JLG 20VP Operator Manual

OPERATORS & SAFETY

Models

10VP
15VP
20VP

AUSTRALIAN OFFICE

JLG INDUSTRIES, INC.

P.O. Box 5119
11 Bolwarra Road
Port Macquarie, Australia
Telephone: [phone]
Fax: [phone]

3120727

April 20, 2000

EUROPEAN OFFICE

JLG INDUSTRIES (EUROPE)

Kilmarting Place,
Tannochside Park
Uddingston, Scotland, G71 5PH
Telephone: [phone]
Main Fax: [phone]
Parts Fax: [phone]

CORPORATE OFFICE

JLG INDUSTRIES, INC.

1 JLG Drive
McConnellsburg, PA.
17233-9533
USA
Telephone: [phone]
Fax: [phone]

– JLG Lift –

FOREWORD

The purpose of this manual is to provide users with the operating procedures essential for the promotion of
proper machine operation for its intended purpose. It is important to over-stress proper machine usage. All
information in this manual should be READ and UNDERSTOOD before any attempt is made to operate the
machine. YOUR OPERATING MANUAL IS YOUR MOST IMPORTANT TOOL - Keep it with the machine.

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.
BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND

OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER­ATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UN DER PROPER
OPERATING CONDITIONS, WITH N O DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/
OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL
FROM JLG INDUSTRIES, PER OSHA REGULATIONS.

THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS
WHICH MAY LEAD TO SERIOUS INJURY OR DEATH IF IGN ORED.

Safety of personnel and proper use of the machine are of primary concern, DANGER, WARNING, CAUTION,
IMPORTANT, INSTRUCTIONS and NOTE are i nserted throughout this manual to emphasize these areas.

They are defined as follows:

DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUA­TION WHICH, IF NOT AVOIDED WILL RESULT IN SERIOUS
INJURY OR DEATH.

CAUTION INDICATES A POTENTIALLY HAZA RDOUS SITUA­TION WHICH, IF NOT AVOID E D, MAY RESULT IN MINOR OR
MODERATE INJURY. IT MAY ALSO BE USED TO ALERT
AGAINST UNSAFE PRACTICES.

Also in this Manual "Notes:" are used to provide infor­mation of special intere st.

JLG INDUSTRIES, INC. MAY HAVE ISSUED SAFETY RELATED BULLETINS FOR YOUR JLG PRODUCT. CONTACT JLG INDUS­TRIES, INC. OR THE LOCAL AUTHORIZED JLG DISTRIBUTOR FOR INFORMATION CONCERNING SAFETY RELATED BULLE­TINS WHICH MAY HAVE BEEN ISSUED FOR YOUR JLG PRODUCT. ALL ITEMS REQUIRED BY THE SAFETY RELATED
BULLETINS MUST BE COMPLETED ON THE AFFECTED JLG PRODUCT.

WARNING INDICATES A POTENTIALLY HAZARDOUS SITU­ATION WHICH, IF NOT AVOIDED COULD RESULT IN SERI­OUS INJURY OR DEATH.

IMPORTANT OR INSTRUCTIONS PROCEDURES ESSENTIAL
FOR SAFE OPERATION AND WHICH, IF NOT FOLLOWED
MAY RESULT IN A MALFUNCTION OR DAMAGE TO THE
MACHINE.

Due to the continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.

This page intentionally left blank.

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

All procedures herein are based on the use of t he
machine under pro per op era ting con ditio ns, w ith no de vi­ations from original design intent ... as per OSHA regula­tions.

READ & HEED!

The ownership, use, service, and/or maintenance of this
machine is subject to various federal, state and local laws
and regulations. It is the responsibility of the owner/user to
be knowledgeable of these laws and regulations and to
comply with them. The most prevalent regulations of this
type are the Federal OSHA Safety Regulations*. Listed
below, in abbreviated form are some of the requirements
of Federal OSHA regulations in effect as of the date of
publication of this hand book.

The listing of these requirements shall not relieve the
owner/user of the responsibility and obligation to deter­mine all applicable laws and regulations and their exact
wording and requirements, and to comply with the
requirements. Nor shall the listing of these requirements
constitute an assumption of responsibility of liability on the
part of JLG Industries, Inc.

