JLG X20JPLUS Operator, Safety, Maintenance And Service Manual Download

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Operator,

Safety,

Maintenance

and

service

Manual

Original

Instructions

‐

Keep

this

manual

with

the

machine

all

times

Boom

Lift

Models

X20JPLUS

MUX20JP021602

2016, revision02

Summary of Contents for X20JPLUS

Page 1: ...Operator Safety Maintenance and service Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models X20JPLUS MUX20JP021602 2016 revision02...

Page 2: ......

Page 3: ...gine 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 2...

Page 4: ...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...

Page 5: ...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 exten...

Page 6: ...e 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...

Page 7: ...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 th...

Page 8: ...MUX20JP021602 6 Boom Lift Models X20JPLUS...

Page 9: ...A Toll Free 877 JLG SAFE 877 554 7233 Outside USA Phone 240 420 2661 Fax 301 745 3713 E mail ProductSafety JLG com For Accident Reporting Product Safety Publications Current Owner Updates Questions Re...

Page 10: ...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 d...

Page 11: ...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 Ever...

Page 12: ...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 inst...

Page 13: ...atform 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 res...

Page 14: ...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 machin...

Page 15: ...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 c...

Page 16: ...l Number Notified Body ECO Certificazioni S p A EC Number 0714 Address Via Mengollna 33 48108 Faenza Italy Certificate Number Reference Standards EN ISO 12100 2010 EN 280 2013 JLG Industries Inc hereb...

Page 17: ...nited 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 W...

Page 18: ...c 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...

Page 19: ...part hydraulic di stributor or on the machine frame near of the lifting forks fasteners Fig 4 Example CE plate xsm1 Manufactured by HINOWA S p A Via Fontana 37054 NOGARA VR ITALY Model Date of manufac...

Page 20: ...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 Maximu...

Page 21: ...each stabilizer 3 04 daN cm2 No Of operators 2 No Of operators with optional single operator basket 1 JIB type of articulated joint 89 0 89 Max working gradient 1 1 75 Max stabilization slope 15 Total...

Page 22: ...ng Petrol Air Power 9 5 Kw 12 7cv 3600rpm Max speed 3600 rpm Maximum torque 29 8 Nm 2500rpm Number of cylinders 1 Displacement 440 cm Sound power level at operator s ear 88 dB Measured sound power lev...

Page 23: ...7 4 5 Electrical system technical specifications lithium Granted sound power level 104 dB Hydraulic oil tank capacity 40 l Pump petrol engine 2x4 cm Pump diesel engine 2x4 cm Hydraulic system max pre...

Page 24: ...NS MUX20JP021602 For further information see wiring diagram enclosed with the manual and the paragraph on maintenance of electrical components Sound power level at operator s ear 70 dB Measured sound...

Page 25: ...elow illustrates the terms used to identify the parts of the machine LEGENDA Fig 6 Terminology machine components 1 Tracked undercarriage 2 Revolving turret 3 Turntable rotation motor 4 Emergency cont...

Page 26: ...n the transmission 16 Third arm 17 Stabilizer plate 18 JIB tie rod 19 First extension arm 20 Jib cylinder 21 Right and left JIB arm 22 Second extension arm 23 Remote control 24 Basket or cage 25 Baske...

Page 27: ...cts persons and explains what the operator must do to prevent them Operators must always act professionally complying with safety standards making sure not to underestimate their responsibility to the...

Page 28: ...OF SUCH SAFETY SY STEMS THE EMPLOYER AND OR USER IS RESPONSIBLE FOR CHOOSING THE SYSTEM TO BE USED 7 8 SAFETY VALVES AND ELECTRICAL SYSTEM SAFETY COMPONEN TS It is prohibited to modify and or tamper...

Page 29: ...e Petrol is extremely flammable and explosive in particular conditions Refuel in well ventilated areas and with the engine at rest Avoid smoking and producing sparks in the refuelling and fuel storage...

Page 30: ...em 7 10 4 After cleaning Dry the machine carefully before starting it again for example using compressed air If washing the machine with water cleaners do not aim the spray di rectly onto adhesive lab...

Page 31: ...ted never enter its ope rating area Always operate the controls slowly and smoothly and avoid reversing the move ments suddenly When operating outside of the basket ALWAYS keep a MINIMUM distance of 1...

Page 32: ...l measurement shown on the machine s EC declaration of conformity When operating the aerial part of the machine this value is reduced even further as the basket moves away from the main source of nois...

