JLG X19J Operator Manual
Operation, Safety, Maintenance
and service Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
X20JPLUS
X20JPR002
April, 2013
JLG LIFT
FOREWORD
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.
13224 Fountainhead Plaza
Hagerstown, MD 21742
or Your Local JLG Office
(See addresses on manual cover)
In USA:
Toll Free: 877‑JLG‑SAFE (877‑554‑7233)
Outside USA:
Phone: 240‑420‑2661
Fax: 301‑745‑3713
E‑mail: ProductSafety@JLG.com
X20JPR002
X20JPR002
REVISION LOG
Rev. Manual code Date
Original Issue X20JPR002 April, 2013
JLG LIFT
FOREWORD
BOOM LIFT MODELS X20JPLUS
JLG
TABLE OF CONTENTS
CHAPTER 1 PRESENTATION ....................................................................................Page 08
CHAPTER 2 TECHNICAL INFORMATION ...........................................................Page 09
2.1 Description of the machine ...................................................................Page 09
2.1.1 Control position .....................................................................................Page 09
2.1.2 Machine identification plate .................................................................Page 12
2.1.3 Overall dimensions of the machine .....................................................Page 13
2.1.4 Technical specifications .........................................................................Page 14
2.1.4.1 Petrol engine technical specifications ..................................................Page 15
2.1.4.2 Diesel engine technical specifications..................................................Page 15
2.1.4.3 Hydraulic system technical specifications ..........................................Page 15
2.1.4.4 Electrical system technical specifications Thermic ............................Page 16
2.1.4.5 Electrical system technical specifications Lithium ............................Page 16
2.1.5 Terminology ............................................................................................Page 17
2.2 General safety standards .......................................................................Page 18
2.3 Safety warnings.......................................................................................Page 22
2.3.1 Generalities..............................................................................................Page 22
2.3.2 Noise and vibrations ..............................................................................Page 22
2.3.3 Pictograms positioned on the machine ...............................................Page 23
CHAPTER 3 SAFETY DEVICES..................................................................................Page 38
3.1 Battery cutout switch .............................................................................Page 39
3.2 Distributor pressure relief valves.........................................................Page 39
3.3 Cylinder stop valves...............................................................................Page 40
3.4 Alignment photocell on the aerial part of the structure and the
base of the machine ...............................................................................Page 40
3.5 Stabiliser position microswitches.........................................................Page 41
3.6 Jib position microswitch ........................................................................Page 41
3.7 Basket load sensor ..................................................................................Page 42
3.8 Control protection ..................................................................................Page 43
3.9 Spirit level ................................................................................................Page 43
3.10 Pin locking bolts and nuts .....................................................................Page 44
3.11 Safety device electronic control board.................................................Page 44
CHAPTER 4 INSTRUMENTS AND CONTROLS.....................................................Page 46
4.1 Remote control ........................................................................................Page 46
4.1.1 Display .....................................................................................................Page 47
4.1.1.1 Display main screen ...............................................................................Page 47
4.1.2 Joysticks ...................................................................................................Page 51
4.1.3 Push buttons............................................................................................Page 53
4.2 Footswitch ...............................................................................................Page 57
4.3 Control positions ...................................................................................Page 57
CHAPTER 5 EMERGENCY DEVICES .......................................................................Page 58
5.1 Emergency stop button..........................................................................Page 58
5.2 Hand pump .............................................................................................Page 59
5.3 Solenoid valves for emergency descent...............................................Page 59
5.4 Safety device bypass key .......................................................................Page 60
5.5 Emergency position controls.................................................................Page 61
CHAPTER 6 USING THE MACHINE........................................................................Page 66
6.1 Safety standards to adopt before using the platform ................................Page 66
6.1.1 Risk of electrocution...............................................................................Page 66
6.1.2 Danger due to atmospheric conditions ..............................................Page 67
6.1.3 Danger due to the work area ................................................................Page 67
6.2 Procedures for correct use.....................................................................Page 68
6.2.1 Summary table of operator safety standards......................................Page 68
6.3 Working area...........................................................................................Page 70
6.4 Using the elevating work platform (MEWP) .....................................Page 71
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6.4.1 Preliminary checks before starting work ...........................................Page 72
6.4.2 Starting the petrol/diesel engine .........................................................Page 73
6.4.3 Starting the electric motor ...................................................................Page 74
6.4.4 Stopping the engine/motor ...................................................................Page 76
