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Original Instructions, keep this manual with the machine at all times.
Model
3394RT
4394RT
Prior to SN 0200239053
P/N - 3121132
ANSI
July 25, 2016
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.
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 possi-
ble injury or death.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST
BACKGROUND. UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
NOTICE
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROP-
ORANGE BACKGROUND. ERTY.
For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CON- Accident Reporting Standards and Regula-
TACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTA- tions Compliance Infor-
Product Safety Publi-
TIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH mation
cations
MAY HAVE BEEN ISSUED FOR THIS PRODUCT. Questions Regarding Spe-
Current Owner
cial Product Applications
Updates
NOTICE Questions Regarding
Questions Regarding
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER Product Modifications
Product Safety
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
NOTICE JLG Industries, Inc.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES 13224 Fountainhead Plaza
WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING Hagerstown, MD 21742
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE
HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT. or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
REVISION LOG
Original Issue - April 11, 2002
Revised - July 12, 2002
Revised - July 18, 2003
Revised - February 18, 2004
Revised - August 6, 2004
Revised - December 21, 2004
Revised - July 15, 2005
Revised - February 28, 2006
Revised - March 29, 2007
Revised - May 22, 2008
Revised - September 30, 2008
Revised - November 30, 2010
Revised - May 16, 2014
Revised - July 25, 2016
Workplace Inspection
Precautions to avoid all hazards in the work area must
be taken by the user before operation of the machine.
An operator must not accept operating responsibilities Do not operate or raise the platform from a position on
until adequate training has been given by competent trucks, trailers, railway cars, floating vessels, scaffolds or
and authorized persons. other equipment unless the application is approved in
Allow only those authorized and qualified personnel to writing by JLG.
operate the machine who have demonstrated that they Before operation, check work area for overhead hazards
understand the safe and proper operation and mainte- such as electric lines, bridge cranes, and other potential
nance of the unit. overhead obstructions.
Check floor surfaces for holes, bumps, drop-offs, Ensure all safety devices are operating properly. Modifi-
obstructions, debris, concealed holes, and other poten- cation of these devices is a safety violation.
tial hazards.
Check the work area for hazardous locations. Do not
operate the machine in hazardous environments unless MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
approved for that purpose by JLG. MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
Ensure that the ground conditions are adequate to sup-
port the maximum tire load indicated on the tire load Do not operate any machine on which the safety or
decals located on the chassis adjacent to each wheel. instruction placards or decals are missing or illegible.
Do not operate the machine when wind conditions Check the machine for modifications to original compo-
exceed 28 mph (12.5 m/s). nents. Ensure that any modifications have been
approved by JLG.
This machine can be operated in nominal ambient tem-
peratures of 0 F to 104 F (-20 C to 40 C). Consult JLG Avoid accumulation of debris on platform deck. Keep
to optimize operation outside of this temperature mud, oil, grease, and other slippery substances from
range. footwear and platform deck.
Machine Inspection
Do not operate this machine until the inspections and
functional checks have been performed as specified in
Section 2 of this manual.
Do not operate this machine until it has been serviced
and maintained according to the maintenance and
inspection requirements as specified in the machines
Service and Maintenance Manual.
Keep the chassis of the machine a minimum of 0.6m (2 Watch for obstructions around machine and overhead
ft.) from holes, bumps, drop-offs, obstructions, debris, when driving. Check clearances above, on sides, and
concealed holes, and other potential hazards at the bottom of platform when lifting or lowering platform.
ground level.
Never attempt to use the machine as a crane. Do not tie-
off machine to any adjacent structure. Never attach
wire, cable, or any similar items to platform.
Do not cover the platform sides or carry large surface-
area items in the platform when operating outdoors.
The addition of such items increases the exposed wind
area of the machine.
Do not increase the platform size with unauthorized
deck extensions or attachments.
If scissor arm assembly or platform is caught so that one
or more wheels are off the ground, all persons must be During operation, keep all body parts inside platform
removed before attempting to free the machine. Use railing.
cranes, forklift trucks, or other appropriate equipment
to stabilize machine and remove personnel. Always post a lookout when driving in areas where
vision is obstructed.
Crushing and Collision Hazards Keep non-operating personnel at least 6 ft. (1.8 m ) away
from machine during all driving operations.
Approved head gear must be worn by all operating and
ground personnel. Under all travel conditions, the operator must limit
travel speed according to conditions of ground surface,
Keep hands and limbs out of the scissor arm assembly
congestion, visibility, slope, location of personnel, and
during operation.
other factors causing hazards of collision or injury to 1.4 TOWING, LIFTING, AND HAULING
personnel.
Never allow personnel in platform while towing, lifting,
Be aware of stopping distances in all drive speeds. When
or hauling.
driving in high speed, switch to low speed before stop-
ping. Travel grades in low speed only. This machine should not be towed, except in the event
of emergency, malfunction, power failure, or loading/
Do not use high speed drive in restricted or close quar-
unloading. Refer to Emergency Procedures section of
ters or when driving in reverse.
this manual for emergency towing procedures.
Exercise extreme caution at all times to prevent obsta-
Ensure platform is fully retracted and completely empty
cles from striking or interfering with operating controls
of tools prior to towing, lifting or hauling.
and persons in the platform.
