JLG 450A II Series Operation And Safety Manual
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JLG 450A II Series Operation And Safety Manual

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Download this manual See also: Service Maintenance Manual, Safety and Operating Manual
Operation and Safety Manual
Keep this manual with the machine at all times.
Boom Lift Models
450A Series II
450AJ Series II
510AJ
3121179
ANSI
May 22, 2006
®

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  • Page 1 Operation and Safety Manual Keep this manual with the machine at all times. Boom Lift Models 450A Series II 450AJ Series II 510AJ 3121179 ANSI May 22, 2006 ®...
  • 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 ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE WILL HAVE A RED BACKGROUND. A YELLOW BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. – JLG Lift – 3121179...
  • Page 5 • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- Compliance Information TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions • Questions Regarding Spe-...
  • Page 6 Original Issue - January 1, 2003 Revised - April 24, 2003 Revised - August 26, 2003 Revised - June 15, 2004 Revised - May 4, 2005 Revised - February 8, 2006 Revised - May 22, 2006 – JLG Lift – 3121179...

  • Page 7: Table Of Contents

    Function Check......2-5 PLATFORM ....... 4-7 3121179 – JLG Lift –...
  • Page 8 EMERGENCY OPERATION ....5-2 Wheel Installation ..... . . 6-31 – JLG Lift – 3121179...
  • Page 9 Installation......6-35 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-36 SECTION - 7 - INSPECTION AND REPAIR LOG 3121179 – JLG Lift –...
  • Page 10 4-11. Decal Installation - Sheet 6 of 6....4-19 6-1. Serial Number Locations....6-11 6-2. Engine Operating Temperature Specifications - – JLG Lift – 3121179...
  • Page 11 6-21 UCon Hydrolube HP-5046 ....6-9 6-22 Mobil EAL H 46 Specs ..... 6-10 3121179 – JLG Lift –...

  • Page 12: Section - Paragraph, Subject

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally. – JLG Lift – 3121179...

  • Page 13: 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 14: Workplace Inspection

    • Do not operate or raise the platform while on trucks, trail- ers, railway cars, floating vessels, scaffolds or other equip- MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM ment unless approved in writing by JLG. SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU- FACTURER •...

  • Page 15: Operation

    SECTION 1 - SAFETY PRECAUTIONS OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the •...

  • Page 16: 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 – 3121179...

  • Page 17: 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. 3121179 – JLG Lift –...

  • Page 18: 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 – 3121179...

  • Page 19: Crushing And Collision Hazards

    Increase of the area exposed to the wind will decrease stability. • Do not increase the platform size with unauthorized deck extensions or attachments. • During operation, keep all body parts inside platform rail- ing. 3121179 – JLG Lift –...

  • Page 20: 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 – 3121179...

  • Page 21: Additional Hazards / Safety

    • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • Charge batteries only in a well ventilated area. 3121179 – JLG Lift –...
  • Page 22 SECTION 1 - SAFETY PRECAUTIONS This page left blank intentionally. 1-10 – JLG Lift – 3121179...

  • Page 23: 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. 3121179 – JLG Lift –...

  • Page 24: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED 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 PROD- and maintenance recommended by JLG Industries, Inc. UCT MODEL.

  • Page 25: Inspection And Maintenance Table

    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. 3121179 – JLG Lift –...

  • Page 26: Pre-Start Inspection

    6. Fuel (Combustion Engine Powered Machines) – Add the proper fuel as necessary. 7. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure. – JLG Lift – 3121179...

  • Page 27: 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. 3121179 – JLG Lift –...

  • Page 28: Basic Nomenclature - Sheet 1 Of 2

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Basic Nomenclature - Sheet 1 of 2 – JLG Lift – 3121179...

  • Page 29: Basic Nomenclature - Sheet 2 Of 2

    12. Platform Console 13. Jib 14. Fly Boom 15. Base Boom 16. Master Cylinder 17. Tower or Lower Boom 18. Turntable 19. Frame 20. Tower Link Figure 2-2. Basic Nomenclature - Sheet 2 of 2 3121179 – JLG Lift –...

  • Page 30: Daily Walk-Around Inspection - Sheet 1 Of 3

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection - Sheet 1 of 3 – JLG Lift – 3121179...

  • Page 31: General

    1. Platform Assembly and Gate - Lockbolts in place. Footswitch works properly, not modified, disabled or blocked. Latch, stop, and hinges in working condition. Figure 2-4. Daily Walk-Around Inspection - Sheet 2 of 3 3121179 – JLG Lift –...

