JLG X1000AJ Use and care manual

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X1000AJ
X33JP
P/N - 3121783
February, 2019 - Rev A
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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
3121783 a
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var-
ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
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
b3121783
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 BACK-
GROUND.
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 BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR
INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that fol-
low this symbol to avoid possible injury or death.
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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
3121783 c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT
JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR
INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN
ISSUED FOR THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT
THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES
WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS
OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
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 Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Prod-
uct Modifications
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SECTION - REVISION LOG
d3121783
REVISION LOG
Original Issue of Manual. . . . . . . . . . . . . . . . . . . . . . . . February, 2019
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TABLE OF CONTENTS
3121783i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
WORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c
REVISION LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-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 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . .1-10
1.4 TOWING, LIFTING, AND HAULING .. . . . . . . . . . .. 1-11
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . .1-11
Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
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 . . . . . . . . . . . . . . . 2-5
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND
OPERATION
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . 3-3
3.2 PLATFORM CONTROL STATION . . . . . . . . . . . 3-11
Installing the Platform Control Station: . . . . . . . 3-11
Platform Control Functions: .. . . . . . . . . . . . . 3-12
Platform/Remote Control Station LCD Display . 3-15
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
Diesel Starting Procedure . . . . . . . . . . . . . . . . . . 4-2
Diesel Engine Shutdown Procedure . . . . . . . . . . 4-2
Menu Screens: . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . 3-7
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TABLE OF CONTENTS
ii 3121783
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Electric Engine Starting Procedure - AC Voltage
Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4.4 BASE AND BOOM/JIB ALIGNMENT .. . . . . . . . . . .4-4
4.5 TRACKS - DRIVING, STEERING AND TRACK
WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Track width adjust. . . . . . . . . . . . . . . . . . . . . . . . .4-5
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . .4-6
Travelling (Grades and Side Slopes) . . . . . . . . . .4-6
Jib Position for Travelling . . . . . . . . . . . . . . . . . . .4-8
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . .4-9
Variable Outrigger Positioning . . . . . . . . . . . . . . .4-9
Operating with Outriggers Set to 32° -
Restricted Work Area Of Operation . . . . . . . . . . 4-11
Setting Outriggers From the Platform/Remote
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-18
4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . .4-18
Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Platform Level Adjustment . . . . . . . . . . . . . . . . .4-19
Raise And Lower The Tower Boom . . . . . . . . . .4-20
Raise And Lower The Main Boom . . . . . . . . . . .4-20
Extend/Retract The Main Boom. . . . . . . . . . . . . .4-20
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . .4-20
Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-20
Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . 4-20
SkyGuard Operation . . . . . . . . . . . . . . . . . . . . 4-22
Platform Removal/Installation. . . . . . . . . . . . . . . 4-23
4.8 BATTERY CHARGING - DIESEL/AC-ELECTRIC. . 4-24
Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-25
4.9 BATTERY CHARGING - LITHIUM-ION MACHINE 4-25
Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-26
Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Cold Weather Charging . . . . . . . . . . . . . . . . . . . 4-28
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-29
4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-30
Lifting with a Forklift. . . . . . . . . . . . . . . . . . . . . . 4-30
