JLG X20JPLUS Manual

Operator,Safety,Maintenance
andserviceManual
OriginalInstructions‐Keepthismanualwiththemachineatalltimes
BoomLiftModels
X20JPLUS
MUX20JP021602
2016, revision02

MUX20JP021602
1BoomLiftModelsX20JPLUS
Tableofcontents
1. Preface......................................................................................................Pag.8
1.1. Attention‐danger...................................................................................Pag.8
1.2. Warning ....................................................................................................Pag.8
1.3. Note...........................................................................................................Pag.8
2. Howtousethemanual.........................................................................Pag.9
3. Normativereference............................................................................Pag.11
4. Warranty................................................................................................Pag.12
5. Liability..................................................................................................Pag.13
6. ECDeclarationConformity................................................................Pag.14
7. Technicalinformations........................................................................Pag.16
7.1. Descriptionofthemachine..................................................................Pag.16
7.2. Machineidentificationplate ...............................................................Pag.17
7.3. Overalldimensionsofthemachine....................................................Pag.18
7.4. Technicaldata ........................................................................................Pag.19
7.4.1. Technicaldatapetrolengine................................................................Pag.20
7.4.2. TechnicaldataDieselengine ...............................................................Pag.20
7.4.3. Hydraulicsystemtechnicalspecifications.........................................Pag.21
7.4.4. Electricalsystemtechnicalspecificationsthermalengine...............Pag.21
7.4.5. Electricalsystemtechnicalspecificationslithium ............................Pag.21
7.5. Terminology...........................................................................................Pag.23
7.6. Generalsafetystandards......................................................................Pag.25
7.7. Clothingandprotectiveequipment ...................................................Pag.26
7.8. Safetyvalvesandelectricalsystemsafetycomponents...................Pag.26
7.9. Fireprevention ......................................................................................Pag.27
7.10. Preventingdamagecausedbywashingthemachine......................Pag.27
7.10.1. Cleaningthemachine ...........................................................................Pag.27
7.10.2. Washingtheoutsideofthemachine ..................................................Pag.28
7.10.3. Cleaningtheelectricalsystem .............................................................Pag.28
7.10.4. Aftercleaning.........................................................................................Pag.28
7.11. Preventingdamagethatmaybecausedbythemachineduringwork.....
Pag.29
7.12. Safetywarnings .....................................................................................Pag.30

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7.12.1. Generalities ............................................................................................Pag.30
7.12.2. NoiseandVibration..............................................................................Pag.30
7.12.3. Decalsonthemachine..........................................................................Pag.31
8. Safetydevice.........................................................................................Pag.41
8.1. Batterycut‐outswitch...........................................................................Pag.42
8.2. Distributorpressurereliefvalves .......................................................Pag.42
8.3. Cylinderstopvalves .............................................................................Pag.43
8.4. Alignmentphotocellsoftheaerialpart .............................................Pag.44
8.5. Stabilizerpositionmicroswitches ......................................................Pag.44
8.6. JIBpositionmicroswitch .....................................................................Pag.45
8.7. Ropesintegritymicroswitch...............................................................Pag.45
8.8. Basketloadsensor.................................................................................Pag.47
8.9. Controlprotection.................................................................................Pag.49
8.10. Spiritandelectroniclevel.....................................................................Pag.50
8.11. Pinlockingboltsandnuts....................................................................Pag.51
8.12. Safetydeviceelectroniccontrolboard ...............................................Pag.52
8.13. Boomspositionsensors ........................................................................Pag.52
8.14. Externaltemperaturesensor(optional) .............................................Pag.53
9. Instrumentsandcontrols....................................................................Pag.54
9.1. Remotecontrol.......................................................................................Pag.54
9.1.1. Display....................................................................................................Pag.55
9.1.2. Joystick....................................................................................................Pag.59
9.1.3. Pushbuttons ..........................................................................................Pag.61
9.2. Footswitch(optional)...........................................................................Pag.64
9.3. Controlposition.....................................................................................Pag.65
9.3.1. Controlpositioninthebasket .............................................................Pag.65
9.3.2. Controlpositionattheground............................................................Pag.65
9.3.3. Emergencycontrolposition.................................................................Pag.66
9.3.4. Maintenancecontrolposition..............................................................Pag.67
9.4. RemoteControlMOVE(optional)......................................................Pag.69
9.5. SkyGuardTMsystem(optional)...........................................................Pag.69
10. Emergencydevice................................................................................Pag.71
10.1. Emergencystopbutton ........................................................................Pag.71
10.2. Handpump............................................................................................Pag.72
10.3. Solenoidvalvesforemergencydescent .............................................Pag.73
10.4. Safetydevicebypasskey......................................................................Pag.73
10.5. Emergencypositioncontrols ...............................................................Pag.74

