JLG Boom Lift X660SJ X22SJL X22SJP Operation Safety Manual 31221531

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JLG Boom Lift X660SJ X22SJL X22SJP Operation Safety Manual 31221531
Size: 7.00 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Operation Safety Manual
Model: JLG X660SJ X22SJL X22SJP Boom Lift
Part Number: 31221531
Publication Date: 2025
Number of Pages: 150 Pages

Contents:
FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
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 OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

REVISION LOG​

section - 1 - SAFETY PRECAUTIONS​

section - 2 - PREPARATION AND INSPECTION​

section - 3 - MACHINE CONTROLS, INDICATORS AND OPERATION​

section - 4 - MACHINE OPERATION​

section - 5 - EMERGENCY PROCEDURES​

section - 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE​

Section 1. SAFETY PRECAUTIONS

1.1 General​

1.2 Pre-Operation​

1.3 Operation​

Table 1-1. Minimum Approach Distances (M.A.D.)​

Table 1-2. Beaufort Scale (For Reference Only)​

1.4 Towing, Lifting, and Hauling​

1.5 Maintenance​

SECTION 2. PREPARATION AND INSPECTION

2.1 Personnel Training​

1. Reading and understanding the Operation and Safety Manual.​

2. Thorough understanding of the intended purpose and function of the MEWP controls, including platform, ground, and emergency descent controls.​

3. Control labels, instructions, and warnings on the machine.​

4. Applicable regulations, standards, and safety rules.​

5. Use of approved fall protection equipment.​

6. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction.​

7. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, and drop-offs exist.​

8. Means to avoid the hazards of unprotected electrical conductors.​

9. Selection of the appropriate MEWPs and available options for the work to be performed considering specific job requirements, with involvement from the MEWP owner, user, and/or supervisor.​

10. The responsibility of the operator to ensure all platform occupants have a basic level of knowledge to work safely on the MEWP, and to inform them of applicable regulations, standards, and safety rules.​

11. The requirement for familiarization in addition to training.​

2.2 Preparation, Inspection, and Maintenance​

1. Location of the manual storage compartment and the requirement to ensure the required manual(s) are present on the MEWP;​

2. Purpose and function of the machine controls and indicators at the platform and ground control stations;​

3. Purpose, location, and function of the emergency controls;​

4. Operating characteristics and limitations;​

5. Features and devices;​

6. Accessories and optional equipment.​

Table 2-1. Inspection and Maintenance Table​

SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION

Figure 3-1. Basic Machine Component Locations​

1. Platform​

2. Platform Fold-Down Entry Ladder​

3. SkyGuard™ Sensor​

4. Platform/Remote Control Station​

5. Jib​

6. Outriggers (Stabilizers)​

7. Turntable​

8. Main Boom​

9. Ground Emergency Stop​

10. Lithium Battery (Lithium/Bi-Energy Options)​

11. Diesel Engine (Combustion/Bi-Energy Options)​

12. Ground Control - Boom/Platform​

13. Fuel Tank (*Opposite Side)​

14. Extendable Track Undercarriage​

15. Forklift Pockets​

16. Ground Control - Outrigger/Tracks​

17. Hydraulic Oil Tank (*Opposite Side)​

18. Battery Charging and Platform Power Cords​

19. Manuals Compartment​

3.1 Ground Control Station​

Figure 3-2. Ground Control Station​

3.2 Platform/Remote Control Station​

Figure 3-3. Platform/Remote Control Station​

Table 3-1. LCD Display Icon Descriptions​

Table 3-1. LCD Display Icon Descriptions (Continued)​

Table 3-2. Lithium/Bi-Energy LCD Display Icon Descriptions​

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION​

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS​

4.3 ENGINE OPERATION​

1. With power on, set the platform/ground control select switch to the platform control box (counter- clockwise) position.​

2. Press and hold the diesel engine START/STOP button on the platform control box until engine starts.​

1. Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature.​

2. Turn off the diesel engine by pressing the diesel engine START/STOP button on the platform control box.​

3. Wait for the display to turn off (complete shut-off).​

4. Push in EMERGENCY STOP switches at the platform and ground, to the off position.​

5. Turn engine key and main power key to off.​

1. Before connecting the machine to the electrical circuit, ensure the key switch is in the OFF position.​

2. Power the machine using a heavy duty AC (alternating current) power cord with sufficient amperage capacity, through the connector (1) positioned near the electric motor.​

3. Turn on the circuit breaker switch (2) positioned behind the clear plastic cover near the electric motor (— symbol is ON, O symbol is OFF).​

4. Power on the electric motor using the electrical motor START/STOP button on the platform control box and operate machine.​

1. When finished operating with the electric motor, turn off breaker switch (2), and unhook the electric AC cord from connector (1).​

Bi-Energy machines start from lithium-ion power by default. The first operation of the joystick will display the lithium-ion power icons on the controller.​

