JLG X390AJ Operator Manual

ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X500AJ
P/N - 3121636
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.
3121636 – 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
RESULT IN SERIOUS INJURY OR DEATH. THIS 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.
b – JLG Lift – 3121636
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
RESULT IN MINOR OR MODERATE INJURY. IT 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.
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.
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.
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 USA
or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)
3121636 – JLG Lift – c

Outside USA:

Phone: 240-420-2661 E-mail: ProductSafety@JLG.com
SECTION - REVISION LOG
Original Issue of Manual. . . . . . . . . . . . . . . . . . . . . 05-07-2014

REVISION LOG

d – JLG Lift – 3121636
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 . . . . . . . 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 Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . .4-2
Gas Engine Shutdown Procedure. . . . . . . . . . . . . .4-3
Electric Engine Starting Procedure -
AC Voltage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3121636 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Electric Engine Starting Procedure -
LITHIUM-ION Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . . . . 4-6
4.5 TRACKS - DRIVING, STEERING AND
TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Track width adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Grades and Side Slopes) . . . . . . . . . . . 4-7
Jib Position for Travelling . . . . . . . . . . . . . . . . . . . . 4-10
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . . . . .4-11
Setting Outriggers From the Platform/
Remote Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Retracting The Outriggers . . . . . . . . . . . . . . . . . . .4-14
4.7 BOOM/PLATFORM OPERATION . . . . . . . . . . . . . . . . 4-15
Overload Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Engine Pre-Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Platform Level Adjustment. . . . . . . . . . . . . . . . . . . 4-15
Raise And Lower The Tower Boom . . . . . . . . . . .4-17
Raise And Lower The Main Boom. . . . . . . . . . . . . 4-17
Telescope The Main Boom . . . . . . . . . . . . . . . . . . .4-17
Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Raise And Lower The Jib . . . . . . . . . . . . . . . . . . . . . 4-17
Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.8 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . . 4-19
4.9 BATTERY CHARGING - GAS/AC-ELECTRIC . . . . . . .4-20
Battery Charging - Daily. . . . . . . . . . . . . . . . . . . . . . 4-20
4.10 BATTERY CHARGING - LITHIUM-ION MACHINE. . 4-21
Charging the Battery Pack . . . . . . . . . . . . . . . . . . . 4-21
Charge Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . .4-23
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lifting - Outrigger Lifting Rings . . . . . . . . . . . . . .4-25
Lifting - Fork Lift Pockets . . . . . . . . . . . . . . . . . . . . . 4-26
Loading and Unloading the Machine on
Transport Vehicles Using Ramps . . . . . . . . . . . . .4-27
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4.13 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
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
Engines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Manual Descent without Engine and
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Outrigger/Track Movement
Emergency Procedure: . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ii – JLG Lift – 3121636
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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. . . . . . . . . . . . . . . . . . . . .5-16
Procedure For Handling Hot Cells . . . . . . . . . . . .5-16
Procedure For Handling Vented Cells . . . . . . . . .5-17
Procedure For Exploded Cells . . . . . . . . . . . . . . . .5-19
Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .6-2
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Lithium-Ion Specifications . . . . . . . . . . . . . . . . . . . .6-4
Machine Major Component Weights . . . . . . . . . . 6-5
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .6-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Rubber Track Maintenance/Replacement. . . . .6-12
Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . . . 6-15
Battery Maintenance and Charging -
Gas/AC-Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . . . . 6-17
Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.5 PLATFORM/REMOTE CONTROL SERVICE
MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . . . 6-30
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-31
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . 6-31
Battery Pack System Components and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Lithium-Ion Machine Fault Codes. . . . . . . . . . . . 6-34
BMS Fault Codes - (Battery Management
System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Battery Charger Fault Codes. . . . . . . . . . . . . . . . . 6-38
SECTION - 7 - INSPECTION AND REPAIR LOG
3121636 – 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. Ground Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Platform/Remote Control Station . . . . . . . . . . . . 3-9
4-1. Ground/Emergency Control Box . . . . . . . . . . . . . 4-2
4-2. Ground/Emergency Control Box-Lithium Ion . 4-5
4-3. Grade and Side Slope Definition . . . . . . . . . . . . . 4-9
4-4. Platform/Remote Control Box . . . . . . . . . . . . . . 4-16
4-5. Platform - Load/Reach Chart - X500AJ. . . . . . .4-18
4-6. Lifting Machine - Lifting Rings Location . . . . .4-25
4-7. Lifting Machine - Fork Lift Pockets Location . 4-26
4-8. Machine Tie-Down Points . . . . . . . . . . . . . . . . . . 4-29
4-9. Decal installation - Standard - Left Side . . . . .4-30
4-10. Decal Installation - Standard - Right Side . . . . 4-31
4-11. Decal installation - Lithium-Ion - Left Side . . .4-35 4-12. Decal Installation - Lithium-Ion - Right Side .4-36
5-1. Platform/Remote Control Station . . . . . . . . . . . . 5-3
5-2. Ground Control Station - Boom
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Hand Pump - On Top Of Hydraulic Tank. . . . . . 5-7
5-4. Hand Pump Decal -
On Top Of Hydraulic Tank . . . . . . . . . . . . . . . . . . . 5-7
5-5. Ground Component Valves -
Outriggers/Track Control - Location. . . . . . . . .5-12
6-1. Lubrication and Maintenance Point
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2. Component Maintenance Intervals -
with Honda Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-3. Component Maintenance Intervals -
Lithium-Ion Machine . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-4. Example of Lithium-Ion Battery Pack
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
iv – JLG Lift – 3121636
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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 X500AJ - Decal Installation - Standard. . . . . . . 4-32
4-2 X500AJ - Decal Installation - Lithium Ion . . . . 4-37
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . .6-2
6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3 Chassis Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-5 Honda iGX440 Specifications . . . . . . . . . . . . . . . . .6-4
6-6 Lithium Ion Specifications . . . . . . . . . . . . . . . . . . . .6-4
6-7 Major Component Weights. . . . . . . . . . . . . . . . . . .6-5
6-8 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6-9 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . 6-7
6-10 Inverter Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-11 Battery Charger Fault Codes . . . . . . . . . . . . . . . . 6-38
3121636 – JLG Lift – v
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
NOTES:
vi – JLG Lift – 3121636

