JLG AM-19 Setup guide

Operators and Safety Manual
Service & Maintenance Manual
Illustrated Parts Manual
Models
AM-19
AM-24
AM-30
AM-36
AC & DC Models
3120596
January 1, 1998
ANSI
Go to Discount-Equipment.com to order your parts

Discount-Equipment.com is your online resource for quality parts & equipment.
Florida: 561-964-4949 Outside Florida TOLL FREE: 877-690-3101
Need parts?
Click on this link: http://www.discount-equipment.com/category/5443-parts/ and
choose one of the options to help get the right parts and equipment you are looking
for. Please have the machine model and serial number available in order to help us
get you the correct parts. If you don’t find the part on the website or on one of the
online manuals, please fill out the request form and one of our experienced staff
members will get back to you with a quote for the right part that your machine needs.
We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto,
Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack,
Lull, Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic,
Dynapac, MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti,
Morrison, Contec, Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S.
Curtis, Gehl Pavers, Heli, Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin,
Rice, CH&E, General Equipment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent,
Stanley, Tamco, Toku, Hatz, Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air,
APT, Wylie, Ingersoll Rand / Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith
Surface Prep,Small Line, Wanco, Yanmar

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. REMEM-
BER 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 STRICTLYFORBIDDEN WITHOUTWRITTEN APPROVAL
FROM JLG INDUSTRIES. PER OSHA REGULATIONS.
W.. THIS "SAFETY ALERT SYMBOL" IS USED TO CALL ATTENTION TO POTENTIAL HAZARDS
L.:..] WHICH MAY LEAD TO DEATH OR SERIOUS INJURY 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:
A DANGER
DANGER INDICATES AN IMMINENTLY HAZ-
ARDOUS SITUATION WHICH, IF NOT AVOIDED
WILL RESULT IN DEATH OR SERIOUS INJURY.
A CAUTION
CAUTION INDICATES A POTENTIALLY HAZ-
ARDOUS SITUATION WHICH, IF NOTAVOIDED,
MAY RESULT IN MINOR OR MODERATE IN-
JURY. IT MAY ALSO BE USED TO ALERT
AGAINST UNSAFE PRACTICES.
A WARNING
WARNING INDICATES A POTENTIALLY HAZ-
ARDOUS SITUATION WHICH, IF NOT AVOIDED
COULD RESULT IN DEATH OR SERIOUS IN-
JURY.
A IMPORTANT
IMPORTANT OR INSTRUCTIONS PROCE-
DURES ESSENTIAL FOR SAFE OPERATION
AND WHICH, IF NOT FOLLOWED MAY RESULT
IN A MALFUNCTION OR DAMAGE TO THE MA-
CHINE.
In this Manual "Notes" are used to provide information of special interest.
Go to Discount-Equipment.com to order your parts

JLG Lift
INTRODUCTION- OPERATION SAFETY PRECAUTIONS JLG Lift
All procedures herein are based on the use of the
machine under proper operating conditions, with no
deviationsfrom 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 abbrevi-
ated form are some of the requirements of Federal
OSHA regulations
in effect as of the date of publica-
tion of this handbook.
The listing ofthese requirements shall not relieve the
owner/user of the responsibility and obligation to de-
termine all applicable laws and regulations and their
exact wording and requirements, and to comply with
the requirements. Nor shall the listing of these re-
quirements constitute an assumption of responsibility
of liability on the part of JLG Industries, Inc.
1. Onlytrained 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
useto determinethattheyare
in safe operating
condition.
5. Load limits specified by the manufacturershall
not be exceeded.
6. Instruction and warning placards must be leg-
ible.
7. Aerial lifts maybe"field modified"forusesother
than those intended by the manufacturer only
if certified in writing by the manufacturer or an
equivalent entity, such as a nationally recog-
nized testing lab, to be in conformityto applica-
ble OSHA safety regulations and to be at least
as safe as itwas priorto modification.
a. Aerial lifts shall notbe used nearelectricpower
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 emer-
gency.
11. Regular inspection ofthe job site and aerial lift
shall be performed by competent persons.
12. Personnel shall always stand on thefloorofthe
platform, not on boxes, planks, railing or other
devices for a work position.
*Applicable Federal OSHAregulations, as ofthe 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 1926.556. Consult the current regulations for
the exact wording and full text
of the requirements
and contact the closest Federal OSHAoffice for spe-
cific interpretations.
-JLG Lift-
Updated 02/95
a
Go to Discount-Equipment.com to order your parts

JLG Lift INTRODUCTION- MAINTENANCE SAFETY PRECAUTIONS JLG Lift
A. GENERAL
This section contains the general safety precautions
which must
be observed during maintenance of the
aerial platform. It is of utmost importancethat mainte-
nance personnel pay strict attention to these warn-
ings and precautions to avoid possible injuryto them-
selves 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.
A WARNING
MODIFICATION OF THE MACHINE WITHOUT CER-
TIFICATION
BY A RESPONSIBLE AUTHORITY
THAT THE MACHINE IS AT LEAST AS SAFE AS
ORIGINALLY MANUFACTURED
IS A SAFETY VIO-
LATION.
The specific precautions to be observed during ma-
chine 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 considera-
tion when engaging
in the maintenance of equip-
ment. Always
be conscious ofcomponent 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 pro-
vided. A WARNING
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, SAFETY IN THISAREA IS THE
RESPONSIBILITY OF THE OWNER/OPERATOR.
B. HYDRAULIC SYSTEM SAFETY
1. It should be particularly noted that the ma-
chines hydraulic systems operate at extremely
high and potentially dangerous pressures.
Every effort should
be made to relieve any
system pressure prior to disconnecting or
re-
moving 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 dis-
connected with minimal fluid loss.