When lifting machine with a forklift, position forks only
Ensure that operators of other overhead and floor level
at designated areas of the machine. Lift with a forklift of
machines are aware of the aerial work platforms pres-
adequate capacity.
ence. Disconnect power to overhead cranes. Barricade
floor area if necessary. Refer to the Machine Operation section of this manual
for lifting and tie-down procedures.
Avoid operating over ground personnel. Warn person-
nel not to work, stand, or walk under a raised platform.
Position barricades on floor as necessary.
Battery Hazards BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
Always disconnect batteries when servicing electrical CLEAN WATER AND SEEK MEDICAL ATTENTION.
components or when performing welding on the
machine.
Charge batteries only in a well ventilated area.
Do not allow smoking, open flame, or sparks near bat-
Avoid overfilling the battery fluid level. Add distilled
tery during charging or servicing.
water to batteries only after the batteries are fully
Do not contact tools or other metal objects across the charged.
battery terminals.
NOTES:
NOTICE
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNI-
CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE
TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE
3. Decals and Placards Check all for cleanliness and IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PER-
legibility. Make sure none of the decals and placards SONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR
are missing (refer to the Decal Installation in Section OPERATION.
3). Make sure all illegible decals and placards are
cleaned or replaced.
4 5 6 20 19 18 17 16 15 5 4
21
1 14
22
2
8 9 10 11 12 13
4 5 6 7 5 4
Figure 2-1. Walk Around Inspection Diagram
NOTE: On each item, make sure there are no loose or missing 9. Main Control Valve - No unsupported wires or hoses;
parts, that they are securely fastened, and that no visible no damaged or broken wires.
damage exists in addition to any other criteria men- 10. Leveling Jack Valve (If equipped) - No unsupported
tioned. wires or hoses; no damaged or broken wires.
NOTE: All wheel lugs are to be torqued at 170 ft lbs (240 Nm).
11. Ground Controls - Placard secure and legible, control 19. Lift Cylinder - See Note.
switches return to neutral position, emergency stop
20. Proximity Switch - See Note.
switch functions properly. Control markings legible.
21. Safety Prop - See Note.
12. Drive Valve (If applicable) - No unsupported wires or
hoses; no damaged or broken wires. 22. Manual Descent - See Note.
13. Hydraulic Reservoir - Recommended hydraulic fluid 23. Platform Control Console (Not Shown) - Placard
level on level indicator on tank. Breather cap secure secure and legible, control lever and switches return
and working. to neutral, all switch guards are in place, trigger
switch and emergency stop switch function prop-
14. Header Valve (4WD only) (If applicable) - See Note.
erly, Operation & Safety manual in storage box.
15. Engine and Hydraulic Pump Assembly - See Note.
24. Platform/Handrail Installation (Not Shown) - See
16. Battery Cables/Routing Installation - See Note. Note.
17. Drive Header Valve (4WD only) (If applicable) - See
Note.
18. Rotary Switch - See Note.
Function Check
Table 2-2. Maximum Cutout Height
Perform the Function Check as follows:
Model High Drive Cutout
1. From the ground control panel with no load in the
platform: 3394RT 6-9 ft (1.9-2.7 m)
a. Check that all switch guards are in place;
4394RT 7-10 ft (2.1-3 m)
b. Operate all functions. Reference Section 4,
Machine Operation;
c. Check auxiliary power (or manual descent) (Refer Table 2-3. Tilt Cutout Settings
to the auxiliary power (or manual descent) sec-
tions of this manual for proper operating proce- Model Front to Back Side to Side
dures.);
5 to 26 ft (8 m)
d. Ensure that all machine functions are disabled 3394RT
5 to full height 4 to 30 ft (9 m)
when the Emergency Stop Button is activated. (ANSI, Aus)
3 to 33 ft (10 m)
2. From the platform control console:
5 to 26 ft (8 m)
a. Ensure that the control console is firmly secured 4394RT
5 to full height 4 to 30 ft (9 m)
in the proper location; (ANSI, Aus)
3 to 43 ft (13 m)
b. Check that all switch guards are in place;
3394RT/4394RT
c. Operate all functions and check all limiting and 3 to full height 3 to full height
(CSA)
cut-out switches. Reference Section 4, Machine
Operation, See Table 2-2 and Table 2-3; 3394RT/4394RT
5 to full height 3 to full height
d. Ensure that all machine functions are disabled (CE)
when the Emergency Stop Button is activated.
3. With the platform in the transport (stowed) position: 4. Raise machine platform approximately 9 ft (2.7 m) on
the 3394RT or 10 ft (3.1 m) on the 4394RT.
a. Drive the machine on a grade, not to exceed the
rated gradeability, and stop to ensure the brakes 5. Place DRIVE control switch to REVERSE position and
hold; carefully drive the machine off the block and ramp.
b. Ensure the platform tilt indicator light is illumi- 6. Have an assistant check to see that the left front wheel
nated. remains locked in position off the ground.
2.3 LOCKOUT CYLINDER TEST 7. Lower the machine platform; the lockout cylinder
should then release and allow wheel to rest on the
ground. It may be necessary to activate DRIVE to
NOTICE release cylinders.
LOCKOUT CYLINDER SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY
TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM 8. Place the 6 inch (15.2 cm) high block with ascension
OPERATION IS SUSPECTED. ramp in front of right front wheel.