1. Only trained and authorized operators shall be per­mitted to operate the aerial lift.

2. A malfunctioning lift shall be shut down until
repaired.

3. The controls shall be plainly marked as to their func­tion.

4. The controls shall be tested each day prior to use to
determine that they are in safe operating condition.

5. Load l imits specified by t he manufacturer sha ll not
be exceeded.

6. Instruction and warning placards must be legible.

7. Aerial lifts may be "field modified" for uses other than
those intended by the manufacturer only if certified
in writing by the manufacturer or an equivalent
entity, such as a nationally recognized testing lab, to
be in conformity to applicable OSHA safety regula­tions and to be at least as safe as it was prior to
modification.

8. Aerial lifts shall not be used near electric power lines
unless the lines have been deenergized or adequate
clearance is maintained (see OSHA 29 CFR 1910.67
and 1926.400).

9. Employees using aerial lifts shall be instructed how
to recognize and avoid unsafe conditions and haz­ards.

10. Ground controls shall not be operated unless per­mission has been obtained from personnel in the
platform, except in case of an emergency.

11. Regular inspection of the job site and aerial lift shall
be performed by competent persons.

12. Personnel shall always stand on the floor of the plat­form, not on boxes, planks, railing or other devices
for work posit ioning.

*Applicable Federal OSHA regulations, as of the date of
publication of this manual include, but are not limited to,
29 CFR 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29
CFR 1926.28, 29 CFR 192 6.400 and 29 CFR 1926.453.
Consult the current regulations for the exact wording and
full text of the requirements and contact the closest Fed­eral OSHA office for specific interpretations.

3120727 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance per­sonnel pay strict attention to these warnings and precau­tions to avoid possible injury to themselves or others or
damage to the equipment. A maintenance program must
be established by a qualified person and must be followed
to ensure that the machine is safe to operate.

MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY
A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST
AS SAFE AS ORIGINALLY MANUFACTURED IS A SAFETY VIOLA­TION.

The specific precautions to be observed du ring machine
maintenance are inserted at the appropriate point in the
manual. These precautions are, for the most part, those
that apply when servicing hydraulic and larger machine
component parts.

Your safety, and that of others, is the first consideration
when engaging in the maintenance of equipment. Always
be conscious of component weight and never attempt to
move heavy parts without the aid of a mechanical device.
Do not allow heavy objects to rest in an unstable position.
When raising a portion of the equipment, ensure that ade­quate support is provided.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANC E,
SAFETY IN THIS AREA IS THE RESPONSIBILITY OF THE OWNER/
OPERATOR.

C. MAINTENANCE

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSON­NEL INJURY OR DEATH AND IS A SAFETY VIOLATION.

• REMOVE ALL RINGS, WATCHES, AND JEWELRY
WHEN PERFORMING ANY MAINTENANCE.

• DO NOT WEAR LONG HAIR UNRESTRAINED, OR
LOOSE FITTING CLOTHING AND NECKTIES WHICH
ARE APT TO BECOME CAUGHT ON OR ENTANGLED
IN EQUIPMENT.

• OBSERVE AND OBEY ALL DANGER, WARNING, CAU­TION AND OTHER INSTRUCTIONS ON MACHINE
AND IN SERVICE MANUAL.

• KEEP STANDING SURFACES AND HAND HOLDS
FREE OF OIL, GREASE, WATER, ETC.

• NEVER WORK UNDER AN ELEVATED PLATFORM
UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED
FROM ANY MOVEMENT BY BLOCKING OR OVER­HEAD SLING.

• BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
PERFORMING ANY OTHER MAINTENANCE, SHUT
OFF ALL POWER CONTROLS.

• BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACE MENT OF ELEC TRICAL CO MPO­NENTS.

• KEEP ALL SUPPORT EQUIPMENT AND ATTACH­MENTS STOWED IN THEIR PROPER PLACE.

• USE ONLY APP ROVED, NONFLAMMABLE CLEANING
SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

1. It should be particularly noted that the machines
hydraulic systems operate at extremely high and
potentially dangerous pressures. Every effort should
be made to relieve any system pressure prior to dis­connecting or removing any portion of the system.

