate when the drive
When pushed back, it energizes the electrically function is selected. Push and release the
operated hydraulic pump, when actuated. (Switch switch, and within 3 seconds move the Drive/Steer control
must be held on for duration of auxiliary pump to activate drive or steer. Before driving, locate the black/
use.)The auxiliary pump functions to provide suffi- white orientation arrows on both the chassis and the plat-
cient oil flow to operate the basic machine functions should form controls. Move the drive controls in a direction match-
the main pump or engine fail. The auxiliary pump will oper- ing the directional arrows for the intended direction of
ate platform rotate, jib lift, jib level, jib telescope, jib stow, travel.
platform level, main boom lift, main telescope and swing.
10. Capacity Select
This switch allows the operator to select

between an operating envelope with a 500 lb.
(227 kg for ANSI markets and 230 kg for CE and
Australia markets) capacity restriction or a 1000
lb. (454 kg for ANSI markets and 450 kg for CE
and Australia markets) capacity restriction.
3-14 – JLG Lift – 3121618

NOTE: To operate the Drive Joystick, pull up on the lock- 13. Main Telescope
ing ring below the handle.
Provides extension and retraction of the main
boom.
14. Lights (If Equipped)
Operates accessory light packages if the

machine is so equipped.
NOTE: The DRIVE control levers are spring-loaded and will automati-
cally return to neutral (OFF) position when released. 15. Jib Lift
12. Drive/Steer Provides raising and lowering of the jib.
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.
3121618 – JLG Lift – 3-15

16. Soft Touch/SkyGuard Override Switch (If equipped)
The machine can be equipped with one of three options. It UPON ACTIVATING THE JIB STOW CONTROL SWITCH, A SLIGHT DELAY WILL BE EXPE-
may have Soft Touch, SkyGuard, or both Soft Touch and Sky- RIENCED BEFORE THE JIB WILL BEGIN TO MOVE.
Guard.
17. Jib Stow
If equipped with Soft Touch, the switch
enables the functions that were cut out Allows the jib to be returned to the stowed
by the Soft Touch system to operate position for transport and also taken out of
again at creep speed, allowing the the transport position for machine usage.
operator to move the platform away from the obstacle that This control operates both jib swing and the
caused the shutdown situation. jib lock pin in a coordinated manner.
If equipped with SkyGuard, the switch
NOTE: The Jib Telescope function only operates in the 500 lb. (227 kg for
enables functions cut out by the Sky-
ANSI markets and 230 kg for CE and Australia markets) capacity
guard system to be operated again,
mode.
allowing the operator to resume use of
machine functions.
18. Jib Telescope
If equipped with both Soft Touch and
SkyGuard, the switch operates like Provides extension and retraction of the jib.
described above and allows the opera-
tor to override the system that has
experienced a cutout situation.
3-16 – JLG Lift – 3121618

19. Soft Touch/SkyGuard Indicator (If Equipped) 22. Function Speed Control
Indicates the Soft Touch bumper is against an object or the This control affects the speed of main boom
SkyGuard sensor has been activated. All controls are cut out telescope, jib telescope, and jib lift. Turning
until the override button is pushed. For Soft Touch, controls the knob all the way counterclockwise until
are then active in the Creep Mode or for SkyGuard, controls it clicks puts drive, main lift, platform rotate,
will work normally. and swing into creep mode.
20. Platform Rotate NOTE: To operate the Main Boom Lift/Swing joystick,
pull up on the locking ring below the handle.
Allows the operator to rotate the platform to
the left or right. NOTE: The Main Boom Lift/Swing joystick is spring
loaded and will automatically return to neutral
(off) position when released.
21. Lock Pin Indicator
23. Main Lift/Swing Controller
When illuminated, indicates the jib is
Provides main lift and swing. Push
centered and the jib lock pin is
forward to lift up, pull backward
engaged. When blinking, indicates the
to boom down. Move right to
jib is in the process of being stowed or centered. The indica-
swing right, move left to swing
tor is off when the lock pin is disengaged and the jib is
left. Moving the joystick activates
stowed (machine in transport position).
switches to provide the functions
selected.
3121618 – JLG Lift – 3-17

Platform Control Indicator Panel 3. Platform Overload Indicator (If Equipped)
Indicates the platform has been over-

(See Figure 3-5., Platform Control Indicator Panel)
loaded.
1. Level System Fault Indicator
Indicates a fault in the electronic leveling 4. Platform Capacity Indicator

system. The fault indicator will flash and
an alarm sound. All functions will default Indicates the maximum platform capacity
to creep if the boom is out of transport selected for the platform.
mode.
One of the capacity lights should be on at
all times. Both lights will flash and an
IF THE LEVEL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUT DOWN THE alarm will sound if the platform is out of
MACHINE, RESET THE EMERGENCY STOP, AND RESTART THE MACHINE. IF THE FAULT the operating envelope for the selected
PERSISTS, RETURN THE PLATFORM TO THE STOWED POSITION, USING MANUAL LEV- capacity.
ELING AS REQUIRED, AND HAVE LEVELING SYSTEM REPAIRED.
2. AC Generator (If Equipped)
Indicates the generator is in operation.
3-18 – JLG Lift – 3121618

1. Level System 6. Glow Plug 11. Cable Service

2. AC Generator 7. Enable 12. Drive Orientation
3. Platform Overload 8. Fuel Level 13. Axles Set
4. Platform Capacity 9. Creep Speed 14. Boom Control System Warning
5. Tilt Alarm Warning 10. System Distress
Figure 3-5. Platform Control Indicator Panel
3121618 – JLG Lift – 3-19

5. Tilt Alarm Warning Light 7. Footswitch/Enable Indicator
IF ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH
BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE BY BLOCKING OR ANY OTHER MEANS.
EXTENDING BOOM OR RAISING BOOM FROM THE TRANSPORT POSITION.
Indicates that the chassis is on a slope. If

the boom is out of transport position and FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY
the machine is on a slope, an alarm will OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.
sound and CREEP is automatically acti-
vated. To operate any function, the footswitch
must be depressed and the function
6. Glow Plug/Wait to Start Indicator
selected within seven seconds. The
NOTE: If the engine fails to start due to cold temperatures or excessive enable indicator shows that the controls
amounts of smoke are produced on startup, wait for the glow are enabled. If a function is not selected
plug/wait to start indicator to go out before starting the engine. within seven seconds, or if a seven second
lapse between ending one function and beginning the next
Indicates the glow plugs are operating. function, the enable light will go out and the footswitch
After turning on ignition, wait until light must be released and depressed again to enable the con-
goes out before starting engine. trols.
Releasing the footswitch removes power from all controls

and applies the drive brakes.
3-20 – JLG Lift – 3121618

NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more 9. Creep Speed Indicator
detailed information concerning the Low Fuel Indicator.
When the Function Speed Control is
8. Fuel Level Indicator turned to the creep position, the indicator
acts as a reminder that all functions are
Indicates the level of fuel in the fuel tank. set to the slowest speed. The light flashes
if the control system puts the machine
into creep speed and will be on continuously if the operator
selects creep speed.
10. System Distress Indicator
The light indicates that the JLG Control

System has detected an abnormal condi-
tion and a Diagnostic Trouble Code has
been set in the system memory. Refer to
the Service Manual for instructions con-
cerning the trouble codes and trouble code retrieval.
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.
11. Cable Service Indicator
When illuminated, the light indicates the

