JLG 41AM Operator Manual

4.3 (3)
Operation and Safety Manual
®
Original Instructions - Keep this manual with the machine at all times.
Model(s) AM Series 20AM 25AM 30AM
ANSI
36AM 41AM
November 12, 2014
NOTES:
FOREWORD

FOREWARD

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.
3121211 – JLG Lift – a
FOREWORD
DANGER
CAUTION
NOTICE

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 – 3121211
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-
NOTICE
NOTICE
TINS. 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.
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. 1 JLG Drive McConnellsburg, PA 17233
FOREWORD
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.
or Your Local JLG Office (See addresses on manual rear cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

3121211 – JLG Lift – c
Phone: 717-485-5161 E-mail: ProductSafety@JLG.com
FOREWORD

REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . . . . . . . . . . . July 6, 2005
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 30, 2006
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 4, 2007
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . May 5, 2008
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . January 5, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . June 14, 2010
Manual Revised . . . . . . . . . . . . . . . . . . . . . . . . November 12, 2014
d – JLG Lift – 3121211
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 TRANSPORTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Tipping Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Tilt Back Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
1.3 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Electrocution Hazard . . . . . . . . . . . . . . . . . . . . . . . . 1-6
1.4 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
1.5 MAINTENANCE SAFETY PRECAUTIONS . . . . . . . . .1-10
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
3121211 – JLG Lift – i
2.4 FUNCTION CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.5 DAILY WALK-AROUND INSPECTION. . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . 3-1
Manual Descent Valve . . . . . . . . . . . . . . . . . . . . . . . 3-3
Platform Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
3.3 DECAL INSTALLATIONS . . . . . . . . . . . . . . . . . . . . . . . . 3-5
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 BATTERY CHARGING & MAINTENANCE -
(DC MODELS ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Battery Maintenance and Safety . . . . . . . . . . . . . . 4-2
Battery Charger Operation . . . . . . . . . . . . . . . . . . . 4-3
Abnormal Cycle Indicator LED. . . . . . . . . . . . . . . . 4-4
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.4 MACHINE SET-UP AND OPERATION. . . . . . . . . . . . . .4-5
Caster Brake Operation . . . . . . . . . . . . . . . . . . . . . . 4-5
Outrigger Installation. . . . . . . . . . . . . . . . . . . . . . . . 4-6
Platform Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 QUICK-CHANGE PLATFORM MOUNTS. . . . . . . . . . .4-9
Platform Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Platform Installation . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 MACHINE SHUT DOWN AND PARK . . . . . . . . . . . . 4-10
4.7 TRANSPORT, LIFTING AND TIE DOWN. . . . . . . . . . 4-11
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Transporting by Pushing. . . . . . . . . . . . . . . . . . . . 4-11
Tilt-Back Assembly Set-up (AM36/AM41) -
Machines Prior to S/N - 0900031618 . . . . . . . . 4-11
Tilt-Back Assembly Set-up (AM36/AM41) -
Machines S/N - 0900031618 to Present . . . . . 4-15
Pickup Truck Loading Device (Option). . . . . . . 4-19
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
ii – JLG Lift – 3121211
SECTION - 5 - OPTIONAL EQUIPMENT
5.1 OPTIONAL EQUIPMENT. . . . . . . . . . . . . . . . . . . . . . . . . 5-1
22" x 25" Quick-Change Platform . . . . . . . . . . . . . 5-1
26" x 26" Quick-Change Platform . . . . . . . . . . . . . 5-1
28" x 26" Quick-Change Platform . . . . . . . . . . . . . 5-1
25" x 26" Step-in Molded Platform
w/Swing-up Gate . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Tool Tray . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Fluorescent Tube Caddy . . . . . . . . . . . . . . . . . . . . . 5-1
Crane Hook . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Straddle Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Ladder for Straddle Extension . . . . . . . . . . . . . . . . 5-1
Extra Power Pack (Battery, Charger & Case) . . . 5-2
Platform Auxiliary Power Lowering Device . . . . 5-2
Laser Positioning Device . . . . . . . . . . . . . . . . . . . . . 5-2
