JLG 41EL Operator Manual

Operation and Safety Manual

Keep this manual with the machine at all times.

Model(s)

EL Series

20EL
25EL
30EL
36EL
41EL

P/N - 3120781

January 17, 2002

FOREWORD

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

REMEMBER ANY EQUIPMENT IS ONLY AS SAFE AS THE OPERATOR.

BECAUSE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND
OPERATION, PROPER SAFETY PRACTICES ARE THE RESPONSIBILITY OF THE USER AND HIS OPER­ATING PERSONNEL.

ALL INSTRUCTIONS IN THIS MANUAL ARE BASED ON THE USE OF THE MACHINE UNDER PROPER
OPERATING CONDITIONS, WITH NO DEVIATIONS FROM THE ORIGINAL DESIGN. ALTERATION AND/
OR MODIFICATION OF THE MACHINE IS STRICTLY FORBIDDEN, WITHOUT WRITTEN APPROVAL
FROM JLG INDUSTRIES, PER OSHA REGULATIONS.

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

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

They are defined as follows:

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

CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUA­TION WHICH, IF NOT AVOIDED, MAY RESULT IN MINOR OR
MODERATE INJURY. IT MAY ALSO BE USED TO ALERT
AGAINST UNSAFE PRACTICES.

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

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

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

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

Other Publications Avaliable:

Service and Manitenance Manual . . . . . . . . .3120782

Illustrated Parts Manual . . . . . . . . . . . . . . . . .3120783

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

This page left intentionally blank.

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS

All procedures herein are based on the use of the
machine under proper operating conditions, with no devi­ations from original design intent ... as per OSHA regula­tions.

READ & HEED!

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

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

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

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

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

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

5. Load limits specified by the manufacturer shall not
be exceeded.

6. Instruction and warning placards must be legible.

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

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

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

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

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

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

*Applicable Federal OSHA regulations, as of the date of
publication of this manual include, but are not limited to,
29 CFR 1910.67, 29 CFR 1926.20, 29 CFR 1926.21, 29
CFR 1926.28, 29 CFR 1926.400 and 29 CFR 1926.453.
Consult the current regulations for the exact wording and
full text of the requirements and contact the closest Fed­eral OSHA office for specific interpretations.

3120781 – JLG Lift – a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A. GENERAL

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

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

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

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

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

C. MAINTENANCE

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

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

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

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

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

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

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

•BATTERY SHOULD ALWAYS BE DISCONNECTED
DURING REPLACEMENT OF ELECTRICAL COMPO­NENTS.

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

• USE ONLY APPROVED, NONFLAMMABLE CLEANING
SOLVENTS.

B. HYDRAULIC SYSTEM SAFETY

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

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

b – JLG Lift – 3120781

EFFECTIVITY CHANGES

June 15, 1999 - Original Issue of Manual

April 20, 2000 – Revised – Added Proposition 65 to front of manual.

January 17, 2002 – Manual Revised

EFFECTIVITY PAGE

3120781 – JLG Lift – c

EFFECTIVITY PAGE

This Page Left Intentionally Blank

d – JLG Lift – 3120781

TABLE OF CONTENTS

SUBJECT - SECTION, PARAGRAPH PAGE NO.

INTRODUCTION - OPERATION/SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .a

INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .b

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

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

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

EFFECTIVITY CHANGES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .c

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

1.4 Transport Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.5 Pre-Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.6 Operating Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4

SECTION 2 - PREPARATION AND INSPECTION

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

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

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

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

2.5 Daily Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

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

2.7 Battery Charging & Maintenance (EL-DC Models Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

SECTION 3 - USER RESPONSIBILITIES & MACHINE CONTROLS

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

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

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

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

SECTION 4 - MACHINE OPERATION

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

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

4.3 Machine Set-up And Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.4 Quick-Change Platform. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.5 Stowing Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

4.6 Transporting And Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

SECTION 5 - OPTIONAL EQUIPMENT

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

5.2 Am-SE - Straddle Extension Kit – Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.3 Am-SE - Straddle Extension Kit – Set-up And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

SECTION 6 - EMERGENCY PROCEDURES

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

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

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

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

SECTION 7 - INSPECTION AND REPAIR LOG

3120781 – JLG Lift – i

TABLE OF CONTENTS

(Continued)

FIGURE NO. TITLE PAGE NO.