9. From platform control station, select LOW drive speed.
NOTE: Ensure platform is fully lowered prior to beginning lockout
cylinder test. 10. Place DRIVE control switch to FORWARD position and
carefully drive the machine up ascension ramp until
1. Place a 6 inch (15.2 cm) high block with ascension right front wheel is on top of block.
ramp in front of left front wheel. 11. Raise machine platform approximately 9 ft (2.7 m) on
2. From platform control station, select LOW drive speed. the 3394RT or 10 ft (3.1 m) on the 4394RT.
3. Place DRIVE control switch to FORWARD position and 12. Place DRIVE control switch to REVERSE position and
carefully drive the machine up ascension ramp until carefully drive the machine off the block and ramp.
left front wheel is on top of block. 13. Have an assistant check to see that the right front
wheel remains locked in position off the ground.
14. Lower the machine platform; the lockout cylinder Changing from LP Gas to Gasoline:
should then release and allow wheel to rest on the
1. With the engine operating on LP gas under a no load
ground. It may be necessary to activate DRIVE to
condition, position the LPG/GAS SELECT switch at the
release cylinders.
platform control station to the GAS SELECT position.
15. If the lockout cylinders do not function properly, have
2. If the engine stumbles because of a lack of gasoline,
qualified personnel correct the malfunction prior to
place the switch to the LPG position until the engine
any further operation.
regains smoothness, then return the switch to the GAS
2.4 DUAL FUEL SYSTEM (IF EQUIPPED) SELECT position. Repeat as necessary until the engine
runs smoothly on gasoline.
Close the hand valve on the LP gas supply tank by turning
clockwise.
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT
ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE
FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.
13 9. Hourmeter
1
10
Ground Control Station (See Figure 3-1) 2. Glow Plug Switch - (Diesel Engine Only) - A momentary
contact, push button type switch that supplies electri-
cal power to the engines glow plugs, when depressed,
to assist cold starting. There is a 5 second default timer
DO NOT OPERATE FROM GROUND CONTROL STATION WITH PERSONNEL IN that will not allow the start button to function before
THE PLATFORM EXCEPT IN AN EMERGENCY. this time has elapsed.
PERFORM AS MANY PRE-OPERATIONAL CHECKS AND INSPECTIONS FROM 3. Circuit Breaker - The circuit breaker will open when
THE GROUND CONTROL STATION AS POSSIBLE. there is a short or overload on the machine.
4. Front Power Deck (If equipped) - A three position,
NOTE: When the machine is shut down for overnight parking or momentary contact switch provides power to the
battery charging, the emergency stop and power select front power deck. When activated, this switch will
switches must be positioned to off to prevent draining the extend or retract the front power deck.
batteries.
5. Ignition/Emergency Stop Switch - A two-position, red,
1. Platform/Ground Control Switch (Power Select Switch) mushroom-shaped ignition/emergency stop switch,
A three position, key-operated power select switch when positioned to ON with the power selector switch
supplies operating power to the platform or ground positioned to ground, furnishes operating power to
controls, as selected. When positioned to platform, the the ground control station. In addition, the switch can
switch provides power to the emergency stop switch be used to turn off power to the function controls in
at the platform controls. When positioned to ground, the event of an emergency. Power is turned on by pull-
the switch provides power to the ground control. The ing the switch out (on), and is turned off by pushing
ground control emergency stop switch provides the switch in (off).
power to the key switch. With the power select switch
in the center off position, power is shut off to both 6. Rear Power Deck (If equipped) - A three position,
platform and ground controls and the key can be momentary contact switch provides power to the rear
removed to disable the machine. power deck. When activated, this switch will extend or
retract the front power deck.
7. Auxiliary Power (If equipped) (Optional with power deck 11. Lift Switch - A three position, momentary contact lift
option only) - This switch is designed to work with the control switch provides raising and lowering of the
optional power decks. If the machine would lose platform when positioned to up or down.
engine power this switch allows the operator to
12. Battery - Illuminates when the charge in the battery is
retract either or both of the power decks.
low.
8. Water Temperature - Illuminates when the engine is
13. Start Switch - A momentary contact, push button type
overheating.
switch that supplies electrical power to the starter
9. Hourmeter - The machine is equipped with an hour solenoid when the emergency stop switch is in the ON
meter to indicate the number of hours the machine position and the start button is depressed.
has been operated.
NOTE: Engine cannot be started while glow plugs are on.
10. Oil Pressure - Illuminates when the engine oil pressure
14. Platform Overload Indicator (If equipped) - Illuminates
drops too low.
when the platform becomes overloaded.
1 2 3
11
7
TURN SIGNAL
LEFT RIGHT
1001110553 A
1705914B
14
10 9 8
Figure 3-2. Platform Control Station
Platform Control Station (See Figure 3-2) b. To adjust the leveling jacks to the left, activate the
switch on top of the controller to the left. To
adjust to the right, activate the switch on top of
NOTICE the controller to the right. The leveling jack indi-
CONTROL BOXES SHOULD NOT BE SWITCHED FROM ONE MACHINE TO cator light for the side selected will be lit.
ANOTHER.