1.1 GENERAL

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage. 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 must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine must not accept operating responsibility 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.
This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. 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.

1.2 PRE-OPERATION

Operator Training and Knowledge

The Operation and Safety Manual must be read and understood in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc.
3121636 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
An operator must not accept operating responsibili­ties until adequate training has been given by com­petent and authorized persons.
Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit.
Read, understand, and obey all DANGERS, WARN­INGS, CAUTIONS, and operating instructions on the machine and in this manual.
Ensure that the machine is to be used in a manner which is within the scope of its intended application as determined by JLG.
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 your utilization and application of the machine.

Workplace Inspection

Precautions to avoid all hazards in the work area must be taken by the user before and during opera­tion of the machine.
Do not operate or raise the platform from a position on trucks, trailers, railway cars, floating vessels, scaf­folds or other equipment unless the application is approved in writing by JLG.
Before operation, check work area for overhead haz­ards such as electric lines, bridge cranes, and other potential overhead obstructions.
Check operating surfaces for holes, bumps, drop­offs, obstructions, debris, concealed holes, and other potential hazards.
Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG.
• Ensure that the ground conditions are adequate to support the maximum outrigger load indicated on the outrigger load decals located on the machine. Do not travel on unsupported surfaces.
1-2 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed.
Do not operate this machine until it has been ser­viced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual.
Ensure 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 PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
Do not operate any machine on which the 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 accumulation of debris on platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1.3 OPERATION

General

Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e. cell phones, two-way radios, etc. that will distract your attention from safely operating the machine.
Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
Before operation, the user must be familiar with the machine capabilities and operating characteristics of all functions.
Never operate a malfunctioning machine. If a mal­function occurs, shut down the machine. Remove the unit from service and notify the proper authori­ties.
Do not remove, modify, or disable any safety devices.
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.
3121636 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
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.
When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the front axle, steer and drive functions will be reversed.
Do not assist a stuck or disabled machine by push­ing or pulling except by pulling at the chassis tie­down lugs.
Fully lower platform and shut off all power before leaving machine.
Remove all rings, watches, and jewelry when operat­ing machine. Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment.
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.

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..
Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the machine when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit.
1-4 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS
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. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.
Keep oil, mud, and slippery substances cleaned from footwear and the platform floor.