Figure 3-6. Fuel Level Indicator boom cables are loose or broken and
must be repaired or adjusted immedi-
ately.
3121618 – JLG Lift – 3-21

12. Drive Orientation Indicator 14. Boom Control System Warning Indicator
When the boom is swung beyond the rear Indicates the platform is outside the oper-
drive tires or further in either direction, ating area and operation of certain boom
the Drive Orientation indicator will illumi- functions may be disabled (i.e. lift, tele-
nate when the drive function is selected. scope). Attempts to use the disabled
This is a signal for the operator to verify functions cause the indicator to flash and
that the drive control is being operated in the proper direc- an alarm to sound. Immediately return the platform to the
tion (i.e. controls reversed situations). ground. If the indicator remains lit, a boom control system
fault or failure has been detected. If a failure is discovered,
13. Axles Set Indicator
the system must be repaired by JLG authorized service per-
sonnel before the machine can be used.
Indicates that the axles are fully extended.
The indicator will flash as the axles are
extending or retracting and be on solid
when fully extended. The light will go out
when the axles are fully retracted.
3-22 – JLG Lift – 3121618

SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION 4.2 BOOM OPERATING CHARACTERISTICS AND
This machine is a self-propelled hydraulic personnel lift equipped LIMITATIONS
with a work platform on the end of an elevating and rotating
boom. Capacities
The primary operator control console is in the platform. From this
control console, the operator can drive and steer the machine in Raising boom above horizontal with or without any load in plat-
both forward and reverse directions. The operator can raise or form, is based on the following criteria:
lower the boom or swing the boom to the left or right. Standard 1. Machine is positioned on a smooth, firm and level surface.
boom swing is 360 degree continuous rotation. The machine has
a Ground Control Console which will override the Platform Con- 2. Axles are fully extended.
trol Console. Ground Controls operate Boom Lift and Swing, and 3. Jib is centered and lock pin is engaged.
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. 4. Load is within manufacturer’s rated capacity.
5. All machine systems are functioning properly.
6. Proper tire pressure.
7. Machine is as originally equipped from JLG.
3121618 – JLG Lift – 4-1

Controlled Arc will function automatically, or when lifting up, telescope out will
function automatically.
When the Boom Control Switch is in the manual mode, lift and
telescope functions are independent functions controlled by the
operator.
When the Boom Control Select switch is in the automatic mode,

the Boom Control System automatically controls lift and tele-
scope when the lift function is selected to move the platform
through a predetermined arc, equivalent to the percentage of
extension. (i.e. If you start at 70% boom extension, you will end
up at approximately 70% boom extension no matter where you
stop in the arc). This means that when lifting down, telescope in
4-2 – JLG Lift – 3121618

Envelope Tracking NOTE: Boom Control System in Automatic Mode: When the boom is
completely elevated along the edge of the backward stability
region and the telescope in function is activated, lift down will
automatically function until the boom is away from the edge of
the backward stability region.
Boom Control System in Manual Mode: The boom will stop when
the end of the envelope is reached and the operator must acti-
vate lift and/or telescope in the proper direction to bring the
boom back into the envelope.
Controlled Angle
The control system automatically maintains a constant elevated
boom angle when swinging the turntable. If the boom angle is at
30 degrees and swing only is activated the control system shall
add lift to maintain the relative boom angle at 30 degrees.
Swing Speed Proportioning

When the platform approaches the edges of the operating enve-
lope all machine functions are slowed down except jib and plat- The Boom Control System sensors sense the distance the plat-
form functions, telescope in or out at the rearward edge and form is extended from the turntable, allowing higher swing
telescope in or out on the forward edge are slowed down auto- speeds with the boom retracted and gradually slower swing
matically by the boom control system to reduce machine speeds as the boom is extended.
motions.
3121618 – JLG Lift – 4-3

Stability 4.3 CAPACITY SELECT

Machine stability is based on two (2) conditions which are called The Boom Control System allows the operator to select
FORWARD and BACKWARD stability. The machine’s position of operation in a 500 lb. (227 kg for ANSI markets and 230
least FORWARD stability is shown in Figure 4-1., and its position
kg for CE and Australia markets) capacity restriction
of least BACKWARD stability is shown in Figure 4-2.
envelope or a 1000 lb. (454 kg for ANSI markets and 450
kg for CE and Australia markets) capacity restriction
envelope. The operator selects the desired capacity
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER- restriction by positioning the Capacity Select switch on
ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE. the platform console. The Capacity Indicator shows the capacity
selected, and both capacity lights will flash and an alarm sound if the
platform is out of the selected capacity range.
NOTE: Operation in the 1000 lb. (454 kg for ANSI markets and 450 kg for
CE and Australia markets) envelope requires the jib to be fully
retracted.
4-4 – JLG Lift – 3121618

MAIN BOOM
EXTENDED 810" (20.57 M) JIB HORIZONTAL &
MAIN BOOM
FULLY EXTENDED
AT 0 DEGREES
MACHINE WILL "TIP OVER" IN THIS

DIRECTION IF OVERLOADED OR
OPERATED ON AN
OUT-OF-LEVEL SURFACE
Figure 4-1. Position of Least Forward Stability
3121618 – JLG Lift – 4-5

.
4-6
PLATFORM
ROTATED
90 DEGREES
JIB FULLY
MACHINE WILL "TIP OVER" IN THIS RETRACTED
DIRECTION IF OVERLOADED OR @ 75 DEGREE
OPERATED ON AN ANGLE
OUT-OF-LEVEL SURFACE
– JLG Lift –
MAIN BOOM FULLY RETRACTED,
3121618 ELEVATED 77 DEGREES
Figure 4-2. Position of Least Backward Stability

4.4 ENGINE OPERATION 1. Turn key of Platform/Ground Select switch to

the Ground position.
NOTE: Initial starting should always be per-
formed from the Ground Control con-
sole.
2. Pull the Power/Emergency Stop switch out.
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.
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME.
SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN- 4. After engine has had sufficient time to warm up, shut engine
UTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE off.
MANUAL.
5. Turn Platform/Ground Select switch to Plat-
NOTE: After turning on ignition, operator must wait form.
until glow plug indicator light goes out
before cranking engine.
3121618 – JLG Lift – 4-7

6. From the Platform, pull the Power/Emergency 3. Turn key of Platform/Ground Select switch to
Stop switch out. the Off position.
Refer to Engine Manufacturer’s manual for detailed
information.
7. Push the Engine Start switch until engine
starts.
NOTE: Footswitch must be in released (up) position before starter will

operate. If starter operates with footswitch in the depressed posi-
tion, DO NOT OPERATE MACHINE.
Shutdown Procedure
IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE

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
engine temperature.
2. Push Power/Emergency Stop switch in.
4-8 – JLG Lift – 3121618

Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera-
tor will be permitted to cycle power and restart the engine
NOTE: Reference the Service and Maintenance Manual along with a for approximately 2 minutes of run time. After the 2 min-
qualified JLG Mechanic to verify your machine setup. utes of run time is complete, the operator may cycle power
and restart the engine for an additional 2 minutes of run
The Fuel Shutoff System monitors the fuel in the tank and senses time. The operator can repeat this process until there is no
when the fuel level is getting low. The JLG Control System auto- more fuel available.
matically shuts the engine down before the fuel tank is emptied
unless the machine is set up for Engine Restart.
If fuel level reaches the Low Fuel range the ¼ tank CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO
indicator will flash once a second and there will be MORE FUEL IS AVAILABLE.
approximately 5 minutes of engine run time left. If
the system is in this condition and automatically • Engine Stop - The engine will shut down. No restarts will
shuts down the engine, or the engine is manually be permitted until fuel is added to the tank.
shut down before the 5 minute run time is com-
plete, the ¼ tank indicator will flash 10 times a sec-
ond and the engine will react according to
machine setup. Setup options are as follows:
• Engine One Restart - When the engine shuts down, the
operator will be permitted to cycle power and restart the
engine once with approximately 2 minutes of run time.
After the 2 minute run time is complete or if the engine is
shut down by the operator prior to the completion of the 2
minute run time, it cannot be restarted until fuel is added
to the tank.
3121618 – JLG Lift – 4-9

4.5 TRAVELING (DRIVING) BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE
CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC-
See Figure 4-4., Grade and Side Slopes - Sheet 2 of 2 TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF
TRAVEL.
NOTE: When the main boom is raised approximately 6 degrees above
horizontal, the high drive function will automatically be in low
drive.
DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL 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.
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE
PLATFORM IS ELEVATED.
4-10 – JLG Lift – 3121618

Figure 4-3. Grade and Side Slopes - Sheet 1 of 2
3121618 – JLG Lift – 4-11

Figure 4-4. Grade and Side Slopes - Sheet 2 of 2
4-12 – JLG Lift – 3121618

Traveling Forward and Reverse 2. Push and release the Drive Orientation Over-
ride switch. Within 3 seconds, slowly move the
1. At Platform Controls, pull out Emergency Stop Drive control toward the arrow matching the
switch, start engine, and activate footswitch. intended direction of machine travel. The indi-
cator light will flash during the 3 second inter-
val until the drive function is selected.
2. Position Drive controller to Forward or Reverse as

4.6 STEERING
desired. Position thumb switch on Drive/Steer controller to
Right for steering right, or to Left for steering left.
This machine is equipped with a Drive Orientation Indicator. The

yellow light on the platform control console indicates that the
4.7 EXTENDING THE AXLES
boom is swung beyond the rear drive tires and the machine may NOTE: The boom must be oriented between the rear wheels to extend
Drive/Steer in the opposite direction from the movement of the or retract the axles.
controls. If the indicator is illuminated, operate the Drive function
in the following manner: The operator must be driving the machine (forward or reverse) in
1. Match the black and order to extend the axles.
white direction arrows
on both platform con- Position the Axle Extend switch to extend the
trol console and the axles or to retract to retract the axles.
chassis to determine
the direction the
machine will travel.
3121618 – JLG Lift – 4-13

4.8 PLATFORM Platform Rotation

To rotate the platform to the left or right, use the
Platform Level Adjustment Platform Rotate control switch to select the direc-
tion and hold until desired position is reached.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
4.9 BOOM
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE
NOTE: When the Boom Control Select Switch is in the Manual mode, WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO
Platform leveling only functions during Main Lift operation. NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN LIGHT IS
When the Boom Control Select Switch is in the Automatic mode, LIT.
Platform Leveling is active during all functions except during
telescope operation. Also, when in the Manual mode, the Con- DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT
trolled Arc and Controlled Angle systems are not active. ALARM INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREE OR GREATER).
CHASSIS MUST BE LEVEL BEFORE SWINGING, OR RAISING BOOM ABOVE HORIZONTAL
During normal operation of the machine, the plat- OR DRIVING WITH THE BOOM ELEVATED.
form will automatically maintain it’s position. To
manually Level Up or Down - Position the Platform/ TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN BOOM IS RAISED
Level control switch Up or Down and hold until the ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION
desired platform position is obtained. MACHINE SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM.
4-14 – JLG Lift – 3121618

Swinging the Boom

TRAVELING WITH BOOM BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE
NOTE: The axles must be fully extended to swing beyond the rear
SLOPES SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL.
wheels (40 degrees).
To swing boom, use Swing control to select Right or

Left direction.
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.
WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO
CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.
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- Raising and Lowering the Boom
GENCY STOP SWITCH TO STOP THE MACHINE.
NOTE: The lift function is not operable above 6 degrees above horizon-
tal if the axles are not fully extended.
To raise or lower the Boom, use Boom Lift control to

select Up or Down movement.
3121618 – JLG Lift – 4-15

Telescoping the Boom 4.10 FUNCTION SPEED CONTROL

NOTE: The telescope function is not operable beyond the transport This control affects the speed of main boom
position if the axles are not fully extended. telescope, jib telescope, and jib lift. Turning the
knob all the way counterclockwise until it clicks
To extend or retract the main boom, use the Telescope puts drive, main lift, platform rotate, and swing
Control Switch to select In or Out movement. into creep mode.
Telescoping the Jib 4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE

ONLY)
To extend or retract the jib, use the Jib Telescope Con-
trol Switch to select In or Out movement. The Machine Safety System Override (MSSO) is
used to override function controls for Emergency
Platform Retrieval only. Refer to Section 6.5,
Machine Safety System Override (MSSO)(CE Only)
for operating procedures.
Stowing/Swinging the Jib
To swing the jib for stowage or machine usage,
use the Jib Stow control to select Right or Left
direction. The jib lock pin will also operate auto-
matically while using the Jib Stow switch.
4-16 – JLG Lift – 3121618

4.12 SKYGUARD OPERATION 4.13 EMERGENCY TOWING

Skyguard is used to provide enhanced control panel protection.
When the SkyGuard sensor is activated, functions that were in
use at the time of actuation will reverse or cutout. The table RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING
below outlines these functions. VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING
NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY
Table 4-1. Skyguard Function Table OR DEATH.
Main Main Drive Drive Platform Platform Jib Jib Jib
Swing MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)
Lift Tele Forward Reverse Level Rotate Lift Rotate Tele
R C/R* R R I R R C C C C C MAXIMUM TOWING GRADE 25%.
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
I = Input is Ignored DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.
Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.
* Reversal only applies to Main Tele Out. Main Tele In would be cut out 1. Retract, lower and position boom in travel position; lock
turntable.
** Reversal applies to Tower Lift Up. Tower Lift Down would be cut out.
3121618 – JLG Lift – 4-17

2. Disconnect drive hubs by inverting disconnect cap. 4.14 SHUT DOWN AND PARK
To shut down and park the machine, the procedures are as fol-
lows:
1. Drive machine to a reasonably well protected area.
2. Ensure boom is lowered over rear drive axle.
3. Push in the Emergency Stop at Platform Controls.
4. Push in the Emergency Stop at Ground Controls. Position
Platform/Ground Select switch to the center Off position.
5. If necessary, cover Platform Controls to protect instruction
placards, warning decals and operating controls from hostile
environment.
Figure 4-5. Drive Disconnect Hub
3. Reconnect the drive hubs by inverting the disconnect cap

when towing is complete.
4-18 – JLG Lift – 3121618

4.15 LIFTING AND TIE DOWN Tie Down

See Figure 4-6.
Lifting WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO
THE BOOM REST.
1. Refer to the Serial Number Plate, refer to the Specifications
section of this manual, or weigh the individual unit to find 1. Place the boom in the stowed position with the turntable
out the Gross Vehicle Weight. locked.
2. Place the boom in the stowed position with the turntable 2. Remove all loose items from the machine.
locked.
3. Secure the chassis and the platform using straps or chains of
3. Remove all loose items from the machine. adequate strength and attached to the designated tie down
points.
4. Attach lifting device and equipment only to the designated
lifting points.
4.16 STOWING THE JIB FOR TRANSPORT
5. Properly adjust the rigging to prevent damage to the
machine and so the machine remains level. 1. Place the boom in the stowed position with the axles
retracted.
2. Hold the Jib Swing control switch to the right until the plat-
form will no longer swing.
NOTE: Automatic platform leveling is disabled when stowing the jib.
3. Push and hold the platform rotate switch until the jib and
platform are in the stowed position under the boom.
3121618 – JLG Lift – 4-19