Page 33: ...TECHNICAL INFORMATIONS 31 MUX20JP021602 Boom Lift Models X20JPLUS 7 12 3 Decals on the machine Here we report the positions of the various boards with pictogram on the machi ne...

Page 34: ...32 Boom Lift Models X20JPLUS TECHNICAL INFORMATIONS MUX20JP021602...

Page 35: ...TECHNICAL INFORMATIONS 33 MUX20JP021602 Boom Lift Models X20JPLUS...

Page 36: ...7 1706898 01 36 1701505 01 08 06924300 01 37 06056300 01 09 1706493 01 38 06164600 01 10 06040500 02 39 06232100 01 11 06040900 06 40 07240300 01 12 06041300 11 41 07320400 04 13 1703814 04 42 0703420...

Page 37: ...uantity Position Code Quantity 172831IT 172831GB L1 06555300 01 L1 06562600 01 L2 06561200 04 L2 06561200 04 L3 06448200 02 L3 06462700 02 L4 06448100 02 L4 06462100 02 L5 07348900 01 L5 073489GB 01 1...

Page 38: ...1 L5 073489NL 01 172831PT 172831DA L1 06563100 01 L1 07138100 01 L2 06561200 04 L2 06561200 04 L3 06463200 02 L3 07138000 02 L4 06462600 02 L4 07137900 02 L5 073489PT 01 L5 073489DA 01 172831NO 172831...

Page 39: ...ection forward Obligation to read the manual before use of machine Fixing point for transport indicates correct fixing point for transport of the machine Crushing hazard feet indicates areas where the...

Page 40: ...machine Danger hight temperature Engine oil level Emergency device for aerial part device that allows to exclude the safety of the aerial part in case of emergency operations Emergency device for und...

Page 41: ...f the platform for rai sing loads Battery pack warnings Corrosive liquid presence of highly corrosive liquid dangerous to the body and eyes High voltage presence of high voltage with danger of electri...

Page 42: ...stickers and plates if there is any sign of wear Failure to heed any warnings due to a safety sticker being damaged lost or ignored may cause serious accidents Anchor position in basket indicates the...

Page 43: ...and consequent ly put the operator s life at risk The Constructor has designed the machine and safety devices in order to guarantee the maximum to its customers however the devices must be checked per...

Page 44: ...closes the machine s electrical circuit while turning it anticlockwise isolates the machi ne s electrical circuit and the key can be removed 8 2 DISTRIBUTOR PRESSURE RELIEF VALVES Fig 7 Battery cut ou...

Page 45: ...r cylinders have a double stop valve which in case of system break down or hose breakage stops the cylinder preventing dangerous platform insta bility situations All cylinders that move the aerial par...

Page 46: ...se conditions are not met a signal is sent that disables the movement of the stabilisers 8 5 STABILIZER POSITION MICRO SWITCHES The position of the stabilisers and their contact with the ground are de...

Page 47: ...itch must be released when the jib arm is closed 8 7 ROPES INTEGRITY MICRO SWITCH The integrity of the ropes system that moves the telescopic arm is verified by a micro switch that detects the positio...

Page 48: ...ancing system is parallel to the machine axle and the micro switch must be released If the micro switch is not released due to an anomaly on one of the two ropes a warning message appears on the remot...

Page 49: ...ive weight inside the basket into an electrical signal The electrical signal is then sent to the electronic board which processes it and identifies any dangerous conditions The remote control display...

Page 50: ...n particular of the system that makes up the basket load sensor always check correct operation whenever objects are struck with the basket or if performing operations that may damage the sy stem e g p...

Page 51: ...ON A protection structure is provided to protect the remote control against the acci dental fall of objects from above and involuntary activation by the operator Fig 23 Basket control protection Alway...

Page 52: ...vely satisfied and checks the power supply to the controls for the aerial part Fig 24 Visible spirit level Fig 25 Electronic level Always check the correct levelling of the machine after every self le...

Page 53: ...the ends and are fitted with self locking nuts or self locking threaded ring nuts to prevent the structure from sub siding Check the correct tightness of all the pin locking devices according to the...

Page 54: ...ied out by the operator on the safety devices filing them by date time and lapse of time during which the operator held the safety device bypass key in position The board is also provided with an even...

Page 55: ...top and an audible alarm will sound Operators must lower the platform to the ground by first placing the function being operated into a neutral position and then selecting controls which will permit t...

Page 56: ...ad in order to gain in depth knowledge of the functions of each device and to be aware of any sugge stions provided by the manufacturer 9 1 REMOTE CONTROL The remote control contains most of the contr...