C. MAINTENANCE
A WARNING
FAILURE TO COMPLY WITH SAFETY PRECAU-
TIONS LISTED
IN THIS SECTION COULD RESULT IN
MACHINE DAMAGE, PERSONNEL INJURY OR
DEATH AND IS A SAFETY VIOLATION.
• REMOVE ALL RINGS, WATCHES, AND
JEWELRYWHEN PERFORMINGANYMAIN-
TENANCE.
• DO NOT WEAR LONG HAIR UNRESTRAIN-
ED, OR LOOSE FITTING CLOTHING AND
NECKTIES WHICH ARE APT TO BECOME
CAUGHT ON OR ENTANGLED IN EQUIP-
MENT.
• OBSERVE AND OBEY ALL DANGER,
WARNING, CAUTION AND OTHER IN-
STRUCTIONS
ON MACHINE AND IN SERV-
ICE MANUAL.
• KEEP STANDING SURFACES AND HAND
HOLDS FREE OF OIL, GREASE, WATER,
ETC.
• NEVER WORK UNDER AN ELEVATED
PLATFORM UNTIL SAFETY PROPS HAVE
BEEN ENGAGED
OR PLATFORM HAS
BEEN SAFELY RESTRAINED FROM ANY
MOVEMENTBY BLOCKING
OR OVERHEAD
SLING.
• BEFORE MAKING ADJUSTMENTS, LUBRI-
CATING
OR PERFORMING ANY OTHER
MAINTENANCE, SHUT OFF ALL POWER
CONTROLS.
• BATTERY SHOULD ALWAYS BE DISCON-
NECTED DURING REPLACEMENT OF
ELECTRICAL COMPONENTS.
• KEEP ALL SUPPORT EQUIPMENT AND AT-
TACHMENTS STOWED IN THEIR PROPER
PLACE.
• USE ONLY APPROVED, NONFLAMMABLE
CLEANING SOLVENTS.
b
-JLG Lift-
Go to Discount-Equipment.com to order your parts

JLG Lift EFFECTIVITY CHANGES JLG Lift
REVISION LOG
October 14, 1994 Original Issue of Manual
January 1, 1995 Revised
February 15, 1995 -Change 1
June 1995 -Change 2
May 1997-Updated
January 1998-Revised
Added optional AM-SE Straddle Extension
Kit- "Set-Up and
Operation" to Section-5 and Parts Section. Added optional
Fiberglass Platform to Parts Section. Also added procedure
for setting height of outrigger socket contactor screws and
outrigger beam contactor plate to Section-9.
Pages Affected:
Cover
Revision Log -Page c
Table of Contents- Page ii
Section 2- Pages 2-3 and 2-4
Section 3 - Pages 3-2 and 3-3
Section 5 - Pages 5-4, 5-5, 5-6
Section 7 - Page
7-1
Section 10-1 -Pages 10-1-2 to 10-1-38 and 10-1-5
Section 10-2 -Pages 10-2-2, 10-2-3, 10-2-9, 10-2-11 to
10-2-13 and 10-2-17
Section 10-3 -Pages 10-3-3, 10-3-8 and 10-3-11
Section 10-4- Pages 10-4-2, 10-4-3 and 10-4-5
Section 10-7- Pages 10-7-2 to 10-7-4
Section 10-8 -Pages 10-8-3 and 10-8-4
Section 10-9 -Page 10-9-1
Section 1 0-1 0 - Page 1 0-1 0-3
Pages Affected:
Cover
Revision Log -Page c
Section 10 Illustrated Parts Table of
Contents- Page 10-0-1
Section 1 0-1 -Pages 10-1-2 to 10-1-5
Section 10-2 -Pages 10-2-7, 10-2-11, 10-2-17 and 10-2-18
Section 10-3 -Pages 10-3-5, 10-3-8, 10-3-9 and 10-3-11
Section 10-4 -Pages 10-4-2 to 10-4-5
Section 10-7 -Pages 10-7-2 and 10-7-4
Section 10-8- Pages 10-8-2 to1 0-8-4
Section 10-10- Pages 10-10-1 to 10-10-4
Pages Affected:
Table of Contents- Page ii
Section 9- Page 9-1, added Page 9-5 (Fig. 9-2.)
Pages Affected:
Section 1
0 Illustrated Parts
-JLG Lift-
c/d Blank
Go to Discount-Equipment.com to order your parts

Go to Discount-Equipment.com to order your parts

JLG Lift TABLE OF CONTENTS JLG Lift
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
TABLE OF
CONTENTS.......................................................... i
LIST OF ILLUSTRATIONS........................................................ ii
LIST OF TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ii
SECTION 1 -SAFETY PRECAUTIONS
1-1. General............................................................ 1-1
1-2. Electrocution Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-3. Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4. Transporting Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-5. Pre-Operational Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1-6. Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SECTION 2- PREPARATION AND INSPECTION
2-1. General . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-2. Preparation For Use . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-3. Delivery and Periodic 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
(DC Machines) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SECTION 3- USER RESPONSIBILITIES AND 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. Stowing
Machine..................................................... 4-3
4-5. Transporting and Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SECTION 5- OPTIONAL EQUIPMENT
5-1. Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-2. AM-SE -Straddle Extension Kit -Set-Up and Operation . . . . . . . . . . . . . . . . . . . . . . 5-1
SECTION 6- EMERGENCY PROCEDURES
6-1. General . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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- SPECIFICATIONS
7-1. Capacities.......................................................... 7-1
7-2. Component Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-3. Performance Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-4. Torque Requirements................................................. 7-2
7-5. Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-6. Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-7. Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-8. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
-JLG Lift-
Go to Discount-Equipment.com to order your parts

ii
JLG Lift TABLE OF CONTENTS JLG Lift
SUBJECT-SECTION, PARAGRAPH PAGE NO.
