JLG Toucan 8e Use and care manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
TOUCAN 8E
TOUCAN 20E
S/N A300052840
to present
31210162
February 01, 2015
English - Operation and Safety
®

FOREWORD
31210162 – JLG Lift – a
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions 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.

FOREWORD
b– JLG Lift – 31210162
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A
YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-
TECTION OF PROPERTY.
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 possible
injury or death.

FOREWORD
31210162 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE
UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-
ERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding Prod-
uct Modifications

FOREWORD
d– JLG Lift – 31210162
REVISION LOG
Original Issue - August 03, 2010
Manual Revised - May 15, 2012
Manual Revised - May 13, 2014
Manual Revised - November 03, 2014
Manual Revised - February 01, 2015

TABLE OF CONTENTS
31210162 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . 1-1
Workplace Inspection . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards. . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards . . . . . . . . . . . . 1-7
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . 1-8
1.5 ADDITIONAL HAZARDS / SAFETY. . . . . . . . . . . . 1-8
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-
RATION, AND INSPECTION
2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Function Check . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Tilt Sensor Check. . . . . . . . . . . . . . . . . . . . . . . 2-8
Overload Sensor Check (if equipped). . . . . . . 2-9
Slack/Broken Chain Sensors Check . . . . . . . 2-10
Gate sensors check (XL basket only) . . . . . . 2-11
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . 3-2
Ground Control Station . . . . . . . . . . . . . . . . . . 3-2
Platform Manual Descent Valves. . . . . . . . . . . 3-6
Mast Manual Descent Valve and Actuator . . . 3-6
Jib Manual Descent Valve . . . . . . . . . . . . . . . . 3-7
Manual Swinging Operating Devices . . . . . . . 3-8
Platform Control Station . . . . . . . . . . . . . . . . . 3-9
3.3 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . 3-15
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING SPECIFICATIONS AND LIMITATIONS .4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Grade and Side Slope . . . . . . . . . . . . . . . . . . . 4-3

TABLE OF CONTENTS
ii – JLG Lift – 31210162
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 STEERING AND TRAVELLING (DRIVING) . . . . . . 4-5
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Travelling (driving) . . . . . . . . . . . . . . . . . . . . . . 4-6
Drive Orientation System (DOS) . . . . . . . . . . . 4-7
4.5 RAISING AND LOWERING THE PLATFORM . . . . 4-7
Raising and lowering the mast . . . . . . . . . . . . 4-8
Raising and lowering the jib . . . . . . . . . . . . . . 4-8
4.6 SWINGING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.7 EMERGENCY CONTROL . . . . . . . . . . . . . . . . . . 4-10
4.8 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Overload Warning Light/Alarm (if equipped) 4-11
Tilt Warning Light/Alarm . . . . . . . . . . . . . . . . 4-11
Slack Chain Warning Light/Alarm . . . . . . . . 4-12
Gate Opening Warning Light (XL Basket Only) 4-13
Soft Touch Warning Light/Alarm (If equipped) 4-13
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . 4-14
4.11 BATTERY CHARGING. . . . . . . . . . . . . . . . . . . . . 4-14
Battery Charger Fault Code. . . . . . . . . . . . . . 4-16
4.12 TIE-DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . 4-17
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.13 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18
Electric Brake Release . . . . . . . . . . . . . . . . . . 4-19
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . .5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . .5-1
Operator Unable to Control Machine. . . . . . . . 5-1
Platform or Jib Caught Overhead . . . . . . . . . . 5-2
5.4 PLATFORM MANUAL DESCENT. . . . . . . . . . . . . .5-2
5.5 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . .5-2
5.6 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
Other Publications Available . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . .6-2
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . .6-10
6.4 CHASSIS HOOD REMOVAL . . . . . . . . . . . . . . . .6-11
6.5 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . .6-12
Battery Maintenance and Safety Practices . . 6-12
Battery Voltage and Electrolyte Specific Gravity . 6-14