Page 57: ...conds are sufficient however the following screen may appear on the display In this case about 10 15 minutes are needed to send all the information from the main board to the remote control The machi...

Page 58: ...reduced speed for the Lithium POSITION 5 Position 5 displays the icon confirming that overhead movements are enabled This icon means that all conditions for using the overhead movements have been che...

Page 59: ...movements POSITION 6 Position 6 displays the icon confirming that track movements stabilisers tracks track extension are enabled This icon means that all conditions for operating the track movements...

Page 60: ...echarge the battery either by keeping the die sel or petrol engine on or by connecting to the network Signals an error in the battery management system of Lithium version The machine has a CANBUS line...

Page 61: ...stick determines the direction of the movement The degree of movement of the joystick determines the speed The more the joystick is moved away from the central neutral position the faster the movement...

Page 62: ...rols Joystick Direzione movimento Joystick Movimento comandato 1 FORWARDS LEFT TRACK FORWARDS BACKWARDS LEFT TRACK BACKWARDS 2 FORWARDS 1 2 ARM UP BACKWARDS 1 2 ARM DOWN 3 FORWARDS 3 ARM UP BACKWARDS...

Page 63: ...e emergency STOP button is represented on the display in position 7 Display p 55 To make the machine operational again the button must be turned and released For the description of the individual func...

Page 64: ...ble rpm according to the selected movement Travel motors in au tomatic displacement variation mode therefore maximum travel speed The three speeds are selected by pressing button 5 in sequence with a...

Page 65: ...BUTTON 12 Enters the auto service menu Service menu on the remote control p 192 Used to automatically lower the stabilisers Used to narrow the tracked undercarriage Allows the preheating of the engin...

Page 66: ...ide of the basket is fitted a foot switch device that must be pushed to allow the movement of the machine from the basket If you try to move the machine wi thout the foot switch pushed the movement wi...

Page 67: ...activated the foot switch must be release and activa ted again if no movements are made for more than 7 second The remote control is connected to the machine using a flexible cable that allows to shif...

Page 68: ...ght indicates that the movements of the aerial part are enabled From this position the movements of the machine can be controlled directly using the levers on the various hydraulic distributors aerial...

Page 69: ...the basket it is forbidden to move the structure from the ground position unless in an emergency situation sudden operator illness te chnical fault 9 3 4 Maintenance control position There is a contr...

Page 70: ...carefully paragraph regarding the use of the optional second remote control Maintenance control position with remote control from the ground p 144 Fig 62 Position connector optional second remote This...

Page 71: ...functions that were in use at the time of actuation will reverse or cut out and the ground alarm will beep The table be low outlines these functions If SkyGuardTM remains activated after function reve...

Page 72: ...te for a short duration and the beeper will sound until the SkyGuardTM sen sor are disengaged Disengage the SkyGuardTM sensor release control press and release the emer gency stop on the remote contro...

Page 73: ...tivated the button must be turned and released to allow the machine to operate again Selection of the emergency stop is indicated on the re mote control display Display p 55 It is important that befor...

Page 74: ...main hydraulic system The hand pump has a ma nual switch used to select whether part of machine to control depending on the selection made according to the logic described in the legend above Fig 66 H...

Page 75: ...es which allow the descent of the aerial part of the structure due to gravity The use of this emergency device depends on the platform s electrical system being powered 10 4 SAFETY DEVICE BYPASS KEY T...

Page 76: ...he bypass of the safety devices carefully read the paragraphs regar ding the use of the safety device release key selector switch The safety device bypass system is used to move the machine with a hig...

Page 77: ...2 Boom Lift Models X20JPLUS This panel houses the following controls Three position control for selecting the control position Fig 72 Engine start button Fig 73 Electric motor start button Fig 74 Aeri...

Page 78: ...be used for mainte nance operations and for it to be enabled the primary remote control must be in the basket or the remote control cable in the basket must be connected to the special adapter To conn...

Page 79: ...0JP021602 Boom Lift Models X20JPLUS Fig 75 Controls distributor of aerial part Fig 76 Decals near the control Ref Description Drive Motion 1 Basket levelling control Moving lever upwards basket closes...

Page 80: ...r downwards il JIB closes 4 Extension arm control Moving lever upwards extension arm out Moving lever downwards extension arm in 5 Third arm control Moving lever upwards 3 arm up Moving lever downward...

Page 81: ...rol for the drive in case of failure 10 5 3 Tracked undercarriage hydraulic distributor The meanings of the levers on the distributor are described below Fig 77 Knob activation proportional val ve aer...

