JLG 860S Operation And Safety Manual
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JLG 860S Operation And Safety Manual

JLG 860S Operation And Safety Manual

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Operation and Safety Manual
ANSI
Original Instructions - Keep this manual with the machine at all times.
®
Boom Lift Models
680S
Prior to S/N 0300189341
3121233
July 4, 2014

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 680S Prior to S/N 0300189341 ANSI 3121233 July 4, 2014 ®...
  • Page 3 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.

  • Page 4: Safety Alert Symbols And Safety Signal Words

    INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- DECAL WILL HAVE AN ORANGE BACKGROUND. TECTION OF PROPERTY. – JLG Lift – 3121233...

  • Page 5: Outside Usa

    FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...

  • Page 6: Revision Log

    Original Issue - July 14, 2006 Revised - October 16, 2006 Revised - September 21, 2007 Revised - November 25, 2009 Revised - March 30, 2012 Revised - May 24, 2012 Revised - July 4, 2014 – JLG Lift – 3121233...

  • Page 7: Table Of Contents

    Traveling Forward and Reverse ... . . 4-6 Function Check......2-5 3121233 – JLG Lift –...
  • Page 8 Wheel Installation ..... . . 6-32 EMERGENCY TOWING PROCEDURES ..5-2 DRAINING OIL BUILD UP FROM THE PROPANE REG- MANUAL DESCENT INSTRUCTIONS – JLG Lift – 3121233...
  • Page 9 Ford - Sheet 1 of 2 ..... . . 6-14 3-5. Platform Control Console - w/Drive Orientation . .3-11 6-5. Engine Operating Temperature Specifications - 3121233 – JLG Lift –...
  • Page 10 GM 3.0L ........6-6 – JLG Lift –...

  • Page 11: Section 1. Safety Precautions

    If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“ JLG”). • Do not operate this machine until complete training is per- formed by authorized persons.

  • Page 12: Workplace Inspection

    • Do not operate any machine on which safety or instruction placards or decals are missing or illegible. ment unless approved in writing by JLG. • Avoid any buildup of debris on the platform floor. Keep • Do not operate the machine in hazardous environments mud, oil, grease, and other slippery substances from foot- unless approved for that purpose by JLG.

  • Page 13: Operation

    • Do not carry materials directly on platform railing. Contact yard anchorage point. Attach only one (1) lanyard per lan- JLG for approved material handling accessories. yard anchorage point. • When two or more persons are in the platform, the opera- tor shall be responsible for all machine operations.

  • Page 14: Electrocution Hazards

    • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach. • Never use the boom assembly to enter or leave the plat- form. – JLG Lift – 3121233...

  • Page 15: Minimum Approach Distances (M.a.d.)

    50,000 volts. One foot additional clearance is required for • Allow for machine movement and electrical line swaying. every additional 30,000 volts or less. 3121233 – JLG Lift –...

  • Page 16: Tipping Hazards

    DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. – JLG Lift – 3121233...

  • Page 17: Crushing And Collision Hazards

    Increase of the area exposed to the wind will decrease stability. • Do not increase the platform size with unauthorized deck • During operation, keep all body parts inside platform rail- extensions or attachments. ing. 3121233 – JLG Lift –...

  • Page 18: Towing, Lifting, And Hauling

    Disconnect power to overhead cranes. • Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if neces- sary. – JLG Lift – 3121233...

  • Page 19: Additional Hazards / Safety

    • When performing welding or metal cutting operations, • Charge batteries only in a well ventilated area. precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. 3121233 – JLG Lift –...
  • Page 20 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. 1-10 – JLG Lift – 3121233...

  • Page 21: Section 2 - User Responsibilities, Machine Preparation, And Inspection

    4. Use of approved fall protection device. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 3121233 – JLG Lift –...

  • Page 22: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT and maintenance required by JLG Industries, Inc. Consult MODEL.
  • Page 23 At intervals as specified in the Service and Main- Owner, Dealer, or User Qualified JLG Service and Maintenance tenance Manual. Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121233 – JLG Lift –...

