jcb S1530E, S1930E, S2032E, S2632E, S2646E Operator's Manual
...
OPERATOR'S MANUAL
MOBILE ELEVATING WORK PLATFORM
S1530E, S1930E, S2032E, S2046E,
S2632E, S2646E, S3246E, S4046E, S4550E
EN - 9831/3200 ISSUE 3 - 09/2017
THIS MANUAL SHOULD ALWAYS STAY WITH THE MACHINE
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
OPERATOR'S
MANUAL
MOBILE ELEVATING WORK PLATFORM
S1530E, S1930E, S2032E,
S2046E, S2632E, S2646E,
S3246E, S4046E, S4550E
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Machine Delivery and Installation
Even if you have operated this type of equipment
before, it is very important that your new machines
operations and functions are explained to you by
a JCB Dealer Representative following delivery of
your new machine.
Following the installation you will know how to gain
maximum productivity and performance from your
new product.
Please contact your local JCB dealer if the
Installation Form (included in this manual) has not
yet been completed with you.
Your local JCB Dealer is
EN - 9831/3200 - ISSUE 3 - 09/2017
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2017 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Notes:
9831/3200-3
Table of Contents
Contents Page No.
Acronyms Glossary ........................................................................................................................................ iv
Introduction
About this Manual
Model and Serial Number ..................................................................................................................... 1
Using the Manual .................................................................................................................................. 1
Left-Hand Side, Right-Hand Side ......................................................................................................... 1
Cross References ................................................................................................................................. 2
Location of Manual ............................................................................................................................... 2
Safety
Safety - Yours and Others .................................................................................................................... 3
Safety Warnings .................................................................................................................................... 3
General Safety ...................................................................................................................................... 4
Clothing and Personal Protective Equipment (PPE) ............................................................................ 4
About the Product
Introduction
General .................................................................................................................................................. 5
Name and Address of the Manufacturer .............................................................................................. 5
Product Compliance .............................................................................................................................. 5
Description
General .................................................................................................................................................. 6
Intended Use ......................................................................................................................................... 6
Log Moving/Object Handling ................................................................................................................. 6
Danger Zone ......................................................................................................................................... 6
Main Component Locations .................................................................................................................. 7
Product and Component Identification
Machine ................................................................................................................................................. 9
Safety Labels
General ................................................................................................................................................ 10
Safety Label Identification ................................................................................................................... 10
Operation
Introduction
General ................................................................................................................................................ 15
Operating Safety
General ................................................................................................................................................ 16
Worksite Safety ................................................................................................................................... 17
Risk Assessment ................................................................................................................................ 17
Walk-Around Inspection
General ................................................................................................................................................ 19
Entering and Leaving the Operator Station
General ................................................................................................................................................ 20
Battery Isolator
General ................................................................................................................................................ 22
Stopping and Parking
General ................................................................................................................................................ 24
Getting the Machine Moving
General ................................................................................................................................................ 25
Slopes
General ................................................................................................................................................ 26
i 9831/3200-3 i
Table of Contents
Driving on Slopes ............................................................................................................................... 26
Driving the Machine
General ................................................................................................................................................ 28
Operating Levers/Pedals
Control Layouts ................................................................................................................................... 29
Working with the Platform
General ................................................................................................................................................ 32
Extending and Retracting the Platform ............................................................................................... 35
Folding and Unfolding the Guardrails ................................................................................................. 35
Moving a Disabled Machine
General ................................................................................................................................................ 37
Lifting the Machine
General ................................................................................................................................................ 39
Transporting the Machine
General ................................................................................................................................................ 41
Loading the Machine onto the Transporting Vehicle/Trailer ............................................................... 41
Operating Environment
General ................................................................................................................................................ 43
Preservation and Storage
Storage
General ................................................................................................................................................ 45
Take out of Storage ............................................................................................................................ 45
Maintenance
Introduction
General ................................................................................................................................................ 47
Owner/Operator Support ..................................................................................................................... 47
Service/Maintenance Agreements ...................................................................................................... 48
Obtaining Spare Parts ........................................................................................................................ 48
Maintenance Safety
General ................................................................................................................................................ 49
Fluids and Lubricants ......................................................................................................................... 49