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10.5.1. Selectionpanel,emergencystopandstarting...................................Pag.74
10.5.2. Aerialparthydraulicdistributor ........................................................Pag.76
10.5.3. Trackedundercarriagehydraulicdistributor ...................................Pag.79
11. Usingthemachine................................................................................Pag.82
11.1. Safetystandardstoadoptbeforeusingtheplatform.......................Pag.82
11.1.1. Riskofelectrocution .............................................................................Pag.82
11.1.2. Dangerduetoatmosphericconditions..............................................Pag.82
11.1.3. Dangerduetotheworkarea...............................................................Pag.84
11.2. Proceduresforcorrectuse....................................................................Pag.84
11.2.1. Summarytableofoperatorsafetystandards ....................................Pag.85
11.3. Workingarea..........................................................................................Pag.87
11.4. Useoftheelevatingworkplatform(MEWP)....................................Pag.88
11.4.1. Preliminarychecksbeforestartingwork...........................................Pag.89
11.4.2. StartingthePetrol/Dieselengine.........................................................Pag.89
11.4.3. Startingtheelectricmotor....................................................................Pag.91
11.4.4. Stoppingtheengine/motor ..................................................................Pag.93
11.4.5. StoppingthemotorLithiumversion..................................................Pag.93
11.4.6. Travel ......................................................................................................Pag.94
11.4.7. JIBboommovementfortravel ............................................................Pag.96
11.4.8. Parkingthemachineonaslopeoronunevenground....................Pag.98
11.4.9. Stabilisingandlevellingthemachine.................................................Pag.98
11.4.10. Automaticloweringandraisingofthestabilisers .........................Pag.102
11.4.11. Trackextension....................................................................................Pag.104
11.4.12. Movingthebasket...............................................................................Pag.106
11.4.13. Manuallylevellingofthebasket.......................................................Pag.109
11.5. Aerialpartemergencymanoeuvres .................................................Pag.112
11.5.1. Activationofemergencydescentfromthebasket .........................Pag.112
11.5.2. Operatingthemachinefromtheemergencycontrolpositiononthe
groundiftheoperatoristakenill .....................................................Pag.114
11.5.3. Emergencydescentinthecasewherethestabilisersareaccidentally
retracted................................................................................................Pag.117
11.5.4. Emergencydescentcontrolledfromthegroundusingthehandpumpin
theeventoffaultsonallenergysupplysystems............................Pag.120
11.5.5. Emergencyoperationoftheundercarriageintheeventofmovementsof
theaerialpart .......................................................................................Pag.124
11.5.5.1. Machinerealignment..........................................................................Pag.124
11.5.5.2. Movingtheundercarriagewiththemachinenotaligned.............Pag.125
11.5.6. Emergencyoperationsonthecarriage:movingtheplatformstabilisers
usingthehandpumptoallowthemachinetobetransported ....Pag.128