  • Page 24: Pre-Start Inspection

    MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. 4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities – JLG Lift – 3121233...

  • Page 25: Function Check

    Check that all guards protecting the switches or locks are in place; c. Operate all functions and check all limiting and cut- out switches; d. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in. 3121233 – JLG Lift –...
  • Page 26 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Basic Nomenclature - Sheet 1 of 2 – JLG Lift – 3121233...
  • Page 27 7. Base Boom Section 8. Mid Boom Section 9. Fly Boom Section 10. Boom Assembly 11. Power Track 12. Jib (If Equipped) 13. Platform 14. Platform Console Figure 2-2. Basic Nomenclature - Sheet 2 of 2 3121233 – JLG Lift –...
  • Page 28 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 2 – JLG Lift – 3121233...

  • Page 29: General

    13. Main Hydraulic Pump - See Inspection Note. ble, control markings legible. 14. Platform Rotator - See Inspection Note. 3. Boom Sections/Uprights/Turntable - See Inspection Note. Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 2 3121233 – JLG Lift –...

  • Page 30: Horizontal And Capacity Limit Switches

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES Figure 2-4. Horizontal and Capacity Limit Switches - Sheet 1 of 2 2-10 – JLG Lift – 3121233...

  • Page 31: Horizontal And Capacity Limit Switches

    Activates platform capacity light to indicate the platform capacity at a designated boom height. Angle Switch Boom Elevation Reduces drive speed when boom is raised above horizontal. Switch Figure 2-5. Horizontal and Capacity Limit Switches - Sheet 2 of 2 3121233 – JLG Lift – 2-11...
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-6. Limiting and Cut-Out Switches - Sheet 1 of 2 2-12 – JLG Lift – 3121233...
  • Page 33 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-7. Limiting and Cut-Out Switches - Sheet 2 of 2 3121233 – JLG Lift – 2-13...

  • Page 34: Oscillating Axle Lockout Test (If Equipped)

    2. From platform control station, start engine ground, it may be necessary to activate Drive to release cylinders. 2-14 – JLG Lift – 3121233...
  • Page 35 Reverse and drive machine off of block and fied personnel correct the malfunction prior to any fur- ramp. ther operation. 11. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground. 3121233 – JLG Lift – 2-15...
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-16 – JLG Lift – 3121233...

  • Page 37: Section 3 - Machine Controls And Indicators

    Telescope, box or by the ground controls for these symbols and the Swing, Lift, Platform Level Override, and Plat- corresponding functions. form Rotate functions. 3121233 – JLG Lift –...
  • Page 38 A two-position red mushroom shaped switch furnishes power to PLATFORM/GROUND SELECT switch when Provides raising and lowering of the main boom. pulled out (on). When pushed in (off), power is shut off to the PLATFORM/GROUND SELECT switch. – JLG Lift – 3121233...

  • Page 39: Ground Control Station

    1. Indicator Panel 2. Telescope 3. Swing 4. Lift 5. Platform/Ground Select Switch 6. Hourmeter 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power/Function Enable 9. N/A 10. Platform Leveling Override 11. Platform Rotate Figure 3-1. Ground Control Station 3121233 – JLG Lift –...
  • Page 40 A three position switch permits rotation of the platform. WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.) – JLG Lift – 3121233...

  • Page 41: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 5. Malfunction Indicator Indicates that the JLG Control System has detected a (See Figure 3-2., Ground Control Indicator Panel - Sheet 1 of 2 malfunction and a Diagnostic Trouble Code has been and Figure 3-3., Ground Control Indicator Panel - Sheet 2 of 2)
  • Page 42 10. Charge Pump Filter 3. High Engine Coolant Temp. 7. Glow Plug 11. Engine Air Filter 4. High Engine Oil Temp. 8. Platform Overload Figure 3-2. Ground Control Indicator Panel - Sheet 1 of 2 – JLG Lift – 3121233...
  • Page 43 10. Not Used 3. Engine Water Temp. 7. Glow Plug 11. Not Used 4. Engine Oil Temp. 8. Platform Overload 12. Drive and Steer Disable Figure 3-3. Ground Control Indicator Panel - Sheet 2 of 2 3121233 – JLG Lift –...

