JLG X23J, X700AJ Operator Manual

Operation, Safety, Maintenance and service Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models

X23J

X23JR062

January, 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: [phone]

Fax: [phone]

E mail: [e-mail]

X23JR062

JLG LIFT

FOREWORD

REVISION LOG

Rev.	Manual code	Date
Original Issue	X23JR002	January, 2011
01	X23JR012	February, 2011
02	X23JR022	February, 2011
03	X23JR032	March, 2011
04	X23JR042	March, 2012
05	X23JR052	December, 2012
06	X23JR062	January, 2013

X23JR062

BOOM LIFT MODELS X23J

JLG

INDEX

CHAPTER	1	PRESENTATION ....................................................................................	Page 08
CHAPTER	2	OPERATOR MANUAL .........................................................................	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	Machine clearance ..................................................................................	Page 13
	2.1.4	Technical data..........................................................................................	Page 14
	2.1.4.1	Petrol engine technical data ..................................................................	Page 15
	2.1.4.2	Diesel engine technical data..................................................................	Page 15
	2.1.4.3	Hydraulic system technical data ..........................................................	Page 15
	2.1.4.4	Electric plant technical data ..................................................................	Page 16
	2.1.4.5	Electrical system technical specifications lithium..............................	Page 16
	2.1.5	Terminology ............................................................................................	Page 17
	2.1.6	Transport and stabilisation position (standard version)...................	Page 21
	2.2	General safety standards .......................................................................	Page 22
	2.3	Safety warnings.......................................................................................	Page 26
	2.3.1	Generalities..............................................................................................	Page 26
	2.3.2	Noise and vibrations ..............................................................................	Page 26
	2.3.3	Pictograms positioned on the machinea .............................................	Page 27
CHAPTER	3	SAFETY DEVICES ..................................................................................	Page 40
	3.1	Battery cut off..........................................................................................	Page 41
	3.2	Distributors over pressure valves ........................................................	Page 41
	3.3	Cylinder cut off valves...........................................................................	Page 42
	3.4	Alignment photocell of the aerial part of the structure and machine base ..	Page 42
	3.5	Outriggers position micro switches .....................................................	Page 43
	3.6	Jib position micro switch .......................................................................	Page 45
	3.7	Ropes integrity micro switch ................................................................	Page 45
	3.8	Basket load sensor ..................................................................................	Page 45
	3.9	Control protections.................................................................................	Page 46
	3.10	Spirit level ................................................................................................	Page 46
	3.11	Screws and nuts locking pins................................................................	Page 47
	3.12	Safety device control circuit board.......................................................	Page 49
	3.13	Outrigger joint lock pins........................................................................	Page 50
	3.14	Arms position sensors............................................................................	Page 50
CHAPTER	4	INSTRUMENTS AND CONTROLS.....................................................	Page 51
	4.1	Remote control ........................................................................................	Page 51
	4.1.1	Display .....................................................................................................	Page 52
	4.1.1.1	Display main screen.................................................................................	Page 52
	4.1.2	Joystick .....................................................................................................	Page 57
	4.1.3	Buttons ......................................................................................................	Page 59
	4.2	Footswitch.................................................................................................	Page 63
	4.3	Control positions ......................................................................................	Page 63
CHAPTER	5	EMERGENCY DEVICES .......................................................................	Page 64
	5.1	Emergency stop button..........................................................................	Page 64
	5.2	Hand pump .............................................................................................	Page 65
	5.3	Solenoid valves for emergency descent...............................................	Page 65
	5.4	Safety devices by pass key ....................................................................	Page 65
	5.5	Emergency position control ..................................................................	Page 66
CHAPTER	6	MACHINE USE ......................................................................................	Page 72
	6.1	Safety standards to adopt before using the platform................................	Page 72
	6.1.1	Electrocution hazard ..............................................................................	Page 72
	6.1.2	Danger due to atmospheric conditions ...............................................	Page 72
	6.1.3	Danger due to the work area ................................................................	Page 73
	6.2	Procedures for correct use .....................................................................	Page 73
	6.2.1	Summary table of the safety standards for the operator ................	Page 73

