JLG 1230ES Operator Manual
Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Model - 1230ES
ANSI
P/N - 3121221
August 15, 2013
NOTES:
SECTION - FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
IT IS A GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. SHOULD
PRESSURE-WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS,
JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY
SATURATION.
3121221 – JLG Lift – A
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
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
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALITY 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 A POTENTIALITY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE AN ORANGE BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
B – JLG Lift – 3121221
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. 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 PROPERTY OR THE JLG PRODUCT.
For :
• Accident Reporting
•Product Safety Publications
•Current Owner
Updates
•Questions Regarding Product Safety
• Standards and Regulations Compliance
Information
• Questions Regarding
Special Product Applications
• Questions Regarding
Product Modifications
Contact :
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on manual rear cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
3121221 – JLG Lift – C
SECTION - REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . November 4, 2005
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 8, 2006
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . July 13, 2006
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . January 23, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . March 19, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 16, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . June 11, 2007
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . May 6, 2008
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . June 22, 2010
Manual Revised. . . . . . . . . . . . . . . . . . . . . . . . . August 15, 2013
REVISION LOG
D – JLG Lift – 3121221
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
In USA:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
REVISION LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Operator Training and Knowledge . . . . . . . . . . . . 1-2
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Crushing and Collision Hazards . . . . . . . . . . . . . . . 1-9
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . .1-10
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 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
2.5 DAILY WALK-AROUND INSPECTION . . . . . . . . . . . . .2-7
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . .3-2
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . .3-3
Battery Charger/Hour Meter Indicators . . . . . . . .3-5
Platform Control Station . . . . . . . . . . . . . . . . . . . . . .3-8
Platform Control and Indicator Panel . . . . . . . . . .3-9
Drive/Lift/Steer Joystick Control. . . . . . . . . . . . . 3-10
3.3 DECAL INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3121165 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.3 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.4 BATTERY CHARGING . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Battery Charger Fault Codes . . . . . . . . . . . . . . . . . .4-3
4.5 AC INVERTER OPERATION (OPTION) . . . . . . . . . . . . .4-4
4.6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6
Platform/Ground Select Switch . . . . . . . . . . . . . . .4-6
Emergency Stop Switch. . . . . . . . . . . . . . . . . . . . . . .4-6
4.7 RAISING AND LOWERING PLATFORM . . . . . . . . . . . .4-7
Raising Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8
Lowering Platform. . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.8 STEERING AND TRAVELING. . . . . . . . . . . . . . . . . . . . 4-12
Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Driving Forward and Reverse . . . . . . . . . . . . . . . 4-13
4.9 PARKING AND STOWING MACHINE. . . . . . . . . . . . 4-15
4.10 TIE DOWN/LIFT LUGS . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.11 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Electric Brake Release . . . . . . . . . . . . . . . . . . . . . . . 4-18
Mechanical Brake Release . . . . . . . . . . . . . . . . . . . 4-19
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
Operator Unable to Control Machine . . . . . . . . . 5-1
Platform Caught Overhead . . . . . . . . . . . . . . . . . . . 5-1
5.3 PLATFORM MANUAL DESCENT . . . . . . . . . . . . . . . . . 5-1
5.4 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5-2
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Other Publications Available Specific
to this Machine:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . 6-2
Platform Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 CRITICAL STABILITY WEIGHTS. . . . . . . . . . . . . . . . . . . 6-4
6.4 LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication Capacities. . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . 6-6
ii – JLG Lift – 3121165
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6.5 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . .6-7
Oil Check Procedure . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.6 BATTERY MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . 6-8