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

1-2. Use Handles Provided On Mast Crossbar To Move Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-2

1-3. Do Not Move Unit on Soft or Uneven Surfaces or Over Obstructions, Bumps, Debris, Etc.. . . . .1-2

1-4. Two People May Be Required on Slopes Up To Five Degrees.

Also Always Travel With Platform End On The Low Side of Slope. . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-5. Read Your Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

1-6. Always Look in the Direction of Movement. Watch for Overhead and Other Obstructions. . . . . .1-4

1-7. Death or Serious Injury Could Occur from a Tip Over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

1-8. All Personnel Must Stand Clear When Platform Is Being Raised Or Lowered. . . . . . . . . . . . . . . .1-5

1-9. Falling from Platform could cause Death or Serious Injury.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5

1-10. Be Sure Area On Tilt Back Side And Under Tilt Back Arm Is Clear Of Personnel

And/Or Obstructions Prior To Using Tilt Back. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

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

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

2-3. Battery Box and Charger Assembly. (D.C. Model Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

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

2-5. Lubrication Locations (See Table below). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

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

3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. Manual Descent Valve Location.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-3. Platform Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

3-4. Decal Locations (Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-5. Decal Locations (1703778 decal from Front View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

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

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

3-8. Decal Locations (Right/Left View) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

4-1. Outrigger Components Installed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4-2. Quick Change Platform Mount.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3. Tilt-Back Assembly Set-Up.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4-4. Loading Machine onto Bed of Pick-Up Truck. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

4-5. EL Tie Down Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

4-6. EL Machine Tie-Down - Method 1. (Typical Flat Bed Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

4-7. EL Machine Tie-Down - Method 2 (Typical Flat Bed Truck) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10

5-1. SE-Adapter - Wiring Kit Hole Locations for Grommet & Spring Clips (Same For Both Sides) . . .5-2

5-2. Straddle Adapter Wiring Harness to AM/EL Wiring Connections. . . . . . . . . . . . . . . . . . . . . . . . . . 5-3

5-3. Straddle Extension Component Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5-4. Lowering AM/EL Machine on Straddle Unit - Side Lifting Rail - Quick Release Pins. . . . . . . . . . .5-6

TABLE NO. TITLE PAGE NO.

1-1 Minimum Safe Approach Distance (to energized power lines or parts) . . . . . . . . . . . . . . . . . . . .1-1

2-1 Lubrication Intervals for Various Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7

4-1 Maximum Platform Capacity. (Standard Platform) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4-2 EL Machine Gross Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

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

ii – JLG Lift – 3120781

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

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

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

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

Table 1-1. Minimum Safe Approach Distance

(to energized power lines or parts)

VOLTAGE RANGE

(PHASE TO PHASE)

0-300V – Avoid Contact

Over 300V to 50KV – 10 ft. [3 m]

Over 50KV to 200KV – 15 ft. [4.6 m]

Over 200KV to 350KV – 20 ft. [6 m]

Over 350KV to 500KV – 25 ft. [7.6 m]

Over 500KV to 750KV – 35 ft. [10.6 m]

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

Figure 1-1. Electrocution Hazard.

MINIMUM SAFE DISTANCE -

Feet [m]

1.2 ELECTROCUTION HAZARD

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

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

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

FOLLOWING TABLE).

3120781 – JLG Lift – 1-1

1.3 TRANSPORTING

Before transporting the machine the user/operator must
be familiar with the proper procedures for transporting the
machine, as well as the weight and size of the machine.

The user/operator should be familiar with the surrounding
work area and surface before transporting the machine.
The work area must be a smooth, firm surface on which
machine is capable of being leveled.

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

common sense and its careful application.

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.

SECTION 1 - SAFETY PRECAUTIONS

1.4 TRANSPORT SAFETY

• COMPLETELY EMPTY PLATFORM OF TOOLS AND
DEBRIS BEFORE MOVING MACHINE.

• FULLY LOWER PLATFORM, REMOVE AND STOW OUT­RIGGERS WHILE MACHINE IS BEING MOVED.

• NEVER ALLOW PERSONNEL IN PLATFORM WHILE
MOVING MACHINE.

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

• ON A LEVEL SURFACE, ALWAYS TRAVEL WITH THE
PLATFORM END LEADING THE WAY.

• WATCH FOR OBSTRUCTIONS AROUND MACHINE
AND OVERHEAD WHEN MOVING.

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

• BEFORE MOVING MACHINE ON FLOORS, TRUCKS
AND OTHER SURFACES, CHECK ALLOWABLE
CAPACITY OF SURFACES.

