Oshkosh X17J, Operation Safety & Maintenance Manual

Page 1: ...Operation Safety Maintenance and service Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models X17J January 2013 X17JR042 ...

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Page 3: ...ons Regarding Special Product Applications Questions Regarding Product Modifications Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 or Your Local JLG Office See addresses on manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside USA Phone 240 420 2661 Fax 301 745 3713 E mail ProductSafety JLG com X17JR042 ...

Page 4: ...X17JR042 REVISION LOG Rev Manual code Date Original Issue X17JR002 December 2010 01 X17JR012 February 2011 02 X17JR022 March 2011 03 X17JR032 May 2012 04 X17JR042 January 2013 JLG LIFT FOREWORD ...

Page 5: ...ge 41 3 3 Cylinder stop valves Page 42 3 4 Alignment photocell on the aerial part of the structure and the base of the machine Page 42 3 5 Stabiliser position microswitches Page 43 3 6 Jib position microswitch Page 43 3 7 Basket load sensor Page 43 3 8 Control protection Page 44 3 9 Spirit level Page 45 3 10 Pin locking bolts and nuts Page 45 3 11 Safety device electronic control board Page 46 CHA...

Page 6: ...5 5 Emergency descent controlled from the ground using the hand pump in the event of faults on all energy supply systems Page 95 6 5 6 Emergency operations on the carriage moving the platform stabilisers using the hand pump to allow the machine to be transported Page 97 6 5 7 Emergency operation of the undercarriage in the event of movements of the aerial part Page 98 6 6 Recharging the radio cont...

Page 7: ... for handling hot cells Page 137 7 22 3 2 Procedure for handling vented cells Page 138 7 22 3 3 Procedure for exploded cells Page 139 7 22 3 4 Lithium battery fire Page 140 7 23 Servicing the engine thermic version Page 142 CHAPTER 8 SAFETY STANDARDS FOR TRANSPORT Page 143 8 1 Removing the basket Page 143 8 2 Loading and unloading the machine on transport vehicles using ramps Page 144 8 3 Lifting ...

Page 8: ...n this manual Every machine supplied is thoroughly adjusted and tested before being delivered The ope rator does not need to perform any adjustments before using the machine Any alterations and or modifications to the specifications of the original machine design without previous written authorisation from the Constructor are PROHIBITED and THE RESPONSIBILITY FOR THESE ACTIONS LIES WITH THE OPERAT...

Page 9: ...al requirements of the following national international safety standards UNI ISO 18893 ISO 16368 ISO 18878 With the exception of stricter local or national regulations in the working area of the MEWP WARRANTY On purchasing a JLG platform a warranty and inspection certificate is issued that clearly indicates the warranty terms and where any repairs or adjustments made to the machine must be reporte...

Page 10: ...p A EC Number 0714 Address Via Mengollna 33 48108 Faenza Italy Certificate Number To Be Advised Reference Standards EN12100 1 2 2003 A1 2009 EN280 2001 A2 2009 JLG Industries hereby declare that the above mentioned machine conforms with the requirements of 2006 42 EC Machinery 2004 108 EC EMC Directive 2000 14 EC Outdoor Noise Signed Date Name Alan S McIntyre Position Manager Engineering Support E...

Page 11: ...r kW Lwa Sound Power Level Applicable Procedure EN ISO 3744 1995 Applicable Directive 2000 14 EC Annex V Internal Control of Production We hereby declare that the above mentioned machine conforms with the requirements of the Noise Emission in the Environment by Equipment for Use Outdoors Directive 2000 14 EC 2005 88 EC Remark This declaration conforms with the requirements of Annex II of the counc...

Page 12: ...the situation described if not prevented can lead to serious injury or death of the persons involved operator ground staff staff present in proximity to the platform maintenance technicians etc WARNING This symbol accompanied by the word WARNING indicates that the situation described represents a potential risk for the structure of the machine Dangerous situations may be determined by this conditi...

Page 13: ...rol and the radio control display shows all the information regarding the use of the machine both aerial part and carriage and the diagnostic functions The aerial part of the machine is controlled by means of hydraulic levers located in the basket and in the emergency control position on board the machine The control positions are defined according to the operations to be carried out as listed bel...

Page 14: ...ket levelling cylinder to be operated in order to compensate for possible misalignments due to system failures Since this is an emergency device and the manoeuvre is dangerous the ope rator must use a tool to activate the distributor It is advisable to carry out this operation with the aerial part completely closed lever fowards rotates the basket towards the machine lever backwards rotates the ba...

Page 15: ...This lever allows the operator to raise or lower the first and second arm of the platform The synchronous movement of first and second arm always ensures the maximum outreach during work and is obtained thanks to the special configuration of the system in fact it does not depend on the operator s ability lever fowards moves first and second arm synch ronously upwards lever backwards moves first an...

Page 16: ...the distributor This control position must be used only for emergency manoeuvres or when servicing the machine REF DESCRIPTION LEVER DIRECTION MOVEMENT OBTAINED PICTOGRAM NEAR THE CONTROL 7 Rotation lever This lever allows the operator to rotate the aerial part of the platform around the axis of the turntable When the machine is aligned this con dition is signalled by the two reference arrows leve...

Page 17: ...ork and is obtai ned thanks to the special configuration of the system in fact it does not depend on the operator s ability lever fowards moves first and second arm synch ronously upwards lever backwards moves first and second arm synch ronously downwards 3 Third arm control lever This lever allows the operator to raise or lower the third arm of the platform lever fowards raises the third arm leve...

Page 18: ...achine at a distance of minimum 1 m from the latter and up to the limit distance allowed by the radio signal this data varies according to the conditions in the environment where the machine is used When controlling the machine from the ground position always make sure that the com ponent that is being moved is completely visible and constantly check its trajectory It is absolutely forbidden to us...

Page 19: ...tswitch must be pushed the footswitch must be release and pressed again if no movements are made for more of 7 second 2 1 3 MACHINE IDENTIFICATION PLATE The rating plate is located on the front of the machine on the electric motor protection guard see photo The drawing is shown below Manufactured by HINOWA S p A Via Fontana 37054 NOGARA VR ITALY Model Date of manufacture G V W Dry Serial number JL...

Page 20: ... 4527 mm Track width 786 1086 mm Maximum height in travel configuration with foot plates removed 1998 mm Maximum approach angle 20 Maximum stabilisation angle 11 Stabiliser base max side stabiliser centre 2890 mm Note standard version with two operator basket X17JR0420113 16 BOOM LIFT MODELS X17J JLG ...