6' 5"/1.96 m 17' 3"/5.25 m
10' /3.05 m
30' 7"/9.33 m 17' 2"/5.24 m

47' 10"/14.57 m
1001159983 A
Figure 4-6. Lifting and Tie Down Chart
4-20 – JLG Lift – 3121618

Figure 4-7. Decal Location Sheet 1 of 9
3121618 – JLG Lift – 4-21

4-22 – JLG Lift – 3121618

3121618 – JLG Lift – 4-23

4-24 – JLG Lift – 3121618

3121618 – JLG Lift – 4-25

4-26 – JLG Lift – 3121618

3121618 – JLG Lift – 4-27

4-28 – JLG Lift – 3121618

3121618 – JLG Lift – 4-29

Table 4-2. Decal Legend
English/
Item # ANSI Korean Chinese Portuguese French/English CE Japan Australia
Spanish
1001160456-C 1001160457-C 1001160458-C 1001160459-C 1001160461-C 1001160462-C 1001160463-C 1001160464-C
1001160460-C
1 -- -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 -- -- -- -- -- -- -- -- --
7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
11 -- -- -- -- -- -- 1705980 1705980 1705980
12 1705514 -- -- -- -- 1705514 -- -- --
13 -- -- -- -- -- -- -- -- --
14 -- -- -- -- -- -- -- -- --
15 1705337 1705339 1001117034 1705904 1705909 1705341 -- 1705338 --
16 -- 1705503 1001117035 1705906 1705915 1705505 -- 1705493 --
4-30 – JLG Lift – 3121618

English/
Spanish
1001160456-C 1001160457-C 1001160458-C 1001160459-C 1001160461-C 1001160462-C 1001160463-C 1001160464-C
1001160460-C
17 -- -- -- -- -- -- -- -- --
18 1703953 1703945 1703943 1705903 1703941 1703942 -- 1703944 --
19 1702968 1705969 1001116846 1705967 1704001 1704000 -- -- --
20 1703797 1703927 1703925 1705895 1703923 1703924 1705921 1703926 1705921
21 1705336 1705345 1001116849 1705896 1705917 1705347 1705822 1705344 1705822
22 1703804 1703951 1703949 1705898 1703947 1703948 1701518 1703950 1701518
23 1703805 1703939 1001116851 17058987 1703935 1703936 1705961 1703938 1705961
24 3252347 1703981 1703982 1705902 1703983 1703984 1705828 1703980 1705828
25 -- -- -- -- -- -- -- -- --
26 -- -- -- -- -- -- -- -- --
27 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
28 1001125175 1001125185 1001125179 1001125187 1001125189 1001125181 1001125177 1001125183 1001125177
29 1001125176 1001125186 1001125180 1001125188 1001125190 1001125182 1001125178 1001125184 1001125178
30 1001131269 -- -- -- -- 1001131269 -- -- --
31 1001163536 1001163536 1001163536 1001163536 1001163536 1001163536 -- 1001163536 --
32 1705868 1705868 1705868 1705868 1705868 1705868 -- 1705868 --
33 1705351 1705427 1705430 1705905 1705910 1705429 -- 1705426 --
34 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505 1701505
3121618 – JLG Lift – 4-31

English/
Spanish
1001160456-C 1001160457-C 1001160458-C 1001160459-C 1001160461-C 1001160462-C 1001160463-C 1001160464-C
1001160460-C
35 1704972 1706061 1706060 1706059 1706063 1706064 1706098 1704972 1706098
36 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511 1705511
37 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445 1001160445
38 -- -- -- -- -- -- -- -- --
39 1001159855 1001159855 1001159855 1001159855 1001159855 1001159855 1001159855 1001159855 1001159855
40 -- -- -- -- -- -- -- -- --
41 -- -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- --
4-32 – JLG Lift – 3121618

English/
Spanish
1001160456-C 1001160457-C 1001160458-C 1001160459-C 1001160461-C 1001160462-C 1001160463-C 1001160464-C
1001160460-C
53 -- -- -- -- -- -- -- -- --
54 -- -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- -- --
61 -- -- -- -- -- -- -- -- --
62 -- -- -- -- -- -- -- -- --
63 -- -- -- -- -- -- -- -- --
64 -- -- -- -- -- -- -- -- 1001112551
65 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
66 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691
3121618 – JLG Lift – 4-33

NOTES:
4-34 – JLG Lift – 3121618

SECTION 5 - LCD DISPLAY PANEL
SECTION 5. LCD DISPLAY PANEL

5.1 DESCRIPTION
This machine utilizes an LCD display panel to assist the operator
by supplying additional information during the operation of the
machine. It is NOT a substitute for the Operation and Safety Man-
ual, nor is it a replacement for thorough operational knowledge
of the machine.
Figure 5-1. LCD Panel
3121618 – JLG Lift – 5-1

5.2 BOOT UP SPLASH SCREEN

When the machine is first powered on, the JLG boot up splash
screen appears followed by three reminder screens. There is a
reminder for the operator to wear a full body harness with a lan-
yard attached to an authorized lanyard anchorage point, a
reminder for the operator to read and understand the Operation
and Safety Manual, and a reminder for the operator to select the
desired capacity range of the machine. Each reminder screen will
show for 3 seconds.
Figure 5-2. Boot Up Splash Screen
Figure 5-3. Manual Screen
5-2 – JLG Lift – 3121618

Figure 5-4. Lanyard Screen Figure 5-5. Select Capacity Zone Screen
3121618 – JLG Lift – 5-3

5.3 MACHINE OPERATING SCREEN images and trays. Each tray provides different machine informa-
tion.
After the reminder screens, the Machine Operating Screen will
appear. The Machine Operating Screen consists of different NOTE: Early versions may not include the speed restriction (snail) icon.
DTC Tray
Console Tray
Machine Status Tray
Icons Tray
Figure 5-6. Machine Operating Screen
5-4 – JLG Lift – 3121618

Diagnostic Trouble Code (DTC) Tray • Key Switch Ground Mode
This tray shows the total number of DTC’s and the DTC Text. If • CAN Bus Lost
there are multiple DTC’s, the operator can scroll through the DTC • Take Foot Out
List to the end. When the tray is empty, this means there are no
• Put Foot In
active DTC’s.
• BCS Lamp On
Console Tray • Broken Cable
This tray represents the platform console information.
• System/Basket Level DTCs
When the machine is in operation, and the footswitch is pressed, • Platform Overload DTCs
the console will show available functions with a green arrow and
unavailable functions with a gray arrow. • Weight Mode Error
NOTE: The green and gray console arrows shown in the examples in this • Swing Left DTC
section may be different depending upon machine setup and • Swing Right DTC
specific operating conditions.
• Jib Unlocked
Icons Tray • Jib Locked
The Icons Tray shows engine RPM plus Creep and Super Creep • Chassis Status
modes. • In Transport and Out of Transport
The RPM level is represented in bars. • Axles Extended, Retracted, Transient
• Machine Tilted
Machine Status Tray
• Envelope Status
The Machine Status Tray is used to display different images based
on the machine status. These include: • Unknown Machine Model
3121618 – JLG Lift – 5-5