TABLE OF CONTENTS
31210162 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Filling System Maintenance . . . . . . . . . . . . . . 6-16
Use of a Battery in a Cold Environment . . . . . 6-16
Battery Not Working Continuously or Inactive
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Battery Troubleshooting . . . . . . . . . . . . . . . . . 6-17
6.6 OIL LEVEL/OIL FILTER . . . . . . . . . . . . . . . . . . . . 6-18
Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . 6-18
Hydraulic Filter Replacement . . . . . . . . . . . . . 6-19
6.7 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . 6-20
Tire Wear and Damage . . . . . . . . . . . . . . . . . . 6-20
Wheel and Tire Replacement . . . . . . . . . . . . . 6-20
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . 6-20
6.8 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Overload System Spring Washer (if equipped) 6-22
Swing Bearing Race . . . . . . . . . . . . . . . . . . . . 6-23
Swing Bearing Teeth. . . . . . . . . . . . . . . . . . . . 6-24
Mast Profiles Races. . . . . . . . . . . . . . . . . . . . . 6-25
Lifting Chains . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
6.9 OVERLOAD SYSTEM VERIFICATION
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.10 TILT SENSOR VERIFICATION . . . . . . . . . . . . . . 6-28
6.11 SUPPLEMENTAL INFORMATION . . . . . . . . . . . 6-29
6.12 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . 6-29
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.13 DTC INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
6.14 DTC CHECK TABLES . . . . . . . . . . . . . . . . . . . . . 6-30
0-0 Help Comments. . . . . . . . . . . . . . . . . . . . 6-30
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
2-2 Platform Controls. . . . . . . . . . . . . . . . . . . 6-32
2-3 Ground Controls . . . . . . . . . . . . . . . . . . . 6-34
2-5 Function Prevented . . . . . . . . . . . . . . . . . 6-36
3-1 Line Contactor Open Circuit . . . . . . . . . . 6-38
3-2 Line Contactor Short Circuit . . . . . . . . . . 6-38
3-3 Ground Output Driver . . . . . . . . . . . . . . . 6-39
4-2 Thermal Limit . . . . . . . . . . . . . . . . . . . . . . 6-42
4-4 Battery Supply . . . . . . . . . . . . . . . . . . . . . 6-44
4-6 Transmission and Drive System . . . . . . . 6-46
6-6 Communication . . . . . . . . . . . . . . . . . . . . 6-47
6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . 6-47
7-7 Electric Motor. . . . . . . . . . . . . . . . . . . . . . 6-48
8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . 6-49
8-2 Platform Load Sense . . . . . . . . . . . . . . . . 6-50
8-6 Steering/Axle . . . . . . . . . . . . . . . . . . . . . . 6-50
8-7 Safety System Override. . . . . . . . . . . . . . 6-51
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
SECTION - 7 - INSPECTION AND REPAIR LOG

TABLE OF CONTENTS
iv – JLG Lift – 31210162
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . 2-5
2-2. Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-3. Overload Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-4. Slack/Broken Chain Sensors . . . . . . . . . . . . . . . . 2-10
2-5. XL Basket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
3-1. Basic Nomenclature - Location of Machine Controls . 3-1
3-2. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. Mast Manual Descent Valve . . . . . . . . . . . . . . . . . . 3-6
3-4. Jib Manual Descent Valve. . . . . . . . . . . . . . . . . . . . 3-7
3-5. Rotary Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-6. Solid Hand Wheel . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
3-7. Platform Control Indicator Panel. . . . . . . . . . . . . . 3-11
3-8. Decal Installation - Sheet 1 . . . . . . . . . . . . . . . . . . 3-15
3-9. Decal Installation - Sheet 2 . . . . . . . . . . . . . . . . . . 3-16
3-10. Decal Installation - Sheet 3 . . . . . . . . . . . . . . . . . . 3-17
4-1. Position of Least BACKWARD stability . . . . . . . . . . 4-2
4-2. Position of Least FORWARD stability . . . . . . . . . . . 4-2
4-3. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . 4-4
4-4. Steer/Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-5. Drive Orientation System (DOS) . . . . . . . . . . . . . . . 4-7
4-6. Lift Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-7. Swing Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-8. Emergency Controls . . . . . . . . . . . . . . . . . . . . . . . 4-10
4-9. Machine Tie-Down . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-10. Lifting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4-11. Lifting the Machine Using a Fork Truck. . . . . . . . . 4-18
4-12. Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . 4-19
6-1. Range Diagram 8E/20E . . . . . . . . . . . . . . . . . . . . . . 6-4
6-2. Range Diagram 8E XL . . . . . . . . . . . . . . . . . . . . . . 6-5
6-3. Operator Maintenance & Lubrication Diagram . . . 6-10
6-4. Chassis Hood Removal . . . . . . . . . . . . . . . . . . . . . 6-11
6-5. Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6-6. Adding Water to Batteries . . . . . . . . . . . . . . . . . . . 6-13
6-7. Draining the Water . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-8. Measuring Electrolyte Specific Gravity . . . . . . . . .6-15
6-9. Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-10. Hydraulic Filter Replacement . . . . . . . . . . . . . . . . 6-19
6-11. Wheel Lug Nut Tightening Sequence . . . . . . . . . .6-20
6-12. Overload System Spring Washer Lubrication . . . . 6-22
6-13. Swing Bearing Race Lubrication . . . . . . . . . . . . . . 6-23
6-14. Swing Bearing Teeth lubrication . . . . . . . . . . . . . . 6-24
6-15. Mast Profiles Races Lubrication . . . . . . . . . . . . . .6-25
6-16. Overload System Verification . . . . . . . . . . . . . . . . 6-27
6-17. Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