Page 21: ...OPERATORBASKET 1 1 JIB TYPEOFARTICULATEDJOINT 88 2 90 MAX WORKING GRADIENT 1 75 2 MAX STABILISATION SLOPE 11 TOTAL WEIGHT IN TRANSPORT CONFIGURATION 2100kg ENGINE HONDA iGX440 12 7 CV 3600 rpm HATZ 1B40 10 CV 3600 rpm ELECTRIC MOTOR 2 2 kw 230V 50Hz 1500 rpm 2 2 kw 110V 50Hz 1500 rpm Optional ELECTRICAL SYSTEM VOLTAGE 12V PUMPS 2x3 15cc MAX TRAVEL SPEED petrol diesel no RPM 1 3km h MAX TRAVEL SPEE...

Page 22: ...l Cooling DIESEL AIR Power SAEJ1349 7 5 kW 10 HP 3600 rpm Maximum adjusted output rpm 3000 3600 rpm Maximum torque 25 Nm 2000 rpm 80 1269 EC Number of cylinders 1 Displacement 462 cm3 Sound pressure level at operator s ear 94 dB Measured sound power level 102 dB Guaranteed sound power level 104 dB 2 1 5 3 HYDRAULIC SYSTEM TECHNICAL SPECIFICATIONS Hydraulic oil tank capacity 25 litres Pump double 2...

Page 23: ... electrical components 2 1 5 5 ELECTRICAL SYSTEM TECHNICAL SPECIFICATIONS LITHIUM Battery 90 Ah 48V Electric motor rated voltage 48V 220V 110V optional rated power 2 kW Sound pressure level at operator s ear 70 dB Measured sound power level 86 dB Guaranteed sound power level 88 dB Onboard battery charger 220V 10V 50 60 Hz Battery charger option 110V 10V 50 60 Hz For further information see wiring ...

Page 24: ... illu strates the terms used to identify the parts of the platform BOOM LIFT MODELS X17J JLG 20 X17JR0420113 0 2 A 0 2 0 5 C 0 2 0 5 C 3 2 3 2 3 2 3 2 1 2 4 5 6 7 8 10 11 12 13 14 32 3 34 33 9 15 16 17 18 19 21 22 23 24 25 28 29 30 31 26 27 35 20 APPOGGIO_POST APPOGGIO_POST THERMIC MOTOR LITHIUM MOTOR ...

Page 25: ...econd third arm transmission 15 Second arm 16 Third fourth arm cylinder 17 Basket levelling cylinder on the transmission 18 Third arm 19 Stabiliser plate 20 First second arm cylinder 2 21 Extension arm 22 Jib tie rods 23 Jib cylinder 24 Jib arms 25 Controls on the basket 26 Failure management radio control 27 Basket or cage 28 Basket support 29 Rotary actuator for basket rotation 30 Basket levelli...

Page 26: ...garding the use of the machine in standard and emergency conditions They must examine under stand and take in all the instructions given in this user manual They must be sure that the safety devices are in perfect working order perform the necessary checks on the machine and be familiar with the conditions of the ground on which the machine is going to be operated and stabilised The presence of at...

Page 27: ...t is tampered with Fire prevention Keep the area around the motor clean removing fragments of wood paper and other flammable products clean any fuel leaks as these may be a potential cause of fire Petrol is extremely flammable and explosive in particular con ditions Refuel in well ventilated areas and with the engine at rest Avoid smoking and producing sparks in the refuelling and fuel storage are...

Page 28: ...onents Follow the instructions provided by the manufacturer of the detergent Clean the machine using water soluble detergents The more the elevating platform is cleaned the more it will need to be greased see par 3 3 Grease points Do not wet the electric motors and the other electrical components directly Do not aim the spray directly onto adhesive labels and rating plates Cleaning the electrical ...

Page 29: ...o the electric motor or other parts of the electric system these must be dried using compressed air to avoid the risk of short cir cuits Preventing damage that may be caused by the machine during work When the machine has been stabilised and work has started never enter its operating area Always operate the controls slowly and smoothly and avoid reversing the movements sud denly When operating out...

Page 30: ...achine Keep the safety signs in good condition and replace them if they are damaged Make sure that any new components on the machine are provided with the correct safety signs 2 3 2 NOISE AND VIBRATIONS The platforms with thermic motor have been tested according to the parameters of European directive 2000 14 EC with the guaranteed sound power level measurement shown on the machine s EC declaratio...

Page 31: ...17J JLG 27 KIT ADESIVI X17J AUFKLEBERSATZ X17J SET OF DECALS X17J KIT ADHESIVOS X17J KIT COLLANTS X17J ADHESIEKIT X17J Ed 24 10 2012 Tav 01 Cod 17063700 29 37 51 29 26 50 26 51 26 29 51 60 71 29 33 29 61 67 60 29 70 16 24 63 14 3 14 30 13 56 31 55 60 19 53 69 32 35 58 57 45 46 28 15 13 7 4 21 13 3 15 28 30 38 48 34 23 47 14 66 14 14 62 29 17 66 29 10 25 68 ...

Page 32: ... OF DECALS X17J KIT ADHESIVOS X17J KIT COLLANTS X17J ADHESIEKIT X17J Ed 24 10 2012 Tav 02 Cod 17063700 60 29 57 29 51 29 26 50 37 51 26 26 29 40 60 40 66 17 29 64 14 2 56 25 5 60 6 27 30 54 43 60 8 48 60 9 30 38 14 66 47 24 14 14 70 65 15 28 3 13 18 4 21 7 13 3 15 28 51 29 14 60 72 ...

Page 33: ...814 06 27 1701504 01 28 06041200 04 29 06041300 14 30 31 06086000 01 32 1701542 01 32 1701505 01 33 07034200 02 34 1608710017 01 35 06899100 01 36 37 07060700 02 38 1704277 02 39 40 06044000 04 41 42 43 06056300 01 44 45 1608710018 01 Pos Code Qty 46 1608710006 01 47 48 49 50 07056700 02 51 1701499 06 52 53 06232100 01 54 06165000 01 55 56 1608710016 02 57 1706898 02 58 1608710008 01 59 60 1001125...

Page 34: ... 06561200 04 47 06462900 02 48 06462300 02 55 1608710011 01 170637ES 06 06562900 01 30 06561200 04 47 06463000 02 48 06462400 02 55 1608710012 01 170637NL 06 06563000 01 30 06561200 04 47 06463100 02 48 06462500 02 55 1608710013 01 Pos Code Qty 170637PT 06 06563100 01 30 06561200 04 47 06463200 02 48 06462600 02 55 1608710014 01 170637SW 06 07137300 01 30 06561200 04 47 07137500 02 48 07137400 02 ...

Page 35: ...31 BOOM LIFT MODELS X17J JLG X17JR0420113 KIT ADESIVI X17J AUFKLEBERSATZ X17J SET OF DECALS X17J KIT ADHESIVOS X17J KIT COLLANTS X17J ADHESIEKIT X17J Ed 08 01 2013 Tav 01 cod 17187700 4 5 9 16 ...