5.4 KEYSWITCH IN GROUND MODE:

If the keyswitch is set to ground mode, the display shows the Key
Switch in Ground Mode Image.
Figure 5-7. Keyswitch In Ground Mode Screen
5-6 – JLG Lift – 3121618

5.5 FUNCTION SPEED

If there is no function speed restriction, a gray snail is shown. If
the machine is in Creep Mode, a green snail icon is shown. If the
machine is in Super Creep Mode, the green snail icon will flash.
Figure 5-8. Function Speed Icons
3121618 – JLG Lift – 5-7

5.6 CAN BUS LOST NOTE: There is no way to get the active DTCs so, the previously active
DTCs will be scrolling along with the CAN Bus Communication
When the control system senses a communication loss with any lost DTC. This DTC needs to be cleared in order for the communi-
of the control modules (BLAM, Chassis, UGM, or Jib Control Mod- cations to reset.
ule), the display will show a CAN Communication lost until the
communications are reset.
Figure 5-9. CAN Bus Lost Screen
5-8 – JLG Lift – 3121618

5.7 TAKE FOOT OUT

When the footswitch is pressed and the control system senses a
Take Foot Out DTC, the displays shows the Take Foot Out image in
the machine status tray.
Figure 5-10. Take Foot Out Screen
3121618 – JLG Lift – 5-9

5.8 PUT FOOT IN When put foot in DTC is active, the display shows Put Foot In
image in the machine status tray.
When the operator operates the machine without putting his
foot on switch, Put Foot In DTC becomes active after timeout.
Figure 5-11. Put Foot In Screen
5-10 – JLG Lift – 3121618

5.9 BCS LAMP ON NOTE: The available controls will be different among the different DTCs.
The image below is ONLY for envelope violation.
When the control system senses forward or backward envelope
violation or moment violation conditions, the BCS Lamp will be
ON. When the BCS Lamp is ON, the display shows a red octagon
image in the machine status tray indicating a potentially hazard-
ous situation.
• The DTCs that triggered this BCS Lamp will be scrolled in
the DTC tray.
3121618 – JLG Lift – 5-11

Figure 5-12. BCS Lamp Screen
5-12 – JLG Lift – 3121618

5.10 BROKEN CABLE shows a red octagon broken cable indicator in the machine sta-
tus tray.
When the control system senses a broken cable, the Broken Cable
lamp on the platform panel is lit. When the lamp is lit, the display
Figure 5-13. Broken Cable Screen
3121618 – JLG Lift – 5-13

5.11 PLATFORM LEVEL this lamp is lit, the display shows a red octagon platform level
DTC indicator in the machine status tray.
Whenever the control system senses a DTC with the platform
level, the platform level lamp is lit on the platform console. When
Figure 5-14. Level System DTC Screen
5-14 – JLG Lift – 3121618

5.12 PLATFORM OVERLOAD

When the boom control system senses that the platform is over-
loaded, the Platform Overload indicator on the platform console
will be lit.
Figure 5-15. Overload DTC Screen
3121618 – JLG Lift – 5-15

5.13 CAPACITY MODE ERROR completely telescoped out, and changes the capacity to
Restricted mode), the capacity mode indicator icon will flash in
If the operator selects the incorrect capacity mode for the jib con- the Machine Status tray every second.
figuration (i.e., if the operator is in Unrestricted mode with the jib
Figure 5-16. Capacity Mode Error Screen
5-16 – JLG Lift – 3121618

5.14 SWING DTCS

When the machine is swung more than what it is allowed for in
either left or right direction, the control system senses a swing
fault. When this DTC is active, the display shows a machine image
with green arc which indicates the allowed angle and the portion
other than the green arc indicates the restricted area to show the
swing DTC. Displays shows operator to extend the axles by flash-
ing the axles.
• Swing DTC will be displayed on the DTC tray with the num-
ber and system distress icon.
• Available functions on the machine are shown with green
arrows. Functions that are not available are grayed out.
• RPM and speed restriction icon will be displayed in the
Icons tray.
NOTE: Image below shows a left swing DTC. For right swing DTC, the
boom will be shown swung to the right.
3121618 – JLG Lift – 5-17

Figure 5-17. Swing DTC Screen
5-18 – JLG Lift – 3121618

5.15 JIB UNLOCKED

When the control system senses that jib pin is unlocked, the dis-
play will show the Jib Unlocked image.
Figure 5-18. Jib Unlocked Screen
3121618 – JLG Lift – 5-19

5.16 JIB LOCKED The display will show a different image on the machine status
tray after 3 seconds have elapsed.
When the boom control system senses jib is locked ONLY for the
first time, the display will show the Jib Locked image on the
machine status tray for 3 seconds.
Figure 5-19. Jib Locked Screen
5-20 – JLG Lift – 3121618

5.17 CHASSIS STATUS shown on the left side of the display or machine status tray. This
image will be shown until the axles are extended.
Axles Retracted In Transport Position
When the axles are retracted regardless of engine state, the dis-
play shows the following screen. The Axles Retracted image is
Figure 5-20. Axles Retracted Screen
3121618 – JLG Lift – 5-21

Axles Extended Engine state, the Axles Extended image will show up on the
machine status tray for first 3 seconds.
When the axles are extended for the first time (meaning previous
state is retracted and current state is extended), regardless of the
Figure 5-21. Axles Extended Screen
5-22 – JLG Lift – 3121618

Axles Retracted In Out of Transport Position Axles In Transient State

When the axles are retracted and the machine is in out of trans- When the operator is extending or retracting the axles, the Axles
port position, the display will switch between axles extended and In Transient State screen will show and the arrows showing axle
retracted every 0.5 seconds to tell the operator to extend the travel direction will flash. When the axles are not fully extended
axles so the boom can be raised. or retracted and no axle functions are selected, the green arrows
will show steadily.
Figure 5-22. Axles In Transient State Screen
3121618 – JLG Lift – 5-23

5.18 MACHINE TILTED MODE

When the control system senses the chassis is on an excessive
slope, the display will show the Machine Tilted image in the
machine status tray.
Figure 5-23. Machine Tilted Mode Screen
5-24 – JLG Lift – 3121618

5.19 ENVELOPE STATUS • The display shows animated boom length and boom
angle information along with the envelope.
Example 1: Platform is not at the edge of the envelope
• Boom movement is proportional to the envelope bound-
• When Unrestricted or Restricted mode is selected, the dis- aries.
play shows envelope image in the machine status tray.
• Platform location is always shown at the end of the boom.
• The color code for the envelope matches the capacity
select decals on the machine. Mode Boom Platform Envelope Color
• When the control system senses that the axles are fully Unrestricted Orange Black Yellow
extended, the selected envelope shows up on the Restricted Orange Black Green
3121618 – JLG Lift – 5-25