Page 82: ...Moving lever downwards stabilizer down Moving lever upwards stabilizer up 3 Left track control Moving lever upwards moves left track forward Moving lever downwards moves left track backward 4 Track e...

Page 83: ...lves ground part The valves is equipped with a manual control for the drive in case of failure 7 Rear right stabiliser con trol Moving lever downwards stabilizer down Moving lever upwards stabilizer u...

Page 84: ...not work in the presence of storms snow fog or wind exceeding 12 m s Do not operate the machine when the ambient temperature drops below 20 C or SAFETY DISTANCE FROM POWER LINES LINE RATED VOLTAGE SA...

Page 85: ...ground is solid Make sure that water has not penetrated into the electrical contacts Beaufort Number Wind Speed Description Land Condi tions mph m s 0 0 0 0 2 Calm Smoke rises vertically 1 1 3 0 3 1...

Page 86: ...ngs obstacles debris and coverings which may hide holes 11 2 PROCEDURES FOR CORRECT USE Below find the procedures for use of the platform as declared by the Constructor Any use different to that state...

Page 87: ...ropriately atta ched to the relevant anchorage points on the basket Remember that the safety harnesses must be checked periodically The use of harnesses is compulsory in ac cordance with local legisla...

Page 88: ...o in crease the working height Always operate the controls slowly and smoothly without reversing move ments suddenly Remember that the basket must only be loaded and unloaded FROM THE GROUND Do not us...

Page 89: ...USING THE MACHINE 87 MUX20JP021602 Boom Lift Models X20JPLUS 11 3 WORKING AREA Fig 82 Working area...

Page 90: ...ore carrying out any operations Remember that the safety harnesses must be checked and TESTED PERIODICALLY In the explanations contained in the following paragraphs it is assumed that the operator has...

Page 91: ...139 Check that there are no broken damaged or missing components Check the correct tightness of the pin locking bolts and nuts or the safety locknut Before using the machine replace tighten and adjus...

Page 92: ...n of the electronic systems of the machine and the activation of the remote con trol At this point press the button on the remote control to start the engine The petrol engine starter is automatic If...

Page 93: ...afety stickers Examine the safety rule summary table in the manual and follow all the in structions given therein Power the machine with an electric cable through the connection positioned at the bott...

Page 94: ...d with plug for at least 32A The maximum cable length must be 10 m e Place an earth plate in the ground and connect it to the machine s ground clamp or if this is not possible make sure the power conn...

Page 95: ...n 3 4 seconds The engine must be started with all the control buttons and joysticks in neutral position Always make sure there are no foreign objects e g Branches that may accidentally operate a contr...

Page 96: ...the speed selector button on the remote control Push buttons p 61 Pay atten tion to the complete clearance of the machine especially if the outriggers are not turned into the transport position During...

Page 97: ...hat there are no obstacles in the travel area considering the overall dimensions of the machine The machine is completely closed and aligned in the transport or stabilisa tion position or with the JIB...

Page 98: ...roach to dangerous inclinations for machine s stability both lateral and longitudi nal a beeper is activated and afterwards the translation is forbidden The only allowed operation to exit this conditi...

Page 99: ...be in the basket The control position on the ground must be used the remote control must not be in place in the basket The aerial part safety device bypass key must not have been activated after the m...

Page 100: ...or on uneven ground When parking the machine on a slope or uneven ground with the stabilisers clo sed make sure that the carriage is in the open position and block the tracks using chocks to prevent t...

Page 101: ...round make sure there is com plete visibility of the trajectory of each individual stabiliser before moving it and check that at the end of the stabilisation procedure the distance between the Always...

Page 102: ...on the display Stabilisation will be completed when the machine is in horizontal position with tolerance of 1 and lifted at least 5 cm from the ground Correct stabilisation will be confirmed by the i...

Page 103: ...see photo below the ma chine is in conditions that allow operation Please note that stabilize the machine on slopes greater than allowable limits see technical data of the machine Technical data p 19...

Page 104: ...o do this run an auto stabilisa tion cycle or lower each stabiliser for one second Incorrect machine stabilisation does not ensure suitable stability to perform operations The Constructor prohibits th...

Page 105: ...dure always control that the spirit level is in the gre en zone If this does not occur contact the after sales service If during lowering one of the stabilisers does not touch the ground the machine w...

Page 106: ...proceed as follows Using the self levelling procedure does not affect the operation of the stabilisers in manual mode Press and hold button 1 on the remote control If problems occur during either of t...

Page 107: ...e remote control for extend the track Press and hold button 9 on the remote control for narrow the track The track extension operations should be performed with the machine stabilised and lifted from...

