JLG X23J Operator Manual

ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X390AJ
P/N - 3128792
NOTES:
SECTION - FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
3128792 – JLG Lift – a
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL DECAL WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.
RESULT IN SERIOUS INJURY OR DEATH. THIS
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
RESULT IN MINOR OR MODERATE INJURY. IT MAY
b – JLG Lift – 3128792
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BUL­LETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHO­RIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
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
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

Contact :

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA
or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

3128792 – JLG Lift – c
Phone: 240-420-2661 E-mail: ProductSafety@JLG.com
SECTION - REVISION LOG
Original Issue of Manual . . . . . . . . . . . . . . . . . July 22, 2011
Manual Revised . . . . . . . . . . . . . . . . . . September 16, 2011

REVISION LOG

d – JLG Lift – 3128792
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
SAFETY ALERT SYMBOLS AND
SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . 1-1
1.2 BEFORE OPERATING THE LIFT . . . . . . . . . . . . . . . 1-2
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . . 1-8
1.4 LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . . 1-9
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . . 1-9
SECTION - 2 - PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND
MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . 3-1
3.2 PLATFORM/REMOTE CONTROL STATION. . . . . . 3-4
Control Position On The Ground: . . . . . . . . . . . . 3-4
Control Position From In The Platform: . . . . . . . . 3-5
Platform/Remote Control Station Functions . . . . 3-6
Platform/Remote Control Station LCD Display . 3-10
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2
Gas/Diesel Starting Procedure . . . . . . . . . . . . . . 4-2
Gas/Diesel Engine Shutdown Procedure . . . . . . 4-3
Electric Engine Starting Procedure -
AC Voltage Machine. . . . . . . . . . . . . . . . . . . . . . . 4-4
3128792 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Electric Engine Starting Procedure -
LITHIUM-ION Machine . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . .4-6
4.5 TRACKS - DRIVING, STEERING AND
TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . .4-7
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . .4-7
Travelling (Grades and Side Slopes) . . . . . . . . . . 4-7
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . . 4-9
Setting Outriggers From the Platform/Remote
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-12
4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . . 4-13
Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . .4-13
Platform Level Adjustment . . . . . . . . . . . . . . . . .4-13
Raise And Lower The Tower Boom . . . . . . . . . .4-15
Raise And Lower The Main Boom . . . . . . . . . . .4-15
Telescope The Main Boom. . . . . . . . . . . . . . . . . 4-15
Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-15
Emergency Lowering . . . . . . . . . . . . . . . . . . . . . 4-17
Platform Removal/Installation . . . . . . . . . . . . . . .4-17
4.8 BATTERY CHARGING -
GAS/DIESEL/AC-ELECTRIC . . . . . . . . . . . . . . . . . 4-18
Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-18
4.9 BATTERY CHARGING - LITHIUM-ION MACHINE .4-19
Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-20
Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4.10 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . 4-22
4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-23
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
4.12 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . 4-26
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . 5-1
Power Main Cut-Off Switch Location . . . . . . . . . . 5-1
Operator Unable to Control Machine. . . . . . . . . . 5-2
Platform or Boom Caught Overhead . . . . . . . . . . 5-2
Manual Descent with Engine Running and
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Manual Descent with Engine Running but without
Electrical Power (Combustion Engine Only) . . . . 5-6
Manual Descent without Engine and
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Outrigger/Track Movement Emergency
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
5.4 SAFETY DEVICES BYPASS KEY USE . . . . . . . . . 5-13
Using The Emergency Descent In The Case Of An Outrigger Losing Contact With The Ground. 5-14 Machine Realignment Emergency Procedure. . 5-15
5.5 LITHIUM-ION BATTERY PACK - HANDLING IN
DANGEROUS CONDITIONS. . . . . . . . . . . . . . . . . 5-17