2. Relieve system pressure by activating the lift DOWN
control with the platform completely lowered to
direct any line pressure back into the return line to
the reservoir. Pressure feed lines to system compo­nents can then be disconnected with minimal fluid
loss.

b – JLG Lift – 3120727

EFFECTIVITY PAGE

EFFECTIVITY CHANGES

September 15, 1997 - Date of Issue
January 20, 2000 - Revised
February 7, 2000 - Revised - Section-2, Page 2-5, (removed lube check requirement for drive wheel gear box).

March 22, 2000 – Revised – Added 20VP UL-EE Option.
April 20, 2000 – Revised – Added Proposition 65 to front of manual.

3120727 – JLG Lift – c

EFFECTIVITY PAGE

This page intentionally left blank.

d – JLG Lift – 3120727

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION INTRODUCTION - - MAINTENANCE SAFETY PRECAUTIONS

A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b

B Hydraulic System Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b

C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b

SECTION 1 - SAFETY PRECAUTIO NS

1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.3 Transporting Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.4 Pre-operational Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1.5 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

SECTION 2 - PREPARATION AND INSPEC TI ON

2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.2 Preparation For Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.3 Delivery And Frequent Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1

2.4 Daily Walk-around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

2.5 Daily Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2.6 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

2.7 Battery Charging & Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS

3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.2 Personnel Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

3.3 Operating Characteristics And Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.4 Controls And Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

3.5 Jlg Pot-Hole Protection Device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

SECTION 4 - MACHINE OPERATION

4.1 Machine Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.2 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

4.3 Machine Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4.4 Quick-change Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.5 Transporting, Lifting And Tie Down Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

SECTION 5 - OPTIONAL EQUIPMEN T

5.1 Optional Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Extendible Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION 6 - EMERGENCY PROCEDURES

6.1 General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6.2 Emergency Controls And Their Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.3 Emergency Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.4 Incident Notification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

SECTION 7 - INSPECTION AND REPAIR LOG

3120727 – JLG Lift – i

TABLE OF CONTENTS

(Continued)

LIST OF FIGURES

FIGURE NO. TITLE PAGE NO.

2-1. Daily Walk-Around Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

2-2. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-3. Charge r Assembly and Power Cor d St or age. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

2-4. Battery Charger Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

2-5. Lubrication Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

2-6. Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

3-1. Ground Controls.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-2. Platform Controller. (OLD STYLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3-3. Platform Controller. (NEW STYLE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-4

3-4. Brake Re l ease Handle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-5. JLGs Pot-Hole-Protecti on Device - PHP Bar Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

3-6. Decal Locations (Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6

3-7. Decal Locations (Rear View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

3-8. Decal Locations (Top View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-8

3-9. Decal Locations (Right/Left View). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 -9

3-10. Wheel Load Decals (10/15/20VP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-10

4-1. Quick-Change Platform Mount. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4-2. Forklift Truck Lifting Pockets and Machine Tie Down Bar Locations. . . . . . . . . . . . . . . . . . . . . . . 4-5

5-1. Extendible Platform. (Platform shown extended) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LIST OF TABLES

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Dista n c e (to e ne r gized power lines or parts) . . . . . . . . . . . . . . . . . . . .1-1

2-1 Lubrication Interval s for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

4-1 Maximum Rated Load Capaci t y (for all platforms ex ce pt E xtendible) . . . . . . . . . . . . . . . . . . . . . .4-2

4-2 Maximum Rated Load Capaci t y (for Extendible Pla t form*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-3 Machine Interlock Swi t ch Operating Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

4-4 Machine Gross Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

ii – JLG Lift – 3120727

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRE CAUTIONS

1.1 GENERAL

This section prescribes the prope r and safe practices for
major areas of machine usage which have been divided
into three basic categories: Transporting, Pre-Operation
and Operation. In order to promote proper usage of the
machine, it is mandatory that a daily routine be estab­lished based on instruction given in this section. A mainte­nance program must also be established by a qual ified
person and must be followed to ensure that the mach ine
is safe to operate.