Figure 5-24. Unrestricted Mode Screen
5-26 – JLG Lift – 3121618

Figure 5-25. Restricted Mode Screen
3121618 – JLG Lift – 5-27

• When operator switches from Unrestricted to Restricted • Display shows animated boom length and boom angle
mode, the envelope shrinks to indicate reduced operating information along with the new envelope.
envelope.
• Boom movement is proportional to envelope boundaries.
Example 2: Platform is edge of the envelope
• Platform location is always at the end of the boom.
• When Unrestricted or Restricted mode is selected, the dis-
play flashes snail image at a rate of 0.5 seconds in the
• The envelope color will match the weight mode selected.
Example 3: Unrestricted mode with envelope tilt condition
• When on the Unrestricted envelope screen, if the operator
experiences a tilt condition where tilt is less than what the
machine is configured for, then the envelope will shrink
further to show that the new envelope.
• Display shows animated boom length and boom angle
information along with the new envelope.
• Boom movement is proportional to envelope boundaries.
• Platform location is always at the end of the boom.
Example 4: Restricted mode with envelope tilt condition
• When on the Restricted envelope screen, if the operator
experiences a tilt condition where tilt is less than what the
machine is configured for, then the envelope will shrink
further to show that the new envelope.
5-28 – JLG Lift – 3121618

5.20 MACHINE MODEL UNKNOWN 1850SJ the display will show the Machine Model Unknown image
on the machine status tray.
As soon as the machine is powered up, the control system checks
the model of the machine and if the model is neither 1500SJ nor
Figure 5-26. Machine Model Unknown Screen
3121618 – JLG Lift – 5-29

NOTES:
5-30 – JLG Lift – 3121618

SECTION 6 - EMERGENCY PROCEDURES
SECTION 6. EMERGENCY PROCEDURES

6.1 GENERAL
This section explains the steps to be taken in case of an emer- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
6.2 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-
6.3 EMERGENCY OPERATION
vided with all necessary details.
Operator Unable to Control Machine
In USA:
JLG Phone: 877-JLG-SAFE (554-7233) IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
OPERATE OR CONTROL MACHINE:
Outside USA: 1. Other personnel should operate the machine from ground
240-420-2661 controls only as required.
E-mail: 2. Other qualified personnel on the platform may use the plat-
form controls. DO NOT CONTINUE OPERATION IF CONTROLS
[email protected] DO NOT FUNCTION PROPERLY.
Failure to notify the manufacturer of an incident involving a JLG 3. Cranes, forklift trucks or other equipment can be used to
Industries product within 48 hours of such an occurrence may remove platform occupants and stabilize motion of the
void any warranty consideration on that particular machine. machine.
3121618 – JLG Lift – 6-1

Platform or Boom Caught Overhead 6.4 EMERGENCY TOWING PROCEDURES

If the platform or boom becomes jammed or snagged in over- Towing this machine is prohibited, unless properly equipped.
head structures or equipment, rescue platform occupants prior to However, provisions for moving the machine have been incorpo-
freeing the machine. rated. For specific procedures, refer to Section 4.
Boom Movement Prevented By Boom Control System

Lowering the boom onto an object or structure, with the boom at
high angles, may cause the boom control system to prevent
movement of the machine. This can include movement necessary
to lift the boom off the object. Movement of the boom can be
regained by observing the following:
1. Shut off the engine.
2. Rescue platform occupants prior to freeing machine.
3. Use cranes, forklifts or other equipment to stabilize motion
of the machine as required.
4. From the ground control position, use the Auxiliary Power
System to carefully raise the boom off the object.
5. Once clear, restart the engine and return the platform to the
ground.
6. Inspect the machine for damage before continued use of the
machine.
6-2 – JLG Lift – 3121618

6.5 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.
machine and function controls are locked out
from the platform due to a platform overload sit- 4. Press and hold the MSSO switch and the control switch for
uation. 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.
3121618 – JLG Lift – 6-3

NOTES:
6-4 – JLG Lift – 3121618

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
this machine. Operating Specifications
The maintenance portion of this section is intended as informa- Table 7-1. Operating Specifications
tion to assist the machine operator to perform daily maintenance
tasks only, and does not replace the more thorough Preventive Capacity - ANSI
Maintenance and Inspection Schedule included in the Service Unrestricted 500 lbs (227 kg)
and Maintenance Manual. Restricted 1000 lbs (454 kg)
Other Publications Available: Capacity - CE & Australia
Service and Maintenance Manual .............................................3121619 Unrestricted 500 lbs (230 kg)
Restricted 1000 lbs (450 kg)
Illustrated Parts Manual ................................................................3121620
Maximum Travel Grade, stowed 40%
Position (Gradeability) see Figure 4-3.
Maximum Travel Grade, stowed 5°

Position (Side Slope) see Figure 4-4.
Drive Speed 2.8 mph (4.5 kph)
Drive Speed at Elevation 0.3 mph (0.48 kph)
Gross Machine Weight - Approximate 59,900 lb. (27170 kg.)
3121618 – JLG Lift – 7-1

Table 7-1. Operating Specifications Table 7-2. Dimensional Data
Ground Bearing Pressure - Maximum 119.6 psi (8.41 kg/cm2) Platform Height (500 lb./230 kg. capacity) 185 ft. 7 in. (56.56 m)
Maximum Wind Speed 28 mph (12.5 m/s) Platform Height (1000 lb./450 kg. capacity) 165 ft. 2 in. (50.34 m)
Maximum Manual Force 90 lbs (400N) Horizontal Reach from centerline of rota-
tion
Maximum System Voltage 12 volts Unrestricted Capacity 80 ft. 0 in. (24.38 m)
Restricted Capacity 68 ft. 11 in. (21.01 m)
Maximum Main Relief Hyd. Pressure 5000 psi (345 Bar)
Horizontal Reach over end
Unrestricted Capacity 70 ft. 6 in. (21.59 m)
Dimensional Data Restricted Capacity 59 ft. 6 in. (18.13 m)
Table 7-2. Dimensional Data Horizontal Reach over side
Unrestricted Capacity 71 ft. 9 in. (21.86 m)
Turning Radius (Axles Retracted) Restricted Capacity 60 ft. 8 in. (18.49 m)
Outside 31 ft. 2.75 in. (9.52 m)
Inside 23 ft. 4.25 in. (7.12 m) Overall Width
Axles Retracted 8 ft. 2 in. (2.48 m)
Turning Radius (Axles Extended) Axles Extended 16 ft. 6.5 in. (5.04 m)
Inside 7 ft. 6.75 in. (2.3 m)
Outside 21 ft. 7.75 in. (6.6 m) Wheelbase
Axles Retracted 17 ft. 1.5 in. (5.22 m)
Machine Height (stowed) 10 ft. 0.5 in. (3.06 m) Axles Extended 15 ft. 0.5 in. (4.59 m)
Machine Length (stowed) 47 ft. 9.5 in. (14.57 m) Tailswing 7 ft. 7.5 in. (2.32 m)
Machine Length (Transport Position) 63’ 9.5" (19.44 m) Ground Clearance (Axle) 9.75 in. (0.25 m)
7-2 – JLG Lift – 3121618