Page 36: ...BOOM LIFT MODELS X17J JLG 32 X17JR0420113 KIT ADESIVI X17J AUFKLEBERSATZ X17J SET OF DECALS X17J KIT ADHESIVOS X17J KIT COLLANTS X17J ADHESIEKIT X17J Ed 08 01 2013 Tav 02 cod 17187700 4 4 1 13 17 ...

Page 37: ... 1 18 07264800 2 Pos Code qty 171877IT 1 07188700 1 7 10 11 12 13 07188100 1 14 16 1705720001 1 Pos Code qty 171877GB 1 07201700 1 7 10 11 12 13 07202100 1 14 16 1705720002 1 Pos Code qty 171877FR 1 07201800 1 7 10 11 12 13 07202200 1 14 16 1705720003 1 Pos Code qty 171877DE 1 07188800 1 7 10 11 12 13 07188200 1 14 16 1705720004 1 ...

Page 38: ... 10 11 12 13 07188300 1 14 16 1705720006 1 Pos Code qty 171877PT 1 07202000 1 7 10 11 12 13 07202400 1 14 16 1705720007 1 Pos Code qty 171877SW 1 07189000 1 7 10 11 12 13 07188400 1 14 16 1705720010 1 Pos Code qty 171877DA 1 07189100 1 7 10 11 12 13 07188500 1 14 16 1705720011 1 Pos Code qty 171877NO 1 07189200 1 7 10 11 12 13 07188600 1 14 16 1705720012 1 ...

Page 39: ...ATION TO READ THE MANUAL BEFORE USE OF MACHINE 1703814 FIXING POINT FOR TRANSPORT INDICATES CORRECT FIXING POINT FOR TRANSPORT OF THE MACHINE 06041200 CRUSHING HAZARD FEET INDICATES AREAS WHERE THERE IS A DANGER OF CRU SHING LOWER LIMBS FOR THE OPERATOR 06041300 CRUSHING HAZARD PERSON INDICATES AREAS WHERE THERE IS A DANGER OF CRU SHING UPPER LIMBS FOR THE OPERATOR 06040300 06040500 06040800 06040...

Page 40: ...06085900 EMERGENCY DEVI CE FOR AERIAL PART DEVICE THAT ALLOWS TO EXCLUDE THE SAFETY OF THE AEREAL PART IN CASE OF EMERGENCY OPE RATIONS 06086000 EMERGENCY DEVI CE FOR UNDERCAR RIAGE DEVICE THAT ALLOWS TO EXCLUDE THE SAFETY OF THE UNDERCARRIAGE IN CASE OF EMERGENCY OPERATIONS 06086600 WARNING KEEP SAFE DISTANCE AND CRUSHING HAZARD PERSON 0 6 4 0 4 0 0 0 0 6 0 5 6 3 0 0 0 6 0 6 0 0 0 0 06085900 0608...

Page 41: ...RUCTIONS FOR USING THE EMER GENCY HAND PUMP 06924300 BE CAREFULL AT WORK USING SAFETY HAR NESSES USE PROTECTI VE EQUIPMENT HEL MET PROHIBITION OF WELD ON THE MACHI NE PROHIBITION OF USE SYSTEMS TO INCREASE THE AREA OF WORK INSIDE THE BASKET PROHIBITION OF WORKING IN THE VICINITY OF VOLTAGE ELECTRIC PROHIBI TION OF USE OF THE PLATFORM FOR RAI SING LOADS 0 6 1 6 5 0 0 0 1701499 1001125483 06560500 0...

Page 42: ...QUID Presence of highly corro sive liquid dangerous to the body and eyes HIGH VOLTAGE Presence of high voltage with danger of electric shock DANGER OF EXPLO SION Formation of potentially explosive mixture inside the battery NO NAKED FLAMES Do not smoke or use naked flames when recharging and near the vehicle Risk of explosion RECYCLING It is highly recommended to comply with legislative and enviro...

Page 43: ...X17JR0420113 BOOM LIFT MODELS X17J JLG 39 ...

Page 44: ...tor s life at risk The Con structor designed the machine and the safety devices so as to guarantee the maximum safety to its customers however the devices must be checked periodically as described in this manual and they must never be tampered with The service function on the radio control can be used as an aid in checking electrical safety devices Never intervene on the safety devices If they are...

Page 45: ...it anticlockwi se isolates the machine s electrical circuit and the key can be removed BEFORE DISCONNECTING THE BATTERY BY MEANS OF THIS DEVICE MAKE SURE THAT THE ENGINE KEY IS IN POSITION OFF THE RADIO CONTROL EMERGENCY STOP BUTTON HAS BEEN PRESSED AND THE RADIO CONTROL AND ELECTRONIC BOARD ARE OFF 3 2 DISTRIBUTOR PRESSURE RELIEF VALVES All platform distributors have a pressure relief valve that ...

Page 46: ...basket from falling due to gravity These valves are set when the platform is tested by qualified personnel and must not be tampered with for any reason whatsoever 3 4 ALIGNMENT PHOTOCELLS ON THE AERIAL PART OF THE STRUCTURE AND THE BASE OF THE MACHINE The platform has two safety photocells that ensure that the aerial part of the machine is com pletely lowered and aligned with the base and that the...

Page 47: ...slot made in the jib transmission The microswitch must be released when the jib arm is clo sed Check the condition and correct operation of the JIB microswitch every day 3 7 BASKET LOAD SENSOR The load sensor on the basket is made up of a basket sup port with two shafts that only allow the vertical move ment of the basket The basket support is supplied by the load cell itself Two strain gauges are...

Page 48: ...ar 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 system e g pru ning painting etc Before any elevating manoeuvre always make sure that the two closing covers on the ver tical pins are completely screwed in 3 8 CONTROL PROTECTION A protection structure is provided to prote...

Page 49: ...lf levelling operation Approximate levelling outside of the limits set by the manufacturer is very dangerous and can affect the stability of the platform which represents a risk even deadly for the operator and other persons working on the machine and near it Never tamper with the spirit level this device is set by the Constructor during testing before sale Only technicians authorised by JLG using...

Page 50: ... 11 SAFETY DEVICE ELECTRONIC CONTROL BOARD The platform has an electronic control board see photo that enables the power supply to the ON OFF proportional coils after verification of the safety conditions by the sen sors positioned on the machine The control procedure on the electronic board may be bypassed using the key selector switch with spring return safety device bypass key The electronic bo...