  • Page 44: Platform Station

    During this time the lights on the indicator panel will also blink once as a bulb check. Indicates the Drive and Steer Disable function has been 2. Horn activated. If pressed, this switch supplies power to the horn. – JLG Lift – 3121233...
  • Page 45 DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORI- 4. Main Telescope Control. ZONTAL. This control allows extension and retraction of the main boom. 3121233 – JLG Lift –...

  • Page 46: Platform Control Console

    14. Engine Start / Aux Power 3. Main Lift / Swing 7. Drive Speed / Torque Select 11. Fuel Select 15. Light Panel 4. Telescope 8. Platform Rotate 12. Lights Figure 3-4. Platform Control Console 3-10 – JLG Lift – 3121233...

  • Page 47: Platform Control Console - W/Drive Orientation

    13. Steer Select 18. Soft Touch Indicator 4. Telescope 9. Platform Level Override 14. Engine Start / Aux Power 5. Drive/Steer 10. Not Used 15. Light Panel Figure 3-5. Platform Control Console - w/Drive Orientation 3121233 – JLG Lift – 3-11...
  • Page 48 This switch allows the operator to rotate the basket to there is no waiting period when switching fuels while the the left or right. engine is running. 3-12 – JLG Lift – 3121233...
  • Page 49 To re-synchronize the front and rear axles, position the rear drive wheels to the forward drive position by select- 3121233 – JLG Lift – 3-13...

  • Page 50: Platform Control Indicator Panel

    Creep Mode. 3-14 – JLG Lift – 3121233...
  • Page 51 IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL. 3121233 – JLG Lift – 3-15...
  • Page 52 TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS. FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT- TOM. 3-16 – JLG Lift – 3121233...

  • Page 53: Platform Light Panel

    9. Creep Speed Indicator 2. AC Generator 6. Glow Plug 10. Engine Malfunction Indicator 3. Overload 7. Enable 11. Cable Service Indicator 4. Capacity 8. Fuel Level 12. Soft Touch Indicator Figure 3-6. Platform Light Panel 3121233 – JLG Lift – 3-17...

  • Page 54: Platform Light Panel - W/Drive Orientation

    2. AC Generator 7. Enable 11. Cable Service 3. Overload 8. Fuel Level 12. Not Used 4. Capacity 9. Creep Speed 13. Drive Orientation 5. Tilt Alarm Warning Figure 3-7. Platform Light Panel - w/Drive Orientation 3-18 – JLG Lift – 3121233...
  • Page 55 PLATFORM TO THE STOWED POSITION, SHUT DOWN THE MACHINE, 10. Malfunction Indicator AND HAVE THE BOOM CABLES INSPECTED. The light indicates that the JLG Control System has 12. Soft Touch Indicator (If Equipped) detected a malfunction and a Diagnostic Trouble Code has been set in the system memory.
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-20 – JLG Lift – 3121233...

  • Page 57: Section 4 - Machine Operation

    4. Proper tire pressure. unable to do so. The Ground Control is also to be used in Pre-Start Inspection. 5. Machine is as originally equipped from JLG. Stability Machine stability is based on two (2) conditions which are called FORWARD and BACKWARD stability. The machine’s position of least FORWARD stability is shown in (See Figure 4-2.), and its position of least BACKWARD stability is shown...

  • Page 58: Engine Operation

    1. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch until engine starts. – JLG Lift – 3121233...

  • Page 59: Shutdown Procedure

    2. Push POWER/EMERGENCY STOP switch in. 3. Turn MASTER switch to Off. Refer to Engine Manufacturer’s manual for detailed informa- BOOM FULLY tion. ELEVATED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-1. Position of Least Backward Stability 3121233 – JLG Lift –...

  • Page 60: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION TELESCOPE FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED TURNTABLE ROTATED ON AN OUT-OF-LEVEL SURFACE 90 DEGREES FROM STOWED POSITION Figure 4-2. Position of Least Forward Stability – JLG Lift – 3121233...

