JLG X500AJ Operator Manual
ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X550AJ
P/N - 3128791
September 26, 2011
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.
3128791 – 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 – 3128791
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:
3128791 – 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 26, 2011
REVISION LOG
d – JLG Lift – 3128791
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. . . . . . . . . . . . . . . . . . . . . . . 4-3
3128791 – 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 . . . . . . . . . . . .4-5
4.5 TRACKS - DRIVING, STEERING AND
TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . .4-6
Track width adjust. . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . .4-6
Travelling (Grades and Side Slopes) . . . . . . . . . . 4-7
Jib Position for Travelling . . . . . . . . . . . . . . . . . . . 4-9
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . 4-10
Setting Outriggers From the Platform/
Remote Console . . . . . . . . . . . . . . . . . . . . . . . . .4-12
Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-13
4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . . 4-14
Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . .4-14
Platform Level Adjustment . . . . . . . . . . . . . . . . .4-14
Raise And Lower The Tower Boom . . . . . . . . . .4-16
Raise And Lower The Main Boom . . . . . . . . . . .4-16
Telescope The Main Boom. . . . . . . . . . . . . . . . . 4-16
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-16
Emergency Lowering . . . . . . . . . . . . . . . . . . . . . 4-18
Platform Removal/Installation . . . . . . . . . . . . . . .4-18
4.8 BATTERY CHARGING -
GAS/DIESEL/AC-ELECTRIC . . . . . . . . . . . . . . . . . 4-19
Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-19
4.9 BATTERY CHARGING - LITHIUM-ION MACHINE .4-20
Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-20
Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-22
4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-24
Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
4.12 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . 4-27
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
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
ii – JLG Lift – 3128791
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lithium-Ion Specifications. . . . . . . . . . . . . . . . . . . 6-4
Machine Major Component Weights . . . . . . . . . . 6-4
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
Rubber Track Maintenance/Replacement . . . . . 6-13
Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . 6-16
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) . . . . . . . . . . . . . 6-27
Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-28
SECTION - 7 - INSPECTION AND REPAIR LOG
3128791 – 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. . . . . . . . . . . . . . 4-15
4-4. Platform - Load/Reach Chart . . . . . . . . . . . . . . 4-17
4-5. Lifting Machine - Attach Points . . . . . . . . . . . . . 4-24
4-6. Machine Tie-Down Points. . . . . . . . . . . . . . . . .4-26
4-7. Decal installation - Standard - Right Side . . . .4-27
4-8. Decal Installation - Standard - Left Side. . . . . . 4-28
4-9. Decal installation - Lithium-Ion - Left Side . . . .4-33
4-10. Decal Installation - Lithium-Ion - Right Side . . .4-34
5-1. Platform/Remote Control Station . . . . . . . . . . . .5-3
5-2. Ground Control Station - Boom Control Valves. 5-5
5-3. Main Flow Control Valve Location . . . . . . . . . . .5-6
5-4. Hand Pump - On Top Of Hydraulic Tank . . . . . . 5-7
5-5. Ground Component Valves -
Outriggers/Steer/Tracks - Location . . . . . . . . .5-12
6-1. Lubrication and Maintenance Point Locations. .6-5
6-2. Component Maintenance Intervals -
X550AJ - with Honda Engine . . . . . . . . . . . . . . . 6-7
6-3. Component Maintenance Intervals -
X550AJ - with Hatz Diesel Engine . . . . . . . . . . . 6-8
6-4. Component Maintenance Intervals -
X550AJ - 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 X550AJ - Decal Installation - Standard . . . . . . . 4-29
4-2 X550AJ - Decal Installation -
Lithium-ION Machine . . . . . . . . . . . . . . . . . . . . 4-35
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 iGX440 Specifications . . . . . . . . . . . . . . . 6-3
6-6 Hatz 1B40 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 – 3128791
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.
3128791 – 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 – 3128791
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.
3128791 – 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 – 3128791
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)
3128791 – 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 – 3128791
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.
3128791 – 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 – 3128791
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.
3128791 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
NOTES:
1-10 – JLG Lift – 3128791
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.
3128791 – 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 – 3128791
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
3128791 – 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 – 3128791
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.
3128791 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
1
2
3
4
5
6
15
78
9
10
11
12
13
16
14
17
4
18
19
Figure 2-1. Basic Machine Nomenclature (Right Side View)
2-6 – JLG Lift – 3128791
SECTION 2 - PREPARATION AND INSPECTION
Basic Machine Nomenclature
1. Main Boom
2. Tower Boom Assembly
3. Gas or Diesel Engine
4. Outrigger
5. Electric Components Compartment -
(Left Side of Machine)
6. Ground/Emergency controls
7. Tracked Undercarriage
8. Tur nt ab le
9. Hand Pump - (Right Side of Machine)
10. Hydraulic Oil tank - (Right Side of Machine)
11. Electric Engine
12. Track and Outrigger Valves/Manual Controls -
(Under Cover)
13. Jib
14. Ladder
15. Platform
16. Manuals Compartment
17. Platform/Remote Control Station
18. Lithium ION - Battery Charger LED Indicator
19. Lithium ION - Battery Pack, Inverter, and Battery
Charger Compartment
3128791 – JLG Lift – 2-7
SECTION 2 - PREPARATION AND INSPECTION
1
2
4
4
4
4
10
6
7
8
9
5
3
11
Figure 2-2. Daily Walk-Around Inspection
2-8 – JLG Lift – 3128791
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 Control Station - Switches and
levers return to neutral, decals/placards secure and
legible, control markings legible.
3. Platform Rotator & Machine Bubble Level - See
Inspection Note.
4. Outriggers - See Inspection Note; pads pivot freely.
5. Electrical Components/Cover Assembly - 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- Check for
proper lubrication. See Inspection Note.
10. Hydraulic Tank and Hand Pump Assembly -
Hydraulic oil level correct and See Inspection Note.
11. Electric Engine and Ground Components Hydraulic Valve Sets - See Inspection Note.
3128791 – JLG Lift – 2-9
SECTION 2 - PREPARATION AND INSPECTION
NOTES:
2-10 – JLG Lift – 3128791
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