6.4.5 Stopping the motor lithium version ....................................................Page 76
6.4.6 Travel ........................................................................................................Page 77
6.4.7 Jib arm movement for travel.................................................................Page 80
6.4.8 Parking the machine on a slope or on uneven ground ....................Page 82
6.4.9 Stabilising and levelling the machine..................................................Page 82
6.4.10 Automatic lowering and raising of the stabilisers ............................Page 86
6.4.11 Track gauge extension............................................................................Page 88
6.4.12 Moving the basket .................................................................................Page 89
6.4.13 Manually levelling the basket ..............................................................Page 93
6.5 Emergency operations on the aerial part ...........................................Page 94
6.5.1 Emergency descent controlled from the basket .................................Page 94
6.5.2 Operating the machine from the emergency control position
on the ground if the operator is taken ill ............................................Page 95
6.5.3 Emergency descent in the case where the stabilisers are
accidentally retracted .............................................................................Page 96
6.5.4 Emergency descent controlled from the ground using the hand
pump in the event of faults on all energy supply systems .............Page 98
6.5.5 Emergency operations on the carriage: moving the platform
stabilisers using the hand pump to allow the machine
to be transported.....................................................................................Page 100
6.5.6 Emergency operation of the undercarriage in the event of
movements of the aerial part ................................................................Page 101
6.6 Electrical disconnection of the remote control ...................................Page 103
6.7 Recharging the battery ..........................................................................Page 104
6.8 Main intended uses of the platform.....................................................Page 108
6.8.1 Systems.....................................................................................................Page 108
6.8.2 Closed environments .............................................................................Page 108
6.8.3 Pruning.....................................................................................................Page 108
6.8.4 Repair and maintenance of roofing and gutters ................................Page 109
6.8.5 Painting, sand‑blasting and plastering................................................Page 109
6.8.6 Use in marine environments.................................................................Page 109
CHAPTER 7 MAINTENANCE....................................................................................Page 110
7.1 Safety instructions for greasing and lubrication ................................Page 110
7.2 Table of recommended lubricants ........................................................Page 110
7.3 Greasing points .......................................................................................Page 112
7.4 Greasing the telescopic arm ..................................................................Page 113
7.5 Safety instructions for maintenance operations.................................Page 113
7.6 Operating the machine from the second control position on the
ground using the optional second remote control during
maintenance ............................................................................................Page 114
7.7 Periodic maintenance intervals.............................................................Page 115
7.8 Electric motor ..........................................................................................Page 117
7.8.1 Electric motor maintenance ..................................................................Page 117
7.9 Inspection and maintenance .................................................................Page 118
7.10 General periodic checks.........................................................................Page 120
7.11 Maintenance on the rubber tracks .......................................................Page 121
7.11.1 Checking the track tension....................................................................Page 121
7.11.2 Loosening/tightening the tracks...........................................................Page 121
7.11.3 Checking the rubber tracks ...................................................................Page 122
7.11.4 Replacing the rubber tracks ..................................................................Page 124
7.12 Checking tightness of nuts and bolts...................................................Page 125
7.13 Checking the hydraulic oil level...........................................................Page 129
7.13.1 Hydraulic oil............................................................................................Page 129
7.14 Checking for leaks in the hydraulic system........................................Page 129
7.15 Checking the condition of the filter cartridge ....................................Page 130
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7.16 Checking that all the plates are present on the machine
and intact .................................................................................................Page 130
7.17 Checking the operating pressure of the hydraulic system...............Page 131
7.18 Checking tightness of the fastening screws on the pin retainers
and the locknuts......................................................................................Page 131
7.19 Replacing /checking extension ropes...................................................Page 132
7.19.1 Checking wear and deformation of ropes and pulleys.....................Page 132
7.20 Three‑monthly inspection .....................................................................Page 133
7.21 Five‑yearly inspection............................................................................Page 135
7.22 Checking wear on the telescopic arm slides.......................................Page 136
7.23 Checking extension pulley wear ..........................................................Page 136
7.24 Checking tightness of the turntable bolts............................................Page 136
7.25 Battery: checks and maintenance ‑ thermic version ..........................Page 136
7.25.1 Checking the electrolyte level ‑ thermic version................................Page 137
7.25.2 Recharging the battery ‑ thermic version............................................Page 137