  • Page 32: Daily Walk-Around Inspection - Sheet 3 Of 3

    No evidence of damage. 13. Auxiliary Hydraulic Pump - See Inspection Note. 14. Main Hydraulic Pump - See Inspection Note. 15. Platform Rotator - See Inspection Note. Figure 2-5. Daily Walk-Around Inspection - Sheet 3 of 3 2-10 – JLG Lift – 3121179...

  • Page 33: Oscillating Axle Lockout Test (If Equipped)

    10. With boom over left side of machine, place Drive control wheel is on top of block. lever to Reverse and drive machine off of block and ramp. 4. Carefully activate Swing control lever and position boom over right side of machine. 3121179 – JLG Lift – 2-11...
  • Page 34 12. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary activate Drive to release cylinders. 2-12 – JLG Lift – 3121179...

  • Page 35: Section 3. Machine Controls And Indicators

    Telescope, 3. Articulating Jib Boom (If Equipped) Swing, Tower Lift, Main Lift, Jib Lift, Platform Level Override, and Platform Rotate functions. This switch provides raising and lowering of the jib. 3121179 – JLG Lift –...

  • Page 36: Ground Control Station - A Models

    4. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 5. Power/Emergency Stop 6. Platform/Ground Select 7. Hourmeter 8. Swing 9. Tower Lift 10. Main Lift 11. Telescope 12. Indicator Panel Figure 3-1. Ground Control Station - A Models – JLG Lift – 3121179...

  • Page 37: Ground Control Station - Aj Models

    4. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 5. Power/Emergency Stop 6. Platform/Ground Select 7. Hourmeter 8. Swing 9. Tower Lift 10. Main Lift 11. Telescope 12. Indicator Panel Figure 3-1. Ground Control Station - AJ Models 3121179 – JLG Lift –...
  • Page 38 Platform/Ground Select switch when pulled out (on). When pushed in (off), power is shut off to the Plat- The Swing control switch provides 360 degrees non- form/Ground Select switch. continuous turntable rotation when positioned to the right or left. – JLG Lift – 3121179...

  • Page 39: Ground Control Indicator Panel

    Indicates that engine coolant temperature is abnormally high and service is required. 4. Engine Oil Temperature Indicator (Deutz) Indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required. 3121179 – JLG Lift –...

  • Page 40: Ground Control Indicator Panel

    6. Low Fuel 2. Low Engine Oil Pressure 7. Glow Plug Wait 3. Engine Coolant Temp. Overload 9. Engine Air Filter By-Pass 4. Engine Oil Temp. 5. Engine Malfunction Figure 3-2. Ground Control Indicator Panel – JLG Lift – 3121179...
  • Page 41 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Engine Malfunction Indicator 7. Glow Plug Wait Indicator The light indicates that the JLG Control System has Indicates the glow plugs are on. The glow plugs are detected a malfunction and a Diagnostic Trouble Code automatically turned on with the ignition circuit and has been set in the system memory.

  • Page 42: Platform Control Station

    3. Horn pump or engine fail. The auxiliary pump will operate tower boom lift, tower telescope, main boom lift, main If pressed, this switch supplies power to the horn. telescope and swing. – JLG Lift – 3121179...

  • Page 43: Platform Control Console

    13. Function Speed 2. Platform Leveling Override 6. Fuel Select 10. Jib 14. Main Lift/Swing 3. Horn 7. Lights 11. Tower Lift 4. Power/Emergency Stop 8. Drive/Steer 12. Platform Rotate Figure 3-3. Platform Control Console 3121179 – JLG Lift –...
  • Page 44 10. Articulating Jib Boom (if equipped) NOTE: Main lift and swing functions may be selected at the same This switch controls the raising or lowering of the jib. time. Maximum speed is reduced when both functions are selected. 3-10 – JLG Lift – 3121179...

  • Page 45: Platform Control Indicator Panel

    1. AC Generator (Green) light will go out and the footswitch must be released and depressed again to enable the controls. Indicates the generator is in operation. 3121179 – JLG Lift – 3-11...
  • Page 46 NOTE: For engine starting, the footswitch must be in the released 8. System Malfunction Indicator (up) position. The light indicates that the JLG Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service...