SECTION 8- PROCEDURES
8-1 . General . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-2. Servicing and Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8-3. Lubrication Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4
8-4. Mast Assembly and Disassembly Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8-5. Mast to Base Frame Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
8-6. Mast Chains and Sequencing Cables Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
8-7. Preventive Maintenance
and Inspection Schedule............................ 8-14
SECTION 9- TROUBLESHOOTING
9-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-2. Troubleshooting Information... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-3. Hydraulic Circuit Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9-4. Outrigger Interlock Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
SECTION 10-ILLUSTRATED PARTS MANUAL
Illustrated Parts- Table of Contents. . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-0-1
FIGURE NO.
LIST OF ILLUSTRATIONS
TITLE
1-1.
1-2.
2-1.
2-2.
3-1.
3-2.
4-1.
4-2.
4-3.
4-4.
4-5.
5-1.
5-2.
5-3.
5-4.
5-5.
7-1.
7-2.
8-1.
8-2.
9-1.
9-2.
Pushing Machine
on a Smooth, Firm Surface .............................. .
Pushing Machine
on a Slope ........................................... .
Daily Walk-Around Inspection ........................................... .
Battery Box & Charger Assembly (DC models only)
......................... .
Ground Control Station
................................................ .
Platform Control Station ............................................... .
Outriggers Installed
................................................... .
Pushing Machine
on a Smooth, Firm Surface .............................. .
Pushing Machine on a Slope
........................................... .
Tilt-Back Assembly Set-Up ............................................. .
Loading Machine onto Pickup Truck for Transport
.......................... .
Straddle Adaptor Wiring Harness Installation ............................... .
Straddle Adaptor -AC Control Box Wiring Connections ...................... .
Straddle Adaptor - DC Ground Control Station Wiring Connections ............. .
Straddle Extension -ComponentAssembly ................................ .
Lowering AccessMaster
on Straddle Unit -Side Lifting Rail Quick-Release Pins ... .
Torque Chart
........................................................ .
Lubrication Chart ..................................................... .
AccessMaster Mast Assembly
.......................................... .
Mast Chains/Cables Routing Diagram
.................................... .
Base Frame Outrggr. Socket Contactor Heads and Outrggr.
Beam Contactor Plate .
Hydraulic Diagram (AC & DC Machines) .................................. .
LIST OF TABLES
PAGE NO.
1-2
1-3
2-3
2-5
3-2
3-3
4-2
4-4
4-5
4-6
4-8
5-2
5-3
5-3
5-4
5-6
7-3
7-4
8-7
8-15
9-1
9-5
TABLE NO. TITLE PAGE NO.
1·1. Minimum Safe Approach Distances (to energized power lines).............. 1-1
7-1. Recommended Hydraulic Oils. . . •••. •. •. . . . •••. •. . . . •. . •• •. . . . . . . . . . . . . 7-2
7-2. Lubrication Specifications. . . . . . . . . . ••••. . . . . . . •. ••. . •. . . •. • •. •. . . . . . . . 7-2
8·1. Chain Stretch Tolerance. •. . . . . . . . . . . . . . . . . . . . . . . . •••. •. . •. . •. . . . . . . . . . 8-3
8·2. Preventive Maintenance and Inspection Schedule......................... 8-16
9-1. A.C. Units
Troubleshooting............................................ 9-2
9-2. D.C. UnitsTroubleshooting . . . . . . •. . •. . . . . . . . . . . . . . . . •. ••. . . . . . . . . . . . . . 9-3
Updated -5/97 -
JLGUft-
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 1 - SAFETY PRECAUTIONS JLG Lift
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 instruc-
tions of the machine under the supervision of
an
experienced and qualified operator, has been com-
pleted. If there is a question
on application and/or
operation, JLG Industries Product Safety and Reli-
ability should
be consulted.
A WARNING
MODIFICATION OF THE MACHINE WITHOUT AP-
PROVALOF JLG INDUSTRIES,
OR CERTIFICATION
BY A NATIONALLYRECOGNIZED TESTING LAB TO
BE IN CONFORMITY WITH APPLICABLE OSHA
REGULATIONS, AND TO BE
AT LEASTAS SAFE AS
BEFORE MODIFICATION,
IS PROHIBITED AND IS A
VIOLATION OF OSHA RULES.
1-2. ELECTROCUTION HAZARD
Minimum safe approach distances (M.S.A.D.) to en-
ergized (exposed or insulated) power lines and parts.
A DANGER
DO NOT maneuver machine or personnel to dis-
tance less than M.S.A.D (See Table 1-1.). ASSUME
all electrical parts and
wiring are ENERGIZED un-
less known otherwise.
THIS MACHINE DOES NOT PROVIDE PROTECTION
FROM CONTACT WITH
OR PROXIMITY TO AN
ELECTRICALLY CHARGED CONDUCTOR. MAIN-
TAIN A CLEARANCE OF
AT LEAST 10 FEET (3M)
BETWEEN ANY PART OF THE MACHINE AND ANY
ELECTRICAL LINE OR APPARATUS CARRYING UP
TO 50,000 VOLTS. ONE FOOT (0.3 M) ADDITIONAL
CLEARANCE IS REQUIRED FOR EVERY ADDI-
TIONAL 30,000 VOLTS
OR LESS. ALLOW FOR
PLATFORM SWAY, ROCK OR SAG AND ELECTRI-
CAL LINE SWAYING, (SEE FOLLOWING TABLE).
Table 1-1.