Page 108: ...onnected in other way to the structure the machine can lift two persons and their tools See Technical data p 19 for data related to the admitted load on basket During machine lowering near where the u...

Page 109: ...selection on the display d Use joysticks on the remote control to move the aerial part as described in the paragraph regarding the description of the controls Joystick p 59 e If the movements are sel...

Page 110: ...then in position 5 The alarm will only be reset when the overload is removed Normal machine ope ration can be resumed only then BASKET LIFTING ALARM If when using the machine at a height for whatever...

Page 111: ...ts in this situation which allow you to go back in a zone of free rotation LIMITED ROTATION AREA is an area near the engine battery pack where this may be hit by the first boom FREE ROTATION AREA is t...

Page 112: ...by closing the extendable structure completely this only if the problem was met while the basket was at a high position only carry out this operation if no basket levelling exceeds 10 If this is not...

Page 113: ...repeated frequently have the basket checked by an authorised workshop the manual levelling control is only allowed from the basket with the extendible structure completely closed and aligned Differen...

Page 114: ...the occupant s from the basket The intervention procedures are given below 11 5 1 Activation of emergency descent from the basket The emergency descent procedure of the basket can be actuated from th...

Page 115: ...igura tion of the machine at the time when the emergency situation occurred 2 Check the control by means of icon 8 on the display Fig 108 Display icons 3 Activate the joystick re lative to the arm tha...

Page 116: ...osition see the paragraph Emergency position controls p 74 The sole purpose of the emergency descent from the ground is to operate in the event of system breakdown and to bring the basket to the groun...

Page 117: ...engine Start the motor using the corre sponding button in case of Petrol Diesel version If the switch needs key to be operated withdraw it from the engine keys group Fig 112 Emergency control panel s...

Page 118: ...he protection and put the keys back in their original position 5 Move the aerial part of the machine using the manual levers positio ned on the distributor on the ground as descri bed on the decal pla...

Page 119: ...hen stabilise the machine again the electrical emergency de scent function can be used which involves only the return of the aerial part If this is not possible due to the presence of objects that int...

Page 120: ...SS icon 2 Position the emergency key on the electrical components compart ment removing it from the side where this is le ad sealed Fig 116 Emergency key location 3 Turn the emergency key anticlockwis...

Page 121: ...losed first second boom folding extension boom in JIB boom folding The third boom can be rotated and lowered only with the extension boom completely retracted Do not carry out any opera tions other th...

Page 122: ...ground controls for the arm movements To perform the emergency descent in the conditions described above proceed as follows The sole purpose of the emergency descent from the ground is to operate in t...

Page 123: ...ement of the aerial part Fig 121 Hand pump manual selector 3 Withdraw the key enabling the emergency descent and a key ope ning the distributor con trols protection if any from the engine keys group i...

Page 124: ...l part enable 6 Use the levers and or buttons corresponding to the ON OFF coils ac cessible from the bottom of the distributor pro tection so as to enable the required mo vement following the instruct...

Page 125: ...the transport configura tion machine closed and aligned to raise the stabilisers and lower them again Only then it will be possible to work with the machine at a height con trolling it from the basket...

Page 126: ...If this occurs one of the two EMERGENCY PROCEDURES de scribed below can be applied 11 5 5 1 Machine realignment The manoeuvre described below must be carried out only and exclusively with the machine...

Page 127: ...g the undercarriage with the machine not aligned 3 Turn the emergency key anticlockwise and hold it in position Fig 128 Emergency BY PASS decals Fig 129 Emergency BY PASS icon Fig 130 Emergency BY PAS...

Page 128: ...1 Open the electrical com ponents compartment Fig 131 Electrical box 2 Place the emergency key on the electrical compo nents compartment re moving it from the machine s key holder where it is sealed w...

Page 129: ...onents compartment Fig 134 Emergency BY PASS icon Fig 135 Emergency BY PASS actived Use the travel control with extreme care to avoid causing damage to the machine or people Move to a suitable positio...

Page 130: ...ort the machi ne proceed as follows The hydraulic hand pump can be used to move the stabilisers and set the ma chine in the transport configuration only after closing completely the aerial part of the...

Page 131: ...corre sponding to side of ma chine to move right or left Fig 138 Hand pump manual selector 4 Manually switch the ae rial tracked part switch via the fuse in the centre of the magnet using the correspo...

Page 132: ...art switch and proportional val ve and put the hand pump handle in the original position 6 While keeping operated the proportional valve use the ON OFF coil le vers and buttons to enable the required...