7.25.3 Replacing the battery ‑ thermic version ..............................................Page 138
7.25.4 Battery disposal.......................................................................................Page 138
7.26 Battery pack operating specifications..................................................Page 139
7.26.1 Components and diagrams ...................................................................Page 140
7.26.2 Personal protective equipment.............................................................Page 142
7.26.3 Handling in dangerous conditions ......................................................Page 142
7.26.3.1 Procedure for handling hot cells ..........................................................Page 143
7.26.3.2 Procedure for handling vented cells....................................................Page 144
7.26.3.3 Procedure for exploded cells.................................................................Page 145
7.26.3.4 Lithium battery fire ................................................................................Page 147
7.27 Servicing the engine ...............................................................................Page 149
CHAPTER 8 SAFETY STANDARDS FOR TRANSPORT ........................................Page 150
8.1 Removing the basket..............................................................................Page 150
8.2 Loading and unloading the machine on transport vehicles
using ramps .............................................................................................Page 151
8.3 Lifting the machine.................................................................................Page 152
8.3.1 Lifting the machine using a forklift ....................................................Page 153
8.3.2 Lifting the machine using ropes or chains ........................................Page 154
8.3.3 What to use to attach the platform.......................................................Page 155
8.4 Transporting the machine......................................................................Page 156
CHAPTER 9 SERVICE MENU ON THE REMOTE CONTROL .............................Page 157
9.1 Input menu ..............................................................................................Page 157
9.2 Error menu...............................................................................................Page 159
9.3 Operating hours menu...........................................................................Page 159
9.4 Settings menu..........................................................................................Page 159
9.5 Joystick menu ..........................................................................................Page 159
CHAPTER 10 TROUBLESHOOTING...........................................................................Page 160
CHAPTER 11 CHECKS TO BE COMPLETED ON THE MACHINE
FOLLOWING REPAIRS.........................................................................Page 168
11.1 Checking correct operation of the controls.........................................Page 168
11.2 Checking operation of the safety devices............................................Page 168
CHAPTER 12 HYDRAULIC SYSTEM..........................................................................Page 169
12.1 Hydraulic system diagram thermic version.......................................Page 169
12.1.1 Key to the hydraulic system diagram thermic version.....................Page 170
CHAPTER 13 WIRING DIAGRAM ..............................................................................Page 171
BOOM LIFT MODELS X20JPLUS
JLG
X20JPR0020413
PREFACE
The aim of this manual is to provide the user with the necessary instructions and essential
operating procedures to ensure correct and safe use of the machine for its intended purpo‑
ses, as well as to prevent serious injury to the operator and other persons.
IMPORTANT
IT IS MANDATORY TO KEEP TO ALL THE INSTRUCTIONS GIVEN IN THIS MANUAL.
THIS MANUAL MUST BE CAREFULLY READ AND UNDERSTOOD BEFORE OPERA‑
TING THE MACHINE.
As this manual is an essential work tool, it must be kept with the machine at all times, in the
special compartment, so as to be available for clarification whenever required.
As the manufacturer cannot control the conditions of the machine and the operations this is
used for, THE USER IS RESPONSIBLE for ensuring compliance with the safety procedures
described in this manual.
Every machine supplied is thoroughly adjusted and tested before being delivered. The ope‑
rator does not need to perform any adjustments before using the machine.
Every alteration and/or modification of the features of the original machine design without
previous written authorisation from the Constructor are PROHIBITED and THE RESPONSI‑
BILITY FOR THESE ACTIONS FALLS ON THE OPERATOR.
THE EMPLOYER MUST MAKE SURE THAT THE OPERATOR HAS THE REQUISITES
NECESSARY TO OPERATE THE MACHINE CORRECTLY AND THAT SUCH OPERA‑
TOR HAS CAREFULLY EXAMINED AND UNDERSTOOD THE INFORMATION
GIVEN IN THIS USER AND OPERATION MANUAL, RECEIVING SUITABLE TRAI‑
NING REGARDING USE OF THE MACHINE IN STANDARD AND EMERGENCY
CONDITIONS.
THE EMPLOYER MUST ALSO TRAIN OPERATORS REGARDING ANY NATIONAL
STANDARDS THAT ARE IN ADDITION TO THE INSTRUCTIONS CONTAINED IN
THIS DOCUMENT.
If the manual is damaged or lost, a copy must be requested directly from JLG.
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Note: All of the photos and drawings in this manual have been added to simplify com‑
prehension by the reader. Your machine may differ from the photos and drawings provi‑
ded.
NORMATIVE REFERENCES
The machine has been designed, built and inspected according to that prescribed in the
EN280 prA2:2009 harmonised standard, which supplies the presumption of conformity with
the Essential Safety Requisites of the 2006/42/CE Machinery Directive even if a type C Volun‑
tary Technical Standard.
According to that stated in EN280 prA2, the JLG platform is classified in GROUP B, as the
vertical projection of the centre of gravity of the load can be outside of the tilting lines and in
TYPE 1 as traversing is only allowed with the platform at rest.
The stability tests of the machine have been made in accordance with what described in
paragraph 6.1.4.2 of the EN280 with load test calculated in conformity with 5.2.4 and have
been successful.
In addition what prescribed in this manual it is necessary to apply the technical require‑
ments of the following national/international safety standards:
‑ UNI ISO 18893
‑ ISO 16368
‑ ISO 18878
With the exception of stricter local or national regulations in the working area of the MEWP.
WARRANTY
On purchasing a JLG platform, a warranty and inspection certificate is issued that clearly
indicates the warranty terms and where any interventions on the machine must be reported.