Page 51: ...ach devi ce and to be aware of any suggestions provided by the manufacturer Before starting to use the platform the operator must read and perfectly understand all the instructions contained in this manual 4 1 RADIO CONTROL The radio control contains most of the controls required for normal operation of the machi ne s carriage The radio control comprises push buttons joysticks and the display The ...

Page 52: ...the increasing number on the bottom left side In this case about 20 minutes are needed to send all the information from the main board to the radio control The machine cannot work during this period Do not stop the machine or operate it during this period 4 1 1 1 DISPLAY MAIN SCREEN The radio control is switched on and off using the red button on the centre see photo To activate the radio control ...

Page 53: ...om the machine the latter will not complete the syn chronization procedure and the signal search status will keep appearing on the display To verify if the electronic board is on make sure that the leds of the receiver are on Once the machine and the radio control have been started the main screen giving a general overview of the machine status will appear For the sake of simplicity and clarity a ...

Page 54: ...otor is off no X indicates that it is on POSITION 4 Position 4 displays the selected speed or the reduced speed for the Lithium SLOW NORMAL FAST REDUCED 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 checked and the aerial part can be lifted No icon on means that the aerial part c...

Page 55: ...of the icon ena bling the overhead movements OVERLOAD ERROR DISPLAY POSITION 6 Position 6 displays the icon confirming that track movements stabilisers tracks track exten sion are enabled This icon means that all conditions for operating the track movements have been checked No icon on means that the stabilisers cannot be used and the track cannot be extended The machine however can travel even wh...

Page 56: ... it is advisable to recharge the battery either by keeping the diesel or petrol engine on or by connecting to the network In this position also other functional signals can be displayed that are useful for machine dia gnostics X17JR0420113 52 BOOM LIFT MODELS X17J JLG The angular position sensor is not working correctly only on machines with variable stabilisation area The machine has a CANBUS lin...

Page 57: ...ing the radio control battery charge and the radio signal level Position 8 is also used to show the selection of the emergency descent operation from the basket with solenoid valves on the cylinders In addition to the main screen described above there are other functional displays that will be described successively X17JR0420113 BOOM LIFT MODELS X17J JLG 53 ...

Page 58: ...e the joystick is moved away from the central neutral position the faster the movements obtained X17JR0420113 54 BOOM LIFT MODELS X17J JLG JOYSTICK JOYSTICK SHIFTING DIRECTION MOVEMENT CONTROLLED 1 FORWARDS LEFT TRACK FORWARDS BACKWARDS LEFT TRACK BACKWARDS 8 FORWARDS RIGHT TRACK FORWARDS BACKWARDS RIGHT TRACK BACKWARDS S5 S1 S2 S3 S4 S6 S11 S7 S8 S9 S10 S12 SERVICE STOP START STOP START STOP AUTO...

Page 59: ...r brings the machine to a standstill and switches the radio control off In order to allow the machine to become operational again and to switch the radio control on it is necessary to rotate the button For the description of the individual functions see paragraph 6 Using the machine BUTTON 1 Used to automatically raise the stabilisers BUTTON 2 Used to access the menu for the manual movements of th...

Page 60: ...ssible speed for the tracks NORMAL variable rpm according to the selected movement Travel motors always with maximum displacement therefore medium travel speed FAST variable rpm according to the selected movement Travel motors in automatic displa cement variation mode therefore maximum travel speed The three speeds are selected by pressing button 5 in sequence with a cyclical routine The selected ...

Page 61: ...essed with the motor on this will be stopped If the start buttons are pressed with an emergency STOP button pressed starting will be impossible This condition is indicated by the icon STOP in position 7 If the operator attempts to start one of the two motors while the other is already running starting will be impossible and the icon showing the motor already on will appear at the cen tre of the sc...

Page 62: ...you try to move the machine without the footswitch pushed the movement will be prohibited and a message on the display will appear infor ming that it is necessary push the pedal to work If you have not made moves to 7 seconds after pressing the pedal this must be release and pressed again to resume work 4 3 CONTROL POSITIONS See paragraph 2 1 1 Control position X17JR0420113 58 BOOM LIFT MODELS X17...

Page 63: ...st is located on the carria ge just above the turntable the second on the radio control and the third is connected to the basket Once the device has been activated the button must be turned and released to allow the machine to operate again Selection of the emergency stop is indicated on the radio control display It is strongly recommended to comply with the rule whereby the platform must not be o...

Page 64: ... control energises these solenoid valves 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 elec trical system being powered 5 4 SAFETY DEVICE BYPASS KEY The machine has a key device that acts on the electrical circuit bypassing the platform safety systems The device is situated on the cover of the electrical compon...

Page 65: ... not allowed to use this device 5 5 EMERGENCY POSITION CONTROLS SELECTION PANEL EMERGENCY STOP START AND EMERGENCY CONTROL ENABLING SWITCH This panel houses the following controls Emergency STOP If pressed stops the motor and stops the machine To make the machine operational again the button must be turned and released START BUTTONS Enable the selected engine motor to be started provided that all ...

Page 66: ...d personnel would place the operator in the basket in the unpleasant condition of not being able to carry out any movement and of being subjected to the movements control led from the ground If this should occur press the emergency button and call for help or use the emergency descent devices AERIAL PART HYDRAULIC DISTRIBUTOR The hydraulic distributor is fitted with levers for the selection of the...

Page 67: ...ont left stabiliser control Moving lever 2B downwards front L stabiliser down Moving lever 2A upwards front L stabiliser up 3 Left track control Moving lever 3A downwards moves left track forward Moving lever 3B upwards moves left track backward 4 Track extension control Moving lever 4A downwards extends track Moving lever 4B upwards narrows track 5 Right track control Moving lever 5A downwards mo...

Page 68: ... Pictogram near the control 6 Front right stabiliser control Moving lever 6A downwards front R stabiliser down Moving lever 6B upwards front R stabiliser up 7 Rear right stabiliser control Moving lever 7A downwards rear R stabiliser down Moving lever 7B upwards rear R stabiliser up ...

Page 69: ...considering the pos sible range of movement of the platform and its oscillation as well as the possible oscilla tion of the power lines Before starting operation examine the work area taking note of overhead power lines moving machinery such as overhead cranes and road rail and building equipment 6 1 2 DANGER DUE TO ATMOSPHERIC CONDITIONS DO NOT WORK IN UNFAVOURABLE ATMOSPHERIC CONDITIONS Do not w...

Page 70: ...his table can be found near the controls positioned on the basket where it is well visible from the control position The elevating platform can only be used by specialised previously trained personnel All operations of the extensible structures must be performed from the control position in the basket The travel and stabilisation operations must be carried out after checking that there is complete...