• TWO PEOPLE ARE REQUIRED ON SLOPES UP TO 5
DEGREES. A FORKLIFT MUST BE USED WHEN MOV­ING UNITS ON SLOPES GREATER THAN 5 DEGREES.

Figure 1-3. Do Not Move Unit on Soft or Uneven Sur-

faces or Over Obstructions, Bumps, Debris, Etc.

• ALWAYS TRAVEL UP OR DOWN A SLOPE WITH THE
PLATORM END OF THE MACHINE POSITIONED
TOWARDS THE LOW SIDE OF THE SLOPE. THE
OPERATOR AND ASSISTANT MUST WALK BESIDE
AND GUIDE THE MACHINE WITH THE HANDLES ON
THE MAST CROSSBAR.

• NEVER POSITION THE UNIT SIDEWAYS ON A SLOPE.

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

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

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

Figure 1-2. Use Handles Provided On Mast Crossbar

To Move Machine.

1-2 – JLG Lift – 3120781

SECTION 1 - SAFETY PRECAUTIONS

Figure 1-4. Two People May Be Required on Slopes Up To Five Degrees.

Also Always Travel With Platform End On The Low Side of Slope.

1.5 PRE-OPERATIONAL SAFETY

Figure 1-5. Read Your Manual.

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

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

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

• BEFORE OPERATION CHECK WORK AREA FOR
OVERHEAD ELECTRIC LINES. (SEE ELECTROCUTION

HAZARD, SECTION 1-2.)

• 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.

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

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

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

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

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

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

3120781 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

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

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

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

1.6 OPERATING SAFETY

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

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

• OPERATE AC UNITS WITH AN EXTENSION CORD
WIRE RATED AT A MINIMUM OF 15 AMPS.

• THE MACHINE IS EQUIPPED WITH AN OUTRIGGER
INTERLOCK SYSTEM THAT WILL NOT ALLOW THE
PLATFORM TO BE RAISED UNLESS ALL FOUR OUT­RIGGERS ARE PROPERLY INSTALLED AND MACHINE
IS LEVELED.

Figure 1-7. Death or Serious Injury Could Occur from a

Tip Over

AND ALL WHEELS ARE COMPLETELY OFF THE
GROUND.

• DO NOT OPERATE MACHINE ON SOFT FOOTING
THAT WILL ALLOW LEVELING JACKS TO SETTLE
INTO OR BREAK THROUGH SURFACE.

• NEVER OPERATE A MALFUNCTIONING MACHINE. IF
A MALFUNCTION OCCURS, SHUT DOWN THE
MACHINE, REMOVE IT FROM SERVICE, AND NOTIFY
PROPER AUTHORITIES.

Figure 1-6. Always Look in the Direction of Movement.

Watch for Overhead and Other Obstructions.

• DO NOT ENTER PLATFORM UNTIL ALL LEVELING
JACKS HAVE BEEN PROPERLY ADJUSTED AND THE
UNIT’S BASE FRAME IS LEVEL ACCORDING TO THE
BUBBLE LEVELING INDICATOR ON BASE FRAME,

• WHEN APPLICABLE BY REASON OF LOCAL REGULA­TIONS OR JOBSITE/EMPLOYER SAFETY RULES,
PERSONNEL IN THE PLATFORM SHALL AT ALL TIMES
WEAR APPROVED FALL PROTECTION DEVICES
OTHER SAFETY GEAR AS REQUIRED. A LANYARD
ATTACHMENT IS SUPPLIED ON THE SIDE OF THE
MACHINE’S MAST.

1-4 – JLG Lift – 3120781

SECTION 1 - SAFETY PRECAUTIONS

Figure 1-8. All Personnel Must Stand Clear When Plat-

form Is Being Raised Or Lowered.

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

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

• DO NOT ATTACH OVERHANGING LOADS TO THE
PLATFORM OR INCREASE THE PLATFORM SIZE WITH
UNAUTHORIZED DECK EXTENSIONS OR ATTACH­MENTS.