LIABILITY
The Constructor is exonerated from any liability and obligation for any injury/damage cau‑
sed to persons/objects due to any of the reasons listed below:
• Failure to comply with the instructions indicated in this USE AND MAINTENANCE
MANUAL regarding running, use and maintenance of the machine;
• Violent or sudden actions or incorrect manoeuvres when using or servicing the machine;
• Modifications made to the structure or machine components without previous authori‑
sation from the Constructor and/or without the use of suitable equipment;
• Strange events with respect to normal and correct use of the machine, described in this
USE AND MAINTENANCE MANUAL.
• Use of non‑original spare parts not authorised by the manufacturer.
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JLG
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BOOM LIFT MODELS X20JPLUS
JLG
EC DECLARATION OF CONFORMITY
EC DECLARATION OF
CONFORMITY
Manufacturer
Address
Technical File:
Authorised contact
Machine Type:
Model Type:
Serial Number:
Notified Body:
EC Number:
Address
JLG Industries Inc
1 JLG Drive
McConnellsburg
PA17233
USA
JLG Industries Inc
JLG Technology & Development Centre
Bruntingthorpe Aerodrome & Proving Ground
Lutterworth, Leicestershire
LE17 5QS
United Kingdom.
Alan S. McInt
Mobile Elevating Work Platform
...
...
ECO Certificazioni S.p.A
0714
Via Mengollna
33 - 48108
Faenza
Italy
yre
Position:
Manager, Engineering
Support - Europe
Certificate Number:
Reference Standards:
JLG Industries hereby declare that the above mentioned machine conforms
with the requirements of:
2006/42/EC Machiner
2004/108/EC EMC Directive
2000/14/EC Outdoor Noise
Signed:
Name: Alan S. McIntyre Position: Manager,Engineering Support-
Remark:
An
y modification to the above described machine violates the validity of this declaration.
This declaration conforms with the requirements of annex II-A of the council directive
2006/42/EC
Machine manufactured for JLG Industries Inc. by HINOWA S.p.a via Fontana 37054
NOGARA VR Ital
y
To Be Advised
EN12100-1 & 2:2003 + A1:2009
EN280:2001 + A2:2009
y
Date: ...
Europe
Place: Bruntingthorpe, UK
7
BOOM LIFT MODELS X20JPLUS
JLG
X20JPR0020413
y
y
EC DECLARATION OF
CONFORMITY
Manufacturer
Address
Machine Type:
Model Type:
Serial Number:
Document Control:
Measured
Lwa
Guaranteed
Lwa ...dB(A)
Engine Power:
...kW
Lwa = (Sound Power Level)
JLG Industries Inc
1 JLG Drive
McConnellsburg
PA17233
USA
Mobile Elevating Work Platform
...
...
HINOWA S.p.A
Via Fontana - 37054
Nogara
Italy
...dB(A)
Technical File:
JLG Industries Inc
JLG Technology &
Development Centre
Bruntingthorpe
Aerodrome & Proving
Ground
Lutterworth,
Leicestershire
LE17 5QS
United Kingdom.
Applicable Procedure:
Applicable Directive:
EN ISO 3744:1995
2000/14/EC Annex V Internal Control of Production.
We hereby declare that the above mentioned machine
conforms with the requirements of the "Noise Emission in
the Environment by Equipment for Use Outdoors"
Directive 2000/14/EC & 2005/88/EC
Remark:
This declaration conforms with the requirements of Annex II of the council directive
2000/14/EC
An
modification to the above described machine violates the validity of this declaration.
Machine manufactured for JLG Industries Inc. by HINOWA S.p.a via Fontana 37054
NOGARA VR Ital
1. PRESENTATION
This manual describes the warning signs used to draw the reader’s attention to several parti‑
cularly important warnings.
The safety warnings are divided into two main types, which are identified and described
below.
DANGER
This symbol accompanied by the word DANGER indicates that the situation
described, if not prevented, can lead to serious injury or death of the persons
involved (operator, ground staff, staff present in proximity to the platform, main‑
tenance technicians etc.).
WARNING
This symbol accompanied by the word WARNING indicates that the situation
described represents a potential risk for the structure of the machine.
Dangerous situations may be determined by this condition (including injury or
death) for the persons involved.
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2. TECHNICAL INFORMATION
2.1. DESCRIPTION OF THE MACHINE
The JLG machine is a self‑propelled hydraulic lifting device, equipped with a rotating work
basket positioned at the top of an extendable articulated structure, which also rotates. The
JLG lifting device is destined for the POSITIONING OF PERSONS AND THEIR EQUIP‑
MENT AND MATERIALS IN HIGH POSITIONS WITH RESPECT TO GROUND LEVEL.
2.1.1 CONTROL POSITION
‑ CONTROL POSITION IN THE BASKET
The JLG aerial work platform has been designed to be controlled by the operator in the
basket using a remote control, where all of the machine functional controls are gathered,
positioned in the relevant support inside the basket (see photo). A pedal (optional) is also
present in the basket in order to allow the movement of the aerial part (see picture).