Minimum Safe Approach Distance
(to energized power lines
or parts)
VOLTAGE RANGE I MINIMUM SAFE
(PHASE TO PHASE)
DISTANCE- FEET [M]
0-300V -Avoid Contact
Over 300V to 50KV - 10ft. [3m]
Over 50KV to 200KV - 15ft. [4.6 m]
Over 200KV to 350KV -20ft. [6 m]
Over 350KV to 500KV -25ft. [7.6 m]
Over 500KV to 750KV -35ft. [106m]
Over750KVto1000KV
-45ft. [13.7
m]
1-3. TRANSPORTING
Before transporting the machine the user/operator
must
be familiar with the proper proceduresfor trans-
porting the machine, as well as the weight and size of
the machine.
The user/operator should
be familiar with the sur-
rounding work area and surface before transporting
the machine. The work area must be a smooth, firm
surface
on which machine is capable of being lev-
eled.
Note
Remember
that the key to safe and proper usage is
common sense and its careful application.
A WARNING
FAILURE TO COMPLY WITH SAFETY PRECAU-
TIONS LISTED
IN THIS SECTION AND ON MACHINE
MAY RESULT IN MACHINE DAMAGE, PERSONNEL
INJURY
OR DEATH AND IS A SAFETY VIOLATION.
1-4. TRANSPORT SAFETY
• COMPLETELY EMPTY PLATFORM OF TOOLS
AND DEBRIS BEFORE MOVING MACHINE.
• FULLY LOWER PLATFORM, REMOVE AND
STOW OUTRIGGERS WHILE MACHINE IS BE-
ING MOVED.
• NEVER ALLOW PERSONNEL
IN PLATFORM
WHILE MOVING MACHINE.
A WARNING
FAILURE TO OBSERVE THE FOLLOWING TIPPING
HAZARD INSTRUCTIONS COULD CAUSE THE UNIT
-JLG Lift-
1-1
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 1 - SAFETY PRECAUTIONS JLG Lift
TO TIP OVER OR BE HARD TO CONTROL WHEN
BEING MOVED, WHICH COULD RESULT IN SERI-
OUS INJURYOR DEATH DUE TO BEINGPINNEDOR
CRUSHED BY THE UNIT.
• ON A LEVEL SURFACE, ALWAYS TRAVEL
WITH THE PLATFORM END LEADING THE
.. WAY.
• WATCH FOR OBSTRUCTIONS AROUND MA-
CHINE AND OVERHEAD WHEN MOVING.
• CHECK TRAVEL PATH FOR PERSONS,
HOLES, BUMPS, DROP-OFFS, OBSTRUC-
TIONS, DEBRIS, AND COVERINGS WHICH
MAY CONCEAL HOLES AND OTHER HAZ-
ARDS, AS TIPPING COULD OCCUR. (SEE FIG-
URE 1-1.)
• BEFORE MOVING MACHINE ON FLOORS,
TRUCKS AND OTHER SURFACES, CHECK
ALLOWABLE CAPACITY OF SURFACES.
• DO NOT MOVE ON SOFT OR UNEVEN SUR-
FACES, AS TIPPING WILL OCCUR.
• TWO PEOPLE ARE REQUIRED ON SLOPES
UP TO 5 DEGREES. A FORKLIFT MUST BE
USED WHEN MOVING UNITS ON SLOPES
GREATER THAN 5 DEGREES.
(SEE FIGURE 1-2.)
• 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 ASSIS-
TANT MUST WALK BESIDE UNITAND GUIDE
THE MACHINE WITH THE PLATFORM HAND-
RAILS.
• NEVER POSITION THE UNITSIDEWAYS ON A
SLOPE.
• KEEP CLEAR FROM BEHIND AND
IN FRONT
OF UNIT. (SEE FIGURE 1-1. & 1-2.)
• USE CAUTION AND CHECK CLEARANCES
WHEN MOVING MACHINE IN RESTRICTED
OR CLOSE QUARTERS.
• ALWAYS USE AN ASSISTANTWHEN MOVING
MACHINE IN AREAS WHERE VISION IS OB-
STRUCTED.
• KEEP NON-OPERATING PERSONNEL AT
LEAST 6 FEET (1.8 M) AWAY FROM MACHINE
DURING TRANSPORTING OPERATIONS.
CORRECT! way to push on a
SMOOTH/FIRM surface.
OPERATOR
MUST WALK
BESIDE UNIT
AND HOLD
ONTO THE
SIDE OF
PLATFORM
INCORRECT!
KEEP CLEAR
FROM BEHIND
AND IN
FRONT OF UNIT
A WARNING
WITH OPERATOR PUSHING MACHINE FROM
PLATFORM END, MACHINE COULD TIP IF AN OB-
STRUCTION ON SURFACE IS ENCOUNTERED.
Figure 1-1. Pushing Machine on a
SMOOTH, FIRM surface.
1-5. PRE-OPERATIONAL SAFETY
• READ YOUR MANUAL. UNDERSTAND WHAT
YOU'VE READ -THEN BEGIN OPERATIONS.
• ALLOW ONLY THOSE AUTHORIZED AND
QUALIFIED PERSONNEL TO OPERATE MA-
CHINE WHO HAVE DEMONSTRATED THAT
THEYUNDERSTAND SAFE AND PROPER OP-
ERATION AND MAINTENANCE
OF THE UNIT.
• AN OPERATOR MUST NOT ACCEPTOPERAT-
ING RESPONSIBILITIES UNTIL ADEQUATE
TRAINING HAS BEEN GIVEN BY COMPETENT
AND AUTHORIZED PERSONS.
1-2
-JLG Lift-
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 1 - SAFETY PRECAUTIONS JLG Lift
CORRECT! way to travel UP
or DOWN a SLOPE.
GUIDE MACHINE WITH
OPERATOR AND
ASSISTANT ON SIDES
OF MACHINE
PLATFORM END
TOWARDS
BOTTOM
OF SLOPE
...