NOTE: You can not adjust the level of the machine with the EASI-
1. Auto Leveling Jacks - (Optional) - When depressed the CLADDER option installed.
light will illuminate on the indicator pad, enabling
2. Front Deck Extension Select (Optional) - This button
that function for 5 seconds. Moving the control han-
must be depressed in conjunction with the control
dle forward will lower the leveling jacks. Moving the
handle to operate the power deck extension. Moving
control handle backward will raise the leveling jacks.
the controller forward extends the deck. Moving the
Once the machine is level the jacks will discontinue
control backward retracts the deck.
extending and the jack set light will turn on.
3. Dual Fuel Select/Glow Plug - This switch is set up to
NOTE: After initial ground contact is made, the auto level func-
change from gasoline to propane on a machine
tion will pause 2-5 seconds and then begin to properly
equipped with the dual fuel option. On a machine
level the machine. Once level, the tilt light on the platform
equipped with a diesel engine this switch serves as a
control box will stop blinking.
glow plug switch.
NOTE: There is an override feature on the Auto Leveling system
4. Rear Deck Extension Select (Optional) - This button
that allows the operator to adjust (trim) the level of the
must be depressed in conjunction with the control
machine to the left or right when the platform is com-
handle to operate the power deck extension. Moving
pletely lowered. Use the following instructions to adjust
the controller forward extends the deck. Moving the
the level of the machine.
control backward retracts the deck.
a. Select the leveling jack selection switch and
5. Generator Start Switch - (Optional) - This toggle
squeeze the trigger switch on the controller.
switch, when used, turns the generator on and sets
the engine speed.
6. Overload Indicator (If Equipped) - Indicates the plat- handle backward will retract the power deck
form has been overloaded. An audible alarm will also extension. After selecting the leveling jack func-
signal when the platform is overloaded. tion, moving the control handle forward will
extend all four leveling jacks. moving the hand
NOTE: If the Overload Indicator is illuminated, all functions will controller backward will retract the leveling jacks.
be prevented from the platform controls. Using the The speed on all selected functions, (except level-
ground controls or manual descent, fully lower the
ing jacks), is proportionally controlled by the dis-
machine and reduce the weight in the platform so as to tance of travel of the hand controller. The thumb-
not exceed the rated workload indicated on the capacity operated steer switch on top of the hand control-
decal.
ler activates the steer wheels in the direction acti-
7. Controller and Steer Switch vated (right or left).
a. Control Handle - The control handle controls five b. Steer Switch/Auto Leveling Trim Adjust - The steer
functions: drive, lift, power deck, leveling jacks switch/auto leveling trim adjust is located at the
and steer. The drive, lift, power deck or leveling top of the control handle. Selecting the drive
jack function switch must be selected and the red function and depressing the switch to the right
trigger switch must be depressed and held during will steer the wheels to the right. Depressing the
controller movement, prior to moving the control switch to the left will steer the wheels to the left.
handle. After selecting the drive function, moving When auto leveling is selected this switch is used
the control handle forward will drive the machine to manually adjust (trim) the leveling of the
forward and moving the control handle back- machine to the left or right. Refer to Section 4.3
wards will drive the machine backward. After for leveling jack operating procedures.
selecting the lift function, moving the control 8. Lift Select - When selected, the lift function will be
handle forward will lift the platform up and mov- active for 5 seconds. Moving the control handle in the
ing the control handle backward will lower the forward or reverse direction within the 5 seconds will
platform. After selecting a power deck function, cause lift motion to occur at a speed determined by
moving the control handle forward will extend the range selected by the Low/High switch and the
the power deck extension and moving the control distance the controller is moved from center. The pro-
portional control does not effect the lift down func- pulling the switch out (on), and is turned off by push-
tion. ing the switch in (off ).
11. Drive Select Switch - When selected, the drive function
will be active for 5 seconds. Moving the control handle
DO NOT LIFT DOWN WITHOUT COMPLETELY RETRACTING THE PLATFORM in the forward or reverse direction within the 5 sec-
EXTENSION(S). onds will cause drive motion to occur at a speed deter-
mined by the range selected by the speed switch and
9. Speed Switch - The three position speed switch per- the distance the controller is moved from center.
mits the operator to select either high engine/high
speed, high engine/low speed or mid engine/low 12. Horn - This push-button switch, when activated, per-
speed. mits the operator to warn jobsite personnel when the
machine is operating in the area.
13. Start/Auxiliary Power - This switch, when depressed,
DO NOT USE HIGH RANGE WHEN DRIVING IN CLOSE QUARTERS OR WHEN sends power to the start solenoid when the emer-
DRIVING IN REVERSE. gency stop switch is in the on position. This switch
also serves as the auxiliary power switch when
NOTE: High drive speed is disabled when the platform is raised equipped.
above the high drive cutout height (refer to Table 2-2).
When platform is lowered below high drive cutout height, 14. Turn Signal Switch (Option) - This switch when pushed
high drive speed is enabled. forward to front of machine turns on the right side
turn signals. When pulled rearward turns on the left
10. Emergency Stop Switch - A two-position, red, mush- side turn signals.
room-shaped emergency stop switch functions to
provide power to the platform control station and also 15. Head/Tail Lights Switch (Option) - This switch when
to turn off power to the platform function controls in switched-on turns on the machine head and tail lights
the event of an emergency. With the power select for when operating in a dark work area.
switch positioned to platform, power is turned on by
3 4
2 5
1 6 1. Power Deck
2. Drive
3. Lift
4. Fuel Gauge
5. Tilt
6. System Fault
7. Leveling Jacks Fully Retracted
8. Leveling Jacks Operational
1705189A
9. Leveling Jacks Set
7
9 8
1705390A
Indicator Control Panel (See Figure 3-3) 6. System Fault Indicator - This warning light will flash
the appropriate distress code (flash code).
