JLG 41AM Operator Manual
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
P/N - 3121211
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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