Procedure For Handling Hot Cells. . . . . . . . . . . 5-17
ii – JLG Lift – 3128792
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Procedure For Handling Vented Cells . . . . . . . . 5-18
Procedure For Exploded Cells . . . . . . . . . . . . . . 5-20
Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . . 5-21
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . .6-2
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lithium-Ion Electrical Specifications. . . . . . . . . . . 6-4
Major Component Weights. . . . . . . . . . . . . . . . . . 6-4
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Rubber Track Maintenance/Replacement . . . . . 6-13
Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . 6-15
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-16
Battery Maintenance and Charging -
Gas/Diesel/AC-Electric . . . . . . . . . . . . . . . . . . . . 6-16
6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . . 6-17
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.5 PLATFORM/REMOTE CONTROL
SERVICE MENU. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Service Button. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-20
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-21
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . 6-21
Battery Pack System Components and
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-24
BMS Fault Codes - (Battery Management
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-28
SECTION - 7 - INSPECTION AND REPAIR LOG
3128792 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Basic Machine Nomenclature . . . . . . . . . . . . . .2-6
2-2. Daily Walk-Around Inspection . . . . . . . . . . . . . .2-8
3-1. Swing Control Valve . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Ground Control Station . . . . . . . . . . . . . . . . . . .3-3
3-3. Platform/Remote Control Station . . . . . . . . . . . .3-9
4-1. Ground/Emergency Control Box . . . . . . . . . . . . 4-2
4-2. Grade and Side Slope Definition . . . . . . . . . . . .4-8
4-3. Platform/Remote Control Box. . . . . . . . . . . . . . 4-14
4-4. Platform - Load/Reach Chart . . . . . . . . . . . . . . 4-16
4-5. Lifting Machine - Attach Points . . . . . . . . . . . . . 4-24
4-6. Machine Tie-Down Points. . . . . . . . . . . . . . . . .4-25
4-7. Decal installation - Standard - Right Side . . . .4-26
4-8. Decal Installation - Standard - Left Side . . . . . . 4-27
4-9. Decal installation - Lithium-Ion - Left Side . . . .4-32
4-10. Decal Installation - Lithium-Ion - Right Side . . .4-33
5-1. Platform/Remote Control Station . . . . . . . . . . . .5-3
5-2. Ground Control Station . . . . . . . . . . . . . . . . . . .5-5
5-3. Proportional Flow Valve . . . . . . . . . . . . . . . . . . .5-6
5-4. Hand Pump - On Top of Hydraulic Tank . . . . . . 5-7
5-5. Outrigger/Track Valve Tray - Cover Removed .5-12 6-1. Lubrication and Maintenance Point Locations. .6-5 6-2. Component Maintenance Intervals -
X390AJ - with HONDA Engine . . . . . . . . . . . . . . 6-7
6-3. Component Maintenance Intervals -
X390AJ - with HATZ Diesel Engine . . . . . . . . . .6-8
6-4. Component Maintenance Intervals -
X390AJ - LITHIUM-ION Machine . . . . . . . . . . . . 6-9
6-5. Lithium-Ion Battery Pack Components . . . . . . 6-22
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . 1-5
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . 1-7
2-1 Inspection and Maintenance Table. . . . . . . . . . . 2-3
3-1 LCD Display Icon Descriptions . . . . . . . . . . . . . 3-12
3-2 LCD Display Error Descriptions . . . . . . . . . . . . 3-14
4-1 X390AJ - Decal Installation - Standard . . . . . . . 4-28
4-2 X390AJ - Decal Installation - LITHIUM-ION. . . . 4-34
6-1 Operating Specifications. . . . . . . . . . . . . . . . . . . 6-2
6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Chassis Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 Honda iGX390 Specifications . . . . . . . . . . . . . . . 6-3
6-6 Hatz 1B30 Specifications . . . . . . . . . . . . . . . . . . 6-3
6-7 Lithium Ion Specifications. . . . . . . . . . . . . . . . . . 6-4
6-8 Major Component Weights. . . . . . . . . . . . . . . . . 6-4
6-9 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . 6-6
6-10 Inverter Fault Codes . . . . . . . . . . . . . . . . . . . . . 6-24
6-11 Battery Charger Fault Codes . . . . . . . . . . . . . . 6-28
iv – JLG Lift – 3128792
SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for tow­ing and also proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the informa­tion provided in this manual and the Service and Mainte­nance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine should not operate the machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.
If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR DEATH.

