Page 3 - – JLG Lift –; FOREWORD
FOREWORD 3121138 – JLG Lift – a 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 andoperating procedures essential for the safe and proper machine operati...
Page 4 - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
FOREWORD b – JLG Lift – 3121138 SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALWILL HAVE A RED BACKGROUND. I N D I C A T E S A P O T E N T I A L LY H A Z A R D O U S S I T U A T I O N . I F N ...
Page 6 - REVISION LOG
FOREWORD d – JLG Lift – 3121138 REVISION LOG Original Issue - October 9, 2001 Revised - October 31, 2001 Revised - December 4, 2001 Revised - March 1, 2002 Revised - January 1, 2003 Revised - April 24, 2003 Revised - May 4, 2005 Revised - March 3, 2006 Revised - July 7, 2006 Revised - August 13, 200...
Page 7 - TABLE OF CONTENTS; PAGE; SECTION - 3 - MACHINE CONTROLS AND INDICATORS
TABLE OF CONTENTS 3121138 – JLG Lift – i SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS 1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 Ope...
Page 8 - ii; DRAINING OIL BUILD UP FROM THE PROPANE
TABLE OF CONTENTS ii – JLG Lift – 3121138 SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE 4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Platform Level Adjustment . . ....
Page 9 - iii; LIST OF FIGURES; Horizontal and Capacity Limit Switches -
TABLE OF CONTENTS 3121138 – JLG Lift – iii SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE REGULATOR (PRIOR TO S/N 0300134626) . . . .6-33 6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-35 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35Installation . ....
Page 10 - iv; LIST OF TABLES
TABLE OF CONTENTS iv – JLG Lift – 3121138 SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13 6-4. Engine Operating Temperature Specifications - Ford -...
Page 12 - This page left blank intentionally.
TABLE OF CONTENTS vi – JLG Lift – 3121138 SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally.
Page 13 - SECTION 1 - SAFETY PRECAUTIONS; SECTION 1. SAFETY PRECAUTIONS; Operator Training and Knowledge; • Read and understand this manual before operating the
SECTION 1 - SAFETY PRECAUTIONS 3121138 – JLG Lift – 1-1 SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of ...
Page 14 - Workplace Inspection
SECTION 1 - SAFETY PRECAUTIONS 1-2 – JLG Lift – 3121138 • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machineand in this manual. • Use the machine in a manner which is within the scope of its intended application set by JLG. • All operating personnel...
Page 15 - General
SECTION 1 - SAFETY PRECAUTIONS 3121138 – JLG Lift – 1-3 1.3 OPERATION General • Do not use the machine for any purpose other than posi- tioning personnel, their tools, and equipment. • Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine. • Never slam...
Page 16 - Electrocution Hazards
SECTION 1 - SAFETY PRECAUTIONS 1-4 – JLG Lift – 3121138 • Before operating the machine, make sure all gates are closed and fastened in their proper position. • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similaritems on platform to...
Page 17 - • Maintain distance from electrical lines, apparatus, or any; Voltage Range; NOTE: This requirement shall apply except where
SECTION 1 - SAFETY PRECAUTIONS 3121138 – JLG Lift – 1-5 • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1. • Allow for machine movement and electrical line swaying. • Maintain a cl...
Page 18 - • The minimum approach distance may be reduced if insulat-; Tipping Hazards; • The user must be familiar with the surface before driving.
SECTION 1 - SAFETY PRECAUTIONS 1-6 – JLG Lift – 3121138 • The minimum approach distance may be reduced if insulat- ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Them...
Page 19 - Crushing and Collision Hazards
SECTION 1 - SAFETY PRECAUTIONS 3121138 – JLG Lift – 1-7 • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. • Before driving on floors, bridges, trucks, and other sur- faces, check allowable capacity of the surfaces. • Never exceed the maximum platf...
Page 21 - and clothing at all times.
SECTION 1 - SAFETY PRECAUTIONS 3121138 – JLG Lift – 1-9 1.5 ADDITIONAL HAZARDS / SAFETY • Do not use machine as a ground for welding.• When performing welding or metal cutting operations, precautions must be taken to protect the chassis fromdirect exposure to weld and metal cutting spatter. • Do not...
Page 23 - PERSONNEL TRAINING; Operator training must cover:; Training Supervision
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121138 – JLG Lift – 2-1 SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING The aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only b...
Page 24 - MAINTENANCE
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-2 – JLG Lift – 3121138 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for further requirements f...
Page 25 - Pre-Star t Inspection
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121138 – JLG Lift – 2-3 Table 2-1. Inspection and Maintenance Table Type Frequency Primary Responsibility Service Qualification Reference Pre-Star t Inspection Before using each day; or whenever there’s an Operator change. User ...