Battery Maintenance and Safety Practices . . . . . 6-8
6.7 TIRES AND WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Tire Wear and Damage . . . . . . . . . . . . . . . . . . . . . . . 6-9
Wheel and Tire Replacement . . . . . . . . . . . . . . . . . 6-9
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . .6-10
6.9 DIAGNOSTIC TROUBLE CODES (DTC) . . . . . . . . . . .6-11
6.10 DTC CHECK TABLE INDEX . . . . . . . . . . . . . . . . . . . . . .6-11
6.1 DIAGNOSTIC TROUBLE CODES (DTC)
CHECK TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12
0-0 Help Comments . . . . . . . . . . . . . . . . . . . . . . . . .6-12
2-1 Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-14
2-2 Platform Controls. . . . . . . . . . . . . . . . . . . . . . . .6-14
2-3 Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . .6-16
2-5 Function Prevented. . . . . . . . . . . . . . . . . . . . . .6-16
3-1 Line Contactor Open Circuit. . . . . . . . . . . . . .6-18
3-2 Line Contactor Short Circuit. . . . . . . . . . . . . . 6-19
3-3 Ground Output Driver . . . . . . . . . . . . . . . . . . .6-19
4-2 Thermal Limit (SOA) . . . . . . . . . . . . . . . . . . . . .6-22
4-4 Battery Supply. . . . . . . . . . . . . . . . . . . . . . . . . . .6-22
6-6 Communication . . . . . . . . . . . . . . . . . . . . . . . . .6-23
6-7 Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
7-7 Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . .6-24
8-1 Tilt Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
8-2 Platform Load Sense . . . . . . . . . . . . . . . . . . . . 6-26
9-9 Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . .2-8
3-1. Location of Machine Controls.. . . . . . . . . . . . . . . . . . .3-2
3-2. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . .3-3
3-3. Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4
3-4. Battery Charger and Hour Meter Indicators . . . . . .3-5
3-5. Location of Manual Descent Valve
(Front of Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-6. Location of Brake Release Switch
(Rear of Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7
3-7. Platform Control Station.. . . . . . . . . . . . . . . . . . . . . . . .3-8
3-8. Platform Control/Indicator Panel . . . . . . . . . . . . . . . .3-9
3-9. Platform Control Components . . . . . . . . . . . . . . . . 3-10
3-10. 1230ES - Decal Installation.. . . . . . . . . . . . . . . . . . . . 3-12
4-1. Location of Battery Charger AC Input Plug . . . . . . .4-2
4-2. Location of AC Inverter ON/OFF -
Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
4-3. Platform/Ground Select Switch. . . . . . . . . . . . . . . . . .4-6
3121165 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4-4. Ground Control - Emergency Stop Switch . . . . . . .4-6
4-5. Platform Control - Emergency Stop Switch . . . . . .4-7
4-6. Raising Platform From Ground Control . . . . . . . . . .4-8
4-7. Raising Platform From Platform Control . . . . . . . . .4-9
4-8. Lowering Platform From Ground Control . . . . . . 4-10
4-9. Lowering Platform From Platform Control . . . . . 4-11
4-10. Steering from Platform Control. . . . . . . . . . . . . . . . 4-12
4-11. Driving Forward from Platform Control . . . . . . . . 4-13
4-12. Grade and Slideslope Definition. . . . . . . . . . . . . . . 4-14
4-13. Securing Control Station to Platform. . . . . . . . . . . 4-15
4-14. Tie Down and Lift Lug Locations. . . . . . . . . . . . . . . 4-16
4-15. Lifting Using Spreader Bar. . . . . . . . . . . . . . . . . . . . . 4-17
4-16. Electric Brake Release. . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-17. Brake - Manual Disengage. . . . . . . . . . . . . . . . . . . . . 4-19
5-1. Location of Manual Descent Valve
(Front of Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
6-1. Hydraulic Oil Check Procedure . . . . . . . . . . . . . . . . . .6-7
6-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
6-3. Wheel Lug Nut Tightening Sequence. . . . . . . . . . . .6-9
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-6
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
2-2 Tilt Cutout Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
3-1 1230ES - (ANSI and CE) Decal
Installation Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
4-1 Battery Charger Fault Codes . . . . . . . . . . . . . . . . . . . . 4-3
6-1 Operating Specification . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-5 Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . 6-6
6-10 Hydraulic Oil Specifications (OEM) . . . . . . . . . . . . . . 6-6
6-11 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . 7-1
iv – JLG Lift – 3121165
SECTION 1. SAFETY PRECAUTIONS
SECTION 1 - SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper
and safe machine usage 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
should 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, training, inspection, 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 MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
3121221 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operators and Safety Manual must be read in its
entirety before operating the machine. For clarification,
questions, or additional information regarding any portions
of this manual, contact JLG Industries, Inc.