BOTTOM OF SLOPE
INCORRECT!
BOTTOM OF SLOPE
INCORRECT!
ALWAYS
POSITION
MAST END
TOWARDS
TOP OF
SLOPE
...
TOP OF
SLOPE
A WARNING
TOP OF
SLOPE
A WARNING
TOP OF
SLOPE
Figure 1-2. Pushing Machine on a SLOPE.
-JLG Lift-
• BEFORE OPERATION CHECK WORK AREA
FOR OVERHEAD ELECTRIC LINES. (SEE
ELECTROCUTION HAZARD, SECTION 1-2.)
• ALSO BEFORE OPERATION CHECK WORK
AREA FOR MACHINE TRAFFIC SUCH AS
FORKLIFTS, CRANES, AND OTHER CON-
STRUCTION EQUIPMENT.
• SET-UP MACHINE FOR OPERATION ONLY
ON A SMOOTH, FIRM SURFACE ON WHICH
THE MACHINE IS CAPABLE OF BEING LEV-
ELED.
• 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 HAZ-
ARDS IN THE WORK AREA MUST BE TAKEN
BY THE OPERATOR AND HIS SUPERVISOR
BEFORE STARTING THE WORK.
• DO NOTOPERATETHIS MACHINE UNLESS IT
HAS BEEN SERVICED AND MAINTAINED AC-
CORDINGTOTHE MANUFACTURERS SPECI-
FICATIONS AND SCHEDULE.
• ENSURE DAILY INSPECTION AND FUNCTION
CHECK IS PERFORMED PRIOR
TO PLACING
MACHINE INTO OPERATION. HAVEAUTHOR-
IZED PERSONNEL TAKE ANY NECESSARY
CORRECTIVE ACTION BEFORE PLACING
MACHINE INTO OPERATION.
• NEVER DISABLE OR MODIFY ANY SAFETY
DEVICE. ANY MODIFICATION OF THE MA-
CHINE IS A SAFETY VIOLATION AND IS A
VIOLATION OF OSHAAND ANSI RULES.
• DO NOT OPERATE MACHINE WHEN EX-
POSED TO HIGH WIND, RAIN OR SNOW.
• NEVER OPERATE
OR RAISE PLATFORM
WHEN MACHINE IS ON A TRUCK OR OTHER
VEHICLE.
• APPROVED HEAD GEAR (I.E. HARD HAT,
ETC.) MUST BE WORN WHEN REQUIRED BY
ALL OPERATING AND GROUND PERSON-
NEL.
• READ AND OBEY ALL DANGER, WARNINGS,
CAUTIONS AND OPERATING INSTRUCTIONS
ON MACHINE AND IN THIS MANUAL.
• BE FAMILIAR WITH LOCATION AND OPERA-
TION OF GROUND STATION AND EMER-
GENCY CONTROLS.
1-3
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 1 - SAFETY PRECAUTIONS JLG Lift
1-6. OPERATING SAFETY
• READ YOUR MANUAL, UNDERSTAND WHAT
YOU'VE READ- THEN BEGIN OPERATIONS.
• DO NOTOPERATE ANY MACHINE ON WHICH
DANGER, WARNING, CAUTION OR INSTRUC-
.. TION PLACARDS OR DECALS ARE MISSING
OR ILLEGIBLE.
• NEVER EXCEED MANUFACTURERS RATED
PLATFORM CAPACITY- REFER TO CAPAC-
ITY DECAL ON MACHINE.
• OPERATE AC UNITS WITH AN EXTENSION
CORD WIRE RATED AT A MINIMUM OF 15
AMPS.
• THE MACHINE IS EQUIPPED WITH AN OUT-
RIGGER INTERLOCK SYSTEM THAT WILL
NOT ALLOW THE PLATFORM TO BE RAISED
UNLESS ALL FOUR OUTRIGGERS ARE
PROPERLY INSTALLED AND MACHINE IS
LEVELED.
• DO NOT ENTER PLATFORM UNTIL ALL LEV-
ELING JACKS HAVE BEEN PROPERLY AD-
JUSTED AND THE UNIT'S BASE FRAME IS
LEVEL ACCORDING TO THE BUBBLE LEVEL-
ING INDICATOR ON BASE FRAME, AND ALL
WHEELS ARE COMPLETELY OFF THE
GROUND.
• DO NOTOPERATE MACHINE ON SOFTFOOT-
ING THAT WILL ALLOW LEVELING JACKS TO
SETTLE INTO OR BREAK THROUGH SUR-
FACE.
• NEVER OPERATE A MALFUNCTIONING MA-
CHINE. IF A MALFUNCTION OCCURS, SHUT
DOWN THE MACHINE, RED TAG IT, AND NO-
TIFY PROPER AUTHORITIES.
• ALL PERSONNEL MUST STAND CLEAR
WHEN PLATFORM IS BEING RAISED OR
LOWERED. BE SURE TO WATCH FOR OVER-
HEAD AND OTHER OBSTRUCTIONS.
• CHECK CLEARANCES ABOVE, ON SIDES
AND BOTTOM OF PLATFORM WHEN RAISING
AND LOWERING PLATFORM.
• NEVER USE THE MASTTO GAIN ACCESS TO
OR LEAVE PLATFORM.
• DO NOT ATTACH OVERHANGING LOADS TO
THE PLATFORM OR INCREASE THE PLAT-
FORM SIZE WITH UNAUTHORIZED DECK EX-
TENSIONS OR ATTACHMENTS.
• DO NOT TIE OFF MACHINE TO ANY ADJA-
CENT STRUCTURE. NEVER ATTACH WIRE,
CABLE OR ANY SIMILAR ITEMS TO PLAT-
FORM.