  • Page 61: Traveling (Driving)

    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. BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. 3121233 – JLG Lift –...

  • Page 62: Traveling Forward And Reverse

    2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected. – JLG Lift – 3121233...
  • Page 63 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes 3121233 – JLG Lift –...

  • Page 64: Platform

    LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE To rotate the platform to the left or right, use the Platform EMERGENCY STOP SWITCH TO STOP THE MACHINE. Rotate control switch to select the direction and hold until desired position is reached. – JLG Lift – 3121233...

  • Page 65: Swinging The Boom

    To raise or lower the Boom, use Boom Lift control to select UP or DOWN movement. FUNCTION SPEED CONTROL This control affects the speed of all boom functions and Plat- form Rotate. When in the CCW maximum position, Drive is placed in creep speed. 3121233 – JLG Lift –...

  • Page 66: 4.10 Emergency Towing

    1. Retract, lower and position boom in travel position; lock turntable. 2. Disconnect drive hubs by inverting disconnect cap. Figure 4-4. Drive Disconnect Hub 3. Reconnect the drive hubs by inverting the disconnect cap when towing is complete. 4-10 – JLG Lift – 3121233...

  • Page 67: Tow Bar (If Equipped)

    1. Retract, lower and position boom in travel position; lock turntable. 2. Lower towbar and connect to towing vehicle 3. Disconnect drive hubs by inverting disconnect cap. Refer to Figure 4-4., Drive Disconnect Hub. 3121233 – JLG Lift – 4-11...
  • Page 68 IN to the actuated position. 2. Reconnect drive hubs by inverting disconnect cap. 3. Disconnect towbar from towing vehicle and place it in the stowed position as shown below. The machine is now in the driving mode. 4-12 – JLG Lift – 3121233...

  • Page 69: 4.12 Shut Down And Park

    Lifting follows: 1. Drive machine to a reasonably well protected area. 1. Call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight. 2. Ensure boom is lowered over rear drive axle. 2. Place the boom in the stowed position with the turntable 3.

  • Page 70: Tie Down

    Position the boom over the front wheels. DO NOT SWING THE BOOM WITH THE MACHINE POSITIONED ON A TRAILER. TIPOVER MAY RESULT. b. Place the boom in the stowed position with the turn- table locked. 4-14 – JLG Lift – 3121233...

  • Page 71: Typical 680S Transport

    SECTION 4 - MACHINE OPERATION Figure 4-5. Typical 680S Transport 3121233 – JLG Lift – 4-15...

  • Page 72: Lifting And Tie Down Chart

    SECTION 4 - MACHINE OPERATION MODELS 800S 66” (168cm) 76” (189cm) 57” (145cm) 860SJ 62” (157cm) 80” (203cm) 53” (135cm) 680S 70” (178cm) 72” (183cm) 61” (155cm) Figure 4-6. Lifting and Tie Down Chart 4-16 – JLG Lift – 3121233...

  • Page 73: Decal Location - Side Entry Platform

    SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Location - Side Entry Platform - Sheet 1 of 5 3121233 – JLG Lift – 4-17...

  • Page 74: Decal Location - Side Entry Platform

    SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Location - Side Entry Platform - Sheet 2 of 5 4-18 – JLG Lift – 3121233...

  • Page 75: Decal Location - Side Entry Platform

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Location - Side Entry Platform - Sheet 3 of 5 3121233 – JLG Lift – 4-19...

  • Page 76: Decal Location - Side Entry Platform

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Location - Side Entry Platform - Sheet 4 of 5 4-20 – JLG Lift – 3121233...

  • Page 77: Decal Location - Side Entry Platform

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Location - Side Entry Platform - Sheet 5 of 5 3121233 – JLG Lift – 4-21...
  • Page 78 Table 4-1. Decal Location Legend Item # Australia Item # Australia 0275865-3 0275865-3 1701499 1701502 1705921 1701503 1705822 1701509 1701518 1705961 1703811 1705828 1703814 1704277 1704412 1705084 1703478 1702631 1707124 1701501 1705978 1705978 1702153 4-22 – JLG Lift – 3121233...
  • Page 79 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Location Legend Table 4-1. Decal Location Legend Item # Australia Item # Australia 0275865-3 0275865-3 3252781 1701691 1704277 3121233 – JLG Lift – 4-23...
  • Page 80 SECTION 4 - MACHINE OPERATION NOTES: 4-24 – JLG Lift – 3121233...