Hour Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Machine Cycle Counter Meter . . . . . . . . . . . . . . . . 5-2
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.2 AM-SE - STRADDLE EXTENSION –
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Straddle Adaptor Wiring Components . . . . . . . 5-3
Straddle Adaptor Wiring Installation . . . . . . . . . 5-3
AM-SE - Straddle Extension –
Set-up And Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Straddle Extension - Components. . . . . . . . . . . . 5-7
Mounting - Straddle Extension to AM . . . . . . . . 5-7
Positioning Straddle Unit and
Lifting AM Machine. . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Lowering AM Machine on Straddle Unit . . . . . 5-10
Straddle and AM Machine Disassembly . . . . . 5-11
SECTION - 6 - EMERGENCY PROCEDURES
6.1 GENERAL INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 6-1
Operator Unable to Control Machine. . . . . . . . . 6-1
Platform Caught Overhead . . . . . . . . . . . . . . . . . . 6-1
Righting of Tipped Machine . . . . . . . . . . . . . . . . . 6-1
6.3 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 6-2
3121211 – JLG Lift – iii
SECTION - 7 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 7-2
Machine Specifications . . . . . . . . . . . . . . . . . . . . 7-2
Electrical Specifications . . . . . . . . . . . . . . . . . . . . 7-3
Battery Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-3
Platform Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Machine Component Weights . . . . . . . . . . . . . 7-5
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . 7-5
7.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . 7-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Battery Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . 7-10
SECTION - 8 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around inspection. . . . . . . . . . . . . . . . . . 2-7
3-1. Ground Control Station.. . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Manual Descent Valve Location.. . . . . . . . . . . . . . . . 3-3
3-3. Manual Descent Valve Location.. . . . . . . . . . . . . . . . 3-4
3-4. Platform Control Station.. . . . . . . . . . . . . . . . . . . . . . . 3-4
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
3-5. Decal Installation. (ANSI/CSA)
(Machines prior to S/N-0900031618) . . . . . . . . . . . .3-5
3-6. Decal Installation (CE)
(Machines prior to S/N-0900031618) . . . . . . . . . . . .3-8
3-7. Decal Installation. (ANSI/CSA)
(Machines S/N-0900031618 to Present). . . . . . . . 3-11
3-8. Decal Installation (CE)
(Machines S/N-0900031618 to Present). . . . . . . . 3-14
4-1. Battery Fluid Level. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Battery Box and Charger Assembly.
(D.C. Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-3. Dual Voltage Charger - Front Panel. . . . . . . . . . . . . .4-4
4-4. Setting & Releasing Caster Brake . . . . . . . . . . . . . . . .4-5
4-5. Outrigger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-6. Quick Change Platform Mount. . . . . . . . . . . . . . . . . .4-9
4-7. Tilt-Back Assembly Set-Up. . . . . . . . . . . . . . . . . . . . . 4-12
4-8. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . 4-16
4-9. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . . . . . . . . 4-17
4-10. Tilt-Back Assembly Set-Up -
Machines S/N - 0900031618 to Present. . . . . . . . . . . . . . . 4-18
4-11. Loading Machine onto Bed of Pick-Up Truck. . . 4-20
5-1. Hour Meter Location. (Option) . . . . . . . . . . . . . . . . . .5-2
5-2. SE-Adapter - Wiring - Grommet & Spring Clip
Mounting Hole Locations.
(Same For Both Sides) . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Straddle Adapter Wiring Harness to AM Wiring
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
5-4. Straddle Extension Component Assembly. . . . . . . 5-8
5-5. Side Lifting Rail - Quick Release Pins.. . . . . . . . . . . 5-11
LIST OF TABLES
1-1 Minimum Approach Distance (M.A.D.) . . . . . . . . . . 1-6
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
3-1 Decal Installation Chart (ANSI and CSA). . . . . . . . . 3-6
3-2 Decal Installation Chart (CE Specification) . . . . . . 3-9
3-3 Decal Installation Chart (ANSI and CSA). . . . . . . . 3-12
3-4 Decal Installation Chart (CE Specification) . . . . . 3-15
4-1 Maximum Platform Capacity. . . . . . . . . . . . . . . . . . . . 4-8
4-2 AM Machine Gross Weights. . . . . . . . . . . . . . . . . . . 4-23
7-1 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . 7-6
7-2 Lubrication Intervals for Various Components. . . 7-9
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . 8-1
iv – JLG Lift – 3121211