The user/operator of the machine should not accept oper­ating responsibility until this manual has been READ and
UNDERSTOOD, and operating instructions of the
machine under the supervision of an experienced and
qualified operator, has been completed. If there is a q ues­tion on application and/or operation, JLG Industries Prod­uct Safety and Reliability personnel should be consulted.

MODIFICATION OF THE MACHINE WITHOUT APPROVAL OF JLG
INDUSTRIES, OR CERTIFICATION BY A NATIONALLY RECOG­NIZED TESTING LAB TO BE IN CONFORMITY WITH APPLICABLE
OSHA REGULATIONS AND ANSI STANDARDS, AND TO BE AT
LEAST AS SAFE AS BEFORE MODIFICATION, IS PROHIBITED,
AND IS A VIOLATION OF OSHA RULES.

1.2 ELECTROCUTION HAZARD

Minimum safe approach distances (M.S.A.D.) to ener­gized (exposed or insulated) power lines and parts.

DO NOT MANEUVER MACHINE OR PERSONNEL TO DISTANCE
LESS THAN M.S.A.D (SEE TABLE 1-1.). ASSUME ALL ELECTRI­CAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN
OTHERWISE.

THIS MACHINE DOES NOT PROVIDE PROTECTION FROM CON­TACT WITH OR PROXIMITY TO AN ELECTRICALLY CHARGED
CONDUCTOR. MAINTAIN A CLEARANCE OF AT LEAST 10 FT.
(3M) BETWEEN ANY PART OF THE MACHINE AND ANY ELECTRI­CAL LINE OR APPARATUS CARRYING UP TO 50,000 VOLTS. 1
FT. (0.3M) ADDITIONAL CLEARANCE IS REQUIRED FOR EVERY
ADDITIONAL 30,000 VOLTS OR LESS. ALLOW FOR PLATFORM
SWAY, ROCK OR SAG AND ELECTRICAL LINE SWAYING, (SEE
FOLLOWING TABLE).

Table 1-1. Minim um Safe Appr oach Distance

(to energized power lines or parts)

VOLTAGE RANGE

(PHASE TO PHASE)

0-300V Avoid Contact

Over 300V to 50KV 10 ft. [3 m]

Over 50KV to 200KV 15 ft. [4.6 m]
Over 200KV to 350KV 20 ft. [6 m]
Over 350KV to 500KV 25 ft. [7.6 m]
Over 500KV to 750KV 35 ft. [10.6 m]

Over 750KV to 1000KV 45 ft. [13.7 m]

MINIMUM SAFE DISTANCE -

Feet [m]

1.3 TRANSPORTING MACHINE

Before transporting (haulin g ) the machine the user/ opera­tor must be familiar with the proper procedures for trans­porting the machine (see Section 4-5), as well as the
weight and size of the machine.

The user/operator should be familiar with the surrounding
work area and surface before transporting the machine.
The work area must be a firm surface capable of support­ing the combined weight of the trans port vehicl e and the
machine.

NOTE: Remember that the key to safe and proper usage is

common sense and its careful application.

ALWAYS RELEASE THE DRIVE MOTOR BRAKES ON THE
MACHINE WHEN MANUALLY PUSHING, PULLING, OR WHEN
TRANSPORTING MACHINE BY FORK-LIFT TRUCK. THIS WILL
ALLOW THE REAR DRIVE WHEELS, GEAR BOX DRIVE SHAFT
AND GEARS TO ROTATE FREELY PREVENTING ANY DAMAGE
TO THE DRIVE SYSTEM.

IF MACHINE IS PLACED ON A TRANSPORT VEHICLE, RE­ENGAGE THE BRAKES IN COMBINATION WITH PROPER
MACHINE TIE DOWN, TO RESTRAIN MACHINE FROM ANY MOVE­MENT DURING TRANSPORT.

ALWAYS REMEMBER TO RE-ENGAGE THE BRAKE SYSTEM
BEFORE OPERATING MACHINE.

.

FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN
THIS SECTION AND ON MACHINE COULD RESULT IN MACHINE
DAMAGE, PERSONAL INJURY OR DEATH AND IS A SAFETY VIO­LATION.