Page 26 - Parent Metal Crack
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-4 – JLG Lift – 3121138 Pre-Start Inspection The Pre-Start Inspection should include each of the follow-ing: 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to...
Page 27 - Function Check; Perform the Function Check as follows:
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121138 – JLG Lift – 2-5 Function Check Perform the Function Check as follows: 1. From the ground control panel with no load in the plat-form: a. Check that all guards protecting the switches orlocks are in place; b. Operate all ...
Page 32 - HORIZONTAL AND CAPACITY LIMIT; Figure 2-4. Horizontal and Capacity Limit Switches - Sheet 1 of 2
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-10 – JLG Lift – 3121138 2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES Figure 2-4. Horizontal and Capacity Limit Switches - Sheet 1 of 2
Page 33 - Operation Characteristic
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121138 – JLG Lift – 2-11 Figure 2-5. Horizontal and Capacity Limit Switches - Sheet 2 of 2 Item Description Operation Characteristic 1 Boom Capacity Length Switch Activates platform capacity light to indicate the platform capaci...
Page 36 - From platform control station, start engine
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-14 – JLG Lift – 3121138 2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIMEA SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEMOPERATION IS SUSPECTED. NOTE: Ensure boom i...
Page 39 - SECTION 3 - MACHINE CONTROLS AND INDICATORS; SECTION 3. MACHINE CONTROLS AND INDICATORS; CONTROLS AND INDICATORS
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-1 SECTION 3. MACHINE CONTROLS AND INDICATORS 3.1 GENERAL T H E M A N U FA C T U R E R H A S N O D I R E C T C O N T R O L O V E R M A C H I N EA P P L I C AT I O N A N D O P E R AT I O N . T H E U S E R A N D O P E R A T O R A R ERES...
Page 40 - Provides 360 degrees continuous turntable rotation.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-2 – JLG Lift – 3121138 1. Indicator Panel. The LED Indicator Panel contains indicator lights thatsignal problem conditions or functions operating duringmachine operation. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SW...
Page 43 - This switch provides raising and lowering of the jib.
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-5 8. Engine Start/Auxiliary Power Switch orEngine Start/ Auxiliary Power Switch /Function Enable. To start the engine, the switch must be held"UP" until the engine starts. To use auxiliary power, the switch must beheld “DOWN”...
Page 44 - Ground Control Indicator Panel
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-6 – JLG Lift – 3121138 Ground Control Indicator Panel (See Figure 3-2. and Figure 3-3.) 1. Battery Charging Indicator Indicates a problem in the battery or charging circuit,and service is required. 2. Low Engine Oil Pressure Indicator. Indicates that eng...
Page 47 - Platform Overload Indicator (If Equipped); Platform Station; Horn
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-9 8. Platform Overload Indicator (If Equipped) Indicates the platform has been overloaded. 9. Hydraulic Oil Filter Indicator (Prior to S/N 85332) Indicates the return oil filter is too restrictive and in thebypass mode and needs to b...
Page 48 - Main Lift/Swing Controller
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-10 – JLG Lift – 3121138 NOTE: MAIN LIFT, SWING, and DRIVE control levers are spring-loaded and will automatically return to neutral (OFF) posi-tion when released. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES C...
Page 51 - Function Speed Control
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-13 6. Function Speed Control Controls the speed of Boom and Swing Functions.Rotate CCW for slower speed and CW for faster speed.To adjust to creep, turn knob fully CCW until it clicks. 7. Drive Speed/Torque Select The forward positio...
Page 53 - Drive Orientation Override; Platform Control Indicator Panel
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-15 16. Drive Orientation Override When the boom is swung over the rear tires or further ineither direction, the Drive Orientation indicator will illumi-nate when the drive function is selected. Push andrelease the switch, and within ...
Page 54 - Level System Fault Indicator
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-16 – JLG Lift – 3121138 1. Level System Fault Indicator Indicates a fault in the electronic leveling system. Thefault indicator will flash and an alarm sound. All func-tions will default to creep if the boom is extended morethan 20 inches (51 cm) or elev...
Page 55 - Glow Plug Indicator; TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3121138 – JLG Lift – 3-17 6. Glow Plug Indicator Indicates the glow plugs are operating. After turning onignition, wait until light goes out before cranking engine. 7. Footswitch/Enable Indicator To operate any function, the footswitch must bedepressed and...