• TO AVOID FALLING -USE EXTREME CAU-
TION WHEN ENTERING OR LEAVING PLAT-
FORM ABOVE GROUND. ENTER OR EXIT
THRU GATE ONLY. PLATFORM MUST BE
WITHIN 1 FOOT (0.3 M) OF ADJACENT- SAFE
AND SECURE -STRUCTURE. ALLOW FOR
ANY VERTICAL MOVEMENT OF PLATFORM
(UP OR DOWN) WHEN ENTERING OR LEAV-
ING PLATFORM.
• NO HORSEPLAY IS PERMITTED IN PLAT-
FORM.
• DO NOT ALLOW PERSONNEL TO TAMPER
WITH, SERVICE, OR OPERATE THIS MA-
CHINE FROM THE GROUND WITH PERSON-
NEL IN PLATFORM EXCEPT IN AN EMER-
GENCY.
• DURING OPERATION KEEPALLBODYPARTS
INSIDE PLATFORM RAILINGS.
• NEVER POSITION LADDERS, STEPS, OR
SIMILAR ITEMS ON UNIT TO PROVIDE ADDI-
TIONAL 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 MA-
CHINE. DO NOT PERFORM WORKTHATWILL
SUBJECT UNIT TO A HORIZONTAL FORCE
OR CREATE A ROCKING MOTION OF THE
PLATFORM.
• DO NOT OPERATE WITHOUT SLIDE BAR
GATE (OR SWING GATE ON PLASTIC BASKET
MODELS) IN PLACE AND PROPERLY CLOS-
ED. THIS IS A SAFETY VIOLATION.
• ALWAYS ENSURE THAT POWER TOOLS ARE
PROPERLY STOWED AND NEVER LEFT
HANGING BY THEIR CORD FROM THE PLAT-
FORM WORK AREA.
• AVOID ACCUMULATION OF DEBRIS ON
PLATFORM WORK AREA. KEEP MUD, OIL,
GREASE AND OTHER SLIPPERY SUB-
STANCES FROM FOOTWEAR AND PLAT-
FORM DECK.
1-4
-JLG Lift-
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 2 - PREPARATION
AND INSPECTION JLG Lift
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 ma-
chine. It is importantthatthe information contained in
this section be read and understood before any at-
temptis madeto operate the machine. Ensure that all
the necessary inspections have been completed suc-
cessfully before placing the machine into service.
These procedures will aid in obtaining maximum
service life and safe operation.
A IMPORTANT
SINCE THE MACHINE MANUFACTURER HAS NO
DIRECT CONTROL OVER THE FIELD INSPECTION
AND MAINTENANCE, THIS IS THE RESPONSIBIL-
ITY 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 re-
sulting 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. liftworks smoothly) coupled with
a series of visual inspections.
The mandatory re-
quirements are given in Section 2-4, Daily Walk
Around Inspection.
It should be assured that the items appearing in the
Delivery and Frequent Inspection and Functional
Check are complied with priorto putting the machine
into service.
2-3.
DELIVERY AND FREQUENT INSPECTION
Thefollowing check list provides a systematic inspec-
tion to assist in detecting defective, damaged, or
improperly installed parts. The check list denotes the
items to be inspected and conditions to examine.
Frequent inspection shall be performed every three
(3) months
or more often when required by environ-
ment, severity, and frequency
of usage.
• Handrail Assemblies
Properly installed; no loose or missing parts; no
visible damage.
• Platform Assembly
No visible damage; free of dirt and debris. Plat-
form gate 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 se-
cured; no visible damage; proper cable tension.
• Mast Chains & Cables
No visible damage; proper chain/cable tension;
evidence of proper lubrication. Chain/cable
sheaves, sheave pins and rollers properly se-
cured; no visible damage.
• Controi/(Power) Cable(s) for Platform
No visible damage; cable properlytensioned and
seated in control cable sheaves; control cable
sheaves not damaged and rotating freely.
• Lift Cylinder
No rust, nicks, scratches or foreign material on
piston rod. No leakage. Evidence of proper lubri-
cation.
• Frame
No visible damage; loose or missing hardware
(top and underside); outriggersockets notbent
or
damaged; outrigger beam locking pins properly
secured; outrigger interlock LED's properly se-
cured and undamaged.
-JLG Lift-
2-1
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 2 - PREPARATION AND INSPECTION JLG Lift
• Wheels and Casters
Free rolling; no loose or missing parts; no visible
damage.
• Hydraulic Oil Supply
Check the hydraulic oil level at the hydraulic fluid
reservoir through the access hole on the side of
the ground control panel. Unscrew the breather
cap and check the fluid level indicator on the
dipstick.
Iffluid level is low, see Section 7 - Specifications;
Sub-Section 7-5. "Lubrication"; Table 7-1. "Rec-
ommended Hydraulic Oils" for use in machine.
• Machine Controls - (Platform and Ground)
Switches operable; no visible damage; placards
secure and legible.
• Batteries -(DC Models)
Proper electrolyte level; cable connections tight;
no visible damage; no corrosion at battery cable
connections.
• Power Cord -(AC Models)
No visible damage; connector and cable properly
secured.
• Electric Motor/Hydraulic Pump and Valve
No leakage; unit secure.
• Placards
No visible damage; placards secure and legible.
2-4.
DAILY WALK-AROUND INSPECTION
It is the user/operator's responsibility to inspect the
machine before the start of each workday. It is rec-
ommended that each user/operator inspect the ma-
chine before operation, even if the machine has al-
ready been put into service under another user/op-
erator. This Daily Walk-Around Inspection is the pre-
ferred method of inspection.