Page 71: ...ines and electrical equipment It is prohibited to operate in unfavourable atmospheric conditions It is prohibited to anchor cables ropes or the like to the platform and to use the platform as a lifting device It is prohibited to secure ladders stools or the like to the platform basket to increase the working height Always operate the controls slowly and smoothly without reversing movements sud den...

Page 72: ...6 3 WORKING AREA X17JR0420113 68 BOOM LIFT MODELS X17J JLG Rotation 360 Rotation 360 ...

Page 73: ...f dangerous situations and for any emergency operations This implies that the personnel on the ground must be suitably trained regarding the func tions of the controls and the procedures for use and that they have read the manual Failure to comply with even one safety provision may cause injury damage to the opera tors and or the machine Keep a first aid box and a fire extinguisher near the work a...

Page 74: ...th the electrical parts Make sure there is no corrosion and there are no cracks around welded points Check the condition and correct tensioning of the track belts see the paragraph on main tenance operations Check that there are no broken damaged or missing components Check the correct tightness of the pin locking bolts and nuts or the safety locknuts Before using the machi ne replace tighten and ...

Page 75: ...be checked on the radio control display where no icon should appear in position 7 If the operator attempts to start the machine with the emergency stop button still pres sed an error message will appear on the display when the start button is pressed The engine can be started from the ground using the start key or directly by means of the radio control In this case it is necessary to move the engi...

Page 76: ...anual and follow all the instructions given therein Power the machine with an electric cable through the connection positioned at the bottom near the electric motor Close the switch located in the electrical panel near the motor see photo Before doing this a Make sure that the specifications of the power line correspond to the voltage and fre quency indicated on the electric motor rating plate b C...

Page 77: ...s already run ning starting will be impossible and the icon showing the motor already on will appear at the centre Use the button on the radio control to start the motor THE ENGINE MUST BE STARTED WITH ALL THE CONTROL BUTTONS AND JOY STICKS IN NEUTRAL POSITION Always make sure there are no foreign objects e g branches that may accidentally operate a control as the platform may move suddenly out of...

Page 78: ...HIUM VERSION To switch off the electric motor release the button or the lever on the remote control or relea se the emergency control key The motor will stop automatically in 3 4 seconds The electric motor can only be considered stopped if one of the emergency stop buttons on the machine is pressed Whenever a movement of the machine has been completed and work needs to continue with the machine of...

Page 79: ...indicated by an icon in position 2 on the radio control if the jib is not completely folded the allowable working load is 120 kg and this is indicated in position 2 on the radio control If the operator attempts to open the jib with more than 120 kg in the basket an error message appears in the middle of the display If the allowable load limits are exceeded all aerial movements are disabled an alar...

Page 80: ...all dimensions of the machine especially if the stabilisers are not turned to the transport position It is prohibited to get on or off the basket if this is not completely lowered The machines are not type approved for road travel The work and travel areas must be appropriately cordoned off and warning signs displayed according to the relevant laws in force The machine must be loaded onto type app...

Page 81: ...and checking the selection on display Operate joysticks 1 and 8 to move the tracks If the operator attempts to travel with one or more stabilisers on the ground an error message will appear on the display warning the user to raise the stabilisers in order to allow the machine to travel TRAVELLING ON SLOPES The maximum slope for travel is shown in the machine specifications at the beginning of this...

Page 82: ...ng area Work must only be performed with the machine stabilised at an inclination under the limits specified by the manufacturer Always keep a distance from embankments or ditches that is equivalent to the depth of such and observe the required safety distance from power lines Avoid any contact with objects or persons when lowering the stabilisers STABILISATION PROCEDURE Before moving the stabilis...

Page 83: ...y Always perform stabilisation at slow speed Press and hold the automatic stabilisation button 7 see the corresponding paragraph If the movements are selected with the machine not completely closed and aligned an error message will be shown on the display Stabilisation will be completed when the machine is in horizontal position with toleran ce of 1 and lifted at least 5 cm from the ground Correct...

Page 84: ...ser 4 Pressing it once again shows the initial display In the manual menu pressing buttons 1 and 7 raises or lowers the selected stabiliser To verify the inclination of the chassis a spirit level is provided on the machine when the air bubble it contains is completely inside the green area see photo below the machine is in conditions that allow operation Please note that stabilize the machine on s...

Page 85: ...y cause serious injury to or even death of its occupants and per sonnel on the ground If one of the orange lights positioned on each stabiliser should flash even when the stabi liser is lifted from the ground stop the machine immediately and call the after sales servi ce as this signals the breakage of the corresponding stabiliser microswitch If working with the machine stabilised on slippery surf...

Page 86: ...erify that the trajectory of the stabilizers is free of obstacles and impediments The automatic procedure for levelling the machine extends and retracts the stabilisers and consequently moves the machine Always check that there are no people animals or things in the stabilisation area AUTOMATIC LOWERING OF THE STABILISERS Press and hold button 7 on the radio control The success of the self levelli...

Page 87: ...tabiliser raising cycle is shown on a screen for a few seconds If this screen is not shown the automatic stabiliser raising procedure can still be considered completed once all the four stabilisers have been completely retracted and consequently the relevant cylinders are at the end of their stroke If problems occur during either of these procedures immediately release the selected but ton to stop...

Page 88: ... stabi lised and completely closed To load and unload the basket the icon in position 6 on the radio control must be displayed Loading material into the basket when it is lifted e g from roofs balconies etc causes the machine to overturn exposing the occu pants and personnel on the ground to potential risk of death It is absolutely forbidden to use the machine to lift loads both in the basket and ...

Page 89: ...at all instructions provided in this chapter have been complied with there are no obstacles in the work area all the conditions necessary for working at a height are met the machine is stabilised and levelled icon 5 shown on the display the weight in the basket is below the maximum allowed the radio control is positioned in the basket The aerial part can ONLY be moved from the control position in ...

Page 90: ...NLC if OK the machine is under the maximum inclination limit LOAD if OK the load is less than the maximum working load allowed CESTO if OK the remote control is in place in the basket PEDAL if OK the footswitch is pushed OVERLOAD ALARM If during the basket loading phases the max allowable load is exceeded based on the position of the jib arm all movements of the aerial part will be disabled and an...

Page 91: ...folded or nearly folded there is the risk of the first arm hitting against the engine For this reason free rotation areas and limited rota tion areas are defined LIMITED ROTATION AREA is an area near the engine where this may be hit by the first arm FREE ROTATION AREA is the rest of the rotation area that does not coincide with the limi ted rotation area These two areas are identified through the ...

Page 92: ... on the radio control display will urge the operator to raise the first and second arm In order to be able to continue the movements that have been interrupted raise the first and second arm above the height controlled by the microswitch or rotate them in the opposite direction BOOM LIFT MODELS X17J JLG 88 X17JR0420113 ...