1. Power Deck Indicator - This indicator light will illumi-
7. Leveling Jacks Fully Retracted - This indicator light will
nate anytime a power deck selection is activated.
illuminate when the leveling jacks are fully retracted.
2. Drive Indicator - This indicator light will illuminate
8. Leveling Jacks Operational - This indicator light will
when the drive select function is activated.
illuminate when the leveling jacks are being operated.
3. Lift Indicator - This indicator light will illuminate when
9. Leveling Jacks Set - This indicator light will illuminate
the lift function is activated.
when the leveling jacks are set.
4. Fuel Gauge Indicator - The appropriate light will be
10. Tilt Alarm Warning Horn (Not Shown) - The Tilt Alarm
illuminated according to the amount of fuel remaining
Warning Horn is activated when the chassis is on a
in the lift.
slope greater than the allowable amount.
5. Tilt Indicator - This light will illuminate anytime the
machine is positioned or driven on a tilt greater than
the allowable amount.
DO NOT OPERATE MACHINE IF HIGH DRIVE SPEED OPERATES WHEN PLAT-
FORM IS RAISED ABOVE THE STOWED POSITION.
42 43 17 36 48 43
33
34 37
20
18 18
20
44 46 51 43 19 9 44
31 12 37 4 5
45 47
-or- 32
32
21 50 49 49 49 49
50
21
38
21
22
11
33
34
8
41
39 23 40
Figure 3-5. Decal Location - Sheet 2 of 2 (ANSI)
15 38 44 45
40
31
32
6
18 16
18 10 4 36
16
41
42 36 17 8 41 34
43
19
20
19
19
47 46 46 46 46
47
6 36
33
39
Table 3-2. Decal Legend - CE/AUS Table 3-2. Decal Legend - CE/AUS
CE/AUS CE/AUS
Item # Item #
(0275086-2) (0275086-2)
1-3 -- 21 1703822
4 1700584 22 - 30 --
5 1702631 31 1702773
6 1705515 32 1704885
7 1703687 33 3251813
8 1704412 34 1703162
9 -- 35 --
10 36 1706338
CE 3252533 37 1705019
AUS 3252534 38 1705671
11-14 -- 39 1705372
15 1701509 40
16 1703811 3394RT 1705038
17 1703812 4394RT 1705039
18 1703814 41 1703493
19 1704277 42 1701505
20 1703819
CE/AUS
Item #
(0275086-2)
1702788
1703479
43
1704174
1704175
44 1702962
45
3394RT 1705034
1705035
4394RT 1705036
1705037
46 1701785
47 1705042
NOTES:
function. The high speed select will not operate the lift func- COOL OFF FOR 2 TO 3 MINUTES. IF ENGINE FAILS TO START AFTER SEVERAL
tion. ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.
Starting Procedure 5. If starting the machine from the ground controls, posi-
tion the emergency stop switch to on and depress the
NOTE: Initial starting should always be performed from the start button and hold until the engine starts. If starting
Ground Control Station. from the platform controls, position the platform
1. Check engine oil before attempting to start engine; if emergency stop switch to on and depress the start
necessary, add oil in accordance with Engine Manufac- button and hold until the engine starts.
turers Manual.
NOTICE
2. Pull out the red emergency stop switch (ON).
ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES BEFORE APPLYING ANY
3. Position the platform/ground select switch to the LOAD.
desired operating control station (platform or
ground). 6. After the engine has had sufficient time to warm up,
4. If operating a dual fuel machine, place the LPG/GASO- proceed with operation of the unit.
LINE select switch in the platform to the desired posi-
tion.
NOTE: If the LPG system is selected, ensure that the hand valve on
the LPG supply tank is opened prior to attempting to start
the engine.
NOTICE
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED
PERIOD. SHOULD ENGINE FAIL TO START ONCE AGAIN, ALLOW STARTER TO
4.3 OPERATING CHARACTERISTICS 4. Continue to engage the leveling jacks until the tilt
light stops blinking and is no longer lit.
Leveling Jacks NOTE: If you receive a 2/5 flash code through the system fault
The machine may be equipped with auto leveling jacks with a light at the platform control station the machine is unable
manual adjust feature. These leveling jacks are operated to level. You must reposition and try again.
through one switch unlike the traditional four switch system. 5. To retract the leveling jacks, depress the leveling jack
The leveling jacks are operated by a bang bang valve. selector switch and move the controller backward
until the desired position is obtained.
NOTE: The engine speed will drop when the leveling jacks are
activated. NOTE: The tilt light serves as an indicator that the machine is
outside the allowable lifting operation. When the
Auto Leveling machine reaches a position within level of the specific
market specification, the tilt light will go out. Once the
1. With the machine in the stowed position turn the
light is out, the level adjustment of the machine may still
power on, start machine and depress the leveling jack
be improved. (Refer to Section, Manual Level Adjustment
selection switch located on the front of the platform
(Trim)).
control box.
