JLG Toucan 12E Use and care manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
TOUCAN 12E
TOUCAN 32E
31210313
September 17, 2019 - Rev A
English - Operation & Safety
®
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Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
31210313 – 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 notifica-
tion. Contact JLG Industries, Inc. for updated information.
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FOREWORD
b – JLG Lift – 31210313
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.
INDIC ATES IN FOR MATI ON O R A CO MPANY POL ICY THAT
RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PER-
SONNEL OR PROTECTION 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.
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FOREWORD
31210313 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED
BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL
AU THORI ZED JLG REP R E SENTATIVE FOR INFO R M AT ION
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 PER-
SONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO
PERSONAL PROPERTY 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: [e-mail]
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding Prod-
uct Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Product
Modifications
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FOREWORD
d – JLG Lift – 31210313
REVISION LOG
Original Issue A - September 17, 2019
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TABLE OF CONTENTS
31210313 – 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . .1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND
INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE. . . . 2-2
2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . . . . . . 2-5
2.5 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Overload Sensor Check. . . . . . . . . . . . . . . . . . . . . . . . . 2-10
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 OPERATING CHARACTERISTICS AND LIMITATIONS . . . 3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.4 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Stability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.5 MACHINE CONTROL LOCATIONS. . . . . . . . . . . . . . . . . . . . 3-5
3.6 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.7 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . . . . . . 3-6
Platform Manual Descent Valves. . . . . . . . . . . . . . . . 3-10
Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Mast Manual Descent Valve and Actuator . . . . . . . 3-12
Boom Manual Descent Valve . . . . . . . . . . . . . . . . . . . 3-13
Manual Swinging Operating Devices. . . . . . . . . . . . 3-14
Boom Manual Lift Up Valve . . . . . . . . . . . . . . . . . . . . . 3-15
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TABLE OF CONTENTS
ii – JLG Lift – 31210313
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3.8 PLATFORM CONTROL STATION . . . . . . . . . . . . . . . . . . . . 3-16
Grade and Side Slope . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
3.9 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
3.10 STEERING AND TRAVELING (DRIVING) . . . . . . . . . . . . . . 3-23
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Traveling (driving) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Drive Orientation System (DOS) . . . . . . . . . . . . . . . . . 3-25
3.11 PLATFORM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-26
Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . 3-26
Platform Rotation (If equipped) . . . . . . . . . . . . . . . . . 3-26
3.12 RAISING AND LOWERING THE PLATFORM . . . . . . . . . . 3-27
Raising and lowering the mast . . . . . . . . . . . . . . . . . . 3-27
Raising and lowering the boom . . . . . . . . . . . . . . . . . 3-27
Telescoping the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
3.13 SWINGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
3.14 ALARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-28
Overload Warning Light/Alarm . . . . . . . . . . . . . . . . . 3-28
Tilt Warning Light/Alarm . . . . . . . . . . . . . . . . . . . . . . . 3-28
Slack Chain Warning Light/Alarm . . . . . . . . . . . . . . . 3-29
3.15 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
3.16 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-31
3.17 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Battery Charger Fault Code. . . . . . . . . . . . . . . . . . . . . . 3-33
3.18 TIE-DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3.19 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
SECTION - 4 - EMERGENCY PROCEDURES
4.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Operator Unable to Control Machine . . . . . . . . . . . . . 4-1
Platform or Boom Caught Overhead. . . . . . . . . . . . . . 4-1
4.3 EMERGENCY CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 PLATFORM MANUAL DESCENT . . . . . . . . . . . . . . . . . . . . . 4-3
4.5 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.6 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.7 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SECTION - 5 - GENERAL SPECIFICATIONS AND MAINTENANCE
5.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Other Publications Available Specific to this machine 5-1
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TABLE OF CONTENTS
31210313 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 OPERATOR MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.4 CHASSIS HOOD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . .5-11
5.5 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . .5-11
Battery Maintenance and Safety Practices. . . . . . . 5-11
Battery Voltage and Electrolyte Specific Gravity . 5-14
Filling System Maintenance . . . . . . . . . . . . . . . . . . . . 5-15
Use of a Battery in a Cold Environment. . . . . . . . . . 5-15
Battery Not Working Continuously or Inactive Battery 5-15
Battery Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . 5-16
5.6 OIL LEVEL / OIL FILTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17
Hydraulic Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
