JLG 60FR: Common Issues and Maintenance Tips for Aerial Lifts

[MikePhua]

The JLG 60FR is a popular choice for workers who need to access heights for construction, maintenance, and other industrial tasks. This 60-foot telescopic boom lift is renowned for its versatility, ease of use, and ability to work in tight spaces. However, like all heavy machinery, the JLG 60FR can face mechanical challenges over time. Understanding these issues and how to maintain the machine can help avoid costly repairs and improve performance.
In this article, we’ll cover some common problems encountered with the JLG 60FR, along with troubleshooting tips and best practices for maintenance.
Common Issues with the JLG 60FR
While the JLG 60FR is generally reliable, users have reported certain issues over time. These problems typically involve the hydraulic system, electrical components, and boom functionality. Understanding these common issues can help operators diagnose and address problems early on.

1. Hydraulic System Failures
   One of the most frequent problems reported with the JLG 60FR is issues with the hydraulic system. Hydraulic fluid leaks, low fluid levels, and worn-out hydraulic seals can all cause a loss of power or erratic boom movement. When the hydraulic fluid is low or contaminated, the lift may not operate smoothly, leading to sluggish movements or even failure to extend the boom.
   Solutions:
   • Regularly check hydraulic fluid levels and top up as needed with the recommended fluid.
     
   • Inspect the system for leaks, especially around hoses and seals.
     
   • Replace worn-out hydraulic seals promptly to prevent fluid leakage.
     
   • Clean or replace hydraulic filters regularly to ensure the system is free from contaminants.
     
2. Boom Jamming or Jerky Movements
   Boom jamming or jerky movements are another issue that can arise with the JLG 60FR, especially if the machine has been in use for an extended period. This can be caused by debris inside the boom mechanism, issues with the lift's controls, or problems with the electric motor that powers the boom.
   Solutions:
   • Keep the boom clean and free from debris. Always inspect the boom after use to ensure no objects are obstructing movement.
     
   • Check the boom lift’s electrical wiring and connections. Tighten any loose connections and replace worn-out cables.
     
   • Ensure the motor is functioning smoothly and lubricate moving parts as recommended in the owner’s manual.
     
3. Electrical System Issues
   The electrical system in the JLG 60FR can be prone to malfunctions, especially if the lift has been exposed to harsh weather conditions or heavy use. Common issues include faulty batteries, malfunctioning controllers, or issues with the joystick controls, which can cause erratic or non-responsive movements.
   Solutions:
   • Regularly check and maintain the battery, ensuring that it is fully charged and free from corrosion. Clean battery terminals as necessary.
     
   • Inspect the controller for any signs of damage or wear. Replace any faulty components immediately.
     
   • Calibrate the joystick control system according to the manufacturer’s instructions.
     
4. Tire and Track Wear
   Although the JLG 60FR is designed for rough terrain, the tires or tracks can wear out over time, especially if the lift is used on uneven surfaces or rough ground. Worn tires can reduce the lift’s stability and maneuverability, making it more difficult to operate in challenging conditions.
   Solutions:
   • Regularly inspect the tires or tracks for signs of wear, cracks, or punctures.
     
   • Replace tires or tracks that show significant damage to maintain optimal performance and safety.
     
   • Maintain proper tire pressure to ensure the lift operates smoothly.
     
5. Outriggers Not Extending Properly
   The outriggers on the JLG 60FR provide stability when the lift is extended to its full height. Issues with the outriggers, such as failure to extend properly or uneven positioning, can affect the lift’s balance and safety. Problems with the hydraulic system, debris in the mechanism, or sensor malfunctions can all lead to these issues.
   Solutions:
   • Regularly clean the outriggers and inspect the hydraulic components for leaks or damage.
     
   • Ensure that the outriggers are correctly positioned before use.
     
   • Check the sensors and wiring for malfunctions and replace any faulty parts.
     

Maintenance Tips for the JLG 60FR
Routine maintenance is crucial for keeping the JLG 60FR in good working condition and minimizing downtime. Here are some key maintenance tips:

1. Daily Inspections
   Before using the JLG 60FR, operators should perform a daily inspection to ensure that everything is functioning properly. This includes checking the hydraulic fluid levels, inspecting the boom for debris, and ensuring the tires are properly inflated. Daily inspections can help identify potential issues before they become major problems.
   
2. Proper Lubrication
   Regular lubrication of moving parts is essential for maintaining the smooth operation of the lift. Pay close attention to the boom and other pivot points, as these areas are subject to frequent movement and wear. Follow the manufacturer’s guidelines for lubrication intervals and use the recommended lubricant.
   
3. Hydraulic Fluid Maintenance
   Keeping the hydraulic system in top condition is key to the lift’s performance. Replace the hydraulic fluid as recommended by the manufacturer to avoid contamination and ensure optimal flow. Regularly check for leaks in the system and replace seals when needed.
   
4. Battery Maintenance
   A well-maintained battery is crucial for the smooth operation of the JLG 60FR. Regularly inspect the battery for corrosion, and clean the terminals as needed. Ensure that the battery is fully charged and replace it if it shows signs of reduced capacity or damage.
   
5. Regular Professional Servicing
   In addition to routine checks and maintenance, it’s important to schedule periodic professional servicing. A qualified technician can conduct more in-depth inspections, clean the internal components, and make adjustments to ensure that the machine is in peak working condition.
   

Real-World Example: Overcoming Hydraulic System Challenges
In a recent case, a construction crew experienced delays due to a leaking hydraulic system on their JLG 60FR lift. The crew had been using the lift for several months, and the boom was starting to operate erratically. Upon inspection, they found that the hydraulic fluid had dropped below the recommended levels, and some of the seals had worn out.
The crew quickly replaced the seals, topped up the hydraulic fluid, and cleaned the system to remove any contaminants. After reassembling the lift, they were able to resume work without further issues. This experience underscored the importance of regular inspections and the need to address small problems before they become major repair tasks.
Conclusion: Keep Your JLG 60FR Lift Running Smoothly
The JLG 60FR is a powerful and versatile aerial lift, but like any piece of heavy machinery, it requires regular care and attention to function properly. By staying on top of maintenance, addressing common issues like hydraulic system failures, and taking preventative measures, you can keep your lift in optimal condition for years to come.
Routine inspections, lubrication, and proper care of the electrical and hydraulic systems can help prevent downtime and ensure that the JLG 60FR continues to serve its purpose safely and efficiently on the job site. Whether you’re working at great heights in construction or maintenance, taking the time to maintain your equipment is a small investment that pays off in the long run.