Page 93: ...ble the 3rd arm unscrew the safety screw first loosening its lock nut two 13 mm fixed spanners are needed to perform this operation until releasing the control see photo raise the safety device against the accidental operation of the control and operate it very gently until the basket is levelled also lowering the engine speed gently release the lever to the neutral point and put the safety screw ...

Page 94: ...ESCENT CONTROLLED FROM THE BASKET The basket emergency descent procedure can be controlled from the basket itself only if the electrical system of the machine is working proceed as follows hold button 4 on the radio control paragraph 2 1 1 Control position check the control through icon 8 on the display paragraph 4 2 1 Display main screen use the lever corresponding to the arm being folded until r...

Page 95: ...other uses are prohibited To perform the emergency descent in the conditions described above proceed as follows a Move the control distributor selection switch from the distributor in the basket to the distributor on the ground b If necessary start the engine using the corresponding button c Move the aerial part of the machine using the manual levers positioned on the distri butor on the ground as...

Page 96: ...the aerial part and then stabilise the machine again the electrical emergency descent 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 interfere with the operation person nel on the ground can allow the operator in the basket to close the machine The operators on the ground can bypass the machine s safety devices and...

Page 97: ...A WAY AS TO AVOID ANY OPERATION THAT MAY AFFECT THE STABILITY OF THE MACHINE Once the machine is closed release the key remove it and put it back in its original posi tion The electronic control board records every time the safety device bypass key is used Control the machine ONLY carrying out operations that allow the machine to be closed first second arm folding extension arm in jib arm folding ...

Page 98: ...ng completely the special flywheel see photo located under the distributor protection casing on the carriage Act on the switch thus enabling the emergency distributor from the ground Use the distributor levers to enable the desired movement fol lowing the instructions to be found on the label attached near the controls The sequence of movements is the following retract extension arm fold jib arm f...

Page 99: ... controls for the arm movements PERICOLO IF THIS DEVICE HAS BEEN USED TO MOVE THE MACHINE BEFORE USING THE MACHINE AGAIN TO WORK AT A HEIGHT IT IS COMPULSORY TO SET IT IN THE TRANSPORT CONFIGURATION 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 CONTROLLING IT FROM THE BASKET DISTRIBUTOR PROTECTION ON OFF ...

Page 100: ...be found on the label attached near the controls and at the same time use the hand pump to power the movement The sequence of movements is the following retract extension arm fold jib arm fold first second arm fold third arm Once the emergency operation has been completed return the knob to its original posi tion taking care to put back the protection cap and have the double lead sealing resto red...

Page 101: ... ON OFF coil levers B to enable the required movement and simultaneously ope rate the hand pump to deliver oil to allow the movement photo C To move the right stabilisers move the deviator on the hydraulic hand pump to the corre sponding position Use the ON OFF coil levers B to enable the required movement and simultaneously ope rate the hand pump to deliver oil to allow the movement photo C Once ...

Page 102: ...l components compartment removing it from the machine s key holder where it is sealed with lead see photo Turn the emergency key anticlockwise and hold it in posi tion see sticker The display on the radio control shows the safety device BYPASS icon Realign the machine controlling it from the basket PERORM EXCLUSIVELY THE ROTATION MANOEUVRE Once the machine has been aligned release the key remove i...

Page 103: ...ion see sticker The display shows the safety device BYPASS icon Use the travel control with extreme care to avoid causing damage to the machine or people Move to a suitable position for carrying out procedure A used to realign the machine At the end of the operation release the key remove it put it back in its original position and close the electrical components compartment The electronic control...

Page 104: ...o connect the radio control to the receiver on board the machine using the special cable provided see photo Battery replacement and connection of the radio control to the receiver must be carried out with the machine off and the electronic board not powered engine key in position OFF The radio control battery can be recharged using the battery charger provided on board the machine under the electr...

Page 105: ...harged remove it from the battery charger it is sufficient to remove it from its seat so that its contacts do not coincide with those of the battery charger in order to avoid damage due to excessive charge The connection cable used to connect the radio control to the receiver can also be used in the case where the radio signal is disturbed or too weak in the work area however this is possible only...

Page 106: ...he user to charge the machine If the charge is less than 10 in addition to the audible warning signal reduced speed is activated and an icon comes on in position 4 To start recharging the battery simply connect the main power supply to the socket on the right of the undercar riage distributor support and close the circuit breaker After a few seconds the charge indicator located on the right hand s...

Page 107: ... can only be plugged into an earthed socket If the plug does not go into the socket most probably the socket is old and not earthed In this case contact an electrician to have the socket replaced Do not use adapters to resolve earth plug problems Make sure the power cable does not represent an obstacle If the cable is worn or dama ged have it replaced immediately If extensions or multiple sockets ...

Page 108: ...ue and or Range Unit Single phase power supply voltage Vin 230 10 Veff Frequency f 50 60 Hz Maximum current drawn per phase Ifmax P Pmax 15 Aeff Initial current peak Vin 230Veff 3 A Power factor cosφ P Pmax 0 66 Minimum power consumption Pinmin End of charge 10 W Maximum power consumption Pinmax P Pmax 2 2 kW Output current I 25A A Output voltage U 48V V Maximum power supplied Pmax U U1 I I1 2000 ...

Page 109: ...IRONMENTS To perform operations in closed environments the Constructor recommends the use of the machine with electric motor if this is not possible make sure there is enough ventilation to prevent the accumulation of harmful gases If lighting in the workplace is insufficient additional lighting must be supplied 6 8 3 PRUNING This activity requires very important skills in order to prevent the mac...

Page 110: ...n 6 8 5 PAINTING SAND BLASTING AND PLASTERING This type of use requires meticulous protection of the delicate parts of the machine such as hydraulic cylinder rods gaskets safety devices hydraulic telescopic extension arms and markings on the machine e g rating plate warning stickers capacity table etc If sand enters the grease protecting the extension arms it produces an extremely abrasive mixture...

Page 111: ...nd dispose of them in compliance with laws in force in the country in question It is prohibited to carry out any maintenance operations with the working arm not com pletely lowered and or stabilised machine If operations are being carried out apply a visible sign on the control position stating DANGER Do not move the machine service in progress 7 2 TABLE OF RECOMMENDED LUBRICANTS To top up or repl...

Page 112: ... Syntetic Polyol Esters Readily Biodegradable Virtually Non toxic Fire Resistant Pakelo Hydraulic EP Extra ISO 68 68 180 X Pakelo Hydraulic EP Extra ISO 46 46 160 X Pakelo Hydraulic EP Extra ISO 32 32 160 X Pakelo Hydraulic EP Extra ISO 22 22 180 X SHELL TELLUS S3V 68 68 180 X SHELL TELLUS S3V 46 46 160 X SHELL TELLUS S3V 32 32 160 X SHELL TELLUS S3V 22 22 180 X Proprieties Base Classifications HY...