• 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 maintenance 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 emergency 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 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 potential hazards.
• Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless
approved for that purpose by JLG.
1-2 – JLG Lift – 3121221
SECTION 1 - SAFETY PRECAUTIONS
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel.
• Do not operate the machine when wind conditions exceed
28 mph (ANSI/CSA SPEC) /(CE/AUST SPEC) - Indoor Use
Only.
• This machine can be operated in nominal ambient temperatures of 0
mize operation outside of this temperature range.
o
F to 104o F (-20o C to 40o C). Consult JLG to opti-
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. Modification 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 components. 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.
3121221 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
1.3 OPERATION
General
• 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 malfunction
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.
• Hydraulic cylinders, other than the outrigger cylinders,
should never be left at end of travel (fully extended or fully
retracted) before shutdown or for long periods of time.
Always “bump” control in opposite direction slightly when
function reaches end of travel. This applies both to
machines in operation or in the stowed position.
• 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 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.
• Stow platform assembly and shut off all power before leaving machine.
1-4 – JLG Lift – 3121221
SECTION 1 - SAFETY PRECAUTIONS
Trip and Fall Hazards
• JLG Industries, Inc. recommends that all persons in the platform wear a full body harness with a lanyard attached to an
authorized lanyard anchorage point while operating this
machine. For further information regarding fall protection
requirements on JLG products, contact JLG Industries, Inc.
• Prior to operation, ensure all gates and rails are fastened
and secured in their proper position. Identify the designated lanyard anchorage point(s) at the platform and
securely attach the lanyard. Attach only one (1) lanyard per
lanyard anchorage point
• Use extreme caution 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.
• Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.
3121221 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
Electrocution Hazards
• This machine is not insulated and does not provide protection 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where employer, local or govern-
mental regulations are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up
MINIMUM APPROACH DISTANCE
in Feet (Meters)
1-6 – JLG Lift – 3121221
to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
• 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 be reduced
to a distance within the designed working dimensions of
the insulating barrier. This determination shall be made by
a qualified person in accordance with the employer, local,
or governmental requirements for work practices near
energized equipment
SECTION 1 - SAFETY PRECAUTIONS
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE
(MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED
UNLESS KNOWN OTHERWISE.
3121221 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
Tipping Hazards
• Ensure that the ground conditions are adequate to support
the maximum tire load indicated on the tire load decals
located on the chassis adjacent to each wheel. Do not travel
on unsupported surfaces.
• The user should be familiar with the driving surface before
driving. Do not exceed the allowable sideslope and grade
while driving.
• Do not elevate platform or drive with platform elevated
while on or near a sloping, uneven, or soft surface. Ensure
machine is positioned on a firm, level and smooth surface
before elevating platform or driving with the platform in
the elevated position.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
• Never exceed the maximum work load as specified on the
platform. Keep all loads within the confines of the platform,
unless authorized by JLG.
• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
from holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards at the ground
level.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure. Never attach wire, cable,
or any similar items to platform.
1-8 – JLG Lift – 3121221
SECTION 1 - SAFETY PRECAUTIONS
• Do not cover the platform sides or carry large surface-area
items in the platform when operating outdoors. The addition of such items increases the exposed wind area of the
machine.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If mast assembly or platform is caught so that one or more
wheels are off the ground, all persons must be removed
before attempting to free the machine. Use cranes, forklift
trucks, or other appropriate equipment to stabilize machine
and remove personnel.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Keep hands and limbs off of the mast assembly during
operation.