• GENERAL
Begin the "Walk-Around Inspection" at item 1
listed following. Continue around machine check-
ing each item
in sequencefortheconditions listed
in the "Walk-Around Inspection Check list".
A WARNING
TO AVOID INJURY DO NOT OPERATE MACHINE
UNTIL
ALL MALFUNCTIONS HAVE BEEN COR-
RECTED. USE OF A MALFUNCTIONING MACHINE
IS A SAFETY VIOLATION.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE
POWER
IS "OFF" DURING "WALK-AROUND IN-
SPECTION". Note
Do
not overlook visual inspection of chassis under-
side. Checking this area often results in discovery
of conditions which could cause extensive machine
damage.
1. Wheels and Casters -Properly secured,
wheels and casters turn freely and are properly
lubricated. Check for any visible damage.
2. Base Frame- No visible damage; components
properly secured, no loose wires dangling be-
low base; bubble level in place and functioning
properly.
3. Tilt Back Outrigger -(AM30 & 36 Models
Only) Properly secured; no visible damage; no
parts missing i.e
.. safety pins, gas spring cylin-
ders, caster wheels, etc.
4. Battery/Battery Charger Installation -(DC
Machines) Proper battery electrolyte level, ca-
bles secure, no damage or corrosion. Battery
box pivots freely when machine is tilted for
transporting (AM30 & 36 Models Only).
s. Outrigger Interlock Indicator LED's -Prop-
erly secured, no visible damage.
6. Outrigger Sockets -Properly secured to
frame, no visible damage (cracks, distortion,
etc.). Outrigger lock/release pins in place and
secure, no visible damage. Outriggerinterlock
contacts (inside outrigger sockets) secure and
clean.
7. Outrigger Beams- Novisible damage (cracks,
distortion, etc..), outrigger interlock contacts
properly installed and clean. Leveling jacks
secure, lubricated and functioning properly.
s. Motor/Pump/Reservoir Unit- All properly se-
cured, no visible damage, no evidence of hy-
draulic leaks. Check that hydraulic reservoir
fluid level is to full mark on dipstick, breather
cap is on tight.
2-2 -JLG
Lift-
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 2 - PREPARATION AND INSPECTION JLG Lift
9. Control Valve/Manual Release Valve -Prop-
erly secured, no loose or missing parts, no
visible damage.
10. Ground Controls -Key switch operable, no
visible damage; placards secure and legible;
emergency stop switch, no visible damage and
properly set for operation.
11. Mast Installation -Mast sections properly se-
cured, no visible damage to mast sections, no
10
4--------
(LOCATED HERE
ON DC UNITS
ONLY)
3
(LOCATED~
ON AM30 & AM36
ONLY)
14
6
loose or m1ssmg parts, slide pads properly
secured. Mast chains and cables properly se-
cured and lubricated. Sequencing cables prop-
erly secured and undamaged.
12. Handrail Installation -All railings securely
attached, no visible damage, no missing parts;
sliding entry bar in proper working order. Plat-
form gate working properly, no visible sign of
damage (if so equipped).
Daily Walk-Around
Inspection Items
1. Wheels and Casters
2. Base Frame
3. Tilt-Back Base Assembly
4. Battery Box/Charger
5.
Outrigger Interlock LED's
6. Outrigger Sockets
7. Outrigger Beams
8. Motor/Pump/Reservoir Unit
9. Control Valve/Manual
Release Valve
10. Ground Controls
11. Mast Installation
12. Handrail Installation
13. Platform Assembly
14. Platform Controls
Figure 2-1. Daily Walk-Around Inspection.
-JLG Lift-
Change 1 2-3
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 2 - PREPARATION AND INSPECTION JLG Lift
13. Platform Assembly- Secureto mast; no loose
or missing parts, no visible damage. Control
and power cables, no visible damage; cables
properly tensioned and seated
in control cable
sheaves; control cable sheaves not damaged
and rotate freely.
.. 14. Platform Controls -Up/Down and Function
Enable buttons properly secured, no loose or
missing parts,
no visible damage. Placards
secure and legible, emergency shut-off button
setfor operation. Control markings legible; Op-
erators manual enclosed in manual storage
tube.
In addition to the Daily Walk-Around Inspection, be
sure to include the following as part of the daily
inspection:
• Batteries Charged (DC Models)
Start each day with fully charged batteries. (See
Section 2-7. "Battery Charging")
• Overall Cleanliness
Keep oil, grease, water, etc. wiped from standing
surfaces and hand holds.
•
Placards
Keep all information and operating placardsclean
and unobstructed. Cover areas where placards
are present when using the machine for spraying
paint or any material which could cover these
surfaces and reduce legibility.
• Operators, Safety,
and Maintenance
Manual
Ensure a copy of this manual is enclosed in the
manual storage box.
• Lubrication
For those parts pointed out in the Walk-Around
Inspection requiring lubrication, refer to the Lubri-
cation Chart, Figure 7-2., Section 7, for specific
time interval requirements.
2-5. DAILY FUNCTIONAL CHECK
A WARNING
TO AVOID INJURY DO NOT OPERATE A MACHINE
UNTIL
ALL MALFUNCTIONS HAVE BEEN COR-
RECTED. USE OF A MALFUNCTIONING MACHINE
IS A SAFETY VIOLATION.
Once the walk-around inspection is complete, afunc-
tional check ofall systems should
be performed in an
area free of overhead and ground level obstructions.
Perform a functional check in accordance with the
following procedures:
1. Set-up machine for operation, according to
instructions
in Section 4-3, "Machine Set-Up &
Operation", i.e .. install outriggers, level ma-
chine, make sure all wheels are offground, etc.
2. Enterplatform, raise and lower platform two (2)
to three (3) feet several times. Check for
smooth elevation and lowering of platform.