  • Page 81: Section 5 - Emergency Procedures

    REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY. JLG Industries, Inc. must be notified immediately of any inci- dent involving a JLG product. Even if no injury or property EMERGENCY OPERATION damage is evident, the factory should be contacted by tele- phone and provided with all necessary details.

  • Page 82: Platform Or Boom Caught Overhead

    EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine have been incorporated. For specific procedures, refer to Section 4. PLATFORM WILL NOT REMAIN LEVEL DURING MANUAL DESCENT OPERATION. – JLG Lift – 3121233...

  • Page 83: To Retract And Lower Boom

    4. Pump the hand pump until tight. clockwise until fully open to continue lowering boom. NOTE: When the manual descent operation has been completed, knobs #1, #2, and #3 should be open (counterclock- wise), knob #4 should be closed (clockwise). 3121233 – JLG Lift –...
  • Page 84 SECTION 5 - EMERGENCY PROCEDURES NOTES: – JLG Lift – 3121233...

  • Page 85: Section 6 - General Specifications & Operator Maintenance

    12 ft. (3.6 m) Maximum Drive Speed: 3.5 mph (1.5 m/s) Max. Hydraulic System Pressure 4500 psi (310 Bar) Maximum Wind Speed 28 mph (12.5 m/s) Maximum Manual Force 400 N Electrical System Voltage 12 Volts 3121233 – JLG Lift –...

  • Page 86: Specifications And Performance Data

    Stowed Length 37’ 3.25" (11.4 m) Wheel base 10’ (3.04 m) Ground Clearance 15.625" (0.4 m) Drive Speed Stowed 2WD 3.0 mph (5.5 kph) Stowed 4WD 3.5 mph (5.6 kph) Elevated 0.75 mph (1.2 kph) – JLG Lift – 3121233...

  • Page 87: Capacities

    17,200 lbs. (7802 kg) Cooling System 5 Quarts (4.5 L) 41/18LLx22.5 17,300 lbs. (7850 kg) Crankcase 11 Quarts (10.5 L) w/Filter Total Capacity 16 Quarts (15 L) Caterpillar 10.6 quarts (10 L) 4.5 Quarts (4.25 L) w/Filter 3121233 – JLG Lift –...

  • Page 88: Engine Data

    74 @ 3000 RPM, full load High RPM 2.50 GPH (9.46 lph) Cooling System 16 Quarts (15.14 L) Horsepower 66 @ 3000 RPM, full load Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) – JLG Lift – 3121233...
  • Page 89 1000 Cold Cranking Amps, 210 Low RPM 1800 minutes Reserve Capacity, 12 VDC High RPM - 3044C 2600 Horsepower 64 @ 2600 RPM, full load High RPM - 3.4 2500 Alternator 60 Amp, belt drive 3121233 – JLG Lift –...

  • Page 90: Battery

    1-3-4-2 (247 kg) Max. RPM 2800 18 - 625 Pneumatic 288 lbs. 85 psi (6.5 Bar) (131 kg) 18 - 625 Foam-Filled 601 lbs. (273 kg) 41/ 18LL x 22.5 Foam-Filled 724 lbs. (329 kg) – JLG Lift – 3121233...

  • Page 91: Major Component Weights

    1410 Service Classification GL-3, and sufficient chemical stabil- Boom Assembly 3337 1514 ity for mobile hydraulic system service. JLG Industries Telescope Cylinder recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152. Slave Cylinder Torque Hub (2WD) NOTE: When temperatures remain consistently below 20 Tire &...
  • Page 92 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Aside from JLG recommendations, it is not advisable to mix oils Table 6-14. Mobil DTE 13M Specs of different brands or types, as they may not contain the same ISO Viscosity Grade required additives or be of comparable viscosities.
  • Page 93 Weight at 65° C (150° F) 22 cSt (106SUS) (0.9 kg per liter) Viscosity Index Viscosity at 40° C 37 cSt at 100° C 8.4 cSt Viscosity Index NOTE: Must be stored above 32°F (14°C) 3121233 – JLG Lift –...