TABLE OF CONTENTS
31210162 – JLG Lift – v
SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Approach Distance (M.A.D.). . . . . . . . . . 1-5
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3
3-1 8E & 20E - Decal Installation . . . . . . . . . . . . . . . . 3-18
4-1 Battery Charger Fault Code . . . . . . . . . . . . . . . . . 4-16
6-1 Operating Specifications And Dimensions . . . . . . 6-2
6-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-3 Tires Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-4 Drive Motors - Hydraulic Power Unit . . . . . . . . . . . 6-7
6-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-8
6-7 Hydraulic Oil Specifications - Standard . . . . . . . . . 6-8
6-8 Hydraulic Oil Specifications - Optional. . . . . . . . . . 6-9
6-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-10 Recommended Viscosity Grade. . . . . . . . . . . . . . 6-26
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

TABLE OF CONTENTS
vi – JLG Lift – 31210162
NOTES:

SECTION 1 – SAFETY PRECAUTIONS
31210162 – JLG Lift – 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
machine use, it is mandatory that a daily routine is estab-
lished based on the content of this manual. A maintenance
program, using the information provided in this manual and
the Service and Maintenance Manual, must also be estab-
lished by a qualified person and followed to ensure the
machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine
should not operate the machine until this manual has been
read, training is accomplished, and operation of the machine
has been completed under the supervision of an experi-
enced and qualified operator.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-
AGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read and understand this manual before operating the
machine.
• Do not operate this machine until complete training is per-
formed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, and operating instructions on the machine
and in this manual.
• Use the machine in a manner which is within the scope of
its intended application set by JLG.

SECTION 1 – SAFETY PRECAUTIONS
1-2 – JLG Lift– 31210162
• All operating personnel must be familiar with the emer-
gency controls and emergency operation of the machine
as specified in this manual.
• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
operation of the machine.
Workplace Inspection
• The operator is to take safety measures to avoid all haz-
ards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trail-
ers, railway cars, floating vessels, scaffolds or other equip-
ment unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.
• This machine can be operated in temperatures of 0oF to
104oF (-20oC to 40oC). Consult JLG for operation out-
side this range.
• This machine must be used in a sufficient ambient light.
Machine Inspection
• Before machine operation, perform inspections and func-
tional checks. Refer to Section 2 of this manual for
detailed instructions.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the
Service and Maintenance Manual.
• Be sure the trigger control, platform enable button and all
other safety devices are operating properly. Modification
of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU-
FACTURER.
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from foot-
wear and platform floor.

SECTION 1 – SAFETY PRECAUTIONS
31210162 – JLG Lift – 1-3
1.3 OPERATION
General
• Do not use the machine for any purpose other than posi-
tioning personnel, their tools and equipment.
• Never operate a machine that is not working properly. If a
malfunction occurs, shut down the machine.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and
stop before moving the switch to the next function. Oper-
ate controls with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
• Do not carry materials directly on platform railing. Contact
JLG for approved material handling accessories.
• When two persons are in the platform, the operator shall
be responsible for all machine operations.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
• Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.
• When driving, always position extending structure over
rear axle in line with the direction of travel. Remember, if
extending structure is over the front axle, steer and drive
functions will be reversed.
• Do not assist a stuck or disabled machine by pushing,
pulling, or by using extending structure functions. Only
pull the unit from the tie-down lugs on the chassis.
• Do not place extending structure or platform against any
structure to steady the platform or to support the struc-
ture.
• Stow extending structure and shut off all power before
leaving machine.

SECTION 1 – SAFETY PRECAUTIONS
1-4 – JLG Lift– 31210162
Trip and Fall Hazards
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lan-
yard anchorage point. Attach only one (1) lanyard per lan-
yard anchorage point.
• Before operating the machine, make sure all gates are
closed and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the extending structure to enter or leave the
platform.
• Use extreme caution when entering or leaving platform.
Be sure that the platform is fully lowered. Face the
machine, maintain “three point contact” with the machine,
using two hands and one foot or two feet and one hand
during entry and exit.