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4.12 MACHINE DECALS (X1000AJ) . . . . . . . . . . . . . . . 4-34
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . 5-2
Power Main Cut-Off Switch Location . . . . . . . . . . 5-2
Operator Unable to Control Machine. . . . . . . . . . 5-3
Platform or Boom Caught Overhead . . . . . . . . . . 5-3
Emergency Descent. . . . . . . . . . . . . . . . . . . . . . . 5-4
Using Platform Control Box form Platform . . . . . 5-6
Lifting with Slings or Chains........... ... . 4-30
4.13 MACHINE DECALS (X33JP) . . . . . . . . . . . . . . . . . 4-47
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TABLE OF CONTENTS
3121783iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.4 BYPASS KEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Using Emergency Descent In Case Of An
Outrigger Losing Contact With The Ground . . . . .5-8
Machine Realignment Emergency Procedure . . .5-9
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERA-
TOR 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
Electric Motor Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lithium-Ion Battery Pack Specifications . . . . . . . . 6-4
Major Component Weights. . . . . . . . . . . . . . . . . . 6-4
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-5
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . 6-5
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . 6-7
Engine Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Engine Oil Filter (if equipped). . . . . . . . . . . . . . . 6-13
Engine Fuel Filter/Sediment Bowl (if equipped) 6-13
Engine Cooling System and Fluid (if equipped) 6-13
Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Hydraulic Oil Filter Cartridge . . . . . . . . . . . . . . . 6-14
Rubber Track Maintenance/Replacement . . . . . 6-15
Wire Cable Inspection . . . . . . . . . . . . . . . . . . . . 6-18
Wire Cable Adjustment . . . . . . . . . . . . . . . . . . . 6-19
Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . 6-20
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-20
Battery Maintenance and Charging -
Diesel/AC-Electric. . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . 6-21
Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.5 PLATFORM/REMOTE CONTROL SERVICE
MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-24
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-25
Battery Pack System Components and
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-26
BMS Fault Codes - (Battery Management
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
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TABLE OF CONTENTS
iv 3121783
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Battery Charger Fault Codes . . . . . . . . . . . . . . .6-30
6.7 LITHIUM-ION BATTERY PACK - HANDLING IN
DANGEROUS CONDITIONS . . . . . . . . . . . . . . . . .6-32
Procedure For Handling Hot Cells . . . . . . . . . . .6-32
Procedure For Handling Vented Cells . . . . . . . .6-33
Procedure For Exploded Cells . . . . . . . . . . . . . .6-35
Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . .6-36
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
3-1. Basic Machine Component Locations. . . . . . . . 3-1
3-2. Ground Control Station . . . . . . . . . . . . . . . . . . . 3-4
3-3. Platform Control Station. . . . . . . . . . . . . . . . 3-13
4-1. Grade and Side Slope Definition . . . . . . . . . . . . 4-7
4-2. Outrigger Positions . . . . . . . . . . . . . . . . . . . . . 4-10
4-3. Outrigger Positions (Sheet 1 of 2) . . . . . . . . . . 4-12
4-4. Outrigger Positions (Sheet 2 of 2) . . . . . . . . . . 4-13
4-5. Platform - Load/Reach Chart . . . . . . . . . . . . . .4-14
4-6. Platform/Remote Control Box . . . . . . . . . . . 4-21
4-7. SkyGuard™ Sensor and Override Switch
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-8. Machine Lifting Points . . . . . . . . . . . . . . . . . . . 4-31
4-9 . Lifting Machine - Attach Points . . . . . . . . . . . . 4-32
4-10. Machine Tie-Down Points . . . . . . . . . . . . . . . . 4-33
4-11. X1000AJ - Decal Installation - Sheet 1. . . . . 4-34
4-12. X1000AJ - Decal Installation - Sheet 2. . . . . 4-35
4-13. X1000AJ - Decal Installation - Sheet 3. . . . . 4-36
4-14. X1000AJ - Decal Installation - Sheet 4. . . . . 4-37
4-15. X1000AJ - Decal Installation - Sheet 5. . . . . 4-38
4-16. X1000AJ - Decal Installation - Sheet 6. . . . . 4-39
4-17. X1000AJ - Decal Installation - Sheet 7. . . . . 4-40
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TABLE OF CONTENTS
3121783v
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-2. Hydraulic Oil Operating Temperatures . . . . . . . 6-8
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . 2-3
3-1 LCD Display Icon Descriptions . . . . . . . . . . . . . 3-18
3-2 LCD Display Error Descriptions . . . . . . . . . . . . 3-20
4-1 SkyGuard™ Function Table . . . . . . . . . . . . . . . 4-22
4-2 X1000AJ - Decal Installation - Standard . . . . . . 4-43