  • Page 47: Platform Control Indicator Panel - Sheet 1 Of

    4. Glow Plug 7. Creep Speed 2. Overload 5. Enable 8. System Malfunction 3. Tilt Alarm Warning 6. Fuel Level 9. Soft Touch Figure 3-4. Platform Control Indicator Panel - Sheet 1 of 2 3121179 – JLG Lift – 3-13...

  • Page 48: Platform Control Indicator Panel - Sheet 2 Of

    4. Glow Plug 7. Creep Speed 2. Overload 5. Enable 8. System Malfunction 3. Tilt Alarm Warning 6. Fuel Level 9. Soft Touch Figure 3-5. Platform Control Indicator Panel - Sheet 2 of 2 3-14 – JLG Lift – 3121179...

  • Page 49: Section 4. Machine Operation

    Ground Control Station which will override the Platform Con- trol Station. Ground Controls operate Boom Lift and Swing, 5. Machine is as originally equipped from JLG. and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so.

  • Page 50: Stability

    1. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD. – JLG Lift – 3121179...

  • Page 51: Shutdown Procedure

    3-5 minutes; this allows further reduction of the depressed position, DO NOT OPERATE MACHINE. internal engine temperature. 2. Push POWER/EMERGENCY STOP switch in. 3. Turn MASTER switch to Off. Refer to Engine Manufacturer’s manual for detailed informa- tion. 3121179 – JLG Lift –...

  • Page 52: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION Figure 4-1. Position of Least Forward Stability – JLG Lift – 3121179...

  • Page 53: Traveling (Driving)

    DRIVING WITH ANY PART OF MACHINE WITHIN 6 FEET (2 M) OF AN OBSTRUCTION. BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED. Figure 4-2. Position of Least Backward Stability 3121179 – JLG Lift –...

  • Page 54: Grade And Side Slopes

    SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slopes – JLG Lift – 3121179...

  • Page 55: Traveling Forward And Reverse

    Up or Down and hold until the platform is level. Platform Rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached. 3121179 – JLG Lift –...

  • Page 56: Swinging The Boom

    Raising and Lowering the Main (Upper) Boom a certified JLG service technician. Operate as follows: 1. Position Platform/Ground switch to Platform. To raise or lower the Upper Boom, use Upper Boom Lift switch to select UP or DOWN movement.

  • Page 57: Oscillating Axle Lockout Test (If Equipped)

    LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY trols from hostile environment. TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. Refer to Section 2.3, Oscillating Axle Lockout Test (If Equipped) for procedure. 3121179 – JLG Lift –...

  • Page 58: 4.12 Lifting And Tie Down

    Tie Down Lifting IMPORTANT WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY 1. Refer to the Serial Number Tag, call JLG Industries, or LOWERED INTO THE BOOM REST. weigh the individual unit to find out the Gross Vehicle Weight.

  • Page 59: Lifting And Tie Down Chart

    SECTION 4 - MACHINE OPERATION Figure 4-4. Lifting and Tie Down Chart 3121179 – JLG Lift – 4-11...

  • Page 60: 4.13 Towing

    Prior to towing the machine, complete the following: DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED. 1. Retract, lower and position boom over rear drive wheels in line with direction of travel. Figure 4-5. Drive Disconnect Hub 4-12 – JLG Lift – 3121179...

  • Page 61: Dual Fuel System (Gas Engine Only)

    2. Open hand valve on LP gas supply tank by turning counterclockwise. 3. While engine is operating on GASOLINE under a no- load condition, place FUEL SELECT switch at Platform Control to LP position. 3121179 – JLG Lift – 4-13...

  • Page 62: Decal Installation - Sheet 1 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-6. Decal Installation - Sheet 1 of 6 4-14 – JLG Lift – 3121179...

  • Page 63: Decal Installation - Sheet 2 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-7. Decal Installation - Sheet 2 of 6 3121179 – JLG Lift – 4-15...

  • Page 64: Decal Installation - Sheet 3 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 3 of 6 4-16 – JLG Lift – 3121179...

  • Page 65: Decal Installation - Sheet 4 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 4 of 6 3121179 – JLG Lift – 4-17...

  • Page 66: Decal Installation - Sheet 5 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 5 of 6 4-18 – JLG Lift – 3121179...