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11.6. Electricalconnectionofremotecontrol............................................Pag.131
11.7. Rechargingthebattery .......................................................................Pag.132
11.7.1. BatterychargingPetrol/Dieselengine..............................................Pag.132
11.7.2. ChargingLithiumbatteries................................................................Pag.133
11.8. Mainintendedusesoftheplatform .................................................Pag.137
11.8.1. Systems .................................................................................................Pag.137
11.8.2. Closedenvironments..........................................................................Pag.137
11.8.3. Pruning .................................................................................................Pag.137
11.8.4. Repairandmaintenanceofroofingandgutters.............................Pag.137
11.8.5. Painting,sand‐blastingandplastering ............................................Pag.138
11.8.6. Useinmarineenvironments .............................................................Pag.138
12. Maintenance........................................................................................Pag.139
12.1. Safetyinstructionsforgreasingandlubrication.............................Pag.139
12.1.1. Tableofrecommendedlbrificants ....................................................Pag.139
12.1.2. Greasingpoints....................................................................................Pag.142
12.1.3. Greasingthetelescopicboom............................................................Pag.142
12.2. Safetyinstructionsformaintenanceoperations .............................Pag.143
12.3. Maintenancecontrolpositionwithremotecontrolfromtheground Pag.
144
12.4. Periodicalmaintenanceintervals......................................................Pag.147
12.5. Electricmotormaintenance ...............................................................Pag.150
12.6. Inspectionandmaintenanceintervals .............................................Pag.152
12.6.1. A‐Dailyinspectionsbeforestarting.................................................Pag.152
12.6.2. B‐Periodicalinspections ....................................................................Pag.152
12.6.3. C‐Annualinspections ........................................................................Pag.153
12.6.4. D‐Structuralinspection .....................................................................Pag.154
12.6.5. E‐Maintenance ....................................................................................Pag.154
12.7. Generalperiodicalchecks ..................................................................Pag.155
12.8. Maintenanceonrubbertracks...........................................................Pag.156
12.8.1. Rubbertrackstensioncheck ..............................................................Pag.156
12.8.2. Tensioningrubbertrack .....................................................................Pag.157
12.8.3. Removingrubbertrack.......................................................................Pag.157
12.8.4. Installingrubbertrack ........................................................................Pag.159
12.9. Checkingtightnessofnutsandbolts ...............................................Pag.159
12.10. Hydraulicoillevelcheck....................................................................Pag.164
12.11. Checkingforleaksinthehydraulicsystem ....................................Pag.164
12.12. Checkingtheconditionofthefiltercartridge.................................Pag.164
12.13. Checkingthatalltheplatesarepresentonthemachineandintact ...Pag.
165

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12.14. Checkingtheoperatingpressuresinthehydraulicsystem..........Pag.166
12.15. Checkingextensionropes ..................................................................Pag.168
12.15.1. Checkingwearanddeformationofropesandpulleys .................Pag.168
12.15.2. Three‐monthlyinspection..................................................................Pag.169
12.15.3. RopesTensionAdjustmentProcedure.............................................Pag.170
12.15.4. Five‐yearlyinspection ........................................................................Pag.171
12.16. Checkingwearofthetelescopicarmslideblocks..........................Pag.172
12.17. BatteryPetrol/Dieselengine:maintenance‐replacement‐disposal .Pag.
173
12.18. Batterypackmaintenanceoperatingspecifications.......................Pag.175
12.18.1. Handlingindangerousconditions...................................................Pag.176
12.18.1.1.Personalprotectiveequipment ........................................................Pag.176
12.18.1.2.Procedureforhandlinghotcells......................................................Pag.176
12.18.1.3.Procedureforhandlingventedcells ...............................................Pag.177
12.18.1.4.Procedureforexplodedcells............................................................Pag.179
12.18.1.5.Lithiumbatteryfire............................................................................Pag.180
12.19. Servicingtheenginethermicversion ...............................................Pag.182
12.20. Start‐upofthemachineaftermaintenance .....................................Pag.182
13. Safetystandardsfortransport..........................................................Pag.183
13.1. Removingthebasket...........................................................................Pag.183
13.2. Loadingandunloadingthemachineontransportvehiclesusingramps
Pag.185
13.3. Liftingthemachine .............................................................................Pag.187
13.3.1. Liftingthemachineusingaforklift ..................................................Pag.187
13.3.2. Liftingthemachineusingropesorchains.......................................Pag.189
13.4. Transportingthemachine..................................................................Pag.191
14. Servicemenuontheremotecontrol................................................Pag.192
14.1. Inputmenu...........................................................................................Pag.192
14.2. Languagemenù ...................................................................................Pag.192
14.3. Errorsmenu .........................................................................................Pag.192
14.4. Workinghoursmenu..........................................................................Pag.193
14.5. Joystickmenu.......................................................................................Pag.193
15. Hydraulicsystem...............................................................................Pag.194
16. Wiringdiagram..................................................................................Pag.197