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 Kubota D902 Specifications . . . . . . . . . . . . . . . . 6-3
6-6 Electric Motor 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 Component Maintenance Intervals -
X1000AJ/X33JP - with Diesel Engine . . . . . . . . .6-9
6-11 Component Maintenance Intervals -
X1000AJ/X33JP with Lithium-Ion Battery Pack .6-11
6-12 Inverter Fault Codes . . . . . . . . . . . . . . . . . . . . . 6-26
6-13 Battery Charger Fault Codes . . . . . . . . . . . . . . 6-30
5-1. Platform/Remote Control Station. . . . . . . . . . . . 5-6
6-1. Hydraulic Oil Specifications . . . . . . . . . . . . . . . .6-7
4-19. X1000AJ - Decal Installation - Sheet 9. . . . . 4-42
4-18. X1000AJ - Decal Installation - Sheet 8. . . . . 4-41
4-20. X33JP - Decal Installation - Sheet 1. . . . . . 4-47
4-21. X33JP - Decal Installation - Sheet 2. . . . . . 4-48
4-22. X33JP - Decal Installation - Sheet 3. . . . . . 4-49
4-23. X33JP - Decal Installation - Sheet 4. . . . . . 4-50
4-24. X33JP - Decal Installation - Sheet 5. . . . . . 4-51
4-25. X33JP - Decal Installation - Sheet 6. . . . . . 4-52
4-26. X33JP - Decal Installation - Sheet 7. . . . . . 4-53
4-27. X33JP - Decal Installation - Sheet 8. . . . . . 4-54
4-28. X33JP - Decal Installation - Sheet 9. . . . . . 4-55
4-29. X33JP - Decal Installation - Sheet 10 . . . . . 4-56
4-3 X33JP- Decal Installation -Standard ...... . 4-57
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SECTION 1 - SAFETY PRECAUTIONS
3121783 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 MAN-
UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read, understand, and study the Operation and
Safety Manual 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 3121783
• Only personnel who have received proper training
regarding the inspection, application and operation
of MEWPs (including recognition and avoiding haz-
ards associated with their operation) shall be autho-
rized to operate a MEWP.
• Only properly trained personnel who have received
unit-specific familiarization shall operate a MEWP.
The user shall determine if personnel are qualified to
operate the MEWP prior to operation.
• 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 have a thorough
understanding of the intended purpose and func-
tion of the MEWP controls, including platform,
ground and emergency descent controls.
• 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.
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SECTION 1 - SAFETY PRECAUTIONS
3121783 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 A MEWP 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 3121783
• 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.
• Hydraulic cylinders are subject to thermal expansion
and contraction. This may result in changes to the
platform position while the machine is stationary.
Factors affecting thermal movement can include the
length of time the machine will remain stationary,
hydraulic oil temperature, ambient air temperature
and platform position.
Trip and Fall Hazards
• Prior to operation, ensure all gates are closed and
fastened in their proper position.
• 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
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SECTION 1 - SAFETY PRECAUTIONS
3121783 1-5
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.
• 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 3121783
• 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.
Tipping Hazards
• 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.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
MINIMUM APPROACH DISTANCE
in Feet (Meters)
0to50KV 10(3)
Over50KVto200 KV 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
3121783 1-7
• The user must be familiar with the operating surface
before driving. Do not exceed the allowable sides-
lope and grade while driving.
• Do not elevate platform while on or near a sloping,
uneven, or soft surface. Ensure machine is posi-
tioned on a smooth, firm surface within the limits of
the maximum operating slope before elevating plat-
form.
• Before driving on floors, bridges, trucks, and other
surfaces, check allowable capacity of the surfaces.
• Do not elevate the platform unless the machine is
on a firm operating surface and outriggers are prop-
erly set.
• Never exceed the maximum platform capacity 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). Factors affecting
wind speed are; platform elevation, surrounding
structures, local weather events, and approaching
storms.
• Wind speed can be significantly greater at height
than at ground level.
• Wind speed can change rapidly. Always consider
approaching weather events, the time required to
lower the platform, and methods to monitor current
and potential wind conditions.
• Do not increase the surface area of the platform or
the load. Increase of the area exposed to the wind
will decrease stability.
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