  • Page 67: Decal Installation - Sheet 6 Of 6

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 6 of 6 3121179 – JLG Lift – 4-19...
  • Page 68 1701645 1703996 1703996 1703996 1703996 1703996 1702688 1704112 1704112 1705084 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 4-20 – JLG Lift – 3121179...
  • Page 69 1701509 1701509 1701509 1701509 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1705828 1703980 1703981 1703984 1703982 1703985 3121179 – JLG Lift – 4-21...
  • Page 70 Item # ANSI Australian Japan Korean French/ Chinese Spanish 0272573-5 0272574-3 0273452-2 0272575-4 0272576-4 0272577-6 0272578-4 0272579-5 1705514 3252768 3252768 3252768 3252768 3252768 3252768 3252768 3252768 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 4-22 – JLG Lift – 3121179...

  • Page 71: Section 5. Emergency Procedures

    JLG Industries, Inc. must be notified immediately of any inci- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE dent involving a JLG product. Even if no injury or property AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, damage is evident, the factory should be contacted by tele- THEN FROM THE PLATFORM CONTROLS.

  • Page 72: Emergency Operation

    For specific procedures, refer to Section 4. platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY. 3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine. – JLG Lift – 3121179...

  • Page 73: Section 6. General Specifications & Operator Maintenance

    4.5 mph (2.0 m/s) 510AJ Illustrated Parts Manual ........ 3121182 Maximum Hyd. Operating Pressure 4500 psi (310 Bar) Electrical System Voltage 12 volts Gross Machine Weight (450A) 14,500 lb. (6577 kg) (450AJ) 16,500 lb. (7484 kg) 3121179 – JLG Lift –...

  • Page 74: Reach Specifications

    31.1 ft. (9.48 m) Electrical System Voltage 12 volts Up & Over Height 24.08 ft. (7.34 m) Gross Machine Weight 16,104 lb. (7305 kg) Jib Length 4.5 ft. (1.37 m) Jib Angle 135° (+70°, -65°) – JLG Lift – 3121179...

  • Page 75: Dimensional Data

    7.4 ft. (2.26 m) Gross Machine Weight Tailswing 450A SII 14,500 lbs. (6577 kg) Stowed Height 7.4 ft. (2.26 m) 450AJ SII 16,500 lbs. (7484 kg) Stowed Length 25.1 ft. (7.68 m) Wheel base 7.67 ft. (2.34 m) 3121179 – JLG Lift –...

  • Page 76: Capacities

    Pneumatic 90 psi (6 Bar) 135 lbs. (61 kg) 33/1550x16.5 Foam-Filled 395 lbs. (179 kg) 14 x 16.1 Pneumatic 40 lbs. (3 bar) 91.5 lbs. (41.5 kg) 14 x 16.1 Foam-Filled 426 lbs. (193 kg) – JLG Lift – 3121179...

  • Page 77: Engine

    Mid RPM Rotate, Jib Lift 1500 Tower Lift, Upper Lift, Tele 1800 High RPM 2800 Swing, Basket Level, Basket 1500 Rotate, Jib Lift High RPM 3000 Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) 3121179 – JLG Lift –...

  • Page 78: Deutz F3M2011F

    19:1 total capacity 11 quarts (10.5 L) Firing Order 1-3-4-2 Low RPM 1200 Max. RPM 2800 Mid RPM Tower Lift, Upper Lift, Tele Swing, Basket Level, Basket 1800 Rotate, Jib Lift 1500 High RPM 2800 – JLG Lift – 3121179...

  • Page 79: Major Component Weights

    4 Wheel Drive Axle Firing Order 1-3-4-2 2 Wheel Drive Axle Max. RPM 2800 Table 6-17. Component Weights - 510 Component Pounds Kilograms Engine Only Upper Boom 1257 Frame (Bare) 2105 Turntable (Bare) 1533 695.5 3121179 – JLG Lift –...

  • Page 80: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of Table 6-18.

  • Page 81: Mobil Dte 13M Specs

    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 cp at -20° F 6,200 Viscosity Index 3121179 – JLG Lift –...

  • Page 82: Mobil Eal H 46 Specs

    7.64 lb. per gal. Weight NOTE: Mobil/Exxon recommends that this oil be checked (0.9 kg per liter) on a yearly basis for viscosity. Viscosity at 40° C 45 cSt at 100° C 8.0 cSt Viscosity Index 6-10 – JLG Lift – 3121179...

  • Page 83: 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 machine serial number is stamped on the left side of the frame. Figure 6-1. Serial Number Locations 3121179 – JLG Lift – 6-11...