Page 56 - * UNRESTRICTED CAPACITY
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-18 – JLG Lift – 3121138 1 2 3 4 * 5 6 7 8 9 10 11 ** * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 12 1. Level System2. AC Generator3. Overload4. Capacity 5. Tilt Alarm Warning6. Glow Plug7. Enable8. Fuel Level 9. Creep Speed Indicator10. Engine Malfunc...
Page 58 - Fuel Level Indicator
SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-20 – JLG Lift – 3121138 8. Fuel Level Indicator Indicates the level of fuel in the fuel tank. 9. Creep Speed Indicator When the Function Speed Control is turned to the creepposition, the indicator acts as a reminder that all func-tions are set to the slo...
Page 59 - SECTION 4 - MACHINE OPERATION; SECTION 4. MACHINE OPERATION; OPERATING CHARACTERISTICS AND; Load is within manufacturer’s rated capacity.; Stability
SECTION 4 - MACHINE OPERATION 3121138 – JLG Lift – 4-1 SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION This machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating and rotating boom. The primary operator control station is in the platform. Fromthis control sta...
Page 60 - Starting Procedure; Turn SELECT switch to PLATFORM.
SECTION 4 - MACHINE OPERATION 4-2 – JLG Lift – 3121138 TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOADMACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE. 4.3 ENGINE OPERATION NOTE: Initial starting should always be performed from theGround Control station. Starting Procedure IF ENGINE F...
Page 61 - Shutdown Procedure; Turn MASTER switch to Off.; Figure 4-1. Position of Least Backward Stability
SECTION 4 - MACHINE OPERATION 3121138 – JLG Lift – 4-3 Shutdown Procedure IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN,DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THEENGINE. 1. Remove all load and allow engine to operate at lowspeed for 3-5 minutes; this allows further reduction ...
Page 64 - Traveling Forward and Reverse
SECTION 4 - MACHINE OPERATION 4-6 – JLG Lift – 3121138 Traveling Forward and Reverse 1. At Platform Controls, pull out Emergency Stop switch,start engine, and activate footswitch. 2. Position Drive controller to FORWARD or REVERSE asdesired. This machine is equipped with a Drive Orientation Indicato...
Page 66 - Platform Level Adjustment
SECTION 4 - MACHINE OPERATION 4-8 – JLG Lift – 3121138 4.6 PLATFORM Platform Level Adjustment During normal operation of the machine, the platform willautomatically maintain it’s position. To manually Level Up orDown - Position the Platform/Level control switch Up orD o w n a n d h o l d u n t i l t...
Page 67 - Swinging the Boom
SECTION 4 - MACHINE OPERATION 3121138 – JLG Lift – 4-9 Swinging the Boom To swing boom, use SWING control to select RIGHT or LEFTdirection. WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FORTHE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIP-MENT. Raising and Lowering the Boom To raise o...
Page 68 - EMERGENCY TOWING; Disconnect drive hubs by inverting disconnect cap.
SECTION 4 - MACHINE OPERATION 4-10 – JLG Lift – 3121138 4.10 EMERGENCY TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE ATALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL-LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH....
Page 69 - Prior to towing the machine, complete the following:
SECTION 4 - MACHINE OPERATION 3121138 – JLG Lift – 4-11 4.11 TOW BAR (IF EQUIPPED) RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE ATALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL-LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR D...
Page 70 - Reconnect drive hubs by inverting disconnect cap.
SECTION 4 - MACHINE OPERATION 4-12 – JLG Lift – 3121138 4. Position steer/tow selector valve for towing; pull valveknob OUT for towing. The machine is now in the towingmode. After towing the machine, complete the following: 1. Actuate steer/tow selector valve for steering; push valveknob IN to the a...
Page 71 - SHUT DOWN AND PARK; Drive machine to a reasonably well protected area.; LIFTING AND TIE DOWN; Remove all loose items from the machine.
SECTION 4 - MACHINE OPERATION 3121138 – JLG Lift – 4-13 4.12 SHUT DOWN AND PARK To shut down and park the machine, the procedures are asfollows: 1. Drive machine to a reasonably well protected area. 2. Ensure boom is lowered over rear drive axle. 3. Push in the Emergency Stop at Platform Controls. 4...
Page 72 - Tie Down
SECTION 4 - MACHINE OPERATION 4-14 – JLG Lift – 3121138 Tie Down WHEN TRANSPOR TING THE MACHINE, THE BOOM MUST BE FULLYLOWERED INTO THE BOOM REST. 1. Remove all loose items from the machine. 2. When transporting an 800S/860SJ a step-deck or sin-gle-drop trailer is required. To avoid damage to the pl...