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	6.3	Working area ...........................................................................................	Page 75
	6.4	Use of the elevating work platform (MEWP) .....................................	Page 76
	6.4.1	Preliminary checks before starting work ............................................	Page 77
	6.4.2	Starting the petrol and diesel engine ..................................................	Page 78
	6.4.3	Starting the electric engine ....................................................................	Page 79
	6.4.4	Engine turning of....................................................................................	Page 81
	6.4.5	Stopping the motor lithium version.....................................................	Page 81
	6.4.6	Operative load automatic selection......................................................	Page 82
	6.4.7	Passage from transport configuration to stabilisation
		configuration Standard version............................................................	Page 82
	6.4.8	Traversing ................................................................................................	Page 86
	6.4.9	Jib arm movement for traversing .........................................................	Page 88
	6.4.10	Parking the machine on slopes or on uneven ground.......................	Page 90
	6.4.11	Stabilising and levelling the machine ..................................................	Page 90
	6.4.12	Automatic stabilization and destabilization.......................................	Page 94
	6.4.13	Track widening........................................................................................	Page 96
	6.4.14	Basket movement....................................................................................	Page 96
	6.4.15	Manual levelling of the cage .................................................................	Page 102
	6.5	Aerial part emergency manoeuvres.....................................................	Page 104
	6.5.1	Activation of emergency descent from the basket.............................	Page 104
	6.5.2	Manoeuvre of the machine from the emergency position on the
		ground in the case of sudden indisposition of the operator ............	Page 105
	6.5.3	Activation of the emergency descent in the case of accidental
		destabilisation of the machine ..............................................................	Page 106
	6.5.4	Activation of the emergency descent from the ground in case of operator
		indisposition, engine functioning and electric plant broken down.......	Page 108
	6.5.5	Activation of the emergency descent from the ground with manual
		pump if all energy systems should break down ...............................	Page 110
	6.5.6	Track part emergency manoeuvre: movement of the platform
		outriggers with manual pump to allow machine tran sport............	Page 112
	6.5.7	The manoeuvre illustrated successively must only be performed
		with the machine closed ........................................................................	Page 113
	6.6	Electrical disconnection of the remote control ...................................	Page 116
	6.7	Recharging the battery...........................................................................	Page 117
	6.8	Main declared uses of the platform .....................................................	Page 121
	6.8.1	Plant engineering....................................................................................	Page 121
	6.8.2	Closed rooms...........................................................................................	Page 121
	6.8.3	Use for pruning.......................................................................................	Page 121
	6.8.4	Use for repair and maintenance of roofs and gutters........................	Page 122
	6.8.5	Use for painting, sanding and plastering............................................	Page 122
	6.8.6	Use in marine environment...................................................................	Page 122
CHAPTER	7	MAINTENANCE....................................................................................	Page 123
	7.1	Greasing and lubrication specifications ..............................................	Page 123
	7.2	Table of recommended lubricants ........................................................	Page 123
	7.3	Greasing points .......................................................................................	Page 125
	7.4	Greasing the telescopic extension arm ................................................	Page 125
	7.5	Maintenance safety regulations............................................................	Page 126

7.6Manoeuvre of the machine from the second emergency position from the ground through

	the optional second remote control in case of maintenance operations	......Page 127
7.7	Periodic maintenance limits ..................................................................	Page 128
7.8	Electric motor ..........................................................................................	Page 131
7.8.1	Electric motor maintenance...................................................................	Page 131
7.9	Inspection and maintenance .................................................................	Page 132
7.10	General periodic control ........................................................................	Page 134
7.11	Rubber track maintenance.....................................................................	Page 135
7.11.1	Checking track tension...........................................................................	Page 135
7.11.2	Operations for loosening/tightening the track ...................................	Page 135
7.11.3	Checking the rubber tracks ...................................................................	Page 136
7.11.4	Replacing the rubber tracks ..................................................................	Page 138

