JLG X1000AJ Gebrauchs- und Pflegehandbuch

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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ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,

Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /

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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: 240-420-2661

E-mail: ProductSafety@JLG.com

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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