  • Page 84: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2 6-12 – JLG Lift – 3121179...

  • Page 85: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 3121179 – JLG Lift – 6-13...

  • Page 86: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-4. Engine Operating Temperature Specifications - Ford - Sheet 1 of 2 6-14 – JLG Lift – 3121179...

  • Page 87: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-5. Engine Operating Temperature Specifications - Ford - Sheet 2 of 2 3121179 – JLG Lift – 6-15...

  • Page 88: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 6-16 – JLG Lift – 3121179...

  • Page 89: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-7. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2 3121179 – JLG Lift – 6-17...

  • Page 90: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-8. Engine Operating Temperature Specifications - GM - Sheet 1 of 2 6-18 – JLG Lift – 3121179...

  • Page 91: Engine Operating Temperature Specifications

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-9. Engine Operating Temperature Specifications - GM - Sheet 2 of 2 3121179 – JLG Lift – 6-19...

  • Page 92: Operator Maintenance And Lubrication Diagram

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-10. Operator Maintenance and Lubrication Diagram 6-20 – JLG Lift – 3121179...

  • Page 93: Operator Maintenance

    Interval - Every 3 months or 150 hrs of operation Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C. Open Gear Lubricant - Mobiltac 375 or equivalent. 3121179 – JLG Lift – 6-21...
  • Page 94 Capacity - 17 oz. (0.5 L) - 1/2 Full WILL RESULT IN BLOWING OUTER SEAL IN HOUSING. Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation 6-22 – JLG Lift – 3121179...
  • Page 95 Interval - Change after first 50 hrs. and every 6 months Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition or 300 hrs. thereafter or as indicated by Condition Indicator. Indicator. 3121179 – JLG Lift – 6-23...
  • Page 96 Interval - Every 2 years or 1200 hours of operation, the Full line on the sight gauge remove and clean at time of hydraulic oil change. Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 6-24 – JLG Lift – 3121179...
  • Page 97 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Oil Change w/Filter - Ford 10. Oil Change w/Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N Fill Cap/Spin-on Element (JLG P/N 7014501) 7016641) Capacity - 4.5 Quarts (4.25 L) Capacity - 11 Quarts(10.5 L) Crankcase;...
  • Page 98 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 11. Oil Change w/Filter - Caterpillar 12. Oil Change w/Filter - GM 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 99 Interval - Every Year or 1200 hours of operation Interval - Every Year or 600 hours of operation 15. Fuel Filter - Caterpillar Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 3121179 – JLG Lift – 6-27...
  • Page 100 Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 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 – 3121179...
  • Page 101 Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.6, Propane Comments - Drain oil build up. Refer to Section 6.5, Fuel Filter Replacement DRAINING OIL BUILD UP FROM THE PROPANE REGU- LATOR 3121179 – JLG Lift – 6-29...

  • Page 102: Tires & Wheels

    Tire Damage brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a For pneumatic tires, JLG Industries, Inc. recommends that when particular machine model. If not using a JLG approved replace-...

  • Page 103: Wheel Replacement

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque.

  • Page 104: Wheel Torque Chart

    170 ft. lbs. (55 Nm) (130 Nm) (255 Nm) 4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation. 6-32 – JLG Lift – 3121179...

  • Page 105: Draining Oil Build Up From The Propane Regulator

    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. 3121179 – JLG Lift – 6-33...

  • Page 106: Propane Fuel Filter Replacement

    9. Start the engine and verify all connections are secure. 6. Seal 12. Retaining Bolt 10. Dispose of any drained oil per local regulations in a safe Figure 6-11. Filter Lock Assembly and proper fashion. 6-34 – JLG Lift – 3121179...

  • Page 107: Removal

    8. Tighten the filter retaining bolt to 106 in lbs (12 Nm). 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. 3121179 – JLG Lift – 6-35...

  • Page 108: Propane Fuel System Pressure Relief

    2. Start and run the vehicle until the engine stalls. 3. Turn the ignition switch OFF. RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS- TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS- CONNECTING ANY FUEL LINE. 6-36 – JLG Lift – 3121179...

  • Page 109: 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 3121179 – JLG Lift –...

  • Page 110: Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121179...
  • Page 112 Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (UK) JLG Industries (Europe) JLG Industries (Australia) JLG Industries (Pty) Ltd. Unit 12, Southside Kilmartin Place, P .O. Box 5119 Unit 1, 24 Industrial Complex Bredbury Park Industrial Estate...

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