3. With platform completely lowered, check hy-
draulic oil level in reservoir at ground control
station. Oil level should show full on the dip-
stick. Ifnecessary, add hydraulicfluid to proper
level. NEVER USE HYDRAULIC BRAKE
FLUID, refer to the Lubrication Chart,Figure
7-2,
for specific requirements.
2-6. TORQUE REQUIREMENTS
The Torque Chart, Figure 7-1, consists of standard
torque values based
on bolt diameter and grade, it
also specifies dry and wet torque values in accord-
ance with recommended shop practices. This chart is
provided as an aid to the user/operator in the event
he/she notices a condition that requires prompt atten-
tion during the walk-around inspection or during op-
eration until the proper service personnel can be
notified. Utilizing this Torque Chart in conjunction
with the preventive maintenance section
in Section 8,
will enhance the safety, reliability and performance of
the machine.
2-4 Change 1 -JLG Lift-
Go to Discount-Equipment.com to order your parts

JLG Lift SECTION 2 - PREPARATION AND INSPECTION JLG Lift
2-7. BATTERY CHARGING (DC Machines)
The battery-operated DC Models are equipped with
either a 115 Volt AC -50/60 Hz input or 230 Volt AC
-50/60 Hz input battery charger. Both battery charg-
ers have an output of 12Volts, and are equipped with
a 12-hourtimer. A CAUTION
WHEN ADDING DISTILLED WATER TO THE BAT-
TERIES, A NON-METALLIC CONTAINER AND/OR
FUNNEL MUST BE USED.
NO OPEN FLAMES OR SMOKING WHEN CHARG-
ING BATTERIES.
CHARGE BATTERIES ONLY IN A WELL VENTI-
LATEDAREA.
ENSURE THAT BATTERY ACID DOES NOT COME
INTO CONTACT WITH SKIN OR CLOTHING.
At the end of the work day, the batteries should be
charged forthe next days work. Check the electrolyte
level of the batteries, and adjust accordingly (cells
should
be completely covered but DO NOT OVERFILL,
allow for electrolyte expansion or battery will overflow
while charging). Add only distilled water to batteries.
Connect the battery charger to a properly grounded
receptacle using a suitable extension cord. Set the
battery charger timer switch for the desired charging
time. A fully charged battery will have a specific
gravity of between 1.260 -1.275
on a hydrometer.
If necessary, the machine may be operated while the
battery is charging.
Figure 2-2. Battery Box & Charger Assembly.
(DC Models only)
-JLGCrane-
2-5
2-6 Blank
Go to Discount-Equipment.com to order your parts

Go to Discount-Equipment.com to order your parts

JLG Lift SECTION
3- USER RESPONSIBILITIES & MACHINE CONTROLS JLG Lift
3-1. GENERAL
A IMPORTANT
SINCE THE MANUFACTURER HAS NO DIRECT
CONTROLOVER MACHINEAPPLICATION AND OP-
ERATION, CONFORMANCE WITH GOOD SAFETY
PRACTICES IN THESE AREAS IS THE RESPONSI-
BILITY OF THE USER AND HIS OPERATING PER-
SONNEL.
This section provides the necessary information
needed to understand control functions. Included
in
this section are the operating characteristics and limi-
tations, and functions and purposes of controls and
indicators. It is important that the user/operator read
and understand the proper procedures before oper-
ating the machine. These procedures will aid in ob-
taining optimum service life and safe operation.
3-2. PERSONNEL TRAINING
The aerial lift is a personnel handling device; there-
fore, it is essential that it be operated and maintained
only by authorized personnel who have demon-
strated that they understand the proper use and
maintenance of the machine. It is important that
all
personnel who are assigned to and responsible for
the operation and maintenance of the machine un-
dergo a thorough training program and check out
period in order to become familiar with the charac-
teristics prior to operating the machine.
In addition, personnel operating the machine should
be familiar with ANSI standard A92.3-1990, Respon-
sibilities. This standard contains sections outlining
the responsibilities of the owners, users, operators,
lessors and lessees concerning safety, training, in-
spection, maintenance, application and operation.
Persons under the influence of drugs or alcohol or
who are subject to seizures, dizziness or loss of
physical control must not be permitted to operate the
machine.
• OperatorTraining
Operator training must include instruction in the
following:
1. Use and limitations of the platform controls,
ground controls and emergency controls.
2. Knowledge and understanding of this manual
and of the control markings, instructions and
warnings
on the machine itself.
3. Knowledge and understanding of all safety
work rules of the employer and Federal, State
and
local Statutes, including training in the
recognition and avoidance ofpotential hazards
in thework place; with particularattentiontothe
work to be performed.
4. Proper use of all required personnel safety
equipment.
5. Sufficient knowledge ofthe mechanical opera-
tion ofthe machine to recognize a malfunction
or potential malfunction.
6. The safest means to operate near overhead
obstructions, other moving equipment, obsta-
cles, depressions, holes, drop-offs, etc.
on the
supporting surface.
7. Means to avoid the hazards of unprotected
electrical conductors.
a. Any other requirements of a specific job or
machine application.
• Training Supervision
Training must be done underthe supervision of a
qualified operator or supervisor
in an open area
free of obstructions until the trainee has devel-
oped the ability to safely control an aerial lift in
congested work locations.
• Operator Responsibility
The operator must be instructed that he has the
responsibility and authority to shut down the ma-
chine in case of a malfunction or other unsafe
condition ofeitherthe machine orthe job site and
to request further information from his supervisor
or JLG Distributor before proceeding.
Note
Manufacturer or Distributor will provide qualified
persons for training assistance with first unit(s)
delivered and thereafter as requested by user or his
personnel.
-JLG Lift-
3-1
Go to Discount-Equipment.com to order your parts