Table 7-2. Dimensional Data Tires

Ground Clearance (Chassis) 1 ft. 4.25 in. (0.41 m) Table 7-4. Tire Specifications
Size 445/50D710
Capacities Load Range N
Table 7-3. Capacities Ply Rating 24
Foam Fill Polyurethane HD (55 Durometer) Foam
Hydraulic Oil Tank 75.1 Gal. (284.2 L)
Diameter 46.45 in. (117.9 cm)
Fuel Tank 52.8 Gal. (200 L) Width 16.81 in. (427 mm)
Drive Hub 2.6 quarts (2.5 liters) Rim Size 15x28
Tire & Wheel Weight 1025 lbs. (465 kg)
Swing Gearbox 3 qt. (2.8 L)
Max Tire Load 36000 lbs. (16,329 kg)
3121618 – JLG Lift – 7-3

Engine Data Major Component Weights

Table 7-5. Engine Data - Deutz TD 3.6L
Type Turbo-charged Diesel

DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT
Number of Cylinders 4
OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, PLATFORM) DO NOT
Bore 3.9 in. (98 mm) MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
Stroke 4.7 in. (120 mm)
Table 7-6. Critical Stability Weights
Total Displacement 221 cu.in. (3.6 L)
Firing Order 1-3-4-2 Components LBS. KG.
Output 99.8 hp (74.4 kW)
Tire & Wheel 1025 465
Low Idle Engine RPM 1000 ±50
High Engine RPM 2300±50 Drive Hub & Motor 337 153
Swing Drive 223 101.2
Engine Assembly 822 373
Complete Boom (including jib & platform) 23,600 10705
Main Boom Assembly 21,600 9798
Jib Assembly 1493 677
7-4 – JLG Lift – 3121618

Hydraulic Oil OIL SAMPLING

Table 7-7. Hydraulic Oil This machine is equipped with an oil sampling valve to allow for
verification of hydraulic oil condition. Refer to the Service Manual
Hydraulic System for Oil Sampling procedures.
S.A.E. Viscosity
Operating
Grade
Temperature Range Table 7-8. Mobilfluid 424 Specs
+0° to + 180° F 10W
SAE Grade 10W30
(-18° to +83° C)
+0° to + 210° F 10W-20, 10W30 Gravity, API 29.0
(-18° to +99° C) Density, Lb/Gal. 60°F 7.35
+50° to + 210° F 20W-20 Pour Point, Max -46°F (-43°C)
(+10° to +99° C
Flash Point, Min. 442°F (228°C)
NOTE: Hydraulic oils require anti-wear qualities at least API Service Viscosity
Classification GL-3, and sufficient chemical stability for mobile Brookfield, cP at -18°C 2700
hydraulic system service.
at 40° C 55 cSt
NOTE: Aside from JLG recommendations, it is not advisable to mix oils at 100° C 9.3 cSt
of different brands or types, as they may not contain the same Viscosity Index 152
required additives or be of comparable viscosities. If use of
hydraulic oil other than Mobil 424 is desired, contact JLG Indus-
tries for proper recommendations.
3121618 – JLG Lift – 7-5

Table 7-9. Mobil DTE 13M Specs Table 7-10. UCon Hydrolube HP-5046
ISO Viscosity Grade #32 Type Synthetic Biodegradable

Specific Gravity 0.877 Specific Gravity 1.082
Pour Point, Max -40°F (-40°C) Pour Point, Max -58°F (-50°C)
Flash Point, Min. 330°F (166°C) pH 9.1
Viscosity Viscosity
at 40° C 33cSt at 0° C (32° F) 340 cSt (1600SUS)
at 100° C 6.6 cSt at 40° C (104° F) 46 cSt (215SUS)
at 100° F 169 SUS at 65° C (150° F) 22 cSt (106SUS)
at 210° F 48 SUS Viscosity Index 170
cp at -20° F 6,200
Viscosity Index 140
7-6 – JLG Lift – 3121618

Table 7-11. Mobil EAL H 46 Specs Table 7-12. Exxon Univis HVI 26 Specs
Type Synthetic Biodegradable Specific Gravity 32.1
ISO Viscosity Grade 46 Pour Point -76°F (-60°C)
Specific Gravity .910 Flash Point 217°F (103°C)
Pour Point -44°F (-42°C) Viscosity
Flash Point 500°F (260°C) at 40° C 25.8 cSt
Operating Temp. 0 to 180°F (-17 to 162°C) at 100° C 9.3 cSt
Weight 7.64 lb. per gal. Viscosity Index 376
(0.9 kg per liter) NOTE: Mobil/Exxon recommends that this oil be checked on a
Viscosity yearly basis for viscosity.
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153
3121618 – JLG Lift – 7-7

Figure 7-1. Engine Operating Temperature Specifications
7-8 – JLG Lift – 3121618

HYDRAULIC FLUID OPERATION CHART
MACHINE OPERAT ION USING NON-JLG APPROVED

HYDRAULIC F LUIDS OR OPERAT ION OUT SIDE OF
T HE T EMPERAT URE BOUNDARIES OUT LINED IN
T HE "HYDRAULIC F LUID OPERAT ION CHART " MAY
RESULT IN PREMAT URE WEAR OR DAMAGE TO
COMPONENT S OF T HE HYDRAULIC SYST EM.
Figure 7-2. Hydraulic Oil Operation Chart - Sheet 1 of 2
3121618 – JLG Lift – 7-9

Fluid Properties Base Classifications
Viscosity at 40° C (cSt, Typical)
Readily Biodegradable*
Synthetic Polyol Esters
Virtually Non-toxic**
Fire Resistant***
Viscosity Index
Vegetable Oils
Mineral Oils
Description
Synthetic
Mobilfluid 424 55 145 X
Mobil DTE 10 Excel 32 32 164 X X
Univis HVI 26 26 376 X
Mobil EAL Hydraulic Oil 47 176 X X X
Mobil EAL Envirosyn H46 49 145 X X X
Quintolubric 888-46 50 185 X X X X
* Readily biodegradable classification indicates one of the following:
CO2 Conversion > 60% per EPA 560/6-82-003
CO2 Conversion > 80% per CEC-L-33-A-93
** Virtually Non-toxic classification indicates an LC50 > 5000 ppm per OECD 203
*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval
4150740 B
Figure 7-3. Hydraulic Oil Operation Chart - Sheet 2 of 2
7-10 – JLG Lift – 3121618

Figure 7-4. Maintenance and Lubrication Diagram
3121618 – JLG Lift – 7-11

7.3 MAINTENANCE AND LUBRICATION

NOTE: The following numbers correspond to those in Figure 7-4., Main- LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL
tenance and Lubrication Diagram. CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED
TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.
Table 7-13. Lubrication Specifications
KEY SPECIFICATIONS 1. Swing Bearing - Remote Lube
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel-
lent water resistance and adhesive qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-
Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424
EO Engine (crankcase) API CJ-4
Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within -45° to
Lube® 450°F (-43° to 232° C). JLG P/N 3020042.
Lube Point(s) - 3 Grease Fitting

Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hours of operation
Comments - Apply grease and rotate in 45 degree intervals
until bearing is completely lubricated.
7-12 – JLG Lift – 3121618

2. Swing Gearbox 3. Wheel Drive Hub
Lube Point(s) - Level/Fill Plug

Capacity - 2.6 quarts (2.5 liters) ± 10%
Interval - Check level every 3 months or 150 hrs of operation;
Lube Point(s) - Fill Plug change every 2 years or 1200 hours of operation
Capacity - 3 qt. (2.8 L)
Lube - GL-5
Interval - Check level every 150 hrs/Change every 1200
hours of operation. Fill to cover ring gear.
3121618 – JLG Lift – 7-13

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 fre-
quent basis.
7-14 – JLG Lift – 3121618