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	7.12	Checking tightness of nuts and bolts...................................................	Page 139
	7.13	Checking hydraulic oil level .................................................................	Page 144
	7.13.1	Hydraulic oil............................................................................................	Page 144
	7.14	Checking leakage from the hydraulic system ....................................	Page 144
	7.15	Checking the status of the filtering cartridge .....................................	Page 144
	7.16	Checking the presence and integrity of the machine plates ............	Page 145
	7.17	Checking the working pressures of the hydraulic system ...............	Page 145
	7.18	Checking tightness of the screw fasteners of the pin retainers
		and the locknuts......................................................................................	Page 146
	7.19	Replacing/checking extension ropes and pulleys ..............................	Page 146
	7.19.1	Checking wear and deformation of ropes and pulleys.....................	Page 147
	7.20	Three monthly inspection .....................................................................	Page 148
	7.21	Five year inspection ...............................................................................	Page 150
	7.22	Checking wear of the telescopic arm slide blocks .............................	Page 150
	7.23	Checking extension pulley wear ..........................................................	Page 151
	7.24	Checking tightness of the coupling element screws..........................	Page 151
	7.25	Battery: checks and maintenance thermic version.............................	Page 151
	7.25.1	Checking the electrolyte thermic version............................................	Page 151
	7.25.2	Re charging the battery thermic version.............................................	Page 152
	7.25.3	Replacing the battery thermic version.................................................	Page 153
	7.25.4	Disposal of the battery ...........................................................................	Page 153
	7.26	Battery pack operating specifications..................................................	Page 153
	7.26.1	Components and diagrams ...................................................................	Page 154
	7.26.2	Personal protective equipment .............................................................	Page 156
	7.26.3	Handling in dangerous conditions ......................................................	Page 156
	7.26.3.1	Procedure for handling hot cells ..........................................................	Page 156
	7.26.3.2	Procedure for handling vented cells ....................................................	Page 157
	7.26.3.3	Procedure for exploded cells.................................................................	Page 159
	7.26.3.4	Lithium battery fire ................................................................................	Page 160
	7.27	Engine maintenance thermic version ..................................................	Page 162
CHAPTER	8	SAFETY STANDARDS REGARDING TRANSPORT .......................	Page 162
	8.1	Removing the basket..............................................................................	Page 162
	8.2	Safety standards regarding transport..................................................	Page 163
	8.3	Lifting the machine.................................................................................	Page 164
	8.3.1	How and where to attach the platform ...............................................	Page 165
	8.3.2	What to use to attach the platform.......................................................	Page 165
	8.4	Transporting the machine......................................................................	Page 166
CHAPTER	9	REMOTE CONTROL SERVICE MENU ..............................................	Page 168
	9.1	Menu' input .............................................................................................	Page 168
	9.2	Errors menu.............................................................................................	Page 170
	9.3	Working hours menu .............................................................................	Page 170
	9.4	Set up menu ............................................................................................	Page 170
	9.5	Joystick menu ..........................................................................................	Page 170
CHAPTER	10	TROUBLESHOOTING...........................................................................	Page 171
CHAPTER	11	CHECKS TO MAKE ON THE MACHINE AFTER REPAIRS..........	Page 178
	11.1	Checking the correct functioning of controls .....................................	Page 178
	11.2	Checking functioning of the safety devices ........................................	Page 178
CHAPTER	12	HYDRAULIC SYSTEM ..........................................................................	Page 179
	12.1	Hydraulic system diagram thermic version .......................................	Page 179
	12.2	Key to the hydraulic system diagram thermic version .....................	Page 181
	12.3	Hydraulic system diagram lithium version........................................	Page 182
	12.4	Key to the hydraulic system diagram lithium version........................	Page 184
CHAPTER	13	ELECTRIC PLANT.................................................................................	Page 185
	13.1	Electric plant thermic version ...............................................................	Page 185
	13.2	Electric plant lithium version................................................................	Page 187

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PREFACE

The scope of this manual is to supply the user with the necessary instructions and indispen sable operational procedures in order to favour the correct and safe use of the machine for the objectives to which it is destined and to prevent serious injury to the operator and others.

IMPORTANT

ALL INFORMATION PRESENTED IN THIS MANUAL IS UNQUESTIONABLE AND IT MUST BE READ CAREFULLY AND UNDERSTOOD BEFORE MAKING ANY MANOEU VRES WITH THE MACHINE.

As this manual is the most important work instrument, it must always be kept in the machi ne, in the relevant compartment, in order to always be available at any time for clarifications.

As it is impossible for the manufacturer to check the status of the machine and the opera tions it performs THE USER IS RESPONSIBLE for compliance with the safety procedures described in this manual.