Batteries .............................................................................................................................................. 51
Maintenance Schedules
General ................................................................................................................................................ 55
How to Use the Maintenance Schedules ........................................................................................... 55
Maintenance Intervals ......................................................................................................................... 55
Pre-start Cold Checks, Service Points and Fluid Levels .................................................................... 56
Functional Tests and Final Inspection ................................................................................................ 57
Maintenance Positions
General ................................................................................................................................................ 58
Service Points
General ................................................................................................................................................ 61
Access Apertures
General ................................................................................................................................................ 63
Battery Cover ...................................................................................................................................... 63
Hydraulic Compartment Cover ........................................................................................................... 63
Body and Framework
General ............................................................................................................................................... 65
Safety Equipment
Check (Operation) ............................................................................................................................... 66
ii 9831/3200-3 ii
Table of Contents
Brakes
Park Brake .......................................................................................................................................... 68
Steering System
General ............................................................................................................................................... 69
Tyres
General ............................................................................................................................................... 70
Hydraulic System
General ............................................................................................................................................... 71
Oil ........................................................................................................................................................ 74
Electrical System
General ............................................................................................................................................... 75
Battery ................................................................................................................................................. 75
Battery Isolator ................................................................................................................................... 80
Fuses .................................................................................................................................................. 80
Relays ................................................................................................................................................. 81
Technical Data
Introduction
General ................................................................................................................................................ 83
Static Dimensions
Dimensions .......................................................................................................................................... 84
Weights ............................................................................................................................................... 87
Performance Dimensions
Driving Performance ........................................................................................................................... 90
Noise Emissions
Noise Data .......................................................................................................................................... 94
Vibration Emissions
Vibration Data ..................................................................................................................................... 95
Fluids, Lubricants and Capacities
General ................................................................................................................................................ 96
Electrical System
General ................................................................................................................................................ 97
Fuses .................................................................................................................................................. 97
Hydraulic System
General ................................................................................................................................................ 99
Wheels and Tyres
General .............................................................................................................................................. 100
Fault-Finding
General .............................................................................................................................................. 101
Declaration of Conformity
General .............................................................................................................................................. 103
Data ................................................................................................................................................... 103
Warranty Information
Service Record Sheet ....................................................................................................................... 105
iii 9831/3200-3 iii
Acronyms Glossary
AC Alternating Current
LCD Liquid Crystal Display
LED Light Emitting Diode
MECU Machine Electronic Control Unit
PPE Personal Protective Equipment
RCBO Residual current Circuit Breaker with Over current protection
USB Universal Serial Bus
Table of Contents
iv 9831/3200-3 iv
About this Manual
Introduction
About this Manual
Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range:
Model From: To:
2532501 2537500S1530E
2671002 2672000
2532501 2537500S1930E
2671002 2672000
2532501 2537500S2032E
2671002 2672000
2532501 2537500S2046E
2671002 2672000
2532501 2537500S2632E
2671002 2672000
2532501 2537500S2646E
2671002 2672000
S3246E 2532501 2537500
S4046E 2532501 2537500
S4550E 2533185 2537500
Introduction
Using the Manual
This operator's manual is arranged to give you a good understanding of the machine and its safe operation.
It also contains maintenance and technical data.
Read this manual from the front to the back before you use the machine for the first time, even if you have used
machines of a similar/same type before as the technical specification, systems and controls of the machine
may have changed. Particular attention must be given to all the safety aspects of operating and maintaining
the machine.
If there is anything you are not sure about, ask your JCB dealer or employer. Do not guess, you or others could
be killed or seriously injured.
The general and specific warnings in this section are repeated throughout the manual. Read all the safety
statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
The illustrations in this manual are for guidance only. Where the machines are different, the text and or the
illustration will specify.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur
between specifications of the machine and the descriptions contained in this manual.
All of the optional equipment included in this manual may not be available in all territories
Left-Hand Side, Right-Hand Side
In this manual, 'left' and 'right' mean your left and right when you are stood in the platform facing the operator's
manual storage case.
1 9831/3200-3 1
Introduction
A
B
C
About this Manual
Figure 1.
A Left B Right
C Operator's manual storage case
Cross References
In this manual, cross references are made by presenting the subject title in blue (electronic copy only). The
number of the page upon which the subject begins is indicated within the brackets. For example: Refer to:
Cross References (Page 2).
Location of Manual
The operator's manual is located in a storage case at one end of the platform. The manual should always be
returned to its case after use. Refer to: Main Component Locations (Page 7).
2 9831/3200-3 2
Introduction
Safety
Safety
Safety - Yours and Others
All machinery can be hazardous. When a machine is correctly operated and maintained, it is a safe machine
to work with. When it is carelessly operated or poorly maintained it can become a danger to you (the operator)
and others.