Page 133: ...trol connector and close the remote control sealing plug Make sure there is no moisture in the electric cable connector and close the electric cable sealing plug To reconnect the remote control follow...

Page 134: ...nnected Power the machine by an electric cable connecting it to the socket on the chas sis near the electric motor and activate the main supply switch in the control ca binet of the motor In this cond...

Page 135: ...periods exceeding 24 hours Pay attention the charger works even if the electronic board of the machine is turned off So the batteries can be charging even if the re mote control is off Charge the mach...

Page 136: ...602 Is also possible check the battery charging through the charge indicator located near the battery pack Fig 146 Main supply socket Fig 147 Main supply switch If the machine is on the display on the...

Page 137: ...arging phase YELLOW LED indicates that the battery has reached 80 of rechar ge GREEN LED staggered with red flashings indicates that battery re ached the balance maintenance phase The battery charger...

Page 138: ...c compatibility the battery charger features a three pins plug with earth which can only be plugged into an earthed socket If the plug does not go into the socket most probably the socket is old and n...

Page 139: ...8 3 Pruning This activity requires very important skills in order to prevent the machine from losing stability Remember that if branches or logs fall on the safety devices these will be broken fallin...

Page 140: ...tickers capacity table etc If sand enters the grease protecting the extension arms it pro duces an extremely abrasive mixture affecting the quality of the movements and working life of the machine 11...

Page 141: ...tenance operations with the working arm not completely lowered and or with stabilised machine If operations are being carried out apply a visible sign on the control position stating DANGER Do not mov...

Page 142: ...tes one of the following CO2 Con version 60 per EPA 560 6 82 003 CO2 Conversion 80 per CEC L 33 A 93 Virtually Non toxic classification indicates an LC50 5000 per OECD 203 Fire Resistant classificatio...

Page 143: ...e machine has been produced with biodegradable hydraulic oil in near the hydraulic tank filler cap is a decal indicating the type of oil used and those that are compatible in the case of refilling Whe...

Page 144: ...points 12 1 3 Greasing the telescopic boom Fig 151 Greasing points diagram Respect the greasing intervals indicated and use only the recommended lu bricants in order to protect pins and connections f...

Page 145: ...ng use of the platform Do not dispose of lubricants in the environment but rather collect and dispose of them in compliance with laws in force in the country in question Check the vehicle at least onc...

Page 146: ...fied personnel Proceed as follows to use this function 1 If you have not already or is not installed on the machine ask the kit to use remote control from the ground at an autho rized service Fig 152...

Page 147: ...ided with the optio nal kit to use service from the ground Otherwise leave it con nected to the main re mote Fig 154 Service connector on the basket 4 Select the command from the ground acting on the...

Page 148: ...he machine Remote con trol p 54 Fig 156 Ground remote control example visualization The remote control from the ground allows to perform all the operations possible within the safety limits if in the...

Page 149: ...0 H Dry air filter Petrol Diesel Check Clean X Replace ment X Engine oil Pe trol Die sel Check level X Replace ment X X Replace ment Kubota X Engine oil filter Diesel Check Clean X Replace ment X Engi...

Page 150: ...nkand net Pe trol Clean X Hydrau lic oil Check level X Replace ment X Hydrau lic oil fil ter Replace ment cartrid ge X X Articu lated joint points Grea sing X X Battery Check X Re duction gear oil Che...

Page 151: ...d restore the connection without using oil or gre ase Exten sionarm internal sliding ring if fitted Check wear X Replace ment X Turn table bolt ti ghte ning Check X X Nut fixing pins basket Perfor man...

Page 152: ...12 5 ELECTRIC MOTOR MAINTENANCE The electric motor is located under a protection cover on the chassis of the machi ne Periodically check the condition of the following electric motor components POWER...

Page 153: ...ion of the bearings in the event of noise contact service de partment for replacement as the life of the bearings is reduced significantly in he avy duty operating conditions in the Lithium version th...

Page 154: ...hoses for leaks or loose connections 3 All quick disconnection hoses for proper connection 4 Structural components for obvious damage broken parts and cracks in welds 5 Ladder or steps for damage and...

Page 155: ...sure 6 Hydraulic cylinders for drifting caused by fluid leaks across the sealing valve or the piston rod seal leakage scored and damaged cylinder rods and unu sual noises or vibration 7 All safety mec...

Page 156: ...and number and variability of users 2 Review the inspection and maintenance record of the aerial platform 3 Verify the efficiency of all operating controls 4 Perform a visual inspection of the aerial...