6. Hydraulic Charge Filter 7. High Pressure Filter
Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Change after first 50 hours and every 6 months or Interval - Change after first 50 hours and every 6 months or
300 hours thereafter. 300 hours thereafter.
3121618 – JLG Lift – 7-15

8. Hydraulic Oil 9. Main Valve Filter
Lube Point(s) - Fill Cap

Capacity - 75 Gallons (208 liters) Tank to Full Mark
82 Gallons (310.4 L) System
Lube - HO Lube Point(s) - Replaceable Element
Interval - Check level daily. Change every 2 years or 1200 Interval - Change after first 50 hours and every 6 months or
hours of operation. 300 hours thereafter.
7-16 – JLG Lift – 3121618

10. Oil Change w/Filter - Deutz 11. Fuel Filter - Deutz
Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element

Capacity - 9.6 Quarts (9.1 L) Interval - Every year or 500 hours of operation
Lube - EO
Interval - Check level daily; change every 500 hours or yearly,
whichever comes first. Adjust final oil level by mark on dipstick.
3121618 – JLG Lift – 7-17

12. Fuel Pre-Filter 13. Air Filter
Lube Point(s) - Replaceable Element

Interval - Every year or 500 hours of operation
7-18 – JLG Lift – 3121618

Lube Point(s) - Replaceable Element 7.4 TIRES & WHEELS

Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator
Comments - Check dust valve for dirt daily
Tire Inflation
The air pressure for pneumatic tires must be equal to the air pres-
14. Boom
sure that is stenciled on the side of the JLG product or rim decal
Lube Point(s) - Apply to wear pad contact paths for safe and proper operational characteristics.
Lube - Super Lube®
Interval - Every year or 600 hours of operation. Refer to the Ser- Tire Damage
vice Manual for detailed procedures
For pneumatic tires, JLG Industries, Inc. recommends that when any
15. Radiator cut, rip, or tear is discovered that exposes sidewall or tread area cords
Lube Point(s) - Fill Cap in the tire, measures must be taken to remove the JLG product from
Lube - Anti-Freeze Coolant (Refer to Engine Manual for com- service immediately. Arrangements must be made for replacement
patible coolants) of the tire or tire assembly.
Capacity - 13.2 qt. (12.5 L)
For polyurethane foam filled tires, JLG Industries, Inc. recommends
that when any of the following are discovered, measures must be
taken to remove the JLG product from service immediately and
arrangements must be made for replacement of the tire or tire
assembly.
• a smooth, even cut through the cord plies which exceeds 3

inches (7.5 cm) in total length
• any tears or rips (ragged edges) in the cord plies which
exceeds 1 inch (2.5 cm) in any direction
• any punctures which exceed 1 inch in diameter
3121618 – JLG Lift – 7-19

• any damage to the bead area cords of the tire Wheel Replacement
If a tire is damaged but is within the above noted criteria, the tire
The rims installed on each product model have been designed for
must be inspected on a daily basis to insure the damage has not
stability requirements which consist of track width, tire pressure, and
propagated beyond the allowable criteria.
load capacity. Size changes such as rim width, center piece location,
larger or smaller diameter, etc., without written factory recommen-
Tire Replacement dations, may result in an unsafe condition regarding stability.
JLG recommends a replacement tire be the same size, ply and brand
as originally installed on the machine. Please refer to the JLG Parts
Wheel Installation
Manual for the part number of the approved tires for a particular It is extremely important to apply and maintain proper wheel
machine model. If not using a JLG approved replacement tire, we mounting torque.
recommend that replacement tires have the following characteris-
tics:
• Equal or greater ply/load rating and size of original WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO
PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION
• Tire tread contact width equal or greater than original
OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
• Wheel diameter, width, and offset dimensions equal to the ANGLE OF THE WHEEL.
original
• Approved for the application by the tire manufacturer Tighten the lug nuts to the proper torque to prevent wheels from
(including inflation pressure and maximum tire load) coming loose. Use a torque wrench to tighten the fasteners. If you do
not have a torque wrench, tighten the fasteners with a lug wrench,
Unless specifically approved by JLG Industries Inc. do not replace a then immediately have a service garage or dealer tighten the lug
foam filled or ballast filled tire assembly with a pneumatic tire. When nuts to the proper torque. Over-tightening will result in breaking the
selecting and installing a replacement tire, ensure that all tires are studs or permanently deforming the mounting stud holes in the
inflated to the pressure recommended by JLG. Due to size variations wheels. The proper procedure for attaching wheels is as follows:
between tire brands, both tires on the same axle should be the same.
7-20 – JLG Lift – 3121618

1. Start all nuts by hand to prevent cross threading. DO NOT Table 7-14. 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
35 ft. lbs. 80 ft. lbs. 140 ft. lbs.
(45 Nm) (100 Nm) (185 Nm)
4. Wheel nuts should be torqued before first road use and after
each wheel removal. Check and torque every 3 months or
16 10
14 150 hours of operation.
5 8
12 19
18 4
3 17
20 11
7 6
13 9 2 15
3. The tightening of the nuts should be done in stages. Follow-

ing the recommended sequence, tighten nuts per wheel
torque chart.
3121618 – JLG Lift – 7-21

7.4 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/EC
and is only applicable to CE machines.
For electric powered machines, the equivalent continuous A-
Weighted sound pressure level at the work platform is less than
70dB(A)
For combustion engine powered machines, guaranteed Sound
Power Level (LWA) per European Directive 2000/14/EC (Noise
Emission in the Environment by Equipment for Use Outdoors)
based on test methods in accordance with Annex III, Part B,
Method 1 and 0 of the directive, is 104 dB.
The vibration total value to which the hand-arm system is sub-
jected does not exceed 2,5 m/s2. The highest root mean square
value of weighted acceleration to which the whole body is sub-
jected does not exceed 0,5 m/s2.
7-22 – JLG Lift – 3121618

SECTION 8 - INSPECTION AND REPAIR LOG
SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________
Table 8-1. Inspection and Repair Log
Date Comments
3121618 – JLG Lift – 8-1

SECTION 8 - INSPECTION AND REPAIR LOG
Table 8-1. Inspection and Repair Log
Date Comments
8-2 – JLG Lift – 3121618

TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this manual,
we would like to know who you are. For the purpose of receiving safety-related bulletins, it is
very important to keep JLG Industries, Inc. updated with the current ownership of all JLG
products. JLG maintains owner information for each JLG product and uses this information in
cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the current
ownership of JLG products. Please return completed form to the JLG Product Safety &
Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: ______________________________________________________________________
Serial Number: ____________________________________________________________________
Previous Owner: __________________________________________________________________
Address: _________________________________________________________________________
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121618
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JLG 1850 Operation and Safety Manual

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JLG 1850 Operation and Safety Manual

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Operation and Safety Manual

Boom Lift Models

3121618 – JLG Lift – a

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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Original Issue - March 24, 2014

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

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

SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR

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FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

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TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

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SECTION 1. SAFETY PRECAUTIONS

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• An operator must not accept operating responsibilities until Workplace Inspection

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Machine Inspection 1.3 OPERATION

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

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

Voltage Range MINIMUM APPROACH DISTANCE

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

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

• Do not elevate platform or drive with platform elevated while

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

Beaufort Wind Speed

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1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

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MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

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SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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Table 2-1. Inspection and Maintenance Table

3121618 – JLG Lift – 2-3

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