In this manual and on the machine you will find warning messages, read and understand them. They inform
you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your
employer or JCB dealer to explain them.
Safety is not just a matter of responding to the warnings. All the time you are working on or with the machine
you must be thinking of what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any work until you are sure that you and those around you will be safe.
If you are not sure of anything, about the machine or the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
Safety Warnings
In this manual and on the machine, there are safety notices. Each notice starts with a signal word. The signal
word meanings are given below.
The signal word 'DANGER' indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
The signal word 'WARNING' indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
The signal word 'CAUTION' indicates a hazardous situation which, if not avoided, could result in minor or
moderate injury.
The signal word 'Notice' indicates a hazardous situation which, if not avoided, could result in machine damage.
The safety alert system (shown) also helps to identify important safety messages in this manual and on the
machine. When you see this symbol, be alert, your safety is involved, carefully read the message that follows,
and inform other operators.
Figure 2. The safety alert system
3 9831/3200-3 3
Introduction
Safety
General Safety
Training
To operate the machine safely you must know the machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that apply to the country you are operating in. The operator's
manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a
new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you
will not do your job well, and you will be a danger to yourself and others. In some markets and for work on certain
jobsites you may be required to have been trained and assessed in accordance with an operator competence
scheme. Make sure that you and your machine comply with relevant local laws and jobsite requirements - it
is your responsibility.
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be
alert for hazards.
Clothing
You can be injured if you do not wear the correct clothing. Loose clothing can get caught in the machinery.
Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and
personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume
alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines
which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself
and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such
an area could cause an explosion or fire resulting in death or serious injury.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all local regulations.
Raised Machine
Never position yourself or any part of your body inside the raised scissor pack which is not correctly supported.
If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with prevailing legislative requirements. It must not be altered in
any way which could affect or invalidate its compliance. For advice consult your JCB dealer.
Clothing and Personal Protective Equipment (PPE)
Do not wear loose clothing or jewellery that can get caught on controls or moving parts. Wear protective clothing
and personal safety equipment issued or called for by the job conditions, local regulations or as specified by
your employer.
4 9831/3200-3 4
About the Product
Introduction
About the Product
Introduction
General
Before you start using the machine, you must know how the machine operates. Use this part of the manual
to identify each control lever, switch, gauge, button and pedal. Do not guess, if there is anything you do not
understand, ask your JCB dealer.
Name and Address of the Manufacturer
JCB Access Limited, Lakeside Works, Rocester, Uttoxeter, United Kingdom, ST14 5JP
Product Compliance
Your JCB product was designed to comply with the laws and regulations applicable at the time of its manufacture
for the market in which it was first sold. In many markets, laws and regulations exist that require the owner to
maintain the product at a level of compliance relevant to the product when first produced. Even in the absence
of defined requirements for the product owner, JCB recommend that the product compliance be maintained
to ensure safety of the operator and exposed persons and to ensure the correct environmental performance.
Your product must not be altered in any way which could affect or invalidate any of these requirements. For
advice consult your JCB dealer.
For its compliance as a new product, your JCB and some of its components may bear approval numbers
and marking's, and may have been supplied with a Declaration/Certificate of Conformity. These marking's and
documents are relevant only for the country/region in which the product was first sold to the extent that the
laws and regulations required them.
Re-sales and import/export of products across territories with different laws and regulations can cause new
requirements to become relevant for which the product was not originally designed or specified. In some cases,
pre owned products irrespective of their age are considered new for the purposes of compliance and may be
required to meet the latest requirements which could present an insurmountable barrier to their sale/use.
Despite the presence of any compliance related marking's on the product and components, you should not
assume that compliance in a new market will be possible. In many cases it is the person responsible for import
of a pre owned product into a market that becomes responsible for compliance and who is also considered
the manufacturer.
JCB may be unable to support any product compliance related enquiry for a product which has been moved out
of the legislative country/region where it was first sold, and in particular where a product specification change
or additional certification would have been required in order for the product to be in compliance.
5 9831/3200-3 5
About the Product
Description
Description
General
This machine is a self propelled aerial work platform on the top of an elevating scissor arm mechanism.
Intended Use
The machine is intended to lift the personnel with their tools and position them at a level of working height.
The machine can be used to reach areas located above machinery or equipment positioned at ground level
by use of the extending platform.