From this control position it is possible to control the extendible structure and machine stabi‑
lisation. When the machine is manoeuvred from the control position in the basket, the remo‑
te control must be positioned in the appropriate seat, and the footswitch must be activated
(the footswitch must be release and activated again if no movements are made for more than
7 second). The remote control is connected to the machine using a flexible cable that allows
to shift it if the basket is to be removed or the ground control unit is to be used.
Stabilisation of the machine must be preferably controlled from the basket drive position.
Machine traversing must be carried out from the control position on the ground.
After accessing or leaving the control position in the basket, ALWAYS remember to close
the ladder, to avoid any damage when operating the machine.
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DANGER
ATTENZIONE
CONTROL POSITION ON THE GROUND:
There is a second control position available for the tracked part of the machine. This is not in
a fixed position but rather can be located on the ground within a radius of 2.5 m from the
basket attachment. To control the machine from this position, the operator uses the same
remote control, removing it from its housing in the basket and using the cable provided.
From this control position, the operator IS NOT enabled to control the aerial
part of the machine, but only the tracks, stabilisers and track extension func‑
tion.
DANGER! when controlling the machine from the ground position, keep a
distance of at least 1 m from the tracks.
DANGER! when controlling the machine from the ground position, always
make sure that the component that is being moved is completely visible and
constantly check its trajectory.
‑ EMERGENCY CONTROL POSITION
There is a control position which will be identified as the emergency control position. This is
located on the ground part of the machine, next to the distributor for the aerial part. To ena‑
ble it, press the special selector positioned on the base of the turret (see photo) until the green
warning light comes on. The light indicates that the movements of the aerial part are ena‑
bled.
From this position, the movements of the machine can be controlled directly using the levers
on the various hydraulic distributors, aerial part (see photo 1) and proportional (aerial part,
see photo 2).
The emergency control position was designed to operate on the extensible structure only
for emergency operations by emergency service personnel on the ground, who must in
any case be trained and know the operation of the machine and its safety devices, as well
as for maintenance and checks before starting work.
If an operator is in the basket, it is forbidden to move the structure from the ground posi‑
tion, unless in an emergency situation (sudden operator illness, technical fault).
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THERMIC MOTOR
LITHIUM MOTOR
DANGER
ATTENZIONE
There is a control position available only for scheduled and unscheduled maintenance opera‑
tions, placed near the electrical components compartment on the machine.
On the electric board protection there is an auxiliary connector for the connection of the
optional second remote control (see photo).
To enable this position, use the key selector placed on the base of the turret and connect the
optional second remote control to the machine.
Before proceeding with the connection, carefully read the paragraph regarding the use of
the optional second remote control.
This control position can only be used to carry out checks and maintenance on the machine.
Do not use this position to control the machine during normal operations.
Note: it is absolutely forbidden to move the machine from this position if one ore more
operators are in the basket.
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FOTO 1
FOTO 2
OPTIONAL SECOND REMOTE
CONTROL CONNECTOR POSITION
OPTIONAL SECOND REMOTE
CONTROL CONNECTOR
DANGER
ATTENZIONE
2.1.2 MACHINE IDENTIFICATION PLATE
The manufacturer plate is placed on the protection of the aerial part hydraulic distributor.
The drawing is shown below.
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BOOM LIFT MODELS X20JPLUS
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xsm1;Manufactured by
HINOWA S.p.A.
Via Fontana
JLG Industries. Inc - McConnellsburg. PA - USA
Model
Serial number
Date of manufacture
G.V.W. (Dry)
MAXIMUM ALLOWABLE OPERATING INCLINATION
37054 NOGARA (VR)
ITALY
kg
1°
=+
MAX
12.5 230 70
kgM/S kg kg
2x80
400
07253100
N
2.1.3 OVERALL DIMENSIONS OF THE MACHINE
Maximum length in travel configuration with basket installed ......................5011 mm
Track width ..............................................................................................................795/1095 mm
Maximum height in travel configuration with foot plates removed ..............1998 mm
Maximum attachment angle..................................................................................20°/ 36,4%
Maximum stabilisation angle ................................................................................15°
Max stabiliser base side (disc centre) ..................................................................2922x2925 mm
Nota: standard version with two‑operator basket.
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2.1.4 TECHNICAL SPECIFICATIONS
NB: Side extension is measured from the centre of the turntable to the outside edge of the
basket.