SECTION 1. SAFETY PRECAUTIONS

SECTION 1 - SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, 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 followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine should not operate the machine 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. If there is a question with regard to safety training, inspection, maintenance and operation, please contact JLG Industries, Inc. ("JLG").
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
3121211 – JLG Lift – 1-1

1.2 TRANSPORTING

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

Transport

The platform must be completely empty of tools and debris.
Ensure platform is fully lowered. Remove and stow outrig­gers.
Never allow personnel in platform while moving machine.
To move machine use handles provided on the mast cross-
bar.
SECTION 1 - SAFETY PRECAUTIONS

Tipping Hazards

FAILURE TO COMPLY WITH 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.
On a level surface, always travel with the platform end lead­ing the way.
Watch for obstructions around machine and overhead.
Check travel path for persons, holes, bumps, drop-offs,
obstructions, debris, and coverings which may conceal other hazards.
Before placing machine on floors, trucks and other surfaces, check allowable capacity of surfaces.
1-2 – JLG Lift – 3121211
SECTION 1 - SAFETY PRECAUTIONS
Two persons are required on slopes up to 5°. A forklift must be used when moving units on slopes greater than 5°.
Always travel up or down a slope with the platform end of the machine positioned towards the low side of the slope. the operator and assistant must walk beside to guide the machine.
Never position the unit sideways on a slope.
Do not elevate the platform or move the machine on a soft
surface.
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.
Keep non-operating personnel at least 6 feet (1.8 m) away from machine during moving operations.
3121211 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS

Tilt Back Procedure

(AM36 & AM41 Machines Only)
The platform must be completely empty of tools and debris.
Ensure platform is fully lowered. Remove and stow outrig­gers.
Tilt machine back only on a flat, firm and level surface.
1-4 – JLG Lift – 3121211
SECTION 1 - SAFETY PRECAUTIONS

1.3 PRE-OPERATION

General

Read and understand this manual before operating the machine.
Only authorized and qualified personnel can operate the machine.
Do not operate this machine until complete training is per­formed by authorized personnel.
Before operation check work area for machine traffic such as forklifts, cranes, and other construction equipment.
Set-up machine for operation only on a smooth, firm sur­face on which the machine is capable of being leveled.
Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
Do not operate this machine until it has been serviced and maintained according to requirements specified in the Ser­vice and Maintenance manual.
Before machine operation perform inspections and func­tional checks. Refer to in Section 2 of this manual for detailed instructions.
3121211 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
Warn personnel not to work, stand, or walk under a raised platform. Position barricades on floor, if necessary.
Be sure all safety devices are operating properly. Modifica­tion of these devices is a safety violation.
Never operate machine in high wind, rain or snow.
Do not operate or raise the platform while on trucks, trail-
ers, railway cars, floating vessels, scaffolds or other equip­ment unless approved by JLG.
Approved head gear must be worn by all operating and ground personnel.
Read, understand, and obey all dangers, warnings, cautions and operating instructions on the machine and in this man­ual.
All operating personnel must be familiar with emergency controls and emergency operation of the machine as speci­fied in this manual.

Electrocution Hazard

Table 1-1. Minimum Approach Distance (M.A.D.)
VOLTAGE RANGE
(PHASE TO PHASE)
MINIMUM APPROACH
DISTANCE - Feet (m)
0-50KV 10 (3)
O ve r 50 K V to 2 00 K V 15 (5)
Over 200KV to 350K V 20 (6)
Over 350KV to 500K V 25 (8)
Over 500KV to 750K V 35 (11)
Over 750KV to 1000KV 45 (14)
NOTE: This Minimum Approach Distance shall apply except where
employer, local, or governmental regulations are more stringent.
1-6 – JLG Lift – 3121211
SECTION 1 - SAFETY PRECAUTIONS
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 to 50,000 volts. One foot (0.3m) 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 if 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 employer, local, or governmental require­ments for work practices near energized equipment.