Page 157: ...have a general check run on the machi ne at a certified service centre where the general condition of the machine will be assessed and the form in Appendix 1 of this manual will be filled in Sub seque...

Page 158: ...measure or too tight please follow the proce dure illustrated in the following paragraph As an alternative to the above mentioned procedure you can follow the procedu re below In this case the check i...

Page 159: ...oose it could be expelled under the effect of the pressure of grease seriously endangering the safety of the ope rator When gravel or mud is stuck between the sprocket teeth and track links re move it...

Page 160: ...o drain by unscrewing the valve of not more than one turn at a time Fig 161 Draining valve The grease contained in the hydraulic tracks is under pressure If the valve track tension is too loose it cou...

Page 161: ...y to walk the first teeth in past the idler 5 Make sure that the track links are properly meshed in the sprocket and idler 6 Adjust the track tensioning Tensioning rubber track p 157 7 Lower the under...

Page 162: ...E MUX20JP021602 The values indicated are to be applied unless different instructions are given in this manual Pay special attention to the screws of the stop pins the nuts of bolts and screws of the s...

Page 163: ...MAINTENANCE 161 MUX20JP021602 Boom Lift Models X20JPLUS...

Page 164: ...700 485 660 455 620 41600 605 825 545 740 455 620 14 0 8750 0 5090 45800 570 775 535 730 500 680 45800 670 910 600 815 500 680 1 8 1 0000 0 6060 51500 730 995 685 930 645 875 51500 860 1170 775 1055...

Page 165: ...235 97 8 265 250 235 18 2 5 192 83 5 301 226 271 331 119 5 430 385 325 119 5 365 345 325 20 2 5 245 106 5 426 320 383 469 152 5 610 550 460 152 5 520 490 460 22 2 5 303 132 0 581 436 523 639 189 0 83...

Page 166: ...em in order to identify any possible leaks Leaks from hoses can normally be resolved by tightening the fittings Leaks from gaskets O rings sealing rings etc cannot be eliminated by simply tightening a...

Page 167: ...G THAT ALL THE PLATES ARE PRESENT ON THE MACHI NE AND INTACT Make sure that the prohibition warning danger and control plates positioned on the machine are all present and visible See the paragraph re...

Page 168: ...itting upper pressure intake 2 Go to the control position and switch the machine on A pressure gauge with a minimum scale of 250 bars must be used to carry out this check Make sure that the machine is...

Page 169: ...t the pressure gauge to fitting lower pressure intake 5 Go to the control position and switch the machine on 6 Close one of the two left stabilisers completely and maintain the movement activated Read...

Page 170: ...e surface of the rope in the inter nal area or in correspondence with the cable socket 2 Check that there are no signs of corrosion on the rope 3 Check that there are no signs of kinking crushing or d...

Page 171: ...ll protection sumps from the third arm and the two extensions Use an electric torch to visually check the state of the ropes and the extension pulleys Check the correct rope tension trying to bend the...

Page 172: ...s position them in a way to ac cess the adjustment nuts in order to make the adjustment 2 nuts with relative counter nut for outlet ropes and one nut with relative counter nut for return ropes rocker...

Page 173: ...12 15 4 Five yearly inspection The replacement of the cables and pulleys is advisable every 5 years even in shor ter time according to the working hours Further inspections of the extension system ar...

Page 174: ...lower ones Check the support and the correct distance slipping off and closing the arm completely The slide blocks must be replaced at an authorised workshop After having carried out any maintenance i...

Page 175: ...ine on a level surface is below the minimum allowed level MIN it is possible to top up by removing the sea ling caps and adding distilled water without exceeding the maximum level MAX When the battery...

Page 176: ...174 Boom Lift Models X20JPLUS MAINTENANCE MUX20JP021602 The batteries must be disposed of in compliance with the specific regulations in force...

Page 177: ...ery pack does not require maintenance The only action required by the system is re charging the batteries according to the frequency of use of the machine and in struction written in this manual For c...

Page 178: ...nce operation on the battery pack it is necessary to use at least the Personal Protective Equip ment PPE listed below 12 18 1 2 Procedure for handling hot cells As soon as it has been established that...

Page 179: ...arts to cool down The cell vents The cell explodes If the cell starts cooling check the temperature every hour until ambient tem perature has been reached If a temperature sensor is not available do n...

Page 180: ...ls proceed as follows Evacuate the people exposed to fumes from the area Air the environment until the complete removal of the cell and until the cha racteristic pungent odour has disappeared If the c...

Page 181: ...s a rare event that only occurs when an abnormal condition causes the temperature to rise and reach a critical point However in the event of lithium battery explosion the environment will quickly be f...