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JLG
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X20JPR0020413
PLATFORM CAPACITY 230 kg
PLATFORM HEIGHT (floor) 18,05 m
MAX WORKING HEIGHT 20,15 m
STANDARD BASKET DIMENSIONS 1335 x 690 x H1100 mm
MAX HORIZONTAL EXTENSION IN BASKET 9,20 m
MAX HORIZONTAL OUTREACH 9,70 m
ROTATION (non-continuous) 360°
BASKET ROTATION 124° (+/- 62°)
MAX GROUND REACTION FORCE FOR EACH
STABILISER
2150 daN
MAX GROUND PRESSURE FOR EACH STABILISER 3,04 daN/cm
2
NO. OF OPERATORS 2
NO. OF OPERATORS WITH OPTIONAL SINGLE-OPERATOR
BASKET
1
JIB - TYPE OF ARTICULATED JOINT 89°(+0°/-89°)
MAX WORKING GRADIENT 1°/1,75%
MAX STABILISATION SLOPE 15°
TOTAL WEIGHT IN TRANSPORT CONFIGURATION
(PETROL ENGINE)
2880 kg
ENGINE
HONDA iGX440 - (12,7 cv) / 3600 rpm
PERKINS 402.05 - (14 cv) / 3600 rpm
ELECTRIC MOTOR 2,2 kw / 230V / 50Hz 1500 rpm
ELECTRICAL SYSTEM VOLTAGE 12 V
PUMPS PETROL ENGINE double 2x4 cm³
PUMPS DIESEL ENGINE double 2x4 cm³
MAX TRANSLATION SPEED WITH STANDARD 2NDSPEED
(thermic motor)
0,5/1,3 / 2,5 Km/h
TRAVEL/STAB. SYSTEM PRESSURE 165 bar
AERIAL PART SYSTEM PRESSURE 210 bar
MAX SLOPE ALLOWED IN TRAVEL DIRECTION 15°
MAX WIND SPEED 12,5 m/s
MAX MANUAL FORCE ALLOWED 400 N
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2.1.4.1 TECHNICAL DATA – PETROL ENGINE
Make/Model ................................................................................HONDA iGX440
Fuel/Cooling ................................................................................PETROL/AIR
Power SAEJ1349 ..........................................................................9,5 Kw (12,7cv) / 3600rpm
Max speed ....................................................................................3600 rpm
Maximum torque ........................................................................29,8 Nm/2500 rpm (80/1269/EC)
Number of cylinders ............................................................................1
Displacement ..............................................................................440 cm
3
Sound power level at operator’s ear ........................................88 dB
Measured sound power level ..................................................102 dB
Granted sound power level ......................................................104 dB
2.1.4.2 TECHNICAL DATA – DIESEL ENGINE
Make/Model ................................................................................PERKINS 402.05
Fuel/Cooling ................................................................................DIESEL/AIR
Power SAEJ1349 ..........................................................................10,2 Kw (14cv) / 3600rpm
Max speed ....................................................................................3500 rpm
Maximum torque ........................................................................29,7 Nm/2400 rpm (80/1269/EC)
Number of cylinders ............................................................................2
Displacement ..............................................................................510 cm
3
Sound power level at operator’s ear ........................................90 dB
Measured sound power level ..................................................102 dB
Granted sound power level ......................................................104 dB
2.1.4.3 HYDRAULIC SYSTEM TECHNICAL SPECIFICATIONS
Hydraulic oil tank capacity ......................................................40 litres
Pump petrol engine ....................................................................double pump 2x4 cm
3
Pump diesel engine ....................................................................double pump 2x4 cm
3
Hydraulic system max pressure ..............................................210 bars
For further information, see the hydraulic diagram enclosed with the manual and the para‑
graph on maintenance of the hydraulic components.
2.1.4.4 ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS THERMIC
Battery ................................................................................55 Ah ‑ 240 A ‑ 12V
Alternator petrol engine ..................................................20 A (3600 rpm)
Alternator diesel engine ..................................................15 A (3600 rpm)
Electric motor: ‑ rated voltage ......................................230 V
‑ frequency............................................50 Hz
‑ rated power........................................2,2 kW
For further information, see wiring diagram enclosed with the manual and the paragraph on
maintenance of electrical components.
2.1.4.5 ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS LITHIUM
Battery ................................................................................90 Ah ‑ 70V
Electric motor: ‑ rated voltage ......................................48 V
‑ rated power........................................2 kW
Sound power level at operator’s ear ..............................70 dB
Measured sound power level ..........................................86 dB
Granted sound power level..............................................88 dB
Onboard battery charger ..................................................220V±30V 50÷60Hz
Battery charger (option)....................................................110V±30V 50÷60Hz
For further information, see wiring diagram enclosed with the manual and the paragraph on
maintenance of electrical components.
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JLG
2.1.5 TERMINOLOGY
To make the contents of this manual easier to understand, the diagram provided below illu‑
strates the terms used to identify the parts of the platform.
