JLG 260MRT Operator Manual
Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Model
260MRT
ANSI
P/N - 3121219
June 5, 2012
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.
3121219 – JLG Lift – a
FOREWORD
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, COULD
DECAL WILL HAVE AN ORANGE BACKGROUND.
RESULT IN SERIOUS INJURY OR DEATH. THIS
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 INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
b – JLG Lift – 3121219
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding
Product Safety
FOREWORD
• Standards and Regulations
Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
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.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
3121219 – JLG Lift – c
Phone: 717-485-5161
E-mail: ProductSafety@JLG.com
FOREWORD
REVISION LOG
Original Issue - June 27, 2005
Revised - July 17, 2006
Revised - March 29, 2007
Revised - October 22, 2008
Revised - April 15, 2010
Revised - May 14, 2010
Revised - June 5, 2012
d – JLG Lift – 3121219
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-4
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
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . 1-10
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3 PRE-START INSPECTION. . . . . . . . . . . . . . . . . . . . 2-4
Preparing the Machine for Operation . . . . . . . . . 2-5
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.4 DUAL FUEL SYSTEM (IF EQUIPPED) . . . . . . . . . . 2-7
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
SECTION - 3 - USER RESPONSIBILITIES AND MACHINE
CONTROL
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Placards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-2
Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-2
3.4 PLATFORM CONTROL STATION . . . . . . . . . . . . . . 3-8
Platform Control Front Panel. . . . . . . . . . . . . . . . 3-9
Indicator Panel LED’s . . . . . . . . . . . . . . . . . . . . 3-10
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-1
Power Selector Switch . . . . . . . . . . . . . . . . . . . . 4-1
3121219 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Emergency Stop Switch . . . . . . . . . . . . . . . . . . 4-1
Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 OPERATING CHARACTERISTICS. . . . . . . . . . . . . . 4-3
Leveling Jacks . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Auto Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Manual Level Adjustment (Trim) . . . . . . . . . . . . 4-4
4.4 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Raising . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Lowering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Platform Extension . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.5 DRIVING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Driving Forward . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-8
4.7 PLATFORM LOADING . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 SAFETY PROP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.9 TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Emergency Stop Switch . . . . . . . . . . . . . . . . . . 5-1
Manual Descent . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1
Operator Unable to Control Machine . . . . . . . . . 5-2
Platform Caught Overhead. . . . . . . . . . . . . . . . . 5-2
Righting of Tipped Machine . . . . . . . . . . . . . . . . 5-2
Post-Incident Inspection . . . . . . . . . . . . . . . . . . . 5-2
5.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-3
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . .6-8
6.4 TIRES AND WHEELS . . . . . . . . . . . . . . . . . . . . . . .6-10
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-10
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-11
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.5 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-12
SECTION - 7 - INSPECTION AND REPAIR LOG
ii – JLG Lift – 3121219
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Walk Around Inspection Diagram . . . . . . . . . . . . . .2-8
2-2. Walk Around Inspection Points - Sheet 1 . . . . . . . .2-9
2-3. Walk Around Inspection Points - Sheet 2 . . . . . . .2-10
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-4
3-2. Platform Control Station. . . . . . . . . . . . . . . . . . . . . .3-5
3-3. Indicator Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6
3-4. Platform Control Front Panel . . . . . . . . . . . . . . . . . .3-7
3-5. Decal Location (ANSI) . . . . . . . . . . . . . . . . . . . . . .3-12
3-6. Decal Location (ANSI Export) . . . . . . . . . . . . . . . .3-14
3-7. Decal Location (CE/AUS). . . . . . . . . . . . . . . . . . . .3-16
4-1. Grade and Sideslope Depiction. . . . . . . . . . . . . . . .4-7
4-2. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
6-1. Engine Operating Temperature Specifications
(Kubota)- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-5
6-2. Engine Operating Temperature Specifications
(Kubota)- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . .6-6
6-3. Lubrication Diagram. . . . . . . . . . . . . . . . . . . . . . . . .6-8
LIST OF TABLES
Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . 1-3
Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . 1-7
Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . 2-3
Tilt Sensor Preset Configuration . . . . . . . . . . . . . . . . . . . . 2-6
Decal Legend (ANSI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Decal Legend (ANSI Export) . . . . . . . . . . . . . . . . . . . . . . 3-15
Decal Legend - (CE/AUS) . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Battery Specifications . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . 7-1
3121219 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This page intentionally left blank.
iv – JLG Lift – 3121219
1.1 GENERAL
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
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.
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.
3121219 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• 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.
• 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.
• This machine can be operated in nominal ambient temperatures of 0
to optimize operation outside of this temperature range.
o
F to 104o F (-20o C to 40o C). Consult JLG
1-2 – JLG Lift – 3121219
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED
28 MPH (12.5 M/S).
Table 1-1. Beaufort Scale (For Reference Only)
SECTION 1 - SAFETY PRECAUTIONS
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves r ustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
Wind Speed
mph m/s
Description Land Conditions
Umbrella use becomes difficult.
3121219 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
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.
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.