3120727 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

LIFT MACHINE AT DESIGNATED

LIFTING POINTS ONLY

1.4 PRE-OPERATIONAL SAFETY

• READ YOUR MANUAL. UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

• ALLOW ONLY THOSE AUTHORIZED AND QUALIFIED
PERSONNEL TO OPERATE MACHINE WHO HAVE
DEMONSTRATED THAT THEY UNDERSTAND SAFE
AND PROPER OPERATION AND MAINTENANCE OF
THE UNIT.

•AN OPERATOR MUST NOT ACCEPT OPERATING
RESPONSIBILITIES UNTIL ADEQUATE TRAINING HAS
BEEN GIVEN BY COMPETENT AND AUTHORIZED
PERSONS.

•BEFORE OPERATION CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES. (SEE ELECTROCUTION
HAZARD, SECTION 1-2.)

• STUDY THE WORK AREA FOR AREAS TO AVOID
SUCH AS; SURFACE EDGES THAT DROP-OFF,
HOLES OR DIPS IN SURFACE, OR ANY UNLEVEL
AREAS WHICH COULD CAUSE THE UNIT TO TIP
OVER.

•ALSO BEFORE OPERATION CHECK WORK AREA FOR
MACHINE TRAFFIC SUCH AS FORKLIFTS, CRANES,
AND OTHER CONSTRUCTION EQUIPMENT.

• ENSURE THAT OPERATORS OF OTHER OVERHEAD
AND FLOOR LEVEL MACHINES ARE AWARE OF THE
AERIAL PLATFORMS PRESENCE. DISCONNECT
POWER TO OVERHEAD CRANES. BARRICADE FLOOR
AREA IF NECESSARY.

• PRECAUTIONS TO AVOID ALL KNOWN HAZARDS IN
THE WORK AREA MUST BE TAKEN BY THE OPERA­TOR AND HIS SUPERVISOR BEFORE STARTING THE
WORK.

• DO NOT OPERATE THIS MACHINE UNLESS IT HAS
BEEN SERVICED AND MAINTAINED ACCORDING TO
THE MANUFACTURERS SPECIFICATIONS AND
SCHEDULE.

•ENSURE DAILY INSPECTION AND FUNCTION CHECK
IS PERFORMED PRIOR TO PLACING MACHINE INTO
OPERATION. HAVE AUTHORIZED PERSONNEL TAKE
ANY NECESSARY CORRECTIVE ACTION BEFORE
PLACING MACHINE INTO OPERATION.

• NEVER DISABLE OR MODIFY ANY SAFETY DEVICE.
ANY MODIFICATION OF THE MACHINE IS A SAFETY
VIOLATION AND IS A VIOLATION OF OSHA AND ANSI
RULES.

• DO NOT OPERATE MACHINE WHEN EXPOSED TO
HIGH WIND, RAIN OR SNOW.

•NEVER OPERATE OR RAISE PLATFORM WHEN
MACHINE IS ON A TRUCK OR OTHER VEHICLE.

• APPROVED HEAD GEAR (I.E. HARD HAT, ETC.) MUST
BE WORN WHEN REQUIRED BY ALL OPERATING AND
GROUND PERSONNEL.

•READ AND OBEY ALL DANGER, WARNINGS, CAU­TIONS AND OPERATING INSTRUCTIONS ON
MACHINE AND IN THIS MANUAL.

• BE FAMILIAR WITH LOCATION AND OPERATION OF
GROUND CONTROLS AND EMERGENCY CONTROLS.

1-2 – JLG Lift – 3120727

SECTION 1 - SAFETY PRECAUTIONS

•NEVER POSITION THE UNIT SIDEWAYS ON A SLOPE.

• USE CAUTION AND CHECK CLEARANCES WHEN
MOVING MACHINE IN RESTRICTED OR CLOSE
QUARTERS.

• ALWAYS USE AN ASSISTANT WHEN MOVING
MACHINE IN AREAS WHERE VISION IS
OBSTRUCTED.

General Operating Safety

•KEEP NON-OPERATING PERSONNEL AT LEAST 6
FEET (1.8 M) AWAY FROM MACHINE DURING OPERA­TIONS.