• Watch for obstructions around machine and overhead
when driving. Check clearances above, on sides, and bottom of platform when lifting or lowering platform.
3121221 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
• During operation, keep all body parts inside platform railing.
• Always post a lookout when driving in areas where vision is
obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away
from machine during all driving operations.
• Under all travel conditions, the operator must limit travel
speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors causing hazards of collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When
driving in high speed, switch to low speed before stopping.
Travel grades in low speed only.
• 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 persons in the platform.
• Ensure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence.
Disconnect power to overhead cranes. Barricade floor area
if necessary.
• Avoid operating over ground personnel. Warn personnel
not to work, stand, or walk under a raised platform. Position
barricades on floor as 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/unloading. Refer to emergency towing procedures.
• Ensure platform is fully retracted and completely empty of
tools prior to towing, lifting or hauling.
• When lifting machine with a forklift, position forks only at
designated areas of the machine. Lift with a forklift of adequate capacity.
• Refer to Section 4 for lifting information.
1-10 – JLG Lift – 3121221
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not
operate this machine.
3121221 – JLG Lift – 2-1
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and
at the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection equipment.
5. Enough knowledge of the mechanical operation of
the machine to recognize a malfunction or potential
malfunction.
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and
obstacles, depressions, holes, drop-offs.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has
developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the
job site.
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
Table 2-1 covers the periodic machine inspections and maintenance recommended by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The
frequency of inspections and maintenance must be increased
as necessary when the machine is used in a harsh or hostile
environment, if the machine is used with increased frequency,
or if the machine is used in a severe manner.
2-2 – JLG Lift – 3121221
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
NOTICE
Table 2-1. Inspection and Maintenance Table
Type Frequency
Pre-Start Inspec tion Before using each day; or
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Service
Qualification
Reference
whenever there’s an Operator change.
Pre-Delivery Inspection
(see note below)
Frequent Inspection In service for 3 months or 150 hours, whichever comes
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG
Mechanic
Owner, Dealer, or User Qualified JLG
first; or Out of service for a period of more than 3
Mechanic
Service and Maintenance Manual and
applicable JLG inspection form
Service and Maintenance Manual and
applicable JLG inspection form
months; or Purchased used.
Annual Machine
Inspection
(see note below)
Preventative Maintenance At intervals as specified in the Service and Mainte-
Annually, no later than 13 months from the date of
prior inspection.
nance Manual.
Owner, Dealer, or User Factory Trained Ser-
vice Technician
(Recommended)
Owner, Dealer, or User Qualified JLG
Mechanic
Service and Maintenance Manual and
applicable JLG inspection form
Service and Maintenance Manual
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE
TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
3121221 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.3 PRE-START INSPECTION
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil or battery fluid) or foreign objects. Report any leakage to the
proper maintenance personnel.
2. Structure - Inspect the machine structure for dents,
damage, weld or parent metal cracks or other discrepancies.
.
Parent Metal Crack Weld Crack
3. Decals and Placards – Check all for cleanliness and
legibility. Make sure none of the decals and placards
are missing. Make sure all illegible decals and placards
are cleaned or replaced.
4. Operators and Safety Manuals - Check that a copy of
the Operator and Safety Manual is enclosed in the
weather resistant storage container.
5. “Walk-Around” Inspection – Refer to Figure 2-1. on
page 2-8.
6. Battery – Charge as required.
7. Fluid Levels - Check the hydraulic oil level in the
pump reservoir.
8. Accessories/Attachments - Reference the Operator
and Safety Manual of each attachment or accessory
installed upon the machine for specific inspection,
operation, and maintenance instructions.
9. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems
in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific instructions
on the operation of each function.
2-4 – JLG Lift – 3121221
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.4 FUNCTION CHECK
Perform the Function Check as follows:
1. From the Ground Control Panel with no load in the
platform:
a. Check if the platform/off/ground selector switch
and the platform lift-up/lift-down switch operate
properly.
b. Check that Pot-Hole-Protection system operates
properly, platform raised - bars down, platform
down - bars up.
c. Ensure that all machine functions are disabled
when the Emergency Stop Button is depressed.
d. With platform raised a few feet (meters), check if
the manual descent valve (located at the base of
the mast on the front of the machine), lowers the
platform properly.