Page 182: ...OF CONTACT WITH THE ELECTROLYTE SEE THE PREVIOUS PARAGRAPH PROCEDURE FOR HAN DLING VENTED CELLS P 177 12 18 1 5 Lithium battery fire All metals may burn in certain conditions which depend on certain f...

Page 183: ...m of experienced fire fighting personnel has to be contacted The personnel must be properly trained to fight lithium bat tery fires Evacuate personnel from all areas and sound the fire alarm The fire...

Page 184: ...t bag in the second and seal it Clean the area with plenty of water and keep cleaning with water and soap Dispose of hazardous material in accordance with the local legislation in force FOR THE FIRST...

Page 185: ...ugh the openings of a width less than the basket but more than the machine To remove the basket proceed as follows remove the remote control from the support loosen the aluminium covers on the basket...

Page 186: ...JP021602 withdraw the basket from above Reassemble the basket as follows fit the basket into the fixing pins on the basket support making sure that it moves downwards as parallel to the basket support...

Page 187: ...5 As a general rule if the ramps and the truck trailer rely on free surface without slope variations this requirement is met if the ratio between the length of the ramps and the height of the arrival...

Page 188: ...imum speed possible MAKE SURE THAT THE ENGINE IS AT IDLE SPEED turtle speed select Maintain a constant speed Avoid abrupt starts and braking Make sure before procee ding on the ramps that each track i...

Page 189: ...nsport configuration extensible structure completely closed and aligned stabilisers completely lifted and under carriage extended Otherwise the machine would be unbalanced and lifting dangerous Never...

Page 190: ...of the forklift Proceed approaching careful ly to the machine paying attention not to collide with parts of it and cause dama ges to the structure During the operations of lifting and transport follow...

Page 191: ...s necessary to use a sling bar of adequate size and features with a distance between hooks from 550 to 730 mm The minimum ca pacity required for each rope chain or sling used must be sufficient to ens...

Page 192: ...than 25 mm and the rope diameter cannot exceed 25 mm Fig 180 Ropes or chains lifting diagram The manufacturer of the Platform is not responsible in any way for damages caused to the machine lifting d...

Page 193: ...e photo below Make sure that the dimensions of the machine and the trailer are compa tible with road traffic regulations Fig 181 Fixing hook 1 Fig 182 Fixing hook 2 The fixing system connection points...

Page 194: ...RS RAMPS CURRENTS WORKING HOURS SETTING JOYSTICK ESC 14 1 INPUT MENU This displays the signals received by the board from the various sensors fitted on the machine and from the controls on the remote...

Page 195: ...the spanner icon Fig 45 Lithium error p 58 in position 7 on the remote control display If the machine has problems in the functioning and the icon spanner on the di splay will not reset turning off an...

Page 196: ...194 Boom Lift Models X20JPLUS HYDRAULIC SYSTEM MUX20JP021602 15 HYDRAULIC SYSTEM Riferimento Descrizione 1 Hand pump...

Page 197: ...iser stop valve 11 Stabilizer cylinder 12 Motorgear 13 Track gauge extension cylinder 14 Directional solenoid valve 16 Accumulator 17 Rotation motor 18 Distributor 19 Manifold 20 Balancing valve doubl...

Page 198: ...Boom Lift Models X20JPLUS HYDRAULIC SYSTEM MUX20JP021602 29 Basket levelling cylinder on the transmission 30 Deflection block for closed loop 31 Levelling balancing valve double Riferimento Descrizio...

Page 199: ...WIRING DIAGRAM 197 MUX20JP021602 Boom Lift Models X20JPLUS 16 WIRING DIAGRAM...

Page 200: ...198 Boom Lift Models X20JPLUS WIRING DIAGRAM MUX20JP021602 Fig 183 Petrol...

Page 201: ...WIRING DIAGRAM 199 MUX20JP021602 Boom Lift Models X20JPLUS Fig 184 Diesel...

Page 202: ...200 Boom Lift Models X20JPLUS WIRING DIAGRAM MUX20JP021602 Fig 185 Lithium...

Page 203: ...17 485 6591 Fax 1 301 745 3713 NOTE Leased or rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number _________________...

Page 204: ...202 Boom Lift Models X20JPLUS WIRING DIAGRAM MUX20JP021602 Worldwide locations...

Page 205: ......

Page 206: ...JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA Tel 39 0442 539100 Fax 39 0442 539075 www jlg com Corporate Office...

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JLG X20JPLUS, Operator, Safety, Maintenance And Service Manual

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