• DO NOT OPERATE ANY MACHINE ON WHICH DAN­GER, WARNING, CAUTION OR INSTRUCTION PLAC­ARDS OR DECALS ARE MISSING OR ILLEGIBLE.

•NEVER EXCEED MANUFACTURERS RATED PLAT­FORM CAPACITY - REFER TO CAPACITY DECAL ON
MACHINE.

•NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE, RED TAG IT, AND NOTIFY PROPER
AUTHORITIES.

ALWAYS LOOK IN DIR ECTION OF TRAVE L

1.5 OPERATING SAFETY

FAILURE TO OBSERVE THE FOLLOWING TIPPING HAZARD
INSTRUCTIONS COULD CAUSE THE UNIT TO TIP OVER OR BE
HARD TO CONTROL WHEN BEING MOVED, WHICH COULD
RESULT IN SERIOUS INJURY OR DEATH DUE TO BEING PINNED
OR CRUSHED BY THE UNIT.

Driving Safety

• READ YOUR MANUAL, UNDERSTAND WHAT YOU’VE
READ - THEN BEGIN OPERATIONS.

•WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN MOVING.

•CHECK TRAVEL PATH FOR PERSONS, HOLES,
BUMPS, DROP-OFFS, OBS TRUCTIONS, DEBRIS, AND
COVERINGS WHICH MAY CONCEAL HOLES AND
OTHER HAZARDS, AS TIPPING COULD OCCUR.

•BEFORE MOVING MACHINE ON FLOORS AND OTHER
SURFACES, CHECK AL LOWABLE CAPACITY OF SUR­FAC ES .

•DO NOT OPERATE MACHINE ON SOFT FOOTING
THAT WILL ALLOW THE WHEELS TO SETTLE INTO OR
BREAK THROUGH SURFACE, AS TIPPING WILL
OCCUR.

NEVER OPERATE ON SOFT

OR UNEVEN SURFACES

3120727 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

ALWAYS STAND ON PLATFORM FLOOR
NOT ON BOXES, PLANKS OR RAILINGS

• ALL PERSONNEL MUST STAND CLEAR WHEN PLAT­FORM IS BEING RAISED OR LOWERED. BE SURE TO
WATCH FOR OVERHEAD AND OTHER OBSTRUC­TIONS.

• CHECK CLEARANCES A BOVE, ON SIDES AND BOT­TOM OF PLATFORM WHEN RAISING AND LOWERING
PLATFORM.

• NEVER USE THE MAST TO GAIN ACCESS TO OR
LEAVE PLATFORM.

•DO NOT ATTACH OVERHANGING LOADS TO THE
PLATFORM OR INC REA SE THE PLATFORM S IZ E WI TH
UNAUTHORIZED DECK EXTENSIONS OR ATTACH­MENTS.

•DO NOT TIE OFF MACHINE TO ANY ADJACENT
STRUCTURE. NEVER ATTACH WIRE, CABLE OR ANY
SIMILAR ITEMS TO PLATFORM.

•TRANSFERS BETWEEN A STRUCTURE AND THE
AERIAL PLATFORM EXPOSE OPERATING PERSON­NEL TO FALL POTENTIALS. THIS PRACTICE SHOULD
BE DISCOURAGED WHEREVER POSSIBLE. WHERE
TRANSFER MUST BE ACCO MPLISHED TO PERFO RM
THE JOB, AN APPROVED FALL PROTECTION DEVICE
AND TWO SAFETY LANYARDS WILL BE USED. ONE
LANYARD SHOULD BE ATTACHED TO THE AERIAL
PLATFORM. THE OTHER TO THE STRUCTURE. THE
SAFETY LANYARD THAT IS ATTACHED TO THE

KEEP EVERYONE CLEAR OF A

WORKING PLATFORM

AERIAL PLATFORM SHOULD NOT BE DISCON­NECTED UNTIL SUCH TIME AS THE TRANSFER TO
THE STRUCTURE IS COMPLETE. WHEN RE-ENTER­ING THE PLATFORM THIS PROCEDURE MUST BE
PERFORMED IN REVERSE. TO AVOID FALLING - USE
EXTREME CAUTION WHEN ENTERING OR LEAVING
PLATFORM ABOVE GROUND. ENTER OR EXIT THRU
GATE ONLY. PLATFORM FLOOR MUST BE WITHIN 1
FOOT (0.3 M) OF ADJACENT - SAF E AND SECURE ­STRUCTURE. ALLOW FOR ANY VERTICAL MOVE­MENT OF PLATFORM (UP OR DOWN) WHEN ENTER­ING OR LEAVING PLATFORM.