LEGENDA
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17
1 Tracked undercarriage 19 First extension arm
2 Revolving turret 20 Jib cylinder
3 Turntable + rotation motor 21 Right and left Jib arm
4 Emergency controls 22 Second extension arm
5 Base+electrical component compartment+oil tank 23 Remote control
6 Double gear pump 24 Basket or cage
7
Petrol/diesel engine / Battery pack + inverter +
battery charger (
LITHIUM MOTOR)
25 Basket support
8 Stabiliser 26 Rotary actuator for basket rotation
9 Stabiliser cylinder 27 Basket levelling cylinder on the basket
10 Second arm tie rod 28 Jib transmission
11 Second arm 29 First-second arm transmission
12 Second-third arm cylinder 30 First-second arm cylinder
13 Second-third arm transmission 31 First arm
14 Second-third arm connecting rod 32
15 Basket levelling cylinder on the transmission 33 Electric motor
16 Third arm 34 Double gear pump
17 Stabiliser plate 35 Emergency hand pump
18 Jib tie rod
2.2 GENERAL SAFETY STANDARDS
The functioning of the MEWP must be in compliance with international standards of referen‑
ce (see paragraph “NORMATIVE REFERENCES” in the first pages of the manual) and natio‑
nal or regional standards if stricter.
The operator must read, understand and follow all the instructions and warnings, contained
in this manual and on the machine, regarding the safe use of the MEWP.
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS SECTION
AND PROVIDED ON THE MACHINE CAN DAMAGE THE MACHINE AND CAUSE
INJURY OR EVEN DEATH, AND CONSTITUTES A SERIOUS BREACH OF THE SAFETY
RULES.
This section of the USER AND OPERATION MANUAL describes those procedures or dan‑
gerous situations that can cause damage/injury to objects/persons and explains what the ope‑
rator must do to prevent them.
• Operators must always act professionally, complying with safety standards, making sure
not to underestimate their responsibility to themselves and the surrounding objects and per‑
sons.
• Before starting work, operators must receive complete and clear training regarding the
use of the machine in standard and emergency conditions. They must examine, under‑
stand and take in all the instructions given in this user manual. They must be sure that the
safety devices are in perfect working order, perform the necessary checks on the machine
and be familiar with the conditions of the ground on which the machine is going to be
operated and stabilised.
• The presence of at least one specialist operator is necessary on the ground during work.
This person must know how to use the machine, be aware of the contents of the USER AND
OPERATION MANUAL and be able to intervene if necessary.
• It is prohibited to make modifications to the machine that could jeopardise functioning and
safety, without previous written authorisation from The Constructor which is not liable for
any injury or damage caused by this behaviour.
Clothing and protective equipment
Avoid wearing loose clothing, rings, watches or anything
else that may get caught in moving parts.
When using the machine or performing maintenance, wear a
hard hat, glasses, safety footwear, gloves and acoustic ear‑
muffs after making sure these and all other PPE that the
safety manager considers necessary based on the risk analy‑
sis performed are in perfect working condition.
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BOOM LIFT MODELS X20JPLUS
JLG
ATTENZIONE
DANGER
USE THE TYPE‑APPROVED AND CERTIFIED SAFETY HARNESSES. BEFORE WORKING
AT A HEIGHT, MAKE SURE THAT THE SAFETY HARNESSES ARE CORRECTLY FASTE‑
NED AND CONNECTED TO THE ANCHORAGE POINTS ON THE BASKET.
T
HE USE OF HARNESSES IS COMPULSORY IN ACCORDANCE WITH LOCAL LEGISLATION IN EACH INDI‑
VIDUAL COUNTRY. IN COUNTRIES WHERE THE LAW DOES NOT REQUIRE THE USE OF SUCH SAFETY
SYSTEMS
, THE EMPLOYER AND/OR USER IS RESPONSIBLE FOR CHOOSING THE SYSTEM TO BE USED.
Safety valves and electrical system safety components
It is prohibited to modify and/or tamper with the safety and control valves of the main
hydraulic system and the adjustments of the electric plant. The Constructor is not liable
for injury to persons and damage to objects or to the machine if the standard calibration
of any hydraulic and electric/electronic component is tampered with.
Fire prevention
Keep the area around the motor clean, removing fragments of
wood, paper and other flammable products; clean any fuel
leaks as these may be a potential cause of fire.
Petrol is extremely flammable and explosive in particular con‑
ditions. Refuel in well ventilated areas and with the engine at
rest.
Avoid smoking and producing sparks in the refuelling and
fuel storage area.
After refuelling, make sure to put back the cap correctly. Take care to avoid touching the
exhaust silencer when this is hot, i.e. with the machine running or soon after stopping the
engine.
Preventing damage caused by washing the machine
Do not direct high pressure jets towards the electrical compo‑
nents while washing the machine. Do not use chemical deter‑
gents or petrol that would damage the plastic parts and the
painting.