Page 113: ...EASING THE TELESCOPIC ARM Use a brush to apply grease onto the telescopic exten sion arms a seconda di quello piu corto M OLIO MOTORE T OLIO TRASMISSIONE I OLIO IDRAULICO G GRASSO 500 h 250 h 100 h 50 h o una settimana 10 h o un periodo di lavoro a squadra G M M I I G T I I IMPORTANTE M ENGINE OIL T TRANSMISSION OIL I HYDRAULIC OIL G GREASE or one work shift or one week whichever is shorter IMPORT...

Page 114: ... laid and fitted Tampering with the hydraulic circuit may cause serious danger during 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 once per day or shift for any external damage corrosion struc tural parts welds The person in charge must be informed im...

Page 115: ...ebsite www honda engines eu com 111 BOOM LIFT MODELS X17J JLG X17JR0420113 PART MAINTENANCE WORK BEFORE STARTING AS NEEDED INTERVAL HOURS 10 50 100 250 500 1000 2000 AIR FILTER CHECK CLEAN REPLACE ENGINE OIL CHECK LEVEL CHANGE OIL SUMP CLEAN FUEL TANK AND NET CLEAN HYDRAULIC OIL CHECK LEVEL CHANGE HYDRAULIC OIL FIL TER REPLACE CARTRIDGE ARTICULATED JOINT POINTS GREASE BATTERY CHECK ELECTROLYTE LEV...

Page 116: ...T MAINTENANCE WORK BEFORE STARTING AS NEEDED INTERVAL HOURS 10 50 100 250 500 1000 2000 DRY AIR FILTER CHECK CLEAN REPLACE ENGINE OIL CHECK LEVEL CHANGE ENGINE OIL FILTER CLEAN REPLACE FUEL FILTER CLEAN REPLACE WATER SEPARATOR CLEAN AND DRAIN WATER COOLING SYSTEM CHECK FLUID LEVEL TOP UP CHANGE FLUID HYDRAULIC OIL CHECK LEVEL CHANGE HYDRAULIC OIL FILTER REPLACE CARTRIDGE ARTICULATED JOINT POINTS G...

Page 117: ... of the nuts on the power supply terminals and make sure the insulation is intact FAN Keep air intakes clean and make sure the fan can rotate freely BEARINGS Check the condition of the bearings in the event of noise contact Jlg for replacement as the life of the bearings is reduced significantly in heavy duty operating conditions Note this motor is brushless therefore no brushes need to be checked...

Page 118: ...ured to the platform 6 Operating and emergency controls for proper functioning 7 Placards and warning signs for cleanliness readability of control signs rated capacity and operating manual 8 Platform assembly for loose and missing parts missing or loose lock pins and bolts 9 Platform base for structural damage holes or cracked welds dirt grease or oil that can create a hazard 10 Access ways for ea...

Page 119: ...he inspection must comply with the requirements of points A and B and must include but not be limited to all critical and suspect areas and all accessible structural elements and welds such as the following 1 Stabiliser and stabiliser housing boxes including the underside of the housing 2 Platform rotating elevating and levelling mechanisms 3 Main turret rotating mechanism 4 Brakes 5 All secured p...

Page 120: ...2 All controls must be in the OFF position and all operating systems must be secured against accidental activation by brakes chocks or other means 3 Elevating and rotating assembly and platform must be completely lowered if possible or otherwise secured by blocking or propping 4 The hydraulic oil pressure must be released from all hydraulic circuits before loosening or removing hydraulic component...

Page 121: ...117 BOOM LIFT MODELS X17J JLG X17JR0420113 ...

Page 122: ...rease contained in the hydraulic track is pressurised For this reason do not loosen grease nipple 1 more than 1 turn if the nipple is loosened excessively it may be expelled due to the pressure of the grease putting the safety of the operator at risk Never loosen grease nipple 2 When gravel or mud is stuck between the sprocket and the track links remove it before loo sening 1 Remove the screws and...

Page 123: ... on the bottom of the track in contact with the ground while the guides situated inside the track prevent it from coming off the guide rollers Causes of damage A Breakage of the steel wires Excessive tension causes the steel wires to break in the following conditions when stones or foreign bodies accumulate between the track and the undercarriage chassis when the track comes off the guides in the ...

Page 124: ...r repeated and abrupt changes in direction 4 Abrasion of the pattern may occur especially if slewing on concrete surfaces or on gravel or hard surfaces The damage indicated in paragraph D points 1 2 3 must not be considered critical for the track and even if in presence of gradual and progressive damage the track can still continue working The damage indicated in point 3 leads to the exposure of t...

Page 125: ... mechanism access cover 3 3 To loosen the track slowly unscrew valve 1 anticlockwise giving no more than one turn One turn of valve 1 is sufficient to loosen the track 4 If the grease does not start to come out turn the track slowly 5 Insert 3 steel pipes 4 inside the track in the space between the rollers Turn the sprocket backwards 5 so that the steel pipes move with the track and engage the idl...

Page 126: ...nsion 8 Rest the undercarriage on the ground 7 11 CHECKING TIGHTNESS OF NUTS AND BOLTS Depending on the use of the platform it is essential to check the parts and the nuts and bolts which are subject to loosening Pay particular attention to the chassis components such as idler roller travel gear motors sprockets and guide rollers Check that they are tightened sufficiently according to the fol lowi...

Page 127: ...53 200 285 388 240 325 30100 375 510 340 460 280 380 16 0 7500 0 3730 23800 300 407 220 298 330 449 268 363 33600 420 570 380 515 315 430 7 8 9 0 8750 0 4620 29400 430 583 320 434 475 646 386 523 41600 605 825 545 740 455 620 14 0 8750 0 5090 32400 470 637 350 475 520 707 425 576 45800 670 910 600 815 500 680 1 8 1 0000 0 6060 38600 640 868 480 651 675 918 579 785 51500 860 1170 770 1045 645 875 1...

Page 128: ...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 645 875 12 1 0000 0 6630 59700 845 1150 795 1080 745 1015 59700 995 1355 895 1215 745 1015 1 1 8 7 1 1250 0 7630 68700 1095 1490 1030 1400 965 1310 68700 1290 1755 1160 1580 965 1310 12 1 1250 0 8560 77000 1225 1665 1155 1570 1085 ...

Page 129: ...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 0 830 750 625 189 0 705 665 625 24 3 353 153 5 737 553 663 811 222 0 1065 960 800 220 0 900 845 790 27 3 459 199 5 1080 810 970 1130 286 0 1545 1390 1160 286 0 1315 1235 1160 30 3 5 561 244 0 1460 1100 1320 15...