NOTE: There is a limit switch that senses when all four cylinders
2. While squeezing the trigger switch on the controller, are fully retracted and this will light up the four leveling
move the controller forward.
jack lights in the platform control station.
3. Once the leveling jacks make contact with the ground
surface there will be up to a 5 second delay before the The proximity switch and elevation sensor will not allow
actual auto leveling begins. the jacks to be extended or retracted when the platform is
above the stowed position. If there is a proximity switch
NOTE: Due to varying ground conditions, there may be several failure or elevation sensor failure, the leveling jacks func-
delays between machine level corrections. Be sure ample tion is locked out.
time is allowed for all leveling adjustments to be com-
pleted.
Manual Level Adjustment (Trim) NOTE: You can not adjust the level of the machine with the EASI-
CLADDER option installed.
NOTE: There is an override feature on the Leveling Jack system
that allows the operator to adjust (trim) the level of the Power Deck
machine to the left or right when the platform is com- The power deck is operated through a non proportional valve.
pletely lowered. Use the following instructions to adjust
the level of the machine. When operating the power deck from the platform con-
trols, select front deck extension, rear deck extension or
1. With the machine in the stowed position turn the
power on, start machine and depress the leveling jack both and activate the joystick forward to extend and back-
selection switch located on the front of the platform ward to retract.
control box. NOTE: There is a 5 second time out after the joystick is released. If
2. To adjust (trim) the machine to the right, activate the one extension is selected and released the opposite deck
steer switch on the top of the controller to the right extension cannot be selected for 5 seconds.
until the desired position is reached. When operating the power deck from the ground control
station, activate and hold the auxiliary power switch,
3. To adjust (trim) the machine to the left, activate the
select, activate and hold the proper deck extension to be
steer switch on the top of the controller to the left
adjusted (front or rear). If both decks are selected at the
until the desired position is reached.
same time, only the front deck will be active.
NOTE: Anytime the trim function is used there is a possibility that NOTE: The power deck extension switches function in the direc-
the machine may become out of level. At this time the tion they are operated.
machine will no longer lift but the machine can be low-
ered.
NOTE: The machine must be in the stowed position before the BE SURE AND RETRACT ANY POWER DECK BEFORE LOWERING MACHINE.
trim function is operable.
Lowering retracts the deck. Maximum capacity for each deck exten-
sion is 500 lb (230 kg).
DE
GRA
SIDESLOPE
LEVEL
4.13 TOWING
It is not recommended that this machine be towed, except
in the event of an emergency such as a machine malfunc-
tion or a total machine power failure. Refer to Section 5 for
emergency towing procedures.
X Z
WHEELBASE X Z
(in) (cm) (in) (cm) (in) (cm)
116 295 58 147 39 100
NOTES:
5.5 INCIDENT NOTIFICATION It should be noted that failure to notify the Manufacturer
of an incident involving a JLG Industries product within 48
It is imperative that JLG Industries, Inc. be notified immedi- hours of such an occurrence may void any warranty con-
ately of any incident involving a JLG product. Even if no
sideration on that particular machine.
injury or property damage is evident, the Product Safety
and Reliability Department at the factory should be con-
tacted by telephone and provided with all necessary
details.
Contact at 1-877-JLG-SAFE (554-7223) between the hours
of 8:00 AM - 4:45 PM Eastern Standard time.
Engines
Table 6-5. Ford LRG-425 Specifications Table 6-6. Deutz F3M2011 Specifications
Fuel Gasoline Fuel DIesel
Oil Capacity 4.5 Quarts (4.25 L) w/Filter Oil Capacity 8.5 Quarts (8 L) w/Filter
Idle RPM 1000 Low RPM 900
Low RPM 1800 High RPM 2800
High RPM 2800 Alternator 95 Amp, Belt Drive
Alternator 40 Amp, Belt Drive Battery 112 Amphour, 950 Cold Cranking
Battery 112 Amphour, 950 Cold Cranking Amps, 12 VDC
Amps, 12 VDC Fuel Consumption
Fuel Consumption Low RPM 1.3 GPH (4.9 lph)
Low RPM 3.45 GPH (13.06 lph) High RPM 1.6 GPH (6.0 lph)
High RPM 4.60 GPH (17.41 lph) Horsepower 48 @ 2800 RPM, full load
Horsepower 54 @ 2400 RPM, full load
Cooling System 16 Quarts (15.14 L)
Spark Plug AWSF-52-C
Spark Plug Gap 0.044 in. (1.117 mm)
Table 6-7. Deutz - D 2.9 L4 - T4F Engine Specifications Table 6-8. GM 3.0L Specifications
Emissions EPA - Tier 4 Final Fuel Gasoline or Gasoline/LP Gas
Fuel Type: Diesel No. of Cylinders 4
Oil Capacity 2.35 Gal. (8.9 L) w/Filter HorsePower:
Coolant Capacity 0.79 Gal. (3.0 L) - Engine Only Gasoline 83 hp @ 3000 rpm
Engine RPM Control Deutz Electronic - EMR4 LP 75 hp @ 3000 rpm
Low RPM Set 1200 RPM Bore 4.0 in. (101.6 mm)
High RPM Set 2600 RPM Stroke 3.6 in. (91.44 mm)
Alternator 95 Amp, 12V, Belt Drive Displacement 181 cu.in. (3.0 L, 2966 cc)
Battery 112 Amp-Hour, 950 Cold Cranking Oil Capacity w/filter 4.5 qts. (4.25 L)
Amps, 12 VDC Tier/Stage 3 5.0 qts. (4.73L)
Fuel Consumption: Low RPM 1.3 GPH (4.9 lph) Minimum Oil Pressure:
High RPM 1.6 GPH (6.0 lph) at idle 6 psi (0.4 Bar) @ 1000 rpm
Displacement 3
2.9L - 2925 cm (179 cu. in.) at operation 18 psi (1.2 Bar) @ 2000 rpm
Horsepower 49 Hp (36.4 Kw) @ 2600 RPM Compression Ratio 9.2:1
Tier/Stage 3 10.25:1
Torque Rating 108 Ft. lb. (147 Nm) @ 1600 rpm
Firing Order 1-3-4-2
Cylinder Firing Order 1-3-4-2
Maximum RPM 2800
Engine (Ford) 324 lbs (147 kg) NOTE: Hydraulic oils must have anti-wear qualities at least to API
Service Classification GL-3, and sufficient chemical stabil-
Engine (Deutz) 441 lbs (200 kg)
ity for mobile hydraulic system service. JLG Industries rec-
Engine (GM) 341 lbs (155 kg) ommends Mobilfluid 424 hydraulic oil, which has an SAE
viscosity index of 152.
Battery 65 lbs (30 kg)
NOTE: When temperatures remain below 20 F (-7 C), JLG Indus-
tries recommends the use of Mobil DTE13.
tain the same required additives or be of comparable vis- Table 6-11. Lubrication Specifications
cosities. If use of hydraulic oil other than Mobilfluid 424 is
desired, contact JLG Industries for proper recommenda- KEY SPECIFICATIONS
tions.
MPG Multipurpose Grease having a minimum dripping point of 350 F. Excellent
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.
EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/CD
class, MIL-L-2104B/MIL-L-2104C.
HO Hydraulic Oil. API service classification GL-3, e.g. Mobil 424.
4150548 D
AMBIENT AIR
TEMPERATURE
120F (49C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110F (43C)
100F (38C)
90F (32C)
80F (27C)
ENGINE
SPECIFICATIONS 70F (21C)
SAE 10W-30
SAE 10W-40
SAE 5W-20
SAE 5W-30
SAE 5W-40
60F (16C)
50F (10C)
40F (4C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30F (-1C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20F (-7C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10F (-12C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0F (-18C)
-10F (-23C)
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 -20F (-29C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30F (-34C)
-40F (-40C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
110F (43C) AMBIENT TEMPERATURE PROLONGED OPERATION IN 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
AMBIENT AIR TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS
100F (38C) OF 100F (38C) OR ABOVE
90F (32C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL
70F (21C)
30F (-1C)
20F (-7C)
10F (-12C)
DO NOT START UP HYDRAULIC SYSTEM
0F (-18C) WITHOUT HEATING AIDS WITH MOBILE 424
-10F (-23C) HYDRAULIC OIL BELOW THIS TEMPERATURE
4150548 D
AMBIENT AIR
TEMPERATURE
120F (49C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110F (43C)
100F (38C)
90F (32C)
80F (27C)
ENGINE
SPECIFICATIONS 70F (21C)
SAE 10W-30
60F (16C)
50F (10C)
40F (4C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30F (-1C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20F (-7C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10F (-12C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0F (-18C)
-10F (-23C)
SAE 5W-30
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 -20F (-29C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30F (-34C)
-40F (-40C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
1. Fuel Tank
2. Drive Hubs
3. Hydraulic Oil Tank
4. Sliding Wear Pads
5. Oil Change w/Filter - Ford
6. Oil Change w/Filter - Deutz
7. Oil Change w/Filter - GM
8. Fuel Filter - Ford
9. Fuel Filter - Deutz
10. Fuel Filter (Gasoline) - GM
11. Air Filter
12. Electronic Pressure Regulator (LP Only)
13. Fuel Filter (Propane) - GM
Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7014501) (JLG P/N 7016331)
Capacity - 4.5 qt. (4.25 L) Capacity - 6.3 qt. (5.9 L) engine only
Lube - EO Lube - EO
Interval - 3 Months or 150 hours of operation Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance Comments - Check level daily/Change in accordance
with engine manual. with engine manual.
Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element
(JLG P/N 7016641) (JLG P/N 7027965)
Capacity - 2.35 Gal. (8.9 L) engine only Capacity- 4.5 qt. (4.25 L) w/filter - Tier 2
Lube - EO - 5.0 qt. (4.73 L) w/filter - Tier 3
Interval - Every Year or 600 hours of operation Lube - EO
Comments - Check level daily/Change in accordance Interval - 3 Months or 150 hours of operation
with engine manual. Comments - Check level daily/Change in accordance
with engine manual.
