Service & Maintenance Manual - 3121166 - Safety Precautions

Oct 23, 2026

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Service & Maintenance Manual for models including 3121166, providing critical maintenance safety precautions for working on an aerial platform. It emphasizes strict observance of warnings to prevent injury or equipment damage, including compliance requirements, safe handling of heavy parts, and correct support when lifting. The manual details hydraulic system high-pressure risk, procedures to relieve system pressure, and mandatory practices during maintenance such as replacing equivalent parts, avoiding smoking/refueling during electrical storms, and shutting off all power controls before adjustments or lubrication.

LanguageEnglish

CategoryResearch & Report

FormatPDF

Pages222

Reading Time9 h 19 min

AccessFree to download

SECTION A -INTRODUCTION-MAINTENANCE SAFETY PRECAUTIONS

A General

B Hydraulic System Safety

C Maintenance

SECTION 1 -SPECIFICATIONS

1.1 Specifications

1.2 Torque Requirements

1.3 Lubrication

Service & Maintenance Manual Models 1930ES 2030ES 2630ES 2646ES 3246ES 3121166 November 27, 2013 SECTION A. 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 warningsand precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate. MODIFICATION OF THE MACHINE WITHOUT CERTIFICATION BY A RESPONSIBLE AUTHORITY THAT THE MACHINE IS AT LEAST AS SAFE AS ORIGINALLY MANUFACTURED, IS A SAFETY VIOLATION. The specific precautions to be observed during 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 weight. 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 RESPONSIBILITY OF THE OWNER/OPERATOR. B. HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Relieve system pressure by cycling the applicable control several times with the engine stopped and ignition on, to direct any line pressure back into the reservoir. Pressure feed lines to system components can then be disconnected with minimal fluid loss. C. MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION MAY RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS. • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES. • 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 WARNINGS AND CAUTIONSON MACHINE AND IN SERVICE MANUAL. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS. • USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM. • NEVER WORK UNDER AN ELEVATED SCISSOR UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR SAFETY PROP HAS BEEN ENGAGED. • 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. 3121166 –JLG Lift – a REVISION LOG NOTE: All machines built before mid-year 2010 are equipped with the Sevcon-1600346 Power Module, in mid-year 2010 a new design ZAPI-1001092456 Power Module was introduced for production. ES Scissors built in the USA and Belgium maybe equipped with either one of two different power modules after mid-2010. All China built machines were equipped the ZAPI-1001092456 Power Module. If power module service is required, see Section-3 in order to locate and identify which power module your machine is equipped with. Original Issue-May 27, 2003 Revised-October 31, 2003 Revised-March 19, 2004 Revised-July 8, 2004

FAQs

What is the key safety requirement before modifying the machine?

Modification without certification by a responsible authority that the machine is at least as safe as originally manufactured is a safety violation.

How should system pressure be relieved before disconnecting hydraulic components?

Relieve pressure by cycling the applicable control several times with the engine stopped and ignition on, directing line pressure back into the reservoir before disconnecting lines with minimal fluid loss.

What maintenance precautions are mandatory before performing adjustments or lubrication?

Shut off all power controls before making adjustments, lubricating, or performing other maintenance, and disconnect the battery during replacement of electrical components.

Oct 23, 2026

Upload by sagouaw