The machine is intended to be used in normal conditions for the applications and in the environmental conditions
as described in this manual. Use in any other way not described in the manual is considered contrary to intended
use of this machine.
The machine is not intended for use in mining and quarrying applications, in demolition activities, forestry, any
use underground, or in any kind of explosive atmosphere. This is not an exhaustive list. For any activity not
described here, it is recommended that a risk assessment must be done prior to operation.
If the machine is to be used in applications where there is a high silica concentration, risk due to materials
containing asbestos or similar hazards, additional protective measures such as the use of PPE (Personal
Protective Equipment) may be required.
The machine should not be operated by any person who does not have an appropriate level of qualification,
training or experience of use of this type of machine.
Prior to use of the machine, its suitability (size, performance, specification etc.) should be considered with
regards to the intended application and any relevant hazards that may exist. Contact your JCB dealer for
support in determining the appropriate JCB machine, attachment and any optional equipment that is suitable
for the application and environment.
Log Moving/Object Handling
Do not use the machine to move or handle logs or other objects. You could cause serious injury to yourself
and damage to the machine. Do not use the machine as a crane. Do not overload the platform with tools or
equipment. Refer to: Technical Data (Page 83). For more information, contact your JCB dealer.
Danger Zone
The danger zone is any zone within and/or around the machinery in which a person is subject to a risk to their
health or safety. During operation of the machine, keep all persons out of the danger zone. Persons in the
danger zone could be injured.
Before you do a maintenance task, make the product safe. Refer to: Maintenance Positions (Page 58).
6 9831/3200-3 6
Main Component Locations
K
W
U
T
S
R
K
L
M
N
Q
P
S
V
F
J
G
H
A
B
C
D
E
X
Y
Z
About the Product
Description
Figure 3.
A Gate B Guardrail
C Harness fastening point D Platform control panel
E Operator's Manual F Platform extension
G AC (Alternating Current) Power socket (option) H Extension platform pedal
J Main platform K Warning lights
L Tilt sensor M Front wheel (steering)
N Pot hole protection plate P MECU (Machine Electronic Control Unit) display
Q Ground controller R Rear wheel
S Lift point/forklift position T Manual release valve and emergency lowering
U Pot hole activation plungers V Ladder
W Safety strut X Battery charger
7 9831/3200-3 7
handle
Y Charging plug Z Power to platform plug
About the Product
Description
8 9831/3200-3 8
Product and Component Identification
A
Machine
Your machine has an identification plate as shown. Refer to Figure 4.
Figure 4.
About the Product
Product and Component Identification
A Machine identification plate location
Figure 5. Machine Identification Plate
9 9831/3200-3 9
About the Product
F
F
E
G
H
J
J
A
B
D
C
E
Safety Labels
Safety Labels
General
WARNING Safety labels on the machine warn you of particular hazards. You can be injured if you do not
obey the safety instructions shown.
The safety labels are strategically placed around the machine to remind you of possible hazards.
If you need eye-glasses for reading, make sure you wear them when reading the safety labels. Do not overstretch or put yourself in dangerous positions to read the safety labels. If you do not understand the hazard
shown on the safety label, then refer to Safety Label Identification.
Keep all of the safety labels clean and readable. Replace a lost or damaged safety label. Make sure the
replacement parts include the safety labels where necessary. Each safety label has a part number printed on
it, use this number to order a new safety label from your JCB dealer.
Safety Label Identification
For: S1530E, S1930E .............................................................................................................. Page 10
For: S2032E, S2632E, S4550E ............................................................................................... Page 12
For: S2046E, S2646E, S3246E, S4046E ................................................................................. Page 13
(For: S1530E, S1930E)
Figure 6.
10 9831/3200-3 10
Figure 7.
P
B
K
L
M
R
About the Product
Safety Labels
Table 1. Safety Labels
Item Part No. Description Qty.
A 400/G0761 Crush hazard (to feet). Keep a safe distance. The attachment may roll
forward when released.
B 400/D2107 Electrical hazard. Stay a safe distance away from power lines. 2
C 817/70092 Warning. Read the Operator’s Manual before you operate the machine. 1
D 400/G0762 Pressure hazard. Stop the machine, remove the ignition key and consult
service manual before carrying out any servicing and maintenance work.