Fuel Filter (Propane) - GM 6.5 DRAINING OIL BUILD UP FROM THE PROPANE
REGULATOR
During the course of normal operation, oils may build
inside the primary and secondary chambers of the pro-
pane pressure regulator. These oils may be a result of poor
fuel quality, contamination of the fuel supply chain, or
regional variation in the make up of the fuel. If the build up
of the oil is significant this can effect the operation of the
fuel control system. Refer to Section 6.4, Operator Mainte-
nance, for maintenance intervals. More frequent draining
may be required if the fuel supply has been contaminated.
NOTICE
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERATURE
Interval - 3 Months or 150 hours of operation BEFORE DRAINING. THIS WILL ALLOW THE OILS TO FLOW FREELY FROM THE
Comments - Replace filter. Refer to Section 6.6, Propane REGULATOR.
Fuel Filter Replacement 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.
NOTE: Have a small container ready to collect oil that will drain
freely from the regulator at this point.
7. Once all of the oil has been drained, reinstall the LPG
fuel temperature sensor and reconnect the electrical
connector.
1. Electric Lock Off Solenoid 7. Electrical Connector
8. Open the fuel tank manual valve. 2. Mounting Plate 8. Fuel Outlet
9. Start the engine and verify all connections are secure. 3. Housing Seal 9. O-ring
4. Filter Magnet 10. Filter
10. Dispose of any drained oil per local regulations in a 5. Filter Housing 11. Fuel Inlet
safe and proper fashion. 6. Seal 12. Retaining Bolt
Figure 6-8. Filter Lock Assembly
1. Relieve the propane fuel system pressure. Refer to Sec- 3. Install the housing seal.
tion 6.7, Propane Fuel System Pressure Relief. 4. Drop the magnet into the bottom of the filter housing.
2. Disconnect the negative battery cable. 5. Install the filter into the housing.
3. Slowly loosen the filter housing retaining bolt and 6. Install the retaining bolt into the filter housing.
remove it.
7. Install the filter up to the bottom of the electric lock
4. Pull the filter housing from the electric lock off assem- off.
bly.
8. Tighten the filter retaining bolt to 106 in-lbs (12 Nm).
5. Locate filter magnet and remove it.
9. Open manual shut-off valve. Start the vehicle and leak
6. Remove the filter from the housing. check the propane fuel system at each serviced fitting.
7. Remove and discard the housing seal. Refer to Section 6.8, Propane Fuel System Leak Test.
8. Remove and discard the retaining bolt seal. 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF
9. Remove and discard mounting plate to lock off o-ring
seal
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5
Installation BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE
PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVIC-
NOTICE ING THE PROPANE FUEL SYSTEM COMPONENTS.
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE
INSTALLING NEW SEAL. To relieve propane fuel system pressure:
1. Close the manual shut-off valve on the propane fuel
1. Install the mounting plate to lock off O-ring seal. tank.
2. Start and run the vehicle until the engine stalls. 6.9 TIRES AND WHEELS
3. Turn the ignition switch OFF.
Tire Damage
For pneumatic tires, JLG Industries, Inc. recommends that
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. when any cut, rip, or tear is discovered that exposes sidewall
ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY or tread area cords in the tire, measures must be taken to
FUEL LINE. remove the JLG product from service immediately. Arrange-
ments must be made for replacement of the tire or tire assem-
bly.
6.8 PROPANE FUEL SYSTEM LEAK TEST
For polyurethane foam filled tires, JLG Industries, Inc. recom-
mends that when any of the following are discovered, mea-
sures must be taken to remove the JLG product from service
NEVER USE AN OPEN FLAME OF ANY TYPE TO CHECK FOR PROPANE FUEL SYS- immediately and arrangements must be made for replace-
TEM LEAKS. ment of the tire or tire assembly:
Always inspect the propane fuel system for leaks after per- A smooth, even cut through the cord plies which
forming service. Check for leaks at the fittings of the ser- exceeds 3 in (7.5 cm) in total length.
viced or replaced component. Use a commercially Any tears or rips (ragged edges) in the cord plies which
available liquid leak detector or an electronic leak detector. exceeds 2.5cm (1 in) in any direction.
When using both methods, use the electronic leak detec- Any punctures which exceed 2.5cm (1 in) in diameter.
tor first to avoid contamination by the liquid leak detector. Any damage to the bead area cords of the tire.
If a tire is damaged but is within the above noted criteria, the
tire must be inspected on a daily basis to ensure the damage
has not propagated beyond the allowable criteria.
1. Start all nuts by hand to prevent cross threading. DO Table 6-12. Wheel Torque Chart
NOT use a lubricant on threads or nuts.
TORQUE SEQUENCE
2. Tighten nuts in the following sequence:.
1st Stage 2nd Stage 3rd Stage
40-50 ft lbs 90-105 ft lbs 145-170 ft lbs
(60-70 Nm) (125-150 Nm) (200-240 Nm)
1
5 8
3 4
9 LUG PATTERN
7 6
9 2
Date Comments
Date Comments
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
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
Address: _________________________________________________________________________
_________________________________________________________________________________
Address: _________________________________________________________________________
_________________________________________________________________________________
Name: ___________________________________________________________________________
Title:____________________________________________________________________
JLG Industries, Inc. (717) 485-5161 (Corporate)
1 JLG Drive (800) 544-5438 (Service)
McConnellsburg PA. 17233-9533 (717) 485-6417
USA
www.jlg.com
3121132
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