Hydraulic Oil Replacement . . . . . . . . . . . . . . . . . . . . . 5-17
Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . 5-18
5.7 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . . . 5-19
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
5.8 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21
5.9 LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-25
Swing Bearing Race . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25
Swing Bearing Teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26
Lifting Chains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
5.10 OVERLOAD SYSTEM VERIFICATION . . . . . . . . . . . . . . . . .5-28
5.11 TILT SENSOR VERIFICATION . . . . . . . . . . . . . . . . . . . . . . . .5-29
5.12 SLACK CHAIN SENSORS CHECK. . . . . . . . . . . . . . . . . . . . .5-30
5.13 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . .5-31
SECTION - 6 - INSPECTION AND REPAIR LOG
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TABLE OF CONTENTS
iv – JLG Lift – 31210313
SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Approach Distance (M.A.D.) . . . . . . . . . . . . . . . .1-6
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . . .1-8
2-1 Inspection and Maintenance Table. . . . . . . . . . . . . . . . . . . .2-3
3-1 Battery Charger Fault Code . . . . . . . . . . . . . . . . . . . . . . . . . .3-33
5-1 Operating Specifications And Dimensions. . . . . . . . . . . . .5-2
5-2 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-3 Tires Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4 Drive Motors - Hydraulic Power Unit . . . . . . . . . . . . . . . . . .5-7
5-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-6 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-7 Hydraulic Oil Specifications - Standard . . . . . . . . . . . . . . . .5-8
5-8 Hydraulic Oil Specifications - Optional . . . . . . . . . . . . . . . .5-9
5-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
5-10 Machine Decal Installation Chart. . . . . . . . . . . . . . . . . . . . .5-24
5-11 Recommended Viscosity Grade . . . . . . . . . . . . . . . . . . . . . .5-27
6-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
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TABLE OF CONTENTS
31210313 – JLG Lift – v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . 2-7
2-2. Overload Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
3-1. Position of Least BACKWARD stability . . . . . . . . . . . . . . . . 3-4
3-2. Position of Least FORWARD stability . . . . . . . . . . . . . . . . . 3-4
3-3. Basic Nomenclature - Machine Control Locations . . . . . 3-5
3-4. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
3-5. Flow Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
3-6. Mast Manual Descent Actuator Installation . . . . . . . . . . 3-12
3-7. Boom Manual Descent Valve. . . . . . . . . . . . . . . . . . . . . . . . 3-13
3-8. Manual Swinging Operating Devices . . . . . . . . . . . . . . . . 3-14
3-9. Boom Manual Lift Up Valve . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
3-10. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
3-11. Platform Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-17
3-12. Grade and Side Slope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
3-13. Steer/Drive Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
3-14. Drive Orientation System (DOS) . . . . . . . . . . . . . . . . . . . . . 3-25
3-15. Machine Tie-Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34
3-16. Lifting the Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
3-17. Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36
4-1. Emergency Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
5-1. Range Diagram 12E/32E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
5-2. Range Diagram 12E Plus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Operator Maintenance & Lubrication Diagram. . . . . . . 5-10
5-4. Chassis Hood Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
5-5. Level Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-6. Adding Water to Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
5-7. Draining the Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5-8. Measuring Electrolyte Specific Gravity. . . . . . . . . . . . . . . 5-14
5-9. Hydraulic Oil Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
5-10. Hydraulic Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . 5-18
5-11. Wheel Lug Nut Tightening Sequence . . . . . . . . . . . . . . . 5-20
5-12. Decal Installation - All Market . . . . . . . . . . . . . . . . . . . . . . . 5-21
5-13. Decal Installation - CE Market . . . . . . . . . . . . . . . . . . . . . . . 5-22
5-14. Decal Installation - ANSI Market . . . . . . . . . . . . . . . . . . . . . 5-23
5-15. Swing Bearing Race Lubrication. . . . . . . . . . . . . . . . . . . . . 5-25
5-16. Swing Bearing Teeth lubrication . . . . . . . . . . . . . . . . . . . . 5-26
5-17. Overload System Verification . . . . . . . . . . . . . . . . . . . . . . . 5-28
5-18. Jacking Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5-19. Slack/Broken Chain Sensors. . . . . . . . . . . . . . . . . . . . . . . . . 5-30
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TABLE OF CONTENTS
vi – JLG Lift – 31210313
NOTES:
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SECTION 1 – SAFETY PRECAUTIONS
31210313 – 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. In order to
promote proper machine usage, it is mandatory that a
daily routine is established 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 established by a qualified person and
must be followed to ensure that the machine is safe to
operate.
The owner/user/operator/lessor/lessee of the machine
must not accept operating responsibility until this manual
has been read, training is accomplished, and operation of
the machine has been completed under the supervision of
an experienced and qualified operator.
These sections contain the responsibilities of the owner,
user, operator, lessor, and lessee concerning safety, train-
ing, inspections, maintenance, application, and operation.