E 400/G0767 Explosion hazard. Remove the sources of ignition. 2
F 400/D0831 Warning. Crush hazard. Keep a safe distance from scissor pack/
G 400/G6092 Electrical hazard. Read operator’s manual. 1
H 400/D2141 Warning. Engage safety strut before carrying out maintenance within the
J 332/P7128 Burns to fingers and hands. Stay a safe distance away. 2
K 400/G3529 Warning. Emergency descent control. Pull lever to lower the platform in
L 400/D2576 Warning. Item for emergency use only. 2
M 400/D2979 Warning. Danger of uncontrolled machine movement. Platform to be in
P 400/D1430 Wear safety harness. 4
R 400/G0705 Warning. Read operator’s manual before operating machine. 1
mechanism.
scissor pack.
the event that the operator is incapacitated.
fully lowered position. Use wheel chocks. To release brakes, push valve
and pump lever.
4
1
4
1
1
1
11 9831/3200-3 11
(For: S2032E, S2632E, S4550E)
F
F
E
G
H
J
J
A
B
D
C
E
P
B
K
L
M
R
About the Product
Safety Labels
Figure 8.
Figure 9.
12 9831/3200-3 12
About the Product
F
F
E
G
H
J
J
A
B
D
C
E
Safety Labels
Table 2. Safety Labels
Item Part No. Description Qty.
A 332/P7135 Crush hazard (to feet). Keep a safe distance. The attachment may roll
forward when released.
B 400/D2107 Electrical hazard. Stay a safe distance away from power lines. 2
C 817/70092 Warning. Read the Operator’s Manual before you operate the machine. 1
D 817/70002 Pressure hazard. Stop the engine, remove the starter key and consult the
Service Manual before you complete any service or maintenance work.
E 817/70042 Explosion hazard. Remove sources of ignition. 2
F 400/D0831 Warning. Crush hazard. Keep a safe distance from scissor pack/
mechanism.
G 817/70032 Electrical hazard. Read the Operator’s Manual. 1
H 400/D2141 Warning. Engage safety strut before carrying out maintenance within the
scissor pack.
J 332/P7128 Burns to fingers and hands. Stay a safe distance away. 2
K 400/G3529 Warning. Emergency descent control. Pull lever to lower the platform in
the event that the operator is incapacitated.
L 400/D2576 Warning. Item for emergency use only. 2
M 400/D2979 Warning. Danger of uncontrolled machine movement. Platform to be in
fully lowered position. Use wheel chocks. To release brakes, push valve
and pump lever.
P 400/D1430 Wear safety harness. 4
R 400/G0705 Warning. Read operator’s manual before operating machine. 1
(For: S2046E, S2646E, S3246E, S4046E)
4
1
4
1
1
1
Figure 10.
13 9831/3200-3 13
Figure 11.
P
B
K
L
M
R
About the Product
Safety Labels
Table 3. Safety Labels
Item Part No. Description Qty.
A 332/P7135 Crush hazard (to feet). Keep a safe distance. The attachment may roll
forward when released.
B 400/D2107 Electrical hazard. Stay a safe distance away from power lines. 2
C 817/70092 Warning. Read the Operator’s Manual before you operate the machine. 2
D 817/70002 Pressure hazard. Stop the engine, remove the starter key and consult the
Service Manual before you complete any service or maintenance work.
E 817/70042 Explosion hazard. Remove sources of ignition. 2
F 400/D0831 Warning. Crush hazard. Keep a safe distance from scissor pack/
G 817/70032 Electrical hazard. Read the Operator’s Manual. 1
H 400/D2141 Warning. Engage safety strut before carrying out maintenance within the
J 332/P7128 Burns to fingers and hands. Stay a safe distance away. 2
K 400/G3529 Warning. Emergency descent control. Pull lever to lower the platform in
L 400/D2576 Warning. Item for emergency use only. 2
M 400/D2979 Warning. Danger of uncontrolled machine movement. Platform to be in
P 400/D1430 Wear safety harness. 4
mechanism.
scissor pack.
the event that the operator is incapacitated.
fully lowered position. Use wheel chocks. To release brakes, push valve
and pump lever.
4
1
4
1
1
1
14 9831/3200-3 14
Operation
Introduction
Operation
Introduction
General
The aim of this part of the manual is to guide the operator step-by-step through the task of learning how to
operate the machine efficiently and safely. Read the Operation section through from beginning to end.
The operator must always be aware of events happening in or around the machine. Safety must always be the
most important factor when you operate the machine.