1. With power on, set the platform/ground control select switch to the platform control box (counter- clockwise) position, then press and hold the diesel engine START/STOP button (1) on the platform control box.​

2. Release the diesel engine START/STOP button (1).​

3. Press the diesel engine START/STOP button (1 again to start the engine.​

1. Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature.​

2. Turn off the diesel engine by pressing the diesel engine START/STOP button on the platform control box.​

3. Wait for the display to turn off (complete shut-off).​

4. Push in EMERGENCY STOP switches at the platform and ground, to the off position.​

5. Turn engine key and main power key to off.​

1. Turn on the circuit breaker switch (1) positioned behind the clear plastic cover on the lithium-ion battery (— symbol is ON, O symbol is OFF).​

2. With power on, set the platform/ground control select switch to the platform control box (counter- clockwise) position, then simultaneously press the GO BACK and engine START/STOP buttons (2) on the platform control box.​

3. The Electric Motor and Lithium-Ion Battery Status icons will be visible on the LCD display.​

1. Press the electric power (Lithium-Ion) START/STOP button (1) on the platform control box.​

2. When the shutdown procedure is complete the LCD display will shut off.​

3. Push EMERGENCY STOP switches at the platform and ground in, to the off position.​

4. Turn engine key and main power key to off.​

4.4 BASE AND BOOM/JIB ALIGNMENT​

4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH ADJUST​

Figure 4-1. Grade and Side Slope Definition​

4.6 OUTRIGGER OPERATION​

1. Pull the outrigger lock handle (1) upward to the unlocked open position.​

2. Swing outrigger to the desired position.​

3. Release the handle downward toward the locked position and ensure each outrigger locks in the selected position. Ensure that the handle fully closes into the locked position.​

4. Ensure all four pins have dropped into their seats for each outrigger.​

Figure 4-2. Outrigger Positions​

Figure 4-3. Work Areas Based on Outrigger Positioning​

4.7 Load and Reach Charts​

Figure 4-4. Platform - Load/Reach Chart​

4.8 BOOM/PLATFORM OPERATION​

Figure 4-5. Flush-To-Wall Ascent Mode​

Figure 4-6. Platform/Remote Control Station​

Figure 4-7. SkyGuard™ Sensor and Override Switch Location​

Table 4-1. SkyGuard™ Function Table​

4.8 BATTERY CHARGING​

4.9 SHUT DOWN AND PARK​

1. Drive machine to a reasonably well protected area.​

2. Ensure boom and jib are in the stowed (aligned) position.​

3. Shut down electric engine with the same button on the platform/remote control station used to start it. Complete machine shut down takes approximately 1 minute, LCD display OFF.​

4. At ground and platform controls, push-in emergency stop buttons and remove key at the ground controls. Turn off and remove the key.​

5. Close platform control console lid if necessary to protect instruction placards, warning decals and operating controls from hostile environment, place a cover over this area.​

6. If machine is to be shut down for long periods of time, turn battery disconnect switch, RED handle located on the front of the hydraulic tank/battery tray housing, to the POWER OFF position.​

4.10 LIFTING AND TIE DOWN​

1. Determine gross weight of machine, refer to the serial number tag, or weigh the individual unit to find out the gross vehicle weight.​

2. Place the booms in the stowed position and properly aligned. All outriggers are fully retracted and the tracks are fully widened.​

3. Remove all loose items from the machine.​

4. Properly adjust the rigging to prevent damage to the machine and so the machine remains level.​

5. Width of slings must not exceed 2.36 in (60 mm), the width of the chains must not exceed .984 in (25 mm), the diameter of the ropes must not exceed .984 in (25 mm) in order not to exert a pressure in an abnormal direction on the outrigger plate.​

Figure 4-8. Machine Lifting Points​

Figure 4-9. Lifting Machine - Attach Points​

Figure 4-10. Machine Tie Down Points​

4.11 MACHINE DECALS​

Figure 4-11. Decal Installation​

Figure 4-12. Decal Installation​

Figure 4-13. Decal Installation​

Figure 4-14. Decal Installation​

Figure 4-15. Decal Installation​

Figure 4-16. Decal Installation​

Figure 4-17. Decal Installation - Additional Diesel, Lithium and Bi-Energy​

Table 4-2. Main Decal Set​

Table 4-3. Multi-Language Decal Set​

Table 4-4. Multi-Option Decal Set​

Section 5. EMERGENCY PROCEDURES

5.1 General​

5.2 Incident Notification​

5.3 Emergency Operation​

1. Other personnel should operate the machine from ground controls only as required.​

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.​

3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize machine motion.​

1. Shut off the machine.​

2. Rescue all people in the platform before freeing the machine. Personnel must be out of the platform before operating any controls on the machine.​