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

• TRANSFERS BETWEEN A STRUCTURE AND THE
PLATFORM EXPOSE OPERATORS TO FALL POTEN­TIALS. THIS PRACTICE SHOULD BE DISCOURAGED
WHEREVER POSSIBLE. WHERE TRANSFER MUST BE
ACCOMPLISHED TO PERFORM THE JOB, TWO LAN­YARDS WILL BE USED AND THE PLATFORM MUST BE
WITHIN 1 FOOT (0.3 M) OF THE ADJACENT - SAFE
AND SECURE - STRUCTURE. ONE LANYARD SHOULD
BE ATTACHED TO THE PLATFORM, THE OTHER TO
THE STRUCTURE. THE SAFETY LANYARD THAT IS
ATTACHED TO THE PLATFORM SHOULD NOT BE DIS­CONNECTED UNTIL SUCH TIME AS THE TRANSFER
TO THE STRUCTURE IS COMPLETE.

Figure 1-9. Falling from Platform could cause

Death or Serious Injury.

• DURING PLATFORM OPERATION KEEP ALL B ODY
PARTS INSIDE PLATFORM RAILINGS.

• 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 EXTEND REACH LIMITS OF THIS MACHINE
WITH ADDITIONAL EQUIPMENT SUCH AS PLANKS,
BOXES, ETC.

• DO NOT USE LADDERS ON OR AGAINST MACHINE.
DO NOT PERFORM WORK THAT WILL SUBJECT UNIT
TO A HORIZONTAL FORCE OR CREATE A ROCKING
MOTION OF THE PLATFORM.

• DO NOT OPERATE MACHINE FROM PLATFORM
WITHOUT THE PLATFORM GATE IN PLACE AND
PROPERLY CLOSED. THIS IS A SAFETY VIOLATION.

• ALWAYS ENSURE THAT POWER TOOLS ARE PROP­ERLY STOWED AND NEVER LEFT HANGING BY THEIR
CORD FROM THE PLATFORM WORK AREA.

• AVOID ACCUMULATION OF DEBRIS ON PLATFORM
WORK AREA. KEEP MUD, OIL, GREASE AND OTHER
SLIPPERY SUBSTANCES FROM FOOTWEAR AND
PLATFORM DECK.

• NO HORSEPLAY IS PERMITTED IN PLATFORM.

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

3120781 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

Tilt Back Assembly - Set-up Safety

(EL36 & EL41 Machines Only)

• REMOVE ALL TOOLS OR DEBRIS FROM PLATFORM
BEFORE TILTING MACHINE INTO THE TILT BACK
POSITION.

• STOW ALL OUTRIGGERS.

• ONLY TILT MACHINE BACK TO TILTED POSITION ON A
FLAT, FIRM AND LEVEL SURFACE.

Figure 1-10. Be Sure Area On Tilt Back Side And

Under Tilt Back Arm Is Clear Of Personnel And/Or

Obstructions Prior To Using Tilt Back.

1-6 – JLG Lift – 3120781

SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 GENERAL

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

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

2.2 PREPARATION FOR USE

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

All preparation necessary to place the machine in opera­tion readiness status are the responsibility of manage­ment personnel. Preparation requires good common
sense, (i.e. lift works smoothly) coupled with a series of
visual inspections. The mandatory requirements are given
in Section 2-4, Daily Walk Around Inspection.

2.3 DELIVERY AND FREQUENT INSPECTION

The following check list provides a systematic inspection
to assist in detecting defective, damaged, or improperly
installed parts. The check list denotes the items to be
inspected and conditions to examine. Frequent inspection
shall be performed every three (3) months or more often
when required by environment, severity, and frequency of
usage.

Platform Guard Rail Assemblies

Properly installed; no loose or missing parts; no visible
damage.

Platform Assembly

No visible damage; free of dirt and debris. Platform gate
or slide bar functions properly on machines so equipped.

Mast

No visible damage, abrasions and/or distortions; no bind­ing; mast sections free of dirt or other foreign material.
Sequencing cables properly secured; no visible damage;
proper cable tension.

Mast Chains & Cables

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

Control/(Power) Cable(s) for Platform

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

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

NOTE: This machine requires periodic safety and mainte-

nance inspections. An annual inspection shall be
performed on the aerial platform no later than thir­teen (13) months from the date of the new machine
inspection or prior annual inspection.

Lift Cylinder

No rust, nicks, scratches or foreign material on piston rod.
No leakage. Manual Descent Valve secure; no visible
damage.

Frame

No visible damage; loose or missing hardware (top and
underside); outrigger sockets not bent or damaged; out­rigger beam locking pins properly secured; outrigger
interlock LED’s properly secured and undamaged.

Wheels and Casters

Free rolling; no loose or missing parts; no visible damage.

3120781 – JLG Lift – 2-1