JLG X500AJ Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X500AJ
3121636
June 29, 2018 - Rev F
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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SECTION - FOREWORD
3121636 – JLG Lift – a
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.
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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
b– JLG Lift – 3121636
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
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.
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 BACK-
GROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTEC-
TION OF PROPERTY.
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety mes-
sages that follow this symbol to avoid possible injury or death.
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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
3121636 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS.
CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRE-
SENTATIVE 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 ACCI-
DENT 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:
Phone: [phone]
E-mail: [e-mail]
For :
• Accident Reporting
• Product Safety Publi-
cations
• Current Owner
Updates
• Questions Regarding
Product Safety
• Standards and Regula-
tions Compliance Infor-
mation
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding
Product Modifications
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SECTION - REVISION LOG
d– JLG Lift – 3121636
REVISION LOG
Original Issue A - 05-07-2014
Revised B - 07-08-2015
Revised C - January 22, 2016
Revised D - July 25, 2016
Revised E - March 16, 2017
Revised F - June 29, 2018 - Revised Covers, Prop 65
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TABLE OF CONTENTS
3121636 – JLG Lift – i
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
1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . . 1-1
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Crushing and Collision Hazards. . . . . . . . . . . . . . . . 1-9
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . .1-10
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . .1-10
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
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
Daily Walk-Around Inspection . . . . . . . . . . . . . . . . .2-7
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND
OPERATION
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . .3-3
Ground Control Station - With Enable Lever. . . .3-4
Ground Control Station - With Enable Knob. . . .3-7
3.2 PLATFORM/REMOTE CONTROL STATION . . . . . . 3-10
Maintenance Control Position On The
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Platform/Remote Control Position From The
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Control Position From In The Platform: . . . . . . 3-11
Platform/Remote Control Station Functions . 3-13
Platform/Remote Control Station LCD Display 3-17
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
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TABLE OF CONTENTS
ii – JLG Lift – 3121636
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Gas Engine Starting Procedure . . . . . . . . . . . . . . . . 4-2
Gas Engine Shutdown Procedure . . . . . . . . . . . . . 4-3
Electric Engine Starting Procedure -
AC Voltage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
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
SkyGuard Operation (If Equipped). . . . . . . . . . . .4-19
4.8 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . .4-20
4.9 BATTERY CHARGING - GAS/AC-ELECTRIC . . . . . . .4-21
Battery Charging - Daily. . . . . . . . . . . . . . . . . . . . . .4-21
4.10 BATTERY CHARGING - LITHIUM-ION MACHINE. .4-22
Charging the Battery Pack . . . . . . . . . . . . . . . . . . .4-22
Charge Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . .4-25
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . .4-26
Lifting - Outrigger Lifting Rings . . . . . . . . . . . . . .4-26
Lifting - Fork Lift Pockets . . . . . . . . . . . . . . . . . . . . .4-27
Loading and Unloading the Machine on
Transport Vehicles Using Ramps . . . . . . . . . . . . .4-28
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4.13 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
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
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TABLE OF CONTENTS
3121636 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Manual Descent with Engine Running and
Electrical Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Manual Descent with Engine Running but
without Electrical Power (Combustion
Engines Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Manual Descent without Engine and Electrical
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Outrigger/Track Movement Emergency
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.4 SAFETY DEVICES BYPASS KEY USE . . . . . . . . . . . . . .5-14
Using The Emergency Descent In The Case
Of An Outrigger Losing Contact With The
Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Machine Realignment Emergency Procedure .5-16
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
Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . .6-8
Rubber Track Maintenance/Replacement . . . . 6-14
Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . . . 6-17
Battery Maintenance and Charging -
Gas/AC-Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . . . . 6-19
Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5 PLATFORM/REMOTE CONTROL SERVICE MENU 6-20
Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . . . 6-32
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.6 LITHIUM-ION MACHINE ONLY - ADDITIONAL
MAINTAINANCE INFORMATION . . . . . . . . . . . . . . . 6-33
Cleaning the Machine. . . . . . . . . . . . . . . . . . . . . . . 6-33
Battery Pack System Components and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Lithium-Ion Machine Fault Codes. . . . . . . . . . . . 6-36
BMS Fault Codes -
(Battery Management System) . . . . . . . . . . . . . . 6-39
Battery Charger Fault Codes. . . . . . . . . . . . . . . . . 6-40
6.7 LITHIUM-ION BATTERY PACK - HANDLING IN
DANGEROUS CONDITIONS. . . . . . . . . . . . . . . . . . . . 6-42
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TABLE OF CONTENTS
iv – JLG Lift – 3121636
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Procedure For Handling Hot Cells . . . . . . . . . . . . 6-42
Procedure For Handling Vented Cells. . . . . . . . . 6-43
Procedure For Exploded Cells . . . . . . . . . . . . . . . .6-45
Lithium Battery Fire. . . . . . . . . . . . . . . . . . . . . . . . . .6-46