3. Use cranes, forklifts, or other equipment to stabilize motion of the machine to prevent a tip over as required.​

4. From the ground controls, use the Auxiliary Power System (if equipped) to carefully free the platform or boom from the object.​

5. Once clear, restart the machine and return the platform to a safe position.​

5.4 Manual Descent with Power​

Using Platform/Remote Control Station from Platform​

1. Check emergency stop button (item 13) is in the ON position by turning it clockwise.​

2. Press platform foot switch on platform floor.​

3. Press and hold down button 4 (item 4) with hazard symbol on platform/remote control box. The LCD display (item 14) will indicate the triangle/hazard symbol seen on the button in LCD position 8.​

4. Select a boom function to operate by moving the paddle controller in the direction for lowering. (items 17-21).​

5. When finished, release the emergency lowering switch, controller and foot switch.​

6. Position (press) the emergency stop switch to the OFF position.​

Using Emergency/Ground Control Station from Ground​

1. Check that the main power key switch (item 2) is set to the ON ( I ) position.​

2. Be certain emergency stop button (item 1) is in the ON position by turning it clockwise.​

3. Start engine, if not already running.​

4. At Emergency/Ground Control station, turn mode selector switch (item 4) all the way clockwise and hold.​

5. Check that the green (machine stabilized) indicator light (item 3) is on at the ground Emergency Stop/ key switch panel.​

6. Select a boom function to operate by moving it’s controller in the direction for lowering. (item 5 thru 10) See decals on cover for boom component functions and directional movement.​

7. When finished, release mode selector switch (item 4) back to the neutral position.​

8. When finished, position (press) emergency stop switch (item 1) to the OFF position.​

Figure 5-1. Ground Control Station, Mode Select and Power Switches​

Figure 5-2. Hand Pump Location and Chassis Control Valve Tray​

5.5 Manual Descent Using Hand Pump​

1. Remove the battery compartment cover and chassis control valve tray cover from the machine.​

2. Locate the pump handle secured to machine. (The handle is located in the ground control station cover from the factory.)​

3. Insert pump handle into the pump handle base located in the battery compartment (item 1). The lever on the pump must be set to the left (item 2), check decal above pump.​

4. Remove the diverter valve seal and unscrew the knob on the valve. (See arrow.)​

1. Lift the function enable lever UP and hold, While pumping the hand pump and activating the swing control lever in the desired direction of travel, until the turntable is aligned with the chassis.​

2. Retract the main boom (if necessary).​

3. Lower the Jib​

4. Lower the Main Boom​

5. Level the Platform (if necessary)​

6. Remove the manual pump handle from the pump and secure in its original position. Set the pump lever (item 2) back to the right (original position.)​

5.6 Bypass Switch - Safety Devices​

5.7 Emergency Descent If Outrigger Loses Ground Contact​

1. Locate and use safety device bypass key as stated above.​

2. Activate safety device bypass by turning key in a counterclockwise direction and hold it in position (see decal).​

3. The safety devices BYPASS icon will appear on the platform/remote control box display.​

4. Operate the machine from the platform/remote control ONLY carrying out operations that allow the tower boom lowering, main boom retract and jib lowering. The main boom must be fully retracted prior to operating swing and main boom lowering functions.​

5. Once boom and jib are fully lowered and aligned, release the key and follow instructions above to secure the key.​

5.8 Emergency Realignment Procedures​

1. Open the electric components compartment;​

2. Locate and use the safety device bypass key as described above;​

3. Activate the safety device bypass by turning the key in a counterclockwise direction and holding it in position (see sticker);​

4. The safety devices BYPASS icon will appear on the platform/remote control box LCD display.​

5. Realign the machine while operating the swing function from the platform/remote control box.​

6. Once the machine is aligned, release the key and store it as stated above.​

1. Locate and use the safety device bypass key as described above;​

2. Activate the safety device bypass key by turning it in a clockwise direction and holding it in position (see decal);​

3. The safety devices BYPASS icon will appear on the platform/remote control box display.​

4. Operate drive/steer controls with extreme caution.​

5. Move machine to a proper location to perform "Machine Re-alignment" procedure to realign the machine.​

6. At the end of the operation release the key and store it as is described above.​

SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

6.1 Introduction​

AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF PRESSURE-WASHING THE MACHINE IS NEEDED, ENSURE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASHING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPONENTS, JL...​

6.2 Operating Specifications​

6.3 Service/Maintenance​

6.4 ELECTRIC MOTOR MAINTENANCE​

6.5 PLATFORM/REMOTE CONTROL SERVICE MENU​

6.6 LITHIUM-ION MACHINE - MAINTeNANCE​

6.7 Supplemental Information Only Applicable to CE Machines (EN280-1:2022)​

6.8 Supplemental Information Only Applicable to CE Machines (EN280:2013+A1:2015)​

SECTION 7. INSPECTION AND REPAIR LOG