Operator Training and Knowledge

• Read and understand this manual before towing or operating the machine.
• Do not operate this machine until complete training is performed by authorized persons.
• Only authorized and qualified personnel can operate the machine.
• Read, understand, and obey all DANGERS, WARN­INGS, CAUTIONS, and operating instructions on the machine and in this manual.
• Use the machine in a manner which is within the scope of its intended application set by JLG.
3128792 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• All operating personnel must be familiar with the emer­gency controls and emergency operation of the machine as specified in this manual.
• Read, understand, and obey all applicable employer, local, and governmental regulations as they pertain to towing and operation of the machine.

1.2 BEFORE OPERATING THE LIFT

Workplace Inspection

• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.
• Before operation, check work area for overhead haz­ards such as electric lines, bridge cranes, and other potential hazards.
• Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.
• Do not operate the machine in hazardous environ­ments unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.
• This machine can be operated in temperatures of 14 F to 104o F (-10o C to 40o C). Consult JLG for opera­tion outside this range.
o
1-2 – JLG Lift – 3128792
SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.
• Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.
• Be sure all safety devices are operating properly. Mod­ification of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which safety or instruction placards or decals are missing or illegible.
• Check the machine for modifications to original com­ponents. Ensure that any modifications have been approved by JLG.
• Avoid any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1.3 OPERATION

General

• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
• Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine.
• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next func­tion. Operate controls with slow and even pressure.
• Do not allow personnel to tamper with or operate the machine from the ground with personnel in the plat­form, except in an emergency.
• Do not carry materials directly on platform railing unless approved by JLG.
• When two or more persons are in the platform, the operator shall be responsible for all machine opera­tions.
• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.
• Supplies or tools which extend outside the platform are prohibited unless approved by JLG.
3128792 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Do not assist a stuck or disabled machine by pushing, pulling, or by using extending structure functions.
• Do not place boom or platform against any structure to steady the platform or to support the structure.
• Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an autho­rized lanyard anchorage point. Attach only one (1) lan­yard per lanyard anchorage point.
• Before operating the machine, make sure all gates are closed and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all times. Do not climb on platform rails. Never use ladders, boxes, steps, planks, or similar items on plat­form to provide additional reach.
• Never use the boom assembly to enter or leave the platform.
• Always use the intended access gate to enter or leave the platform.
• Use extreme caution when entering or leaving plat­form. Be sure that the platform is fully lowered. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.
1-4 – JLG Lift – 3128792
SECTION 1 - SAFETY PRECAUTIONS

Electrocution Hazards

• This machine is not insulated and does not provide protection from contact or proximity to electrical cur­rent.
• Maintain safe distance from electrical lines, apparatus, or any energized (exposed or insulated) parts accord­ing to the Minimum Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line sway­ing.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus car­rying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.
MINIMUM APPROACH DISTANCE
in Feet (Meters)
3128792 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
• The minimum approach distance may be reduced if insu­lating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment.
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIB­ITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• The user should be familiar with the surface before operating. Do not exceed the allowable sideslope and grade while operating.
• Do not elevate platform while on a soft surface.
• Before operating on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distrib­ute loads evenly on platform floor.
• Do not raise the platform unless the machine is on firm surfaces and outriggers are properly set.
• Keep the chassis and outriggers of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs,
1-6 – JLG Lift – 3128792
obstructions, debris, concealed holes, and other potential hazards on the floor/surface.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure. Never attach wire, cable, or any similar items to platform.
Table 1-2. Beaufort Scale (For Reference Only)
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises ver tically.
1 1-3 0.3-1.5 Light air Wind motion visible in smoke.
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle.
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion.
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
Wind Speed
Description Land Conditions
mph m/s
Umbrella use becomes difficult.
3128792 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability and could result in a tip-over.
• Do not increase the platform size with unauthorized platform extensions or attachments.
• If boom assembly or platform is in a position that one or more outriggers are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropri­ate equipment to stabilize machine.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personnel.
• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering plat­form, and driving.
• During operation, keep all body parts inside platform railing.
• Always post a lookout when driving in areas where vision is obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all operations.
1-8 – JLG Lift – 3128792
SECTION 1 - SAFETY PRECAUTIONS
• Be aware of stopping distances in all drive speeds. When driving in high speed, slow down the machine using the controllers before stopping.
• Do not use high speed drive in restricted or close quarters or when driving in reverse.
• Under all travel conditions, the operator must limit travel speed according to conditions of ground sur­face, congestion, visibility, slope, location of person­nel, and other factors causing hazards of collision or injury to personnel.
• Exercise extreme caution at all times to prevent obsta­cles from striking or interfering with operating controls and persons in the platform.
• Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1.4 LIFTING, AND HAULING