1.4 OPERATION

Do not operate any machine on which instruction placards or decals are missing or illegible.
Never exceed the maximum platform capacity.
Operate AC units with an extension cord rated at a mini-
mum of 15 amps.
Prior to entering the platform ensure all leveling jacks have been properly installed and the unit’s base frame is level according to the bubble leveling indicator on base frame, and all wheels are completely off the ground.
While operating the machine, always look in the direction of machine movement.
Never operate a machine that is not operating properly. If a malfunction occurs, shut down the machine.
When applicable by reason of local regulations or job-site/ employer safety rules, personnel in the platform shall at all times wear approved fall protection devices. The autho­rized lanyard attachment is on the side of the machine’s mast.
3121211 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
Check work area for clearance overhead, on sides, and bot­tom of platform when lifting and lowering platform.
Never use the mast assembly to enter or leave the platform.
Do not increase the platform size with unauthorized deck
extensions or attachments.
Never attempt to use the machine as a crane.
Do not tie off machine to any adjacent structure.
1-8 – JLG Lift – 3121211
SECTION 1 - SAFETY PRECAUTIONS
Platform to structure transfers at elevated positions are dis­couraged. Where transfer is necessary, enter and exit through the gate only with the platform within 1 foot (0.3 m) of the adjacent safe and secure structure. 100% tie-off is also required in this situation using (2) lanyards. One lan­yard must be attached to the platform, the second lanyard attached to the structure. The lanyard connected to the platform must not be disconnected until the transfer to the structure is complete.
Do not allow personnel to tamper with, or operate the machine from the ground with personnel in the platform, except in an emergency.
During operation, keep all body parts inside platform rail­ing.
Never position ladders, steps, or similar items on unit to provide additional reach for any purpose.
When working from platform both feet must be firmly posi­tioned on deck.
Do not perform work that will subject unit to a horizontal force or create a swaying motion of the platform.
Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.
Avoid any build up of debris on the platform floor. keep mud, oil, grease and other slippery substances from foot­wear and platform floor.
Do not operate machine from platform without the gate in place and properly closed.
3121211 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS

1.5 MAINTENANCE SAFETY PRECAUTIONS

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.
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 replacement of electrical components.
Keep all support equipment and attachments stowed in their proper place.
Use only approved, nonflammable cleaning solvents.
1-10 – JLG Lift – 3121211
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 device.
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, dropoffs.
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.
3121211 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
NOTICE

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 – 3121211
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1. Inspection and Maintenance Table
TYPE FREQUENCY
Pre-Start Inspection
Pre-Delivery Inspec­tion
(See Note Below)
Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
Before using each day; or whenever there’s an Operator change.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
In service for 3 months or 150 hours, whichever comes first; or Out of service for a period of more 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.
PRIMARY
RESPONSIBILITY
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Owner, Dealer, or User Factory-Trained
Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
SERVICE
QUALIFICATION
Service Technician
(Recommended)
and applicable JLG inspection form
and applicable JLG inspection form
Service and Maintenance Manual and applicable JLG inspection form
REFERENCE
3121211 – 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, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.
2. 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.
3. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, AEM Safety Manual (ANSI Markets Only), and ANSI Manual of Responsibili­ties (ANSI Markets Only) is enclosed in the weather resistant storage container.
4. Walk-Around Inspection – Refer to Figure 2-1. on page 2-7.
5. Battery – Charge as required.
6. Fuel – (Combustion Engine Powered Machines Only) –
Add proper fuel as necessary.
7. Hydraulic Oil – Check hydraulic oil level. Add hydrau­lic oil as required.
8. Function Check – Once “Walk-Around” Inspection is complete, perform a function check of all systems in an area free of overhead and ground level obstruc­tions. Refer to Section 3 for specific instructions.
IF MACHINE DOES NOT OPERATE PROPERLY, TURN OFF MACHINE IMMEDI­ATELY! REPORT PROBLEM TO PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
2-4 – JLG Lift – 3121211
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
CAUTION
NOTICE

2.4 FUNCTION CHECK

The function check of all systems should be performed in an area free of overhead and ground level obstructions. Perform a function check as follows:
1. Set-up machine for operation according to instruc­tions in Section 3. Install outriggers, level machine, make sure all wheels are off the ground, etc.
2. Enter platform, raise and lower platform 2 ft to 3 ft (.61m to .92 m) several times. Check for smooth eleva­tion and lowering of platform.
3. With platform completely lowered, check hydraulic oil level in reservoir at ground control station. Maintain an oil level to "Fill to Line" indicator on side of reser­voir. NEVER USE HYDRAULIC BRAKE FLUID.