Electrocution Hazards

This machine is not insulated and does not provide protection from contact or proximity to electrical current.
3121636 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
Maintain 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 addi-
MINIMUM APPROACH DISTANCE
in Feet (Meters)
tional clearance is required for every additional 30,000 volts or less.
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.
1-6 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS

Tipping Hazards

The user must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.
Do not elevate platform or drive with platform ele­vated while on or near a sloping, uneven, or soft sur­face. Ensure machine is positioned on a firm, level and smooth surface before elevating platform or driving with the platform in the elevated position.
Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.
Do not raise the platform unless the machine is on firm surfaces and outriggers are properly set.
Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG.
Keep the chassis and outriggers of the machine a minimum of 2 ft. (0.6m) from holes, bumps, drop­offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
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.
Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beau­fort Scale (For Reference Only).
Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.
Do not increase the platform size with unauthorized deck 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.
3121636 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
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. Flags waving near horizontal. Umbrella
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.
1-8 – JLG Lift – 3121636
Wind Speed
Description Land Conditions
mph m/s
use becomes difficult.
SECTION 1 - SAFETY PRECAUTIONS

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.
Use the boom functions, not the drive function, to position the platform close to obstacles.
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 driving and swing operations.
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 which may cause collision or injury to personnel.
Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.
Do not use high speed drive in restricted or close quarters or when driving in reverse.
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.
3121636 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING

Never allow personnel in platform while towing, lift­ing, or hauling.
Ensure boom is in the stowed position and the turn­table locked prior to towing, lifting or hauling. The platform must be completely empty of tools.
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 MAINTENANCE

This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed dur­ing machine maintenance are inserted at the appropri­ate points in this manual and in the Service and Maintenance Manual. It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property. A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe.

Maintenance Hazards

Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.
Never work under an elevated platform until it has been fully lowered to the full down position, if possi­ble, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.
DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.
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SECTION 1 - SAFETY PRECAUTIONS
Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components.
DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.
Ensure replacement parts or components are identi­cal or equivalent to original parts or components.
Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate sup­port is provided when raising components of the machine.
Do not use machine as a ground for welding.
When performing welding or metal cutting opera-
tions, 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.
Use only approved non-flammable cleaning sol-
vents.
Do not replace items critical to stability, such as bat­teries or solid tires, with items of different weight or specification. Do not modify unit in any way to affect stability.
Refer to the Service and Maintenance Manual for the weights of critical stability items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
3121636 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS

Battery Hazards

Always disconnect batteries when servicing electri­cal components or when performing welding on the machine.
Do not allow smoking, open flame, or sparks near battery during charging or servicing.
Do not contact tools or other metal objects across the battery terminals.
Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing.
BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
Charge batteries only in a well ventilated area.
Avoid overfilling the battery fluid level. Add distilled
water to batteries only after the batteries are fully charged.
1-12 – JLG Lift – 3121636
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.
3121636 – 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 – 3121636
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type Frequenc y
Pre-Start Inspec tion 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 hours, whichever comes
Annual Machine Inspection Annually, no later than 13 months from the date of
Preventative Maintenance At intervals as specified in the Service and Mainte-
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
first; or Out of service for a period of more than 3 months; or Purchased used.
prior inspection.
nance 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 Ser vice and Maintenance Man-
ual and applicable JLG inspec­tion form
Qualified JLG Mechanic Ser vice and Maintenance Man-
ual and applicable JLG inspec­tion form
Factory Trained Service Technician (Recommended)
Qualified JLG Mechanic Ser vice and Maintenance Man-
Service and Ma intenance Man­ual and applicable JLG inspec­tion form
ual
Reference
3121636 – JLG Lift – 2-3
SECTION 2 - PREPARATION AND INSPECTION
Parent Meta l Crac k
Wel d Cr ack

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 Opera­tion 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” Inspection 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 – 3121636
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 con-
trol 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 function
enable switch is released.
2. From the platform control console:
a. Ensure that the control console is firmly secured in
the proper location.
SECTION 2 - PREPARATION AND INSPECTION
b. Check that all guards protecting the function con-
trol 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.
3121636 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-1. Basic Machine Nomenclature (Right Side View)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
2-6 – JLG Lift – 3121636
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