• Never allow personnel in platform while lifting or haul­ing the machine.
• Ensure boom is in the stowed position prior to lifting or hauling. The platform must be completely empty.
• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for lifting information.

1.5 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.
• Charge batteries only in a well ventilated area.
3128792 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
NOTES:
1-10 – JLG Lift – 3128792
SECTION 2 - PREPARATION AND INSPECTION

SECTION 2. PREPARATION AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical con­trol must not operate this machine.

Operator Training

Operator training must cover:
1. Use and limitations of the controls in the platform
and at the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of
the machine to recognize a malfunction or potential malfunction.
6. The safest means to operate the machine where
overhead obstructions, other moving equipment, obstacles, depressions, holes, and drop-offs exist.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a quali­fied person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.
3128792 – JLG Lift – 2-1
SECTION 2 - PREPARATION AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspec­tions and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SER­VICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COM­PLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3128792
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type Frequency
Pre-Start Inspection Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection (See Note)
Frequent Inspection In service for 3 months or 150 ho urs, whichever
Annual Machine Inspection Annually, no later than 13 months from the date
Preventative Maintenance At intervals as specified in the Service and Main-
NOTE: Inspection forms are available from JLG. Refer to Section 6 - Operators Maintenance when performing inspections.
Before each sale, lease, or rental delivery. Owner, Dealer, or
comes first; o r Out of service for a p eriod of more than 3 months; o r Purchased used.
of prior inspection.
tenance Manual.
Primary
Responsibility
User or Operator User or Operator Operation and Safety Manual
User
Owner, Dealer, or User
Owner, Dealer, or User
Owner, Dealer, or User
Service
Qualification
Qualified JLG Mechanic
Qualified JLG Mechanic
Fact ory Train ed Service Technician (Recommended)
Qualified JLG Mechanic
Reference
Service and Maintenance Manual and applicable JLG inspection form
Service and Maintenance Manual and applicable JLG inspection form
Service and Maintenance Manual and applicable JLG inspection form
Service and Maintenance Manual
3128792 – JLG Lift – 2-3
SECTION 2 - PREPARATION AND INSPECTION
Pare nt Met al Cra ck
Weld Crack

Pre-Start Inspection

The Pre-Start Inspection should include each of the fol­lowing:
1. Cleanliness – Check all surfaces for leakage (oil,
fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for dents,
damage, weld or parent metal cracks or other dis­crepancies.
3. Decals and Placards – Check all for cleanliness
and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.
4. Operation and Safety Manuals – Make sure a copy
of the Operation and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is enclosed in the weather resistant storage container.
5. Walk-Around Inspection – Refer to Figure 2-2.
6. Battery – Charge as required.
7. Fuel (Combustion Engine Powered Machines) – Add
the proper fuel as necessary.
8. Engine Oil Supply (Combustion Engine Powered
Machines) - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure
hydraulic oil is added as required.
10. Accessories/Attachments - Reference the Opera-
tion and Safety Manual of each attachment or acces­sory installed upon the machine for specific inspection, operation, and maintenance instructions.
11. Function Check – Once the “Walk-Around” Inspec-
tion is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more spe­cific operating instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
2-4 – JLG Lift – 3128792
MAKE SURE THE ENGINE KEY SWITCH IS ON, THE BATTERY DIS­CONNECT SWITCH IS TURNED (ON), AND THE POWER/EMER­GENCY STOP BUTTONS AT THE GROUND AND PLATFORM CONTROL BOX IS TURNED CLOCKWISE (ON).