• NO HORSEPLAY IS PERMITTED IN PLATFORM.

•DO NOT ALLOW PERSONNEL TO TAMPER WITH,
SERVICE, OR OPERATE THIS MACHINE FROM THE
GROUND WITH PERSONNEL I N PLATFORM EXCEPT
IN AN EMERGENCY.

• DURING OPERATION KEEP ALL BODY PARTS INSIDE
PLATFORM RAILINGS.

•NEVER POSITION LADDERS, STEPS, OR SIMILAR
ITEMS ON UNIT TO PROVIDE ADDITIONAL REACH
FOR ANY PURPOSE.

1-4 – JLG Lift – 3120727

SECTION 2 - PREPARATION AND IN SPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

This section provides the necessary information needed
by those personnel that are responsible to place the
machine in operation readiness, and lists checks that are
performed prior to use of the machine. It is important that
the information contained in this section be read and
understood before any attempt is made to operate the
machine. Ensure that all the necessary inspections have
been completed successfully before placing the machine
into service. These procedures will aid in obtainin g maxi­mum service life and safe operation.

SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON­TROL OVER THE FIELD INSPECTION AND MAINTENANCE, THIS
IS THE RESPONSIBILITY OF THE OW NER/OPERATOR.

2.2 PREPARATION FOR USE

Before a new machine is put into operation it must be
carefully inspecte d for any e vidence of damage resulting
from shipment and inspected pe riodically thereafter, as
outlined in Section 2-3, Delivery and Frequent Inspection.
The unit should be thoroughly checked for hydraulic leaks
during initial start-up and run. A check of all components
should be made to assure their security.

All preparation n ecessar y to pl ace the machin e in oper a­tion readiness status are the responsibility of manage­ment personnel. Preparation requires good common
sense, (i.e. lift works smoothly) coupled with a series of
visual inspections. The mandatory requirements are given
in Section 2-4, Daily Walk Around Inspection.

It should be assured that the items appearing in the Deliv­ery and Frequent Inspection and Functional Check are
complied with prior to putting the machine into service.

2.3 DELIVERY AND FREQUENT INSPECTION

The following check list provides a systematic inspec tion
to assist in detecting defective, damaged, or improperly
installed parts. The check list denotes the items to be
inspected and conditions to examine. Frequ ent in spectio n
shall be performed every three (3) months or 150 hours,
or more often when required by environment, severit y,
and frequency of usage.

Platform Assembly

Properly secured; no visible damage; free of dirt and
debris. Platform gate functions properly.

Mast

No visible damage, abrasions and/or distortions; no bind­ing; mast sections fr ee of dirt or othe r foreign mate rial.
Sequenci ng ca bles pro perl y se cure d; n o vis ibl e dam age;
proper cable tension.

Mast Chains & Cables

No visible damage; proper chain/cable tension; evidence
of proper lubrication. Chain/cable sheaves, sheave pins
and rollers properly secured; no visible damage.

Platform Controller/(Power) Cable(s)

No visible damage; cable properly tensioned and seated
in control cable sheaves; control cable sheave s not dam­aged and rotating freely.

Lift Cylinder (check w/mast extended)

No rust, nicks, scratches or foreign material on piston rod.
No leakage.

Frame

No visible damage; loose or missing hardware (top and
underside).

Drive Wheels and Front Casters

Casters free rolling; no loose or missing parts; no visible
damage. Drive wheel hub retain er ring secure; no damage
to wheel tread; electric drive motors secure; no loose or
missing wires.

Hydraulic Oil Supply

Check the hydraulic oil level of the hydraulic fluid reservoir
located in the l ower ac cess hol e on the rear c over. Main-

tain an oil level to the “Fill To Line” indicator on the side of
reservoir.