Every machine is adjusted and inspected scrupulously before delivery so that the operator does not have to perform adjustments.

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 CHECK THAT THE OPERATOR HAS THE VOCATIONAL REQUISITES NECESSARY FOR RUNNING THE MACHINE CORRECTLY AND THAT HE HAS CAREFULLY EXAMINED AND UNDERSTOOD THAT STATED IN THIS USE AND MAINTENANCE MANUAL, RECEIVING SUITABLE TRAINING REGARDING USE OF THE MACHINE IN STANDARD AND EMERGENCY CONDITIONS.

THE EMPLOYER MUST ALSO TRAIN THE OPERATORS REGARDING ANY NATIO NAL STANDARDS THAT COMMEWSTE THAT CONTAINED IN THIS DOCUMENT.

If the manual is damaged or lost, a copy must be requested directly from JLG.

Note: All of the photos and drawings inserted in this manual have been added to ease comprehension by the reader. The machine you own may differ from some parts of the photos and drawings given.

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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 Essen tial Safety Requisites of the 2006/42/CE Machinery Directive even if a type C Voluntary 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 requirements 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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EC DECLARATION OF CONFORMITY
	EC DECLARATION OF
	CONFORMITY
Manufacturer	JLG Industries Inc
Address	1 JLG Drive
	McConnellsburg
	PA17233
	USA
Technical File:	JLG Industries Inc
	JLG Technology & Development Centre
	Bruntingthorpe Aerodrome & Proving Ground
	Lutterworth, Leicestershire
	LE17 5QS
	United Kingdom.
Authorised contact	Alan S. McIntyre	Position: Manager, Engineering
		Support - Europe
Machine Type:	Mobile Elevating Work Platform
Model Type:	...
Serial Number: ...
Notified Body:	ECO Certificazioni S.p.A
EC Number:	0714
Address	Via Mengollna
	33 - 48108
	Faenza
	Italy
Certificate Number:	To Be Advised
Reference Standards:	EN12100-1 & 2:2003 + A1:2009
	EN280:2001 + A2:2009

JLG Industries hereby declare that the above mentioned machine conforms with the requirements of:

2006/42/EC	Machinery
2004/108/EC	EMC Directive
2000/14/EC	Outdoor Noise

Signed:		Date:	...
Name:	Alan S. McIntyre	Position:	Manager,Engineering Support-
			Europe
		Place:	Bruntingthorpe, UK

Remark:

Any 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 Italy

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EC DECLARATION OF

CONFORMITY

Manufacturer	JLG Industries Inc
Address	1 JLG Drive
	McConnellsburg
	PA17233
	USA
Machine Type:	Mobile Elevating Work Platform
Model Type:	...
Serial Number:	...
Document Control:	HINOWA S.p.A		Technical File:	JLG Industries Inc
	Via Fontana - 37054			JLG Technology &
	Nogara			Development Centre
	Italy			Bruntingthorpe
				Aerodrome & Proving
				Ground
				Lutterworth,
				Leicestershire
				LE17 5QS
				United Kingdom.
Measured
Lwa	dB(A)...
Guaranteed
Lwa	dB(A)...
Engine Power:	kW	...
Lwa	= (Sound Power Level)
Applicable Procedure:	EN ISO 3744:1995
Applicable Directive:	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

Any 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 Italy

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1. PRESENTATION

This manual presents the warning signs used to bring 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 of the platform, main tenance technicians etc.).

ATTENTION

This symbol accompanied by the word ATTENTION indicates that the situation described represents a potential risk for the structure of the machine. Dangerous situations could be determined from this condition (also injury or death) for the persons involved.

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2. OPERATOR MANUAL

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 CAGE

The JLG overhead 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 button is also present in the basket to allow movement of the aerial part (photo).From this control position it is possible to control the extendible structure and machine stabilisation. When the machine is manoeu vred from the control position in the basket, the remote control must be positioned in the appropriate seat, and the footswitch must be pushed (the footswitch must be release and pressed again if no movements are made for more of 7 second). The remote control is con nected to the machine using a flexible cable that allows to shift it if the basket is to be remo ved 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.

ATTENTIONAT ENZIONE

After having reached or left the control position in the basket, ALWAYS remember to close the ladder to avoid any damages during the use of the machine. After having left the con trol position in the basket always remember to close the remote control protection cover.

