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
05-07-2014
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.
1-10 – JLG Lift – 3121636
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
Loading...