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6BoomLiftModelsX20JPLUS

7
MUX20JP021602
BoomLiftModels X20JPLUS
JLGIndustries,Inc.
13224FountainheadPlaza
Hagerstown,MD21742
orYourLocalJLGOffice
ʺWorldwidelocations(p. 202)ʺ
InUSA:
TollFree:877‐JLG‐SAFE(877‐554‐7233)
OutsideUSA:
Phone.:240‐420‐2661
Fax:301‐745‐3713
E‐mail:[email protected]
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

8BoomLiftModels X20JPLUS
PREFACE MUX20JP021602
1. PREFACE
Theaimofthismanualistoprovidetheuserwiththenecessaryinstructionsand
essentialoperatingprocedurestoensurecorrectandsafeuseofthemachinefor
itsintendedpurposes,aswellastopreventseriousinjurytotheoperatorand
otherpersons.
Thismanualdescribesthewarningsignsusedtodrawthereaderʹsattentionto
severalparticularlyimportantwarnings.Thesafetywarningsaredividedinto
threemaintypes,whichareidentifiedanddescribedbelow.
1.1. ATTENTION‐DANGER
1.2. WARNING
1.3. NOTE
Originallanguagesofthemanufacturer:ItalianandEnglish.Allotherlanguages
arecopiesoftheoriginalinstructions.
Thissymbolindicatesthatthesituationdescribed,ifnotprevented,
canleadtoseriousinjuryordeathofthepersonsinvolved(operator,
groundstaff,staffpresentinproximitytothemachine,maintenance
techniciansetc.).
Thissymbolindicatesthatthesituationdescribedrepresentsapotentialrisk
forthestructureofthemachine.Dangeroussituationsmaybedeterminedby
thiscondition(includinginjuryordeath)forthepersonsinvolved.
Thissymbolindicatestipsoradditionalnotesusefulfortheoperatororforthose
whomustperformmaintenance/repaironthemachine.

HOWTOUSETHEMANUAL
9
MUX20JP021602
BoomLiftModels X20JPLUS
2. HOWTOUSETHEMANUAL
Itismandatorytokeeptoalltheinstructionsgiveninthismanual.Thisma‐
nualmustbecarefullyreadandunderstoodbeforeoperatingthemachine.
Asthismanualisanessentialworktool,itmustbekeptwiththemachineatall
times,inthespecialcompartment,soastobeavailableforclarificationwhenever
required.
Asthemanufacturercannotcontroltheconditionsofthemachineandtheopera‐
tionsthisisusedfor,theuserisresponsibleforensuringcompliancewiththesa‐
fetyproceduresdescribedinthismanual.
Everymachinesuppliedisthoroughlyadjustedandtestedbeforebeingdelive‐
red.Theoperatordoesnotneedtoperformanyadjustmentsbeforeusingthema‐
chine.Everyalterationand/ormodificationofthefeaturesoftheoriginalmachine
designwithoutpreviouswrittenauthorizationfromtheconstructorareprohibi‐
tedandtheresponsibilityfortheseactionsfallsontheoperator.
Fig.1Positionofmanualonmachine