  • Page 94: Serial Number Location

    217°F (103°C) Viscosity at 40° C 25.8 cSt at 100° C 9.3 cSt Viscosity Index NOTE: Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity. Figure 6-1. Serial Number Locations 6-10 – JLG Lift – 3121233...
  • Page 95 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE This Page Left Blank Intentionally. 3121233 – JLG Lift – 6-11...

  • Page 96: Engine Operating Temperature Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)

  • Page 97: Engine Operating Temperature Specifications

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS N O T E : AMBIENT AIR TEMPERATURES 110°...

  • Page 98: Engine Operating Temperature Specifications

    WITH THE RECOMMENDED FLUIDS AND A FU LLY CHARGED BATTERY. 0 F(-18 C) -10 F(-23 C) A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 99: Engine Operating Temperature Specifications

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...

  • Page 100: Engine Operating Temperature Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND...

  • Page 101: Engine Operating Temperature Specifications

    (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...

  • Page 102: Engine Operating Temperature Specifications

    -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 103: Engine Operating Temperature Specifications

    (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...
  • Page 104 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-10. Operator Maintenance and Lubrication 6-20 – JLG Lift – 3121233...

  • Page 105: Operator Maintenance

    LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION Comments - Remote Access UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON- DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD- INGLY. 3121233 – JLG Lift – 6-21...
  • Page 106 2 years or 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port. 6-22 – JLG Lift – 3121233...
  • Page 107 Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator (if equipped). 3121233 – JLG Lift – 6-23...
  • Page 108 Lube Point(s) - Fill Cap Interval - Change as necessary Capacity - 116 liters Tank 124 liters System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 6-24 – JLG Lift – 3121233...
  • Page 109 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Suction Strainers 9. Oil Change w/Filter - Ford Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7014501) Capacity - 4.5 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual.
  • Page 110 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - Deutz 11. Oil Change w/Filter - Caterpillar Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7026855) Capacity - 10.6 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual.
  • Page 111 Interval - Every Year or 1200 hours of operation Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 3121233 – JLG Lift – 6-27...
  • Page 112 Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 6-28 – JLG Lift – 3121233...
  • Page 113 Comments - Replace filter. Refer to Section 6.7, Propane Comments - Drain oil build up. Refer to Section 6.6, Fuel Filter Replacement Draining Oil Build Up From The Propane Regulator (Prior to S/N 0300134626) 3121233 – JLG Lift – 6-29...

  • Page 114: Tires & Wheels

    The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or • a smooth, even cut through the cord plies which rim decal for safe and proper operational characteristics.

  • Page 115: Tire Replacement

    Please refer to the for stability requirements which consist of track width, tire pres- JLG Parts Manual for the part number of the approved tires for a sure, and load capacity. Size changes such as rim width, center particular machine model.

  • Page 116: Wheel Installation

    The proper procedure for attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 6-32 – JLG Lift – 3121233...

  • Page 117: Draining Oil Build Up From The Propane Reg

    1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 3121233 – JLG Lift – 6-33...
  • Page 118 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 6-34 – JLG Lift – 3121233...

  • Page 119: Propane Fuel Filter Replacement

    8. Tighten the filter bowl retainer to 106 in lbs (12 Nm). seal. 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 3121233 – JLG Lift – 6-35...
  • Page 120 10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13. Ring 5. Filter Housing Figure 6-11. Filter Lock Assembly 6-36 – JLG Lift – 3121233...

  • Page 121: Propane Fuel System Pressure Relief

    0,5 m/s RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS- TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS- CONNECTING ANY FUEL LINE. 3121233 – JLG Lift – 6-37...
  • Page 122 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 6-38 – JLG Lift – 3121233...

  • Page 123: Section 7 - Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121233 – JLG Lift –...
  • Page 124 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121233...
  • Page 128 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121233 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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