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . . . 2-6
2-2. SkyGuard™ Sensor and Override Switch
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
3-1. Basic Machine Nomenclature . . . . . . . . . . . . . . . . 3-1
3-2. See “Ground Control Station -
With Enable Lever” . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-3. See “Ground Control Station -
With Enable Knob” . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-4. Ground Control Station - with Enable Lever . . 3-6
3-5. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-9
3-6. Platform/Remote Control Station . . . . . . . . . . .3-15
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. SkyGuard™ Sensor and Override Switch
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-19
4-7. Lifting Machine - Lifting Rings Location . . . . .4-27
4-8. Lifting Machine - Fork Lift Pockets Location .4-28
4-9. Machine Tie-Down Points . . . . . . . . . . . . . . . . . .4-30
4-10. Decal installation - Standard - Left Side. . . . . .4-31
4-11. Decal Installation - Standard - Right Side . . . .4-32
4-12. Decal installation - Lithium-Ion - Left Side . . .4-36
4-13. Decal Installation - Lithium-Ion - Right Side .4-37
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TABLE OF CONTENTS
3121636 – JLG Lift – v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5-1. Platform/Remote Control Station . . . . . . . . . . . .5-3
5-2. Ground Control Station - with Enable Lever . .5-5
5-3. Ground Control Station -
Boom Control Valves . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Hand Pump - On Top Of Hydraulic Tank . . . . . .5-8
5-5. Hand Pump Decal - On Top Of
Hydraulic Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-6. Ground Component Valves -
Outriggers/Track Control - Location. . . . . . . . .5-13
6-1. Lubrication and Maintenance Point
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
6-2. Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . .6-8
6-3. Hydraulic Oil Operating Temperatures . . . . . . .6-9
6-4. Component Maintenance Intervals -
with Honda Engine . . . . . . . . . . . . . . . . . . . . . . . . .6-10
6-5. Component Maintenance Intervals -
X500AJ - Lithium-Ion Machine . . . . . . . . . . . . . .6-11
6-6. Example of Lithium-Ion Battery Pack
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-34
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . .1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . .1-8
2-1 Inspection and Maintenance Table . . . . . . . . . . .2-3
3-1 LCD Display Icon Descriptions . . . . . . . . . . . . . . 3-20
3-2 LCD Display Error Descriptions. . . . . . . . . . . . . . 3-22
4-1 SkyGuard Function Table. . . . . . . . . . . . . . . . . . . 4-19
4-2 X500AJ - Decal Installation - Standard. . . . . . . 4-33
4-3 X500AJ - Decal Installation - Lithium
Machine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
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. . . . . . . . . . . . . . . . . . . . . . . . 6-36
6-11 Battery Charger Fault Codes . . . . . . . . . . . . . . . . 6-40
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SECTION 1 - SAFETY PRECAUTIONS
3121636 – JLG Lift – 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
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 Mainte-
nance 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 opera-
tor.
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.
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SECTION 1 - SAFETY PRECAUTIONS
1-2 – JLG Lift – 3121636
•An operator must not accept operating responsibili-
ties until adequate training has been given by com-
petent 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, WARN-
INGS, 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 opera-
tion of the machine.
•Do not operate or raise the platform from a position
on trucks, trailers, railway cars, floating vessels, scaf-
folds or other equipment unless the application is
approved in writing by JLG.
•Before operation, check work area for overhead haz-
ards such as electric lines, bridge cranes, and other
potential overhead obstructions.
•Check operating surfaces for holes, bumps, drop-
offs, 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.
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SECTION 1 - SAFETY PRECAUTIONS
3121636 – JLG Lift – 1-3
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 ser-
viced 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 mal-
function occurs, shut down the machine. Remove
the unit from service and notify the proper authori-
ties.
•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.
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SECTION 1 - SAFETY PRECAUTIONS
1-4 – JLG Lift – 3121636
•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 opera-
tions.
•Always ensure that power tools are properly stowed
and never left hanging by their cord from the plat-
form 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 push-
ing or pulling except by pulling at the chassis tie-
down lugs.
•Fully lower platform and shut off all power before
leaving machine.
•Remove all rings, watches, and jewelry when operat-
ing 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 phys-
ical 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.
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SECTION 1 - SAFETY PRECAUTIONS
3121636 – JLG Lift – 1-5
•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.
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SECTION 1 - SAFETY PRECAUTIONS
1-6 – JLG Lift – 3121636
•Maintain distance from electrical lines, apparatus, or
any energized (exposed or insulated) parts accord-
ing to the Minimum Approach Distance (MAD) as
shown in Table 1-1.
•Allow for machine movement and electrical line
swaying.
•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-
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 bar-
rier. 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0to50KV 10(3)
Over50KVto200KV 15(5)
Over200KVto350 KV 20 (6)
Over350KVto500 KV 25 (8)
Over500KVto750 KV 35(11)
Over750KVto1000 KV 45(14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
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SECTION 1 - SAFETY PRECAUTIONS
3121636 – JLG Lift – 1-7
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 ele-
vated while on or near a sloping, uneven, or soft sur-
face. 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, drop-
offs, 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, Beau-
fort 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 per-
sons must be removed before attempting to stabi-
lize the machine. Use cranes, forklift trucks, or other
appropriate equipment to stabilize machine.
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