2.5 DAILY WALK-AROUND INSPECTION

General

Begin Walk-Around Inspection at item 1 (See Figure 2-1. on page 2-7). Continue around machine checking each item in this
check list.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF DURING WALK-AROUND INSPECTION.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.
NOTE: On each item, make sure there are no loose or missing
parts. That they are securely fastened and that no visible damage exists in addition to any other criteria mentioned.
1. Front Caster Wheels - Properly secured, wheels and casters turn freely. Brakes lock and release - prevent wheels from rolling when locked.
2. Rear Wheels - Properly secured. Wheels turn freely.
3. Tiltback Wheels - Properly secured. Wheels turn
freely.
3121211 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
4. Base Frame - Components properly secured, no loose wires dangling below base; bubble level in place and functioning properly.
5. Tilt Back Assembly - (36AM/41AM Models Only) Prop- erly secured; no parts missing i.e.. safety pins, gas spring cylinder(s), caster wheels, etc.
6. Battery/Charger Box Assembly - (DC Voltage Machines) Proper battery electrolyte level, no cable
corrosion. Battery box pivots freely when machine is tilted for transporting (36AM/41AM Models Only).
7. Outrigger Interlock Indicator LED’s - See note above.
8. Outrigger Sockets - Outrigger lock/release pins in place and secure, no visible damage. Outrigger inter­lock contacts (inside outrigger sockets) secure and clean.
9. Outrigger Beams - Outrigger interlock contacts prop­erly installed and clean (on bottom of outrigger assembly). Leveling jacks secure to the outrigger assembly, lubricated and functioning properly.
10. Motor/Pump/Reservoir Power Unit - No evidence of hydraulic leaks. Check that hydraulic reservoir fluid level is filled to the "Fill to Line" mark on the side of the reservoir.
11. Manual Release Control Valve - See note above.
12. Ground Controls - Key switch operable, placards
secure and legible; emergency stop switch, properly set for operation.
13. Mast Assembly - Inspect mast chains or cables as per note above.
14. Platform Rail Installation - Entry gate/bar in proper working order.
15. Platform Assembly - Secure to mast; Control and power cables properly tensioned and seated in control cable sheaves; control cable sheaves rotate freely.
16. Platform Controls - Placards secure and legible, emergency shut-off button set for operation. Opera­tors manual enclosed in manual storage tube.
2-6 – JLG Lift – 3121211
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
1
2
3
5
8
4
6
7
9
11
10
12
13
16
15
14
1. Caster Wheels and Brakes
2. Rear Wheel
3. Tilt Back Wheel
4. Base Frame
5. Tilt-Back Assembly (Not Shown - 36/41AM only)
6. Battery/Charger Box Assembly
7. Outrigger Interlock Indicator LED’s
8. Outrigger Sockets
9. Outrigger Beams
10. Motor/Pump/Reservoir Power Unit
11. Manual Release Control Valve
12. Ground Controls
13. Mast Assembly
14. Platform Rail Installation
15. Platform Assembly
16. Platform Controls
3121211 – JLG Lift – 2-7
Figure 2-1. Daily Walk-Around inspection
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
NOTES:
2-8 – JLG Lift – 3121211
SECTION 3 - MACHINE CONTROLS AND INDICATORS
NOTICE

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

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 control functions.
3121211 – JLG Lift – 3-1
(See Figure 3-1.)
NOTE: For overnight parking or battery charging, be sure the
POWER ON/OFF KEY SWITCH is positioned to OFF to pre­vent battery drain.
1. POWER ON/OFF Key Switch
A key switch located on the ground control station controls power to all functions on the machine.
2. POWER/EMERGENCY STOP
The two position switch allows power to the platform and ground controls when RESET (ON). When pushed in (OFF), power is shut off to the platform and ground controls.
3. HYDRAULIC RESERVOIR / CIRCUIT BREAKER / FUSE
(located inside the ground control station housing)
The hydraulic oil level can be checked through an access hole in the side of the cover.
NOTE: Check hydraulic oil only when platform is completely low-
ered and after cycling platform up/down a few times.
SECTION 3 - MACHINE CONTROLS AND INDICATORS
2
1
3
A 20 amp reset type circuit breaker is located on the cover of the electrical box on AM-AC Models.
On AM-DC Models, a 5 Amp fuse is located inside the ground control station cover.
Figure 3-1. Ground Control Station.
1. Power ON/OFF Key
2. Power/Emergency Stop
3. Hydraulic Reservoir/Circuit Breaker/Fuse
3-2 – JLG Lift – 3121211
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