1-4 – JLG Lift – 3121219
SECTION 1 - SAFETY PRECAUTIONS
• 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 scissor arm assembly and shut off all power before
leaving machine.
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
3121219 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
.
• Keep both feet firmly positioned on the platform floor at all
times. Never position ladders, boxes, steps, planks, or
similar items on unit to provide additional reach for any
purpose.
• Never use the scissor arm assembly to gain access to or
leave the platform.
• Use extreme caution when entering or leaving platform.
Ensure that the scissor arm 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 oil, mud, and slippery substances cleaned from footwear and the platform floor.
Electrocution Hazards
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
1-6 – JLG Lift – 3121219
SECTION 1 - SAFETY PRECAUTIONS
• Maintain safe clearance from electrical lines, apparatus, or
any energized (exposed or insulated) parts in accordance
with the Minimum Approach Distance (MAD) as specified
in Table 1-1.
• Allow for machine movement and electrical line swaying.
Table 1-2.Minimum Approach Distances (M.A.D.)
Voltag e Ran ge
(Phase to Phase)
0 to 50KV 10 (3)
Over 50 kV to 200 KV 15 (5)
Over 200KV 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 governmental 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 car-
MINIMUM APPROACH DISTANCE
in Feet (Meters)
rying up 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.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
3121219 – 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 uniform 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 0.6m (2 ft.)
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 tieoff machine to any adjacent structure. Never attach wire,
cable, or any similar items to platform.
• 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.
1-8 – JLG Lift – 3121219
SECTION 1 - SAFETY PRECAUTIONS
• If scissor arm 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 out of the scissor arm 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.
• 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 1.8m. (6 ft.) 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.
3121219 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
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.
1.5 MAINTENANCE
General
This section contains general safety precautions which must be
observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are
inserted at the appropriate points in this maunual and in the Service and Maintenance Manual. It is of utmost importance that
maintenance personnel pay strict attention to these precautions
to avoid possible injury to personnel or damage to the machine
or property. A maintenance program must be established by a
qualified person and must be followed to ensure that the
machine is safe.
Maintenance Hazards
• Shut off power to all controls and ensure that all operating
systems are secured from inadvertent motion prior to performing any adjustments or repairs.
• Never work under an elevated platform until it has been
fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with
appropriate safety props, blocking, or overhead supports.
• Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.
• Always disconnect batteries when servicing electrical
components or when performing welding on the machine.
• Shut down the engine (if equipped) while fuel tanks are
being filled.
• Ensure replacement parts or components are identical or
equivalent to original parts or components.
• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in
an unstable position. Ensure adequate support is provided when raising components of the machine.
1-10 – JLG Lift – 3121219
SECTION 1 - SAFETY PRECAUTIONS
• Remove all rings, watches, and jewelry when performing
any maintenance. Do not wear loose fitting clothing or
long hair unrestrained which may become caught or
entangled in equipment.
• Use only clean approved non-flammable cleaing solvents.
• Never alter, remove, or substitute any items such as counterweights, tires, batteries, platforms or other items that
may reduce or affect the overall weight or stability of the
machine.
• Reference the Service and Maintenance Manual for the
weights of critical stability items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE
MANUFACTURER.
Battery Hazards
• Always disconnect batteries when servicing electrical
components or when performing welding on the machine.
• Do not allow smoking, open flame, or sparks near battery
during charging or servicing.
• Do not contact tools or other metal objects across the battery terminals.
• Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in
contact with skin or clothing.
BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN
AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED
AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
• Charge batteries only in a well ventilated area.
• Avoid overfilling the battery fluid level. Add distilled water
to batteries only after the batteries are fully charged.
3121219 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS
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1-12 – JLG Lift – 3121219
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.
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 over-
head 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.
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.
3121219 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table 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.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3121219
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Ty pe Fr equ en cy
Pre-Start Inspection Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection (See Note)
Frequent Inspection In service for 3 months or 150 hours, which-
Annual Machine
Inspection
(See Note)
Preventative Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance
ever comes first; or
Out of service for a period of mo re than 3
months; or
Purchased used.
Annually, no later than 13 months from the
date of prior inspection.
At intervals as specified in the Service and
Maintenance Manual.
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance
Owner, Dealer, or User Factory Trained Service
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance
Primary
Responsibility
Service
Qualification
Technician
(Recommended)
Reference
Manual and applicable JLG
inspection form
Manual and applicable JLG
inspection form
Service and Maintenance
Manual and applicable JLG
inspection form
Manual
3121219 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION AND INSPECTION
Parent Metal Crack
Weld Crack
2.3 PRE-START INSPECTION
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel,
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.
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 – Make sure 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.
6. Battery – Charge as required.
7. Fuel - (Combustion Engine Powered Machines) – Add
the proper fuel as necessary.
8. Engine Oil Supply - Ensure that the engine oil level is at
the full mark on the dipstick and the filler cap is secure
9. Fluid Levels - Be sure to check the engine oil and the
hydraulic oil levels.
10. Accessories/Attachments - Reference the Operator
and Safety Manual of each attachment or accessory
installed upon the machine for specific inspection, operation, and maintenance instructions.
11. 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 – 3121219
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