Function Check

MAKE SURE NO FUNCTIONS (EXCEPT TRACK FUNCTIONS) OPER­ATE WHEN THE OUTRIGGERS ARE NOT PROPERLY SET.
After properly setting up on outriggers, perform the func­tion check as follows:
1. From the ground control console with no load in the
platform:
a. Check that all guards protecting the function
control switches and controllers are in place.
b. Operate all functions.
c. Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in.
d. Ensure all boom functions stop when the func-
tion enable switch is released.
SECTION 2 - PREPARATION AND INSPECTION
2. From the platform control console:
a. Ensure that the control console is firmly secured
in the proper location.
b. Check that all guards protecting the function
control switches and controllers are in place;
c. Operate all functions.
d. Ensure all boom functions stop when the foot
switch is released.
e. Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in.
f. Ensure main lift down, tower lift down, and jib lift
down, work properly when using the emer­gency lowering controls.
3128792 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
9
8
7
11
6
4
4
2
12
13
14
15
16
1
3
10
5
17
18
Figure 2-1. Basic Machine Nomenclature - Right Side Shown
2-6 – JLG Lift – 3128792
SECTION 2 - PREPARATION AND INSPECTION
Basic Machine Nomenclature
1. Main Boom
2. Tower Boom Assembly
3. Gas or Diesel Engine
4. Outrigger
5. Tracked Undercarriage
6. Electric Components Compartment -
(Left Side of Machine)
7. Tur nt ab le
8. Ground/Emergency controls (Left Side of Machine)
9. Hydraulic Oil tank and Hand Pump -
(Right Side of Machine)
10. Electric Engine
11. Track and Outrigger Control Valves - Remove Cover
12. Jib
13. Ladder
14. Platform
15. Manuals Compartment
16. Platform/Remote Control Station
17. Lithium ION - Battery Charger LED Indicator
18. Lithium ION - Battery Pack, Inverter, and Battery
Charger Compartment
3128792 – JLG Lift – 2-7
SECTION 2 - PREPARATION AND INSPECTION
1
4
4
4
4
10
6
7
7
8
9
5
3
11
2
Figure 2-2. Daily Walk-Around Inspection
2-8 – JLG Lift – 3128792
SECTION 2 - PREPARATION AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following check­list.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.
1. Platform Assembly, Footswitch, Ladder and Gate
- Footswitch in good working order, not modified, disabled or blocked. Manuals in storage container, access bar slides up and down properly, platform properly installed and with both caps screwed on. See Inspection Note.
2. Platform/Remote Station - Switches and levers
return to neutral, decals/placards secure and legible, control markings legible.
4. Outriggers - See Inspection Note; pads pivot freely.
5. Electrical Components Compartment - Cover
secure. See Inspection Note.
6. Boom Sections & Ground Control Station - See
Inspection Note.
7. Drive Tracks - Properly Adjusted. See Inspection
Note.
8. Gas/Diesel Engine & Main Hydraulic Pump, Lith­ium ION Battery Pack - Free of debris and See
Inspection Note.
9. Swing Drive & Turntable Bearing - See Inspection note, Check for proper lubrication.
10. Hydraulic Tank - Hydraulic oil level correct and See
Inspection Note.
11. Electric Engine and Hydraulic Pump - See Inspec-
tion Note.
3. Machine Bubble Level - See Inspection Note.
3128792 – JLG Lift – 2-9
SECTION 2 - PREPARATION AND INSPECTION
NOTES:
2-10 – JLG Lift – 3128792
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