Page 111 - SECTION 5 - EMERGENCY PROCEDURES; SECTION 5. EMERGENCY PROCEDURES; GENERAL; [email protected]; EMERGENCY OPERATION; Operator Unable to Control Machine
SECTION 5 - EMERGENCY PROCEDURES 3121138 – JLG Lift – 5-1 SECTION 5. EMERGENCY PROCEDURES 5.1 GENERAL This section explains the steps to be taken in case of anemergency situation while operating. 5.2 INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any inci-dent involving a...
Page 112 - Platform or Boom Caught Overhead; EMERGENCY TOWING PROCEDURES
SECTION 5 - EMERGENCY PROCEDURES 5-2 – JLG Lift – 3121138 Platform or Boom Caught Overhead If the platform or boom becomes jammed or snagged inoverhead structures or equipment, rescue platform occu-pants prior to freeing the machine. 5.4 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited,...
Page 113 - To Retract and Lower Boom; Pump the hand pump until tight.; To Lower Boom with Fully Retracted Telescope; Turn knob #4 counterclockwise until fully open.
SECTION 5 - EMERGENCY PROCEDURES 3121138 – JLG Lift – 5-3 To Retract and Lower Boom 1. Turn knob #1 and #4 clockwise until tight. 2. Turn knobs #2 and #3 counterclockwise 3 turns. 3. Pump the hand pump until tight. 4. After telescope has fully retracted turn knob #4 counter-clockwise until fully ope...
Page 115 - SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE; SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE; Other Publications Available:; OPERATING SPECIFICATIONS; Refer to Capacity Decals on
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-1 SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6.1 INTRODUCTION This section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machi...
Page 117 - Specifications and Performance Data; Table 6-3. Specifications and Performance Data
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-3 Specifications and Performance Data Maximum Travel Grade (Side Slope)* 5° Maximum Ver tical Platform Height: 800S - 80 ft. (24.3 m) 860SJ - 86 ft. (26.2 m) Maximum Horizontal Platform Reach 800S 860SJ 71 ft. (21.6...
Page 118 - Capacities; Fuel Tank
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-4 – JLG Lift – 3121138 Capacities Ground Bearing Pressure - 800S 15-625 15-625FF 41/18LLx22.5 72 psi (5.0 kgm/cm 2 ) 79 psi (5.5 kgm/cm 2 ) 68 psi (4.8 kgm/cm 2 ) Ground Bearing Pressure - 860SJ 15-625 15-625FF 41/18LLx22.5 81 psi (5.7 ...
Page 119 - Engine Data
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-5 Engine Data Table 6-5. Ford LRG-425 Specifications Type Water-cooled Fuel Gasoline Oil Capacity 4.5 Quar ts (4.25 L) w/Filter Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 95 Amp, Belt Drive Fuel Consumption...
Page 121 - Battery
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-7 Battery Tires Table 6-9. GM 3.0L Fuel Gasoline or Gasoline/LP Gas No. of Cylinders 4 BHP Gasoline LP 83 hp @ 3000 rpm75 hp @ 3000 rpm Bore 4.0 in. (101.6 mm) Stroke 3.6 in. (91.44 mm) Displacement 181 cu.in. (3.0 ...
Page 122 - Major Component Weights; Upright
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-8 – JLG Lift – 3121138 Major Component Weights Hydraulic Oil NOTE: Hydraulic oils must have anti-wear qualities at least to APIService Classification GL-3, and sufficient chemical stabil-ity for mobile hydraulic system service. JLG Indu...
Page 125 - SERIAL NUMBER LOCATION; Specific Gravity
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-11 6.3 SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame.If the serial number plate is damaged or missing, the machineserial number is stamped on the left side of the frame. ...
Page 126 - ENGINE
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-12 – JLG Lift – 3121138 -40°F(-40°C) -30F°(-34°C) -20°F(-29°C) -10°F(-23°C) 0°F(-18°C) 10°F(-12°C) 20°F(-7°C) 30°F(-1°C) 40°F(4°C) 50°F(10°C) 60°F(16°C) 70°F(21°C) 80°F(27°C) 90°F(32°C) 100°F(38°C) 110°F(43°C) 120°F(49°C) ENGINE SPECIFI...
Page 135 - OPERATOR MAINTENANCE; Swing Bearing - Internal Ball Bearing
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-21 6.4 OPERATOR MAINTENANCE NOTE: The following numbers correspond to those in Figure 6-10., Operator Maintenance and Lubrication Diagram. LU B R I C A T I O N I N T E R V A L S A R E B A S E D O N M A C H I N E O P...