10 BoomLiftModels X20JPLUS
HOWTOUSETHEMANUAL MUX20JP021602
Theemployermustmakesurethattheoperatorhastherequisitesnecessaryto
operatethemachinecorrectlyandthatsuchoperatorhascarefullyexamined
andunderstoodtheinformationgiveninthisuserandoperationmanual,re‐
ceivingsuitabletrainingregardinguseofthemachineinstandardandemer‐
gencyconditions.
Theemployermustalsotrainoperatorsregardinganynationalstandardsthat
areinadditiontotheinstructionscontainedinthisdocument.
Ifthemanualisdamagedorlost,acopymustberequesteddirectlyfromthema‐
nufacturer.
Allofthephotosanddrawingsinthismanualhavebeenaddedtosimplifycom‐
prehensionbythereader.Yourmachinemaydifferfromthephotosanddrawings
provided.

NORMATIVEREFERENCE
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3. NORMATIVEREFERENCE
Themachinehasbeendesigned,builtandinspectedaccordingtothatprescribed
intheEN280harmonisedstandard,whichsuppliesthepresumptionofconformi‐
tywiththeEssentialSafetyRequisitesofthe2006/42/CEMachineryDirective
evenifatypeCVoluntaryTechnicalStandard.
AccordingtothatstatedinEN280,theplatformisclassifiedinGROUPB,asthe
verticalprojectionofthecentreofgravityoftheloadcanbeoutsideofthetilting
linesandinTYPE1astraversingisonlyallowedwiththeplatformatrest.
Thestabilitytestsofthemachinehavebeenmadeinaccordancewithwhatde‐
scribedintheEN280andhavebeensuccessful.
Inadditionwhatprescribedinthismanualitisnecessarytoapplythetechnical
requirementsofthefollowingnational/internationalsafetystandards:
•UNIISO18893
•ISO16368
•ISO18878
Withtheexceptionofstricterlocalornationalregulationsintheworkingareaof
theMEWP.

12 BoomLiftModels X20JPLUS
WARRANTY MUX20JP021602
4. WARRANTY
Onpurchasingamachine,awarrantyandinspectioncertificateisissuedthatcle‐
arlyindicatesthewarrantytermsandwhereanyinterventionsonthemachine
mustbereported.

LIABILITY
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5. LIABILITY
TheConstructorisexoneratedfromanyliabilityandobligationforanyinjury/da‐
magecausedtopersons/objectsduetoanyofthereasonslistedbelow:
•FailuretocomplywiththeinstructionsindicatedinthisUSEANDMAINTE‐
NANCEMANUALregardingrunning,useandmaintenanceofthemachine;
•Violentorsuddenactionsorincorrectmanoeuvreswhenusingorservicing
themachine;
• Modificationsmadetothestructureormachinecomponentswithoutpre‐
viousauthorisationfromtheConstructorand/orwithouttheuseofsuitableequi‐
pment;
•Strangeeventswithrespecttonormalandcorrectuseofthemachine,descri‐
bedinthisUSEANDMAINTENANCEMANUAL;
•Useofnon‐originalsparepartsnotauthorisedbythemanufacturer;

14 BoomLiftModels X20JPLUS
ECDECLARATIONCONFORMITY MUX20JP021602
6. ECDECLARATIONCONFORMITY
Fig.2ECDeclarationConformity
EC DECLARATION OF
CONFORMITY
Manufacturer: JLG Industries Inc.
Address: 1 JLG Drive
McConnellsburg
PA 17233
USA
Technical File: JLG Industries Inc.
JLG Technology & Development Centre
Bruntingthorpe Aerodrome & Proving Ground
Lutterworth, Leicestershire
LE17 5QS
United Kingdom.
Contact: Barrie Lindsay Position: Director of
Engineering-Europe
Machine Type: Mobile Elevating Work Platform
Model Type:
Serial Number:
Notied Body: ECO Certicazioni S.p.A
EC-Number: 0714
Address: Via Mengollna
33 - 48108
Faenza
Italy
Certicate Number:
Reference Standards: EN ISO 12100:2010
EN 280:2013
JLG Industries Inc. hereby declares that the above mentioned machine
conforms with the requirements of:
2004/108/EC EMC Directive
2006/42/EC Machinery Directive
Signed: Date:
Name: Barrie Lindsay Position: Director of Engineering-Europe
Place: Bruntingthorpe, UK
Remark:
This declaration conforms withthe requirements of annex II-A of the council directive
2006/42/EC
Any modication to the above described machine violates the validity of this declaration.
Machine manufactured for JLG Industries Inc. by HINOWA S.p.a via Fontana 37054 NOGARA
VR Italy