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 MAN-
UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operation and Safety Manual must be read and
understood in its entirety before operating the machine.
For clarification, questions, or additional information
regarding any portions of this manual, contact JLG
Industries, Inc.
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SECTION 1 – SAFETY PRECAUTIONS
1-2 – JLG Lift– 31210313
• An operator must not accept operating responsibilities
until adequate training has been given by competent
and authorized persons.
• Allow only those authorized and qualified personnel to
operate the machine who have demonstrated that they
understand the safe and proper operation and mainte-
nance of the unit.
• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, and operating instructions on the machine
and in this manual.
• Ensure that the machine is to be used in a manner
which is within the scope of its intended application as
determined by JLG.
• 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
your utilization and application of the machine.
Workplace Inspection
• Precautions to avoid all hazards in the work area must
be taken by the user before and during operation of the
machine.
• Do not operate or raise the platform from a position on
trucks, trailers, railway cars, floating vessels, scaffolds or
other equipment unless the application is approved in
writing by JLG.
• Before operation, check work area for overhead hazards
such as electric lines, bridge cranes, and other potential
overhead obstructions.
• Check floor surfaces for holes, bumps, drop-offs,
obstructions, debris, concealed holes, and other poten-
tial hazards.
• Check the work area for hazardous locations. 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 nominal ambient tem-
peratures of -20° C to 40° C (0° F to 104° F). Consult JLG
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SECTION 1 – SAFETY PRECAUTIONS
31210313 – JLG Lift – 1-3
to optimize operation outside of this temperature
range.
• This machine must be used in a sufficient ambient light.
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 machine’s
Service and Maintenance Manual.
• Ensure all safety devices are operating properly. Modifi-
cation of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.
• Check the machine for modifications to original compo-
nents. Ensure that any modifications have been
approved by JLG.
• Avoid accumulation of debris on platform deck. Keep
mud, oil, grease, and other slippery substances from
footwear and platform deck.
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SECTION 1 – SAFETY PRECAUTIONS
1-4 – JLG Lift– 31210313
1.3 OPERATION
General
• Machine operation requires your full attention. Bring
the machine to a full stop before using any device, i.e.
cell phones, two-way radios, etc. that will distract your
attention from safely operating the machine.
• Do not use the machine for any purpose other than
positioning personnel, their tools, and equipment.
• Before operation, the user must be familiar with the
machine capabilities and operating characteristics of all
functions.
• Never operate a malfunctioning machine. If a malfunc-
tion occurs, shut down the machine. Remove the unit
from service and notify the proper authorities.
• Do not remove, modify, or disable any safety devices.
• 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.
Operate controls with slow and even pressure.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the plat-
form, except in an emergency.
• Do not carry materials directly on platform railing unless
approved by JLG.
• When two or more 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.
• Do not assist a stuck or disabled machine by pushing or
pulling except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leav-
ing machine.
• Remove all rings, watches, and jewelry when operating
machine. Do not wear loose fitting clothing or long hair
unrestrained which may become caught or entangled in
equipment.
• Persons under the influence of drugs or alcohol or who
are subject to seizures, dizziness or loss of physical con-
trol must not operate this machine.
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SECTION 1 – SAFETY PRECAUTIONS
31210313 – JLG Lift – 1-5
Trip and Fall Hazards
• Prior to operation, ensure all gates are fastened and
secured in their proper position.
• During operation, occupants in the platform must wear
a full body harness with a lanyard attached to an autho-
rized lanyard anchorage point. Attach only one (1) lan-
yard per lanyard anchorage point.
• Identify the designated lanyard anchorage point(s) at
the platform and securely attach the lanyard. Attach
only one (1) lanyard per lanyard anchorage point.
• Enter and exit only through gate area. Use extreme cau-
tion when entering or leaving platform. Ensure that the
platform assembly is fully lowered. Face the machine
when entering or leaving the platform. Always maintain
“three point contact” with the machine, using two
hands and one foot or two feet and one hand at all
times during entry and exit.
• Keep both feet firmly positioned on the platform floor at
all times. Never position ladders, boxes, steps, planks, or
similar items on unit to provide additional reach for any
purpose.
• Never use extending structure to gain access to or leave
the platform.
• Keep oil, mud, and slippery substances cleaned from
footwear and the platform floor.
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SECTION 1 – SAFETY PRECAUTIONS
1-6 – JLG Lift– 31210313
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 sway-
ing.
• 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.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE
(MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED
UNLESS KNOWN OTHERWISE.
• The minimum approach distance may be reduced if
insulating barriers are installed to prevent contact and
the barriers 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
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.
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