2. From the Platform Control Console:
a. Ensure that the control console is firmly secured
in the proper location.
b. Check that all guards protecting switches are in
place.
c. Operate all functions, drive/lift mode select
switch, horn button, enable trigger, and joystick
functions to ensure proper operation.
d. With the platform elevated 6 in. (15cm) or more
on a smooth, firm, and level surface, drive the
machine to check if the high drive cutout speedlimit is engaged. Drive speed will be reduced from
a top speed of 3mph (4.8 kph) to 0.5 mph (0.8
kph)
e. Ensure that all machine functions are disabled
when the Emergency Stop Button depressed.
3121221 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
3. With the platform in the transport (stowed) position.
a. Drive the machine on a grade, not to exceed the
rated gradeability, and stop to ensure the brakes
hold.
b. Check the tilt indicator light/alarm to ensure
proper operation. The light/alarm should be activated when tilted at or beyond the values in Table
2-2.
Table 2-2. Tilt Cutout Settings
1230ES
ANSI/CSA 3° 1.5°
CE/AUS 3.4° 3.4°
Tilt Setting
(front to back)
Tilt Setting
(side to side)
NOTE: When the tilt indicator warning is activated the following
functions are affected;
ANSI/CSA/AUS Spec. - Drive and Lift functions are disabled, platform must be lowered (stowed) to drive out of
tilt condition.
CE Spec. - Drive and Lift function are NOT disabled.
2-6 – JLG Lift – 3121221
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.5 DAILY WALK-AROUND INSPECTION
Begin the “Walk-Around Inspection” at Item 1, see Figure 2-1. on
page 2-8. Continue checking each item in sequence for the conditions listed in the following checklist.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS “OFF”.
DO NOT OPERATE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING
THIS AREA OFTEN RESULTS IN DISCOVERY OF CONDITIONS WHICH COULD
CAUSE EXTENSIVE MACHINE DAMAGE.
INSPECTION NOTE: On all components, make sure there are no
loose or missing parts, that they are securely fastened, and that
no visible damage, leaks or excessive wear exists in addition to
any other criteria mentioned.
1. Platform Control Console - Placard secure and legible,
control lever and switches return to neutral, and emergency stop switch function properly, manual in storage box.
2. Front Wheel - Drive motor, steer linkage, and steer cylinder - (open side access door) - See Inspection Note
3. Wheels and Tires - Properly secured, no missing lug
nuts. Refer to Section 6.1, TIRES AND WHEELS. Inspect
wheels for damage and corrosion.
4. Pothole Protection System - See Inspection Note
5. Battery Compartment - See Inspection Note.
6. Manual Descent - See Inspection Note
7. Beacon - See Inspection Note
8. Ground Controls - Placard secure and legible, control
switches return to neutral position, emergency stop
switch functions properly. Control markings legible.
9. Hydraulic Pump/Motor, Control Valve Installation - No
unsupported wires or hoses; no damaged or broken
wires - See Inspection Note
10. Mast Assembly - See Inspection Note
11. Platform/Handrail/Gate Installation (Not Shown) - See
Inspection Note
3121221 – JLG Lift – 2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Figure 2-1. Daily Walk-Around Inspection (Shown Top View Cutaway).
2-8 – JLG Lift – 3121221
SECTION 3 - MACHINE CONTROLS AND INDICATORS
NOTICE
SECTION 3. MACHINE CONTROLS AND INDICATORS
3.1 GENERAL
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION, THE USER AND OPERATOR ARE RESPONSIBLE FOR
CONFORMING WITH GOOD SAFETY PRACTICES.
This section provides the necessary information needed to
understand controls and their functions.
3121221 – JLG Lift – 3-1
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