JLG X430AJ Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

Original Instructions - Keep this manual with the machine at all times.

ANSI

Model(s)

X430AJ

3121773

June 29, 2018 - Rev C

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Equipment Financing and

Extended Warranties Available

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

3121773 – 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 – 3121773

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that fol-

low this symbol to avoid possible injury or death.

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.

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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

3121773 – JLG Lift – 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.

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

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: Pr[email protected]om

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SECTION - REVISION LOG

d– JLG Lift – 3121773

REVISION LOG

Original Issue A - March 16, 2017

Revised B - April 3, 2018

Revised C - June 29, 2018 - Revised Covers, Prop 65

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TABLE OF CONTENTS

3121773 – JLG Lift – i

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 . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7

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 . . . . . . . . . . . . . . . 2-6

Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

SECTION - 3 - MACHINE CONTROLS, INDICATORS AND

OPERATION

3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . 3-3

3.2 PLATFORM/REMOTE CONTROL STATION. . . . . . 3-6

Control Position On The Ground: . . . . . . . . . . . . 3-6

Control Position From In The Platform: . . . . . . . . 3-7

Platform/Remote Control Station Functions . . . . 3-9

Platform/Remote Control Station LCD Display . 3-12

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 . . . . . . . . . . 4-3

Electric Engine Starting Procedure - AC Voltage

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TABLE OF CONTENTS

ii – JLG Lift – 3121773

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . .4-5

Platform Rotation Alignment Indicator . . . . . . . . . 4-5

4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH

ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Track width adjust. . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Travelling (Drive and Steer) . . . . . . . . . . . . . . . . .4-7

Travelling (Grades and Side Slopes) . . . . . . . . . . 4-7

Jib Position for Travelling . . . . . . . . . . . . . . . . . . . 4-9

4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . 4-11

Setting Outriggers From the Platform/Remote

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-13

4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . . 4-13

Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-14

Raise And Lower The Tower Boom . . . . . . . . . . 4-14

Raise And Lower The Main Boom . . . . . . . . . . .4-14

Telescope The Main Boom. . . . . . . . . . . . . . . . . 4-15

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-15

Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . 4-15

SkyGuard Operation (If Equipped). . . . . . . . . . . 4-18

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . 4-19

Platform Removal/Installation . . . . . . . . . . . . . . . 4-19

4.8 BATTERY CHARGING - DIESEL/AC-ELECTRIC . . 4-20

Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-20

4.9 BATTERY CHARGING - LITHIUM-ION MACHINE 4-21

Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-21

Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

Cold Weather Charging . . . . . . . . . . . . . . . . . . . 4-23

Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-24

4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-25

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

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

Manual Descent with Engine Running and Electrical

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4

Using Emergency/Ground Controls from

Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Manual Descent with Engine Running but without

Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

Manual Descent without Engine or Electrical

Power.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

Outrigger/Track Movement Emergency

Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

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TABLE OF CONTENTS

3121773 – JLG Lift – iii

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

5.4 SAFETY DEVICES BYPASS KEY USE. . . . . . . . . . 5-13

Using Emergency Descent In Case Of An Outrigger

Losing Contact With The Ground . . . . . . . . . . . . 5-14

Machine Realignment Emergency Procedure . .5-15



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

Machine Maintenance Locations . . . . . . . . . . . . . 6-6

Lubrication Types . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . 6-8

Gas Engine Maintenance Procedures . . . . . . . . 6-12

Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . 6-12

Hydraulic Oil Filter Cartridge . . . . . . . . . . . . . . . 6-13

Rubber Track Maintenance/Replacement . . . . . 6-13

Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . 6-16

Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-16

Battery Maintenance and Charging - Diesel/AC-

Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . 6-17

Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6.5 PLATFORM/REMOTE CONTROL SERVICE

MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-21

Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-21

Battery Pack System Components and

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-22

BMS Fault Codes - (Battery Management

System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24

Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-26

6.7 LITHIUM-ION BATTERY PACK - HANDLING IN

DANGEROUS CONDITIONS . . . . . . . . . . . . . . . . 6-28

Procedure For Handling Hot Cells. . . . . . . . . . . 6-28

Procedure For Handling Vented Cells . . . . . . . . 6-29

Procedure For Exploded Cells. . . . . . . . . . . . . . 6-31

Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . 6-32

SECTION - 7 - INSPECTION AND REPAIR LOG

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