BEFORE WASHING THE MACHINE, ALWAYS REMEMBER TO REMOVE THE REMO‑
TE CONTROL AND CORRECTLY CLOSE THE REMOTE CONTROL AND EQUIP‑
MENT CONNECTION SOCKETS LOCATED ON THE MACHINE.
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BOOM LIFT MODELS X20JPLUS
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19
WARNING
IMPORTANTE
• Cleaning the machine
Always park the machine as shown in the figure in point 2.1.5.
When washing the machine, the ignition block must be disengaged, the key removed and the
emergency stop button pressed.
• Washing the outside of the machine
Never use flammable liquids. Adopt the above safety measures to
prevent sparks due to short‑circuits.
If washing the track with water cleaners, carefully protect all the
important parts and above all the electrical components. Follow the
instructions provided by the manufacturer of the detergent.
Clean the machine using water‑soluble detergents.
The more the elevating platform is cleaned, the more it will need to be greased (see par. 7.3
Grease points).
Do not wet the electric motors and the other electrical components directly. Do not aim the
spray directly onto adhesive labels and rating plates.
• Cleaning the electrical system
Never clean the inverter or the electric motor with water, as this may
cause damage to the electrical system.
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BOOM LIFT MODELS X20JPLUS
JLG
ATTENZIONE
DANGER
DANGER
DANGER
IMPORTANT
1001125483
ATTENZIONE
ATTENZIONE
1001125483
Only use dry detergents, in accordance with the manufacturer’s instructions. Never remove
covers, guards and the like.
‑ Clean the electrical system using a dry, non‑metallic brush and low pressure air.
• After cleaning
Dry the machine carefully before starting it again (for example using compressed air).
If, despite all the precautions, moisture has penetrated into the electric motor or other parts
of the electric system, these must be dried using compressed air to avoid the risk of short‑cir‑
cuits.
Preventing damage that may be caused by the machine during work
When the machine has been stabilised and work has started, never enter its operating area.
Always operate the controls slowly and smoothly and avoid reversing the movements sud‑
denly.
When operating outside of the basket, ALWAYS keep a MINIMUM distance of 1 METRE
from the machine.
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BOOM LIFT MODELS X20JPLUS
JLG
21
WARNING
DANGER
IMPORTANTE
ATTENZIONE
2.3 SAFETY WARNINGS
2.3.1 GENERALITIES
To avoid accidents, before starting work and before performing
any maintenance operations, it is necessary to read, understand
and follow all the precautions and warnings contained in this
manual. The user/operator of the machine must decline all
responsibility for operation until having read this manual and
fully understood how to use the machine under the supervision
of an expert and qualified operator.
Carefully read all the safety messages provided in this manual and the safety signs on the
machine.
Keep the safety signs in good condition and replace them if they are damaged.
Make sure that any new components on the machine are provided with the correct safety signs.
2.3.2 NOISE AND VIBRATIONS
The JLG platforms with electric motor have been tested according to the parameters of Euro‑
pean directive 2000/14 EC, with the guaranteed sound power level measurement shown on
the machine’s EC declaration of conformity.
When operating the aerial part of the machine, this value is reduced even further as the
basket moves away from the main source of noise.
The vibrations transmitted to the operator from the controls and directly from the floor of
the basket are lower than the maximum allowed limits.
BOOM LIFT MODELS X20JPLUS
JLG
22
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23
2.3.3 PICTOGRAMS POSITIONED ON THE MACHINE
Here we report the positions of the various boards with pictograms on the machine.
BOOM LIFT MODELS X20JPLUS
JLG
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BOOM LIFT MODELS X20JPLUS
JLG
X20JPR0020413
BOOM LIFT MODELS X20JPLUS
JLG
25
BOOM LIFT MODELS X20JPLUS
JLG
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X20JPR0020413
POS. CODE Q.ty
36 1701542 1
36 1701505 1
37 06056300 1
38 06164600 1
39 06232100 1
40 07240300 1
41 07320400 4
42 07034200 2
43 07397200 1
44 1608710001 1
45 1608710002 1
46 07199100 1
47 06254800 1
48 06922700 2
49 07350300 4
50 06214200 1
51 06594500 1
52 07071000 1
53 06136900 1
POS. CODE Q.ty
1 6555500 1
2 6555600 1
3 6555700 1
4 6555800 1
5 6041200 4
6 1001125483 6
7 1706898 1
8 6924300 1
9 1706493 1
10 6040500 2
11 6040900 6
12 6041300 11
13 1703814 4
14 6044000 4
15 6086600 2
16 1704277 2
17 1705828 1
18 7056700 6
19 1701499 2
20 7058800 2
21 6040300 4
22 1706098 1
23 7349200 1
24 7056800 3
25 06086000 1
26 06085900 1
27 06706500 1
28 06998800 1
29 07242000 1
30 1702155 1
31 1701504 1
32 06164700 1
33 06165000 1
34 06060000 1
35 06227200 1
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