Page 130: ... oil ONLY use JLG oil 7 13 CHECKING FOR LEAKS IN THE HYDRAULIC SYSTEM Visually check all hoses connections and all other components in the hydraulic system 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 as gaskets usually leak because they are damaged...

Page 131: ...rocessing residues from the hydraulic system 1 Unscrew the cap A and remove the filter cartridge 2 If it is very dirty replace it with a new one having the same characteristics 3 Tighten cap A 7 15 CHECKING THAT ALL THE PLATES ARE PRESENT ON THE MACHINE AND INTACT Make sure that the prohibition warning danger and control plates positioned on the machine are all present and visible See the paragrap...

Page 132: ...aulic system b Go to the control position and switch the machine on c Close one of the two right stabilisers completely and maintain the movement activated Read the pressure value This value relates to the right track distributor Switch the machine off d Connect the pressure gauge to fitting MA ref Hydraulic system e Go to the control position and switch the machine on f Close one of the two left ...

Page 133: ...d of the extension arm cylinder obser ving the schedule indicated in the Routine maintenance table If the wear on the radius of the ring exceeds 3 mm it must be replaced 7 19 CHECKING WEAR ON THE TELESCOPIC ARM SLIDES Visually check the play on the extension arms If the play exceeds 3 mm adjust the plastic registers by screwing them tighter until they rest on the arm top or reach around 1 mm from ...

Page 134: ...y with plenty of running water Before working on the battery ALWAYS disconnect the battery cutout switch 7 21 1 CHECKING THE ELECTROLYTE LEVEL THERMIC VERSION The battery does not need to be topped up However if the electrolyte with the machine on a level surface is below the minimum allowed level MIN it is possible to top up by removing the lid A and adding distilled water without exceeding the m...

Page 135: ...to recharge the battery by proceeding as follows 1 Disconnect the terminals of the machine s electrical system from the battery poles 2 Remove the lid A Figure 1 3 Connect the cables of the battery charger to the battery poles and switch the recharger on 4 Once the charge has been completed switch the device off before disconnecting it from the battery 5 Fasten the terminals to the battery poles t...

Page 136: ...tarting from the negative pole Reconnect the cables always starting from the positive pole When the battery cannot accumulate electric energy any longer replace it with a new one having the same characteristics See the specifications table on the battery 7 21 4 BATTERY DISPOSAL The batteries must be disposed of in compliance with the specific regulations in force X17JR0420113 132 BOOM LIFT MODELS ...

Page 137: ...t amendments 2005 49 EC 2005 83 EC 2006 28 EC Jlg accepts no liability for any damage due to failure to comply with this warning Opening and handling the battery pack is dangerous Failure to observe this warning auto matically voids the warranty NEVER OPEN THE BATTERY PACK The battery pack works at peak performance and in safe conditions with an ambient tempe rature between 20 C and 40 C Using the...

Page 138: ...horised to access the battery pack and replace it RECHARGING Recharge the Battery System only using the special battery charger provided with the machi ne Using a different battery charger may cause damage to the machine and pose a risk to the operator Do not remove the cover and do not tamper with the battery charger Failure to observe these rules voids the machine s warranty may affect the corre...

Page 139: ...Remote control switch 3 100A 48V fuse 4 12V 12Ah battery 5 Starter 6 Suction fan 7 Inverter 8 48V 12V DC DC 9 Relay 10 Fuses 11 Battery management system 12 Battery charge indicator 13 Blower fan 14 Battery case 15 15 cells 90Ah BOOM LIFT MODELS X17J JLG X17JR0420113 ...

Page 140: ... with antistatic coating able to insulate the worker during work on the electrical parts of the system 7 22 3 HANDLING IN DANGEROUS CONDITIONS The battery cells must be handled correctly in order to ensure proper and safe use However if mistakes are made in handling the cells causing explosion or venting the user has to be equipped so as to be able to face this emergency The aim of this section is...

Page 141: ... be assessed Minimum equipment required Infrared temperature probe Safety glasses Hard hat with impact resistant face visor Non conductive pliers Hand arm and body protection Procedure Evacuate the area as soon as abnormal cell temperature has been established Periodically check the temperature of the cell using a remote sensor for the first two hours or until one of the following cases occur The ...

Page 142: ...culite Plastic bags Procedure In the event of electrolyte release from the cells 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 characteristic pungent odour has disappeared If the cell is too hot allow it to cool to ambient temperature before handling it see sec tion 6 1 Wear safety equipment coat glove...

Page 143: ...ace shield Respirator with filter for hydrochloric acid and sulphur dioxide Neoprene gloves Acid resistant lab coats Baking soda calcium oxide or acid absorbent in kit form Vermiculite Plastic bags Procedure In the event of cell explosion proceed as follows Evacuate personnel from the areas contaminated by smoke Ventilate the rooms until the cell has been removed from the area and until the charac...

Page 144: ...ties of water may set fire to the material and the hydrogen gas that is released Once metal fires start they are very hard to extinguish with ordinary equipment This is partly due to the strong heat produced by the burning metal whose temperature may reach 1000 C In addition lithium may react with certain materials commonly used in fire extinguishers like water and CO2 Special extinguishers are re...

Page 145: ...s materials located near the fire Completely cover the fire with extinguishing material Never leave the fire unattended as it may develop again If necessary extinguish the secondary fires with suitable extinguishers After all the material has burned and cooled down carefully mix the residual material to prevent resumption of the fire Put the material in a metal drum cover the surface with plenty o...

Page 146: ...o mouth resuscitation and immediately seek emergency medical help 7 23 SERVICING THE ENGINE THERMIC VERSION Refer to the engine manual provided herewith AFTER ANY MAINTENANCE OPERATION BEFORE USING THE MACHINE TO WORK AT A HEIGHT IT IS COMPULSORY TO PERFORM ALL THE MOVEMENTS CONTROLLING THEM FROM THE GROUND IN ORDER TO MAKE SURE THAT THE HYDRAULIC AND ELECTRICAL SYSTEM ARE IN GOOD WORKING ORDER MA...

Page 147: ...w transit through openings measuring between 1500 and 990 mm IF THE MACHINE IS WITHOUT BASKET ONLY THE TRACKS CAN BE MOVED KEEPING AT A MINIUM DISTANCE OF 1 METRE FROM THE MACHINE To remove the basket proceed as follows remove the radio control from the support loosen the aluminium covers on the basket fixing pins see photo withdraw the basket from above Reassemble the basket as follows fit the ba...

Page 148: ...pproaching the loading surface before the change in inclination ALWAYS check that the JIB arm is COMPLETELY FOLDED Then proceed with great care in order to prevent sudden jolts when passing from