When you understand the operating controls, gauges and switches, practice using them. Drive the machine in
an open space, clear of people. Get to know the 'feel' of the machine and its driving controls.
Do not rush the job of learning, make sure you fully understand everything in the Operation section. Take your
time and work efficiently and safely.
Remember:
• Be careful.
• Be alert.
• Be safe.
15 9831/3200-3 15
Operation
Operating Safety
Operating Safety
General
Training
Make sure that you have had adequate training and that you are confident in your ability to operate the machine
safely before you use it. Practice using the machine and its attachments until you are completely familiar with
the controls and what they do. With a careful, well trained and experienced operator, your machine is a safe
and efficient machine. With an inexperienced or careless operator, it can be dangerous. Do not put your life,
or the lives of others, at risk by using the machine irresponsibly. Before you start to work, tell your colleagues
what you will be doing and where you will be working. On a busy site, use a signalman.
Before doing any job not covered in this manual, find out the correct procedure. Your local JCB distributor will
be glad to advise you.
Machine Condition
A defective machine can injure you or others. Do not operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this manual are completed before using the machine.
Machine Limits
Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do
not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved
modifications or additional equipment.
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you
will be working with other people, make sure any hand signals that may be used are understood by everybody.
Worksites can be noisy, do not rely on spoken commands.
Parking
An incorrectly parked machine can move without an operator. Follow the instructions in the Operator's Manual
to park the machine correctly.
Banks and Trenches
Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there
is danger of collapse.
Safety Barriers
Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced,
place barriers around the work area to keep people away.
Sparks
Explosions and fire can be caused by sparks from the electrical system. Do not use the machine in closed
areas where there is flammable material, vapour or dust.
Regulations
Obey all laws, worksite and local regulations which affect you and your machine.
Electrical Power Cables
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical
power cables.
You are strongly advised to make sure that the safety arrangements on site comply with the local laws and
regulations concerning work near electric power lines.
Before you start using the machine, check with your electricity supplier if there are any buried power cables
on the site.
There is a minimum clearance required for working beneath overhead power cables. You must obtain details
from your local electricity supplier.
Machine Safety
Stop work at once if a fault develops. Abnormal sounds and smells can be signs of trouble. Examine and repair
before resuming work.
16 9831/3200-3 16
Operation
Operating Safety
Travelling at High Speeds
Travelling at high speeds can cause accidents. Always travel at a safe speed to suit working conditions.
Confined Areas
Pay extra attention to proximity hazards when operating in confined areas. Proximity hazards include buildings,
traffic and bystanders.
Safe Working Loads
Overloading the machine can damage it and make it unstable. Study the specifications in the Operator's Manual
before using the machine.
Lightning
If there is lightning, stay away from the machine and do not use the machine. If you are on the machine, exit
the machine and get to safety. Do not attempt to mount or enter the machine.
If the machine is struck by lightning do not use the machine until it has been checked for damage and
malfunction by trained personnel.
Worksite Safety
"Workplace Inspection" will help operators to determine whether the workplace is suitable for operation.
Operators must inspect the workplace before they move machines there. It is the operator's responsibility to
understand and keep in mind the hazards in the workplace, He/she shall pay attention and avoid these problems
when move, install and operate the machine. Check for hazards such as but not limited to:
• Drop-offs, or potholes including those concealed by water mud, etc.
• Slopes.
• Bumps and floor obstructions.
• Debris.
• Over head obstructions and electrical conductors.
• Hazardous locations and atmospheres.
• Inadequate surface and support to withstand all load forces imposed by the platform in all operating
configurations.
• Wind and weather conditions.
• Presence of unauthorized persons.
• Other possible unsafe conditions.
Risk Assessment
It is the responsibility of the competent people that plan the work and operate the machine to make a judgement
about the safe use of the machine, they must take into account the specific application and conditions of use
at the time.
It is essential that a risk assessment of the work to be done is completed and that the operator obeys any
safety precautions that the assessment identifies.
If you are unsure of the suitability of the machine for a specific task, contact your JCB dealer who will be
pleased to advise you.
The following considerations are intended as suggestions of some of the factors to be taken into account when
a risk assessment is made. Other factors may need to be considered.
A good risk assessment depends on the training and experience of the operator. Do not put your life or the
lives of others at risk.
Personnel
• Are all persons who will take part in the operation sufficiently trained, experienced and competent? Are
they fit and sufficiently rested? A sick or tired operator is a dangerous operator.