If fluid level is low, see Table 2-1. “Lubrication In terval
Chart” for information on hydraulic oil.

3120727 – JLG Lift – 2-1

SECTION 2 - PREPARAT ION AND INSPECTION

Controls - (Platform and Ground)

Controls operable; no visib le damage; placar ds secure
and legible.

Batteries

Proper electrolyte level; cable connections tight; no visible
damage; no corrosion at battery cabl e con nections.

Pump Motor/Hydraulic Pump/Valves
andLines

No leakage; units secure.

Placards

No visible damage; placards secure and legible.

2.4 DAILY WALK-AROUND INSPECTION

It is the user/operator’s responsibility to inspect the
machine before the start of each work day. It is recom­mended that each user/operator inspect the machine
before operation, even if the machine has already been
put into service under another user/operator. This Daily
Walk-Arou nd Inspection is the preferred method of inspec­tion.

4. Motor/Pump/Reservoir Unit - Properly secured, no
visible damage, no evidence of hydraulic leaks.
Hydraulic oil level should be filled level with the full
line, (“Fill To Line”) on the side of t he hy drauli c rese r-

voir. Also check that reservoir cap is properly
secured.

5. Ground Controls - Properly secured, no loose or
missing parts, no visible damage; key switch opera­ble, no visible damage; placards secure and legible;
emergency stop switch, no visible damage and
properly set for operation.

6. Mast Assembly - Mast sections properly secured,
no visible damage to mast sections, no loose or
missing parts, slide pads properly secured. Mast
chains/cables properly secured and lubricated.
Sequencing cables properly secured and undam­aged. Platform control and power cables (on side of
mast), no visible damage; cables properly tensioned
and seated in sheaves; cab le sh eaves n ot damaged
and rotating freely . Elevation/Speed Limit switch (top
inside of mast sectio n 1) secure and working prop­erly.

7. Manual Brake Release Control - Handle secure
and undamaged; cables attached properly; control
in working orde r.

General

Begin the “Walk-Around Inspection” at item one listed fol­lowing. Continue ar ound machi ne check ing each item in
sequence for the conditions listed in the “Walk-Around
Inspection Check list”.

TO AV OID INJURY DO NOT OPERATE MACHINE UNTIL ALL MAL­FUNCTIONS HAVE BEEN CORRECTED. USE OF A MALFUNC­TIONING MACHINE IS A SAFETY VIOLATION.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS

“OFF” DURING “WALK-AROUND INSPECTION”.

NOTE: Do not overlook visual inspection of the base frame

underside. Check this area for objects or debris
which could cause extensive machine damage.

1. Drive and Caster Wheels - Properly secured and
lubricated. Check for any visible damage or debris,
stuck to or around wheels.

2. Base Frame - No visible damage; drive wheel motor

components properly secured; JL G’s Pot-Hole-Pro­tection System components secure; no loose wires
or cables dangling below the base; bubble level in
place and functioning properly.

3. Battery/Battery Charger - Proper battery electrolyte
level, cables secure, no damage or corrosion.

8. Platform Assembly - Secure to mast; All railings
securely attached; no loose or missing parts, no vis­ible damage; sliding entry bar in proper working
order. Platform gate working properly, no visible sign
of damage (if so equipped).

9. Platform Controls - Platform up/down, function
enable and horn buttons on faceplate no loose or
missing parts, no visible damage. Joystick control
secure. Placards secure and legible, emergency
shut-off button set for operation. Control markings
legible; Operators manual enclosed in manual stor­age box.

In addition to the Daily W alk-Around Inspection, be sure to
include the following as part of the daily inspection:

Batteries Charged

Start each day with fully charged batteries. (See Section 2-

7. “Battery Charging & Maintenance”)

Overall Cleanliness

Keep oil, grease, water, etc. wiped from standing surfaces
and hand holds.

Placards

Keep all information and operating placards clean and
unobstructed. Cover areas where placards are present
when using the machine for spraying paint or any materi al
which could cover these surfaces and reduce legibility.

2-2 – JLG Lift – 3120727