Page 136 - Wheel Bearings
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-22 – JLG Lift – 3121138 2. Wheel Bearings Lube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hours of operation 3. Wheel Drive Hub Lube Point(s) - Level/Fill PlugCapacity - 17 oz. (0.5 L) - 1/2 FullLube - EPG...
Page 137 - Hydraulic Return Filter
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-23 4. Hydraulic Return Filter Interval - Change after first 50 hrs. and every 6 months or300 hrs. thereafter or as indicated by Condition Indicator. 5. Hydraulic Charge Filter Interval - Change after first 50 hrs. a...
Page 138 - Hydraulic Tank
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-24 – JLG Lift – 3121138 6. Hydraulic Tank Lube Point(s) - Fill CapCapacity - 116 liters Tank 124 liters SystemLube - HOInterval - Check Level daily; Change every 2 years or 1200hours of operation. 7. Platform Filter Interval - Change as...
Page 139 - Suction Strainers
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-25 8. Suction Strainers Lube Point(s) - 2Interval - Every 2 years or 1200 hours of operation, removeand clean at time of hydraulic oil change. 9. Oil Change w/Filter - Ford Lube Point(s) - Fill Cap/Spin-on ElementCa...
Page 142 - Fuel Filter - Caterpillar
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-28 – JLG Lift – 3121138 14. Fuel Filter - Deutz Lube Point(s) - Replaceable ElementInterval - Every Year or 600 hours of operation 15. Fuel Filter - Caterpillar Lube Point(s) - Replaceable ElementInterval - Every Year or 600 hours of op...
Page 144 - Tire Inflation; • a smooth, even cut through the cord plies which
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-30 – JLG Lift – 3121138 6.5 TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the airpressure that is stenciled on the side of the JLG product orrim decal for safe and proper operational characteris...
Page 145 - Tire Replacement; the original; Wheel Replacement
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-31 Tire Replacement JLG recommends a replacement tire be the same size, ply andbrand as originally installed on the machine. Please refer to theJLG Parts Manual for the part number of the approved tires for aparticu...
Page 146 - Wheel Installation; Tighten nuts in the following sequence:
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-32 – JLG Lift – 3121138 Wheel Installation It is extremely important to apply and maintain proper wheelmounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPERTORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI-BLE...
Page 147 - DRAINING OIL BUILD UP FROM THE; Start the engine and bring to operating temperature.; TORQUE SEQUENCE; st Stage
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-33 3. The tightening of the nuts should be done in stages. Fol-lowing the recommended sequence, tighten nuts per wheel torque chart. 4. Wheel nuts should be torqued after first 50 hours of operation and after each w...
Page 148 - Push in the Emergency Switch once the engine stops.
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6-34 – JLG Lift – 3121138 4. Push in the Emergency Switch once the engine stops. 5. Disconnect the electrical connection to the LPG fueltemperature sensor in the auxiliary fuel port of the EPR. 6. Remove the retainer clip for the LPG fuel...
Page 149 - PROPANE FUEL FILTER REPLACEMENT
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-35 6.7 PROPANE FUEL FILTER REPLACEMENT Removal 1. Relieve the propane fuel system pressure. Refer to Pro-pane Fuel System Pressure Relief. 2. Disconnect the negative battery cable. 3. Slowly loosen the Filter housin...
Page 151 - PROPANE FUEL SYSTEM PRESSURE RELIEF; To relieve propane fuel system pressure:; SUPPLEMENTAL INFORMATION; . The highest root mean
SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3121138 – JLG Lift – 6-37 6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312P S I ( 2 1 . 5 B A R ) . TO M I N I MI Z E T H E R I S K O F F I R E A N D P E R S O NA LINJUR Y, RELIEVE THE PROPAN...
Page 153 - SECTION 7 - INSPECTION AND REPAIR LOG; SECTION 7. INSPECTION AND REPAIR LOG; Date
SECTION 7 - INSPECTION AND REPAIR LOG 3121138 – JLG Lift – 7-1 SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments
Page 155 - TRANSFER OF OWNERSHIP
TRANSFER OF OWNERSHIP T o Pr od uc t Own e r: If yo u n o w own b u t ARE NOT the o rigin al pu rc haser o f th e pro d u c t co vered b y th is man u al, we wo uld like to kn ow wh o you are. For th e pu rp ose o f receivin g safety-related bu lletin s , it is very imp o rtan t to keep JLG In dus t...
Page 158 - JLG Worldwide Locations
Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia)P.O. Box 511911 Bolwarra RoadPort MacquarieN.S.W. 2444Australia +61 2 65 811111 +61 2 65813058 JLG Latino Americana Ltda.Rua Eng. Carlos Ste...
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