SECTION 1 – SAFETY PRECAUTIONS
31210162 – JLG Lift – 1-5
Electrocution Hazards
• This machine is not insulated and does not provide pro-
tection from contact or proximity to electrical current.
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
• Maintain a clearance of at least 3 m (10 ft.) between any
part of the machine and its occupants, their tools and their
equipment from any electrical line or apparatus carrying
up to 50 000 volts. A 0,3 m (1 ft.) additional clearance is
required for every additional 30 000 volts or less.
• The minimum approach distance may be reduced if insu-
lating barriers are installed to prevent contact and the bar-
riers are rated for the voltage of the line being guarded.
These barriers shall not be part of (or attached to) the
machine. The minimum approach distance shall be
reduced to a distance within the designed working dimen-
sions of the insulating barrier. This determination shall be
Table 1-1. Minimum Approach Distance (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Meters (Feet)
0 to 50 kV 3 (10)
Over 50 kV to 200 kV 5 (15)
Over 200kV to 350 kV 6 (20)
Over 350 kV to 500 KV 8 (25)
Over 500 kV to 750 kV 11 (35)
Over 750 kV to 1000 kV 14 (45)
NOTE: This requirement shall apply except where employer,
local or governmental regulations are more stringent.

SECTION 1 – SAFETY PRECAUTIONS
1-6 – JLG Lift– 31210162
made by a qualified person in accordance with employer,
local or governmental requirements for work practices
near energized equipment.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• The user should be familiar with the surface before driv-
ing. Do not exceed the allowable sideslope and grade
while driving.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
• Before driving on floors, bridges, trucks, and other sur-
faces, check allowable capacity of the surfaces.
• Do not elevate platform or drive with platform elevated
while on a sloping, uneven, or soft surface.
• Do not raise the platform or drive from an elevated posi-
tion unless the machine is on firm, level and smooth sur-
faces.

SECTION 1 – SAFETY PRECAUTIONS
31210162 – JLG Lift – 1-7
• When travelling on grades (Refer to Section 4), the plat-
form MUST be fully lowered. It is recommended to drive
up the grade in FORWARD gear and in REVERSE down
the slope.
• Keep the chassis of the machine at least 0,6 m (2 ft.) from
holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential hazards on the floor/surface.
• Do not push or pull any object with the extending struc-
ture.
• 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 operate the machine when wind conditions exceed
12.5 m/s (28 mph). Refer to Table 1-2, Beaufort Scale (For
Reference Only).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If extending structure assembly or platform is in a position
that one or more wheels are off the ground, all persons
must be removed before attempting to stabilize the
machine. Use cranes, forklift trucks, or other appropriate
equipment to stabilize machine.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and
bottom of platform when lifting, swinging or lowering plat-
form, and driving.
• During operation, keep all body parts inside platform rail-
ing.
• Always post a lookout when driving in areas where vision
is obstructed.
• Keep non-operating personnel at least 2m (6 ft.) away
from machine during all driving and swinging operations.
• Limit travel speed according to conditions of ground sur-
face, congestion, visibility, slope, location of personnel,

SECTION 1 – SAFETY PRECAUTIONS
1-8 – JLG Lift– 31210162
and other factors which may cause hazard of collision or
injury to personnel.
• Be aware of stopping distances in all drive speeds. When
driving in high speed, slow down the machine using the
controller before stopping.
• Do not use high speed drive in restricted or close quarters
or when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and per-
sons in the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s pres-
ence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
extending structure or platform. Position barricades on
floor if necessary.
1.4 TOWING, LIFTING, AND HAULING
• Never allow personnel in platform while towing, lifting, or
hauling.
• This machine should not be towed, except in the event of
emergency, malfunction, power failure, or loading/unload-
ing. Refer to Emergency Towing Procedures Section of
this Manual for emergency towing procedures.
• Ensure extending structure is in the stowed position prior
to towing, lifting or hauling. The platform and the tool tray
must be completely empty of tools.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capac-
ity.
• Refer to the Machine Operation Section of this Manual for
lifting information.
1.5 ADDITIONAL HAZARDS / SAFETY
• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations,
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.
• Battery fluid is highly corrosive. Avoid contact with skin
and clothing at all times.
• Charge batteries only in a well ventilated area.