• Is supervision needed? Is the supervisor sufficiently trained and experienced?
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Operation
Operating Safety
• As well as the machine operator, are any assistants or lookouts needed?
The Machine
• Is it in good working order?
• Have any reported defects been corrected?
• Have the daily checks been carried out?
• Are the tyres in good condition?
• Is the battery sufficiently charged to complete the job?
Working Area
• Is it level?
• Is the ground solid? Will it support the weight of the machine when loaded?
• How rough is the ground? Are there any sharp projections which could cause damage, particularly to
the tyres?
• Are there any obstacles or hazards in the area, for example, debris, excavations, manhole covers, power
lines?
• Is the space sufficient for safe manoeuvring?
• Are any other machines or persons likely to be in or to enter the area while operations are in progress?
The Route to be Travelled
• How solid is the ground, will it provide sufficient traction and braking? Soft ground will affect the stability
of the machine and this must be taken into account.
• How steep are any slopes, up/down/across? A cross slope is particularly hazardous, is it possible to detour
to avoid them?
Weather
• How windy is it? High wind will adversely affect the stability of a loaded machine.
• Is it raining or is rain likely? The ground that was solid and smooth when dry will become uneven and
slippery when wet, and it will not give the same conditions for traction, steering or braking.
Emergency Plan
Make sure that emergency rescue plan is in place and understood by those involved when operating the
machine from platform controller at height.
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Operation
Walk-Around Inspection
Walk-Around Inspection
General
The following checks must be made each time you return to the machine after leaving it for any period of time.
We advise you also to stop the machine occasionally during long work sessions and do the checks again.
All these checks concern the serviceability of the machine. Some concern your safety. Get your service engineer
to check and correct any defects.
1. Check for cleanliness.
1.1. Remove dirt and debris, especially from around the linkages, rams, pivot points.
1.2. Make sure the platform floor and handrails are clean and dry.
1.3. Clean all of the safety and instructional labels. Replace any label that is missing or cannot be read.
2. Check for damage.
2.1. Examine the machine generally for damaged and missing parts.
2.2. Make sure that all of the fasteners and pivot pins are correctly installed.
2.3. Check the operation of the platform side rails.
2.4. Check the condition of the tyres.
2.5. Check for leaks
3. Make sure that all of the access panels are closed correctly.
3.1. If access panels are installed with locks, we recommend that you lock them to prevent theft or
tampering.
4. Check the operation of all controls.
5. Check the operator's manual is in good condition and is kept in the operator's manual storage compartment.
6. Check the level of the hydraulic fluid and for leaks.
7. Check the visual condition of the batteries, cables and wiring.
8. Check the operation of the safety equipment.
Refer to: Check (Operation) (Page 66).
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Operation
Entering and Leaving the Operator Station
Entering and Leaving the Operator Station
General
CAUTION If the guardrails have been folded down, use extreme caution when entering and leaving the
operator station. Do not operate the controls from the platform when the guard rails are folded.
CAUTION Entering or leaving the operator station must only be made where steps and handrails are
provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your
boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds,
use the handrails.
Make sure the machine is stopped, correctly parked and fully stowed before entering or leaving the platform.
Refer to: Stopping and Parking (Page 24).
When entering and leaving the platform always maintain three points of contact with the guardrails and step.
Do not use the machine controls as handholds.
Entering the Platform
1. Hold the two guardrails, then use the steps to climb up to the platform. Refer to Figure 12.
2. Depress the lever and open the platform door.
3. Step into the platform.
4. Close the platform door and make sure it latches correctly.
Leaving the Platform
1. Park the machine on solid (slabbed or paved), level ground.
2. Depress the lever and open the platform door.
3. Hold both of the guardrails and step backwards out of the platform onto the steps.
4. Close the platform door and make sure it latches correctly.
5. Use the steps to climb down backwards onto the ground.
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Figure 12.
A
Operation
Entering and Leaving the Operator Station
A Lever
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Battery Isolator
A
General
WARNING The batteries remain live even when the isolator key is removed.
Disconnect the Machine Electrics:
1. Turn the key switch to the off position.
2. Get access to the battery isolator.
Refer to: Access Apertures (Page 63).
3. Disconnect the battery isolator by pulling handle. Refer to Figure 13.
Connect the Machine Electrics:
1. Make sure the key switch is at off position.
2. Connect the battery isolator.
Figure 13. Lead Acid Battery
Operation
Battery Isolator
A Battery isolator
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