ECDECLARATIONCONFORMITY
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BoomLiftModels X20JPLUS
Fig.3ECDeclarationConformity
EC DECLARATION OF
CONFORMITY
Manufacturer: JLG Industries Inc.
Address: 1 JLG Drive
McConnellsburg
PA 17233
USA
Machine Type: Mobile Elevating Work Platform
Model Type:
Serial Number:
Document Control: HINOWA S.p.A
Via Fontana - 37054
Nogara
Italy
Technical File: JLG Industries Inc.
JLG Technology &
Development Centre
Bruntingthorpe
Aerodrome & Proving
Ground
Lutterworth,
Leicestershire
LE17 5QS
United Kingdom.
Measured
Lwa dB(A)
Guaranteed
Lwa dB(A)
Engine Power: kW
Lwa = (Sound Power Level)
Applicable Procedure: EN ISO 3744:1995
Applicable Directive: 2000/14/EC Annex V Internal Control of Production.
We hereby declare that the above mentioned machine
conforms with the requirements of the "Noise Emission in
the Environment by Equipment for Use Outdoors" Directive
2000/14/EC as amended by 2005/88/EC
Signed: Date:
Name: Barrie Lindsay Position: Director of Engineering-Europe
Place: Bruntingthorpe, UK
Remark:
Any modication to the above described machine violates the validity of this declaration.
Machine manufactured for JLG Industries Inc. by HINOWA S.p.a via Fontana 37054 NOGARA
VR Italy

16 BoomLiftModels X20JPLUS
TECHNICALINFORMATIONS MUX20JP021602
7. TECHNICALINFORMATIONS
7.1. DESCRIPTIONOFTHEMACHINE
Themachineisaself‐propelledhydraulicliftingdevice,equippedwitharotating
workbasketpositionedatthetopofanextensiblearticulatedstructure,which
alsorotates.Theliftingdeviceisdestinedforthepositioningofpersonsandtheir
equipmentandmaterialsinhighpositionswithrespecttogroundlevel.
RefertorelevantparagraphinrespectofthecontrolstationsʺControlposition
(p. 65)ʺ

TECHNICALINFORMATIONS
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BoomLiftModels X20JPLUS
7.2. MACHINEIDENTIFICATIONPLATE
Themanufacturerplateisplacedontheprotectionoftheaerialparthydraulicdi‐
stributororonthemachineframenearoftheliftingforksfasteners.
Fig.4ExampleCEplate
xsm1;Manufactured by
HINOWA S.p.A.
Via Fontana
37054 NOGARA (VR)
ITALY
Model
Date of manufacture
G.V.W. (Dry)
Serial number
MAXIMUM ALLOWABLE OPERATING INCLINATION
=+
2x80
MAX
07253100
1°
kg
JLG Industries. Inc - McConnellsburg. PA - USA
kgM/S kg kg
12.5 230 70 N 400

18 BoomLiftModels X20JPLUS
TECHNICALINFORMATIONS MUX20JP021602
7.3. OVERALLDIMENSIONSOFTHEMACHINE
Maximumlengthintravelconfigurationwithbasketin‐
stalled
5011mm
Trackwidthclosed/open 795/1095mm
Maximumheightintravelconfigurationwithfootplates
removed
1998mm
Maximumattachmentangle 20°/21°
Maximumstabilisationangle 15°
Maxstabiliserbaseside(disccentre) 2922x2925mm
Fig.5Standardversionwith2personbasket