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CONTROL POSITION ON THE GROUND:

There is a second control position for the track part. This position is not fixed but is located on the ground within a radius equal to 2.5m from the basket attachment. To control the machine, use the same remote control present in the basket, which is withdrawn from its seat and moved away from the basket using the free cable length available.

This control position IS NOT enabled to control the aerial part of the machine, but only the trailers, outriggers and track widening.

ATTENTION: when controlling the machine from the ground position keep at a distance of at least 1m from the tracks.

ATTENTION: when the machine is controlled from the ground position always check there is complete visibility of the component that is

to be moved and its trajectory for the entire duration of the movement.

EMERGENCY CONTROL POSITION

There is a control position that will be identified as the emergency control position. It is on the part of the machine on the ground in correspondence with the aerial part distributor. To enable, act on the relevant selector switch at the base of the turret (see photo) until the green indicator switches on. This indicates movement enabling of the aerial part.

THERMIC MOTOR		LITHIUM MOTOR

From here it is possible to make machine movements by acting directly on the levers present on the various hydraulic distributor elements, aerial (see photo 1) and proportional areas (aerial part see photo 2).

ATTENTIONATT NZIONE

The emergency control position has been designed, to operate on the extendible structure only for emergency manoeuvres by rescue staff on the ground, which must be trained and have know how regarding the functioning of the machine and its safety devices, for main tenance interventions and to perform checks before starting work.

It is prohibited to move the structure from the ground position, if someone is present in the basket, unless it is an emergency situation (sudden indisposition of the operator, tech

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nical breakdown).

PHOTO 1

PHOTO 2

There is a control position usable only for operations of ordinary and extraordinary mainte nance operations, position placed next the machine near the electic components box.

At the back of the protection box of the circuit board an auxiliary connector is placed for the connection of the optional second remote control (see picture).

POSITION OF THE OPTIONAL SECOND	OPTIONAL SECOND REMOTE
REMOTE CONTROL CONNECTOR	CONTROL CONNECTOR

To enable this position it is necessary to operate on 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 read carefully paragraph regarding the use of the optional second remote control.

ATTENZIONEATTENTION

This control position is usable only to carry out controls and maintenance on the machine. Do not use this position to control the machine during normal working 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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2.1.2 MACHINE IDENTIFICATION PLATE

The manufacturer’s plate is located in the front of the machine, on the electric engine protec tion sump.

The image is shown below.

Manufactured by

HINOWA S.p.A.

Via Fontana

37054 NOGARA (VR)

JLG Industries. Inc - McConnellsburg. PA - USA

ITALY

Model
Serial number
Date of manufacture
G.V.W. (Dry)	kg
MAXIMUM ALLOWABLE OPERATING INCLINATION	1°

MAX	12.5	M/S	200	kg	2x80	kg	40	kg	400	N
					=	+

MAX

12.5

M/S

120

kg

1x80

kg

40

kg

200

N

07041700

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2.1.3 MACHINE CLEARANCE

Maximum length in running order with basket installed

................................

6003 mm

Track width ..............................................................................................................

990/1290 mm

Maximum height in running order ......................................................................

1990 mm

Approach angle ......................................................................................................

22°

Maximum stabilisation angle on individual axle ..............................................

13°

Outriggers max. base side......................................................................................

3983 mm

Note: standard version with double manned basket.

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2.1.4 TECHNICAL DATA

	PLATFORM CAPACITY	200 kg	120 kg
	PLATFORM HEIGHT (walkway surface)	19,70 m	21,10 m
	MAX WORKING HEIGHT	21,80 m	23,20 m
	STANDARD BASKET DIMENSIONS	1335 x 690 x H1100 mm
	HORIZONTAL REACH (basket not rotated)	9,75 m	11,13 m
	MAX. HORIZONTAL WORK REACH (basket not rotated)	10,25 m	11,63 m
	ROTATION (non-continuous)	360°	360°
	BASKET ROTATION	124° (+/- 62°)
	MAX GROUND REACTION FORCE FOR EACH STABILISER	2100 daN
	MAX GROUND PRESSURE FOR EACH STABILISER	3 daN/cm2
	NO. OF OPERATORS	2	1
	JIB - TYPE OF ARTICULATED JOINT		85° (-1°/-86°)
	MAX WORKING GRADIENT	1°/1,75%
	MAX STABILISATION SLOPE	13°
	TOTAL EMPTY MACHINE WEIGHT (Petrol vers.)	2990 kg
	TOTAL EMPTY MACHINE WEIGHT (Diesel vers.)	3100 kg
	ENGINE	HONDA iGX440-12,7CV-3600 rpm
		PERKINS 402.05 -14CV-3600 rpm
		2.2 kw/230V/50Hz single phase 1500 rpm
	ELECTRIC MOTOR	2.2 kw/240V/50Hz single phase 1500 rpm
		2.2 kw/110V/50Hz single phase 1500 rpm
	ELECTRICAL SYSTEM VOLTAGE	12 V
	PUMPS	2x4.27cc
	MAX. TRAVERSING SPEED Autotwospeed	1,0 / 1,7 km/h (thermic motor)
	MAX. TRAVERSING SPEED Autotwospeed	0,7 / 1,2 km/h (lithium motor)
	TRAVEL/STAB. SYSTEM PRESSURE	160 bar
	AERIAL PART SYSTEM PRESSURE	200 bar
	MAX SLOPE ALLOWED IN TRAVEL DIRECTION	15°
	MAX WIND SPEED	12,5 m/s
	MAX MANUAL FORCE ALLOWED	400 N

NB: The lateral reach is measured from the coupling attachment centre to the external edge of the cage.

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JLG
2.1.4.1 PETROL ENGINE TEHNICAL DATA
Mark/Model........................................................................	HONDA iGX440
Fuel/Cooling ......................................................................	PETROL/AIR
Power SAEJ1349 ................................................................	9,5 kW (12,7 CV) / 3600 rpm
Maximum adjusted output rpm......................................	3600 rpm
Maximum torque ..............................................................	29,8 Nm/2500 rpm (80/1269/EC)
Number of cylinders..................................................................	1
Displacement......................................................................	440 cm3
Cooling................................................................................	air
Sound pressure level at operator’s ear ..........................	88 dB
Measured sound power level ..........................................	102 dB
Guaranteed sound power level ......................................	104 dB
2.1.4.2 DIESEL ENGINE TECHNICAL DATA
Mark/Model........................................................................	PERKINS 402.05
Fuel/Cooling ......................................................................	DIESEL/LIQUID
Power SAEJ1349 ................................................................	10,2 kW (14 CV) / 3600 rpm
Adjusted maximum speed rpm ......................................	3500 rpm
Maximum torque ..............................................................	29,7 Nm/2400 rpm (80/1269/EC)
Number of cylinders..................................................................	2
Displacement......................................................................	510 cm3
Cooling................................................................................	liquid
Sound pressure level at operator’s ear ..........................	90 dB
Measured sound power level ..........................................	102 dB
Guaranteed sound power level ......................................	104 dB
2.1.4.3 HYDRAULIC SYSTEM TECHNICAL DATA
Hydraulic oil tank capacity..............................................	48 liters
Engine pump......................................................................	double 2x4,27cm3
Hydraulic system max. pressure ....................................	200 bar

For further information, refer to the hydraulic layout attached to the manual and the para graph relative to maintenance of these components.

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2.1.4.4 ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS THERMIC

Battery ................................................................................	55 Ah 417 A 12V
Alternator petrol engine ..................................................	20 A (3600 rpm)
Alternator diesel engine ..................................................	15 A (3600 rpm)
Electric engine: nominal voltage ..................................	230V (110 V, 240 V optional)
frequency............................................	50 Hz (60 Hz optional)
nominal power ..................................	2,2 kW

For further information, refer to the wiring diagram attached to the manual and the para graph relative to maintenance of these components.

2.1.4.5 ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS LITHIUM

Battery ................................................................................		90 Ah 70V
Electric motor:	rated voltage ..................................	80 V
	rated power ....................................	3500 W
Sound pressure level at operator’s ear ..........................		70 dB
Measured sound power level ..........................................		86 dB
Guaranteed sound power level ......................................		88 dB

Onboard battery charger ..................................................	220V±10V 50÷60Hz
Battery charger (option)....................................................	110V±10V 50÷60Hz

Max power absorbed by the battery charger during recharge phase: 3000W

For further information, see wiring diagram enclosed with the manual and the paragraph on maintenance of electrical components.

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2.1.5 TERMINOLOGY

To make the content of this manual easier to understand, a layout is put at the reader’s disposal that gives the exact terms with which the parts of the platform will be identified.

THERMIC MOTOR

KEY

1 Tracked undercarriage

2Emergency controls

3 Overhead part distributors

4Swivelling turret

5 Coupling attachment + rotation motor

6Diesel tank (only in diesel version)

7Base

8 Track part distributors compartment

9Oil tank

10Outrigger joint

11Geared double pump

12Petrol/diesel engine

13Jib return

14Outrigger cylinder

15Outrigger

16First arm

17First arm tie rod

18First second arm cylinder

19First second arm return

20Jib arm

21Jib return

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22Basket on basket levelling cylinder

23Rotary actuator for basket rotation

24Basket support

25Basket access ladder

26Basket

27Use and maintenance manual compartment

28Movement control remote control

29Jib tie rod

30Jib cylinder

31Telescopic arm 2

32Telescopic arm1

33Third arm

34Outrigger plate

35Second third arm return

36Basket levelling cylinder on connection

37Third arm cylinder

38Second arm

39Second arm tie rod

40Double pump with gears

41Proportional valves compartment and hand pump

42Electric components compartment

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LITHIUM MOTOR

KEY

1 Tracked undercarriage

2Emergency controls

3 Overhead part distributors

4Battery charge

5 Coupling attachment + rotation motor

6Swiveling turret

7Base

8 Track part distributors compartment

9Oil tank

10Outrigger joint

11Geared double pump

12Battery pack + inverter + battery charger (LITHIUM MOTOR)

13Electric motor

14Outrigger cylinder

15Outrigger

16First arm

17First arm tie rod

18First second arm cylinder

19First second arm return

20Jib arm

21Jib return

22Basket on basket levelling cylinder

23Rotary actuator for basket rotation

24Basket support

25Basket access ladder

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26Basket

27Use and maintenance manual compartment

28Movement control remote control

29Jib tie rod

30Jib cylinder

31Telescopic arm 2

32Telescopic arm1

33Third arm

34Outrigger plate

35Second third arm return

36Basket levelling cylinder on connection

37Third arm cylinder

38Second arm

39Second arm tie rod

40Ignition key

41Proportional valves compartment and hand pump

42Electric components compartment + buffer battery

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2.1.6 TRANSPORT AND STABILISATION POSITION (STANDARD VERSION)

The overhead platform has rotating outriggers on a joint connecting the frame and outrigger itself.

Regarding the outriggers, two positions are defined:

•TRANSPORT POSITION

•STABILISATION POSITION

The transport position is defined as the completely closed configuration and aligned with the completely lifted and turned outriggers in a way to be parallel to the machine axle. This configuration is the most compact possible for the machine and is that recommended for all traversing operations on flat surfaces.

In the transport configuration, the vicinity of the outrig ger plates to the basket handrail creates a potential shearing hazard, it is appropriately indicated with stickers.

Do not place the hands in this area during traversing phases.

The stabilisation position is defined as that with the outriggers raised from the ground, but turned by about 45° with respect to the machine axis in a way to almost create a square with the outrigger plates positioned on the ends.

A lock pin with spring positioning blocks the outrig gers in one or other position.

IMPORTANTEIMPORTANT

For the stabilization positions of the version with variable stabilization area please read paragraph 6.4.6 Passage from transport configuration to stabilisation configuration Stan dard version.

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2.2 GENERAL SAFETY STANDARDS

ATTENZIONEWARNING

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 STATED ON THE MACHINE CAN CAUSE INJURY OR DEATH OF THE STAFF AND DAMAGE TO THE MACHINE AND CONSTITUTES A SERIOUS INFRACTION OF THE SAFETY STANDARDS.

This section of the USE AND MAINTENANCE MANUAL describes those procedures or dangerous situations that can cause damage/injury to objects/persons and what the operator must do to prevent them.

•The operator must always act as a professional, complying with safety standards, paying attention not to under estimate his responsibility to himself and all objects and persons that surround him.

•Before starting work it is indispensable that the operator has been completely and clearly trained regarding the use of the machine in standard and emergency conditions. That he has examined, understood and taken in all that stated in this user manual. That he is sure that the safety devices are in perfect working order, that the necessary checks on the machine are performed and that he becomes familiar with the conditions of the ground on which he must manoeuvre and stabilise.

•The presence of at least one specialised person is necessary on the ground during working. This person must know how to use the machine and be aware of the content of the USE AND MAINTENANCE MANUAL and can 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.

Protection devices and garments

Do not wear loose clothing, rings, watches or anything else that may become entangled in moving parts.

When using the machine or performing maintenance wear a hard helmet, goggles and accident prevention shoes, gloves and hearing protection after having checked their integrity along with any other IPD that the safety manager deems necessary according to the risk analysis he has performed.

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IMPORTANTEIMPORTANT

ALWAYS WEAR TYPE APPROVED AND CERTIFIED THE SLINGING. WHEN WORKING AT A HEIGHT MAKE SURE YOU ARE WEARING THE SAFETY BELTS CORRECTLY AND THEY HAVE BEEN APPROPRIATELY ATTA CHED TO THE RELEVANT ANCHORAGE POINTS ON THE BASKET.

THE USE OF THE SLINGINGS IS COMPULSORY IN CONNECTION WITH THE LOCAL REGULATINS OF EVERY SINGLE STATE. IN THOSE STATES WHERE THE LAW DOES NOT REQUIRE THE USE OF HOLDING SYSTEMS, THE CHOICE IS OF THE EMPLOYER OR/AND USER

Safety valves and safety components of the electric system

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 engine clean, removing fragments of wood, paper and other inflammable products; clean any fuel leaks as they can be a potential cause of fire.

Petrol is extremely inflammable and explosive in particular conditions. Re fuel in a well aired place with the engine at a standstill.

Do not smoke or make sparks in the re fuel area or fuel stora ge area.

After having re fuelled, make sure the cap is closed securely.

Do not touch the exhaust when hot during machine functioning or immediately after the engine is switched off.

Prevention of damage caused by washing the machine

Do not aim high pressure jets onto electric components when washing the machine. Do not use chemical detergents or petrol that could cause serious damage to plastic components and the paintwork.

ALWAYS REMEMBER TO REMOVE THE REMOTE CONTROL AND COR RECTLY CLOSE THE REMOTE CONTROL CONNECTION SOCKETS AND EQUIPMENT POSITIONED ON THE MACHINE, BEFORE WASHING.

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• Cleaning the machine

Always park the machine as shown in the figure in point 2.1.6.

ATTENTIONAT ENZIONE

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.

ATTENTIONA ENZIONE

The more the elevating platform is cleaned, the more it will need to be greased (see par.

Grease points).

ATTENTIONTENZIONE

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

ATTENTIONATT NZIONE

Never clean the inverter or the electric motor with water, as this may cause damage to the electrical system.

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IMPORTANTEIMPORTANT

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).

ATTENTIONTTENZIONE

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.

Prevention of damage caused by the working machine

When the machine is stabilised and work started, do not enter its radius of action. Systematically manoeuvre the controls slowly and regularly, do not reverse movements abruptly.

During work operations outside of the basket, ALWAYS remain at a MINIMUM DISTANCE OF 1 METER from the machine.

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2.3 SAFETY WARNINGS

2.3.1 GENERALITIES

To prevent accidents, before starting work or carrying out any maintenance, read, understand and follow all precautions and warnings contained in this manual. The user / operator of the machine must refuse all operating responsibility until this manual has been read and he has learned to manoeuvre the machine completely under the surveillance of a skilled and qua lified operator.

Carefully read all safety messages in this manual along with the safety signs on your machi ne.

Keep the safety signs in a good state and replace them if they are damaged. Make sure that any new machine components have the correct safety signs.

2.3.2 NOISE AND VIBRATIONS

The JLG platforms with engine have been tested according to the parameters of the 2000/14 CE European Standard, having a guaranteed sound power level detected, stated in the machines EC Declaration of Conformity.

During the use of machines for aerial operations this value is further reduced due to the moving away of the basket from the main source of noise.

The values of the vibrations transmitted to the operator via the controls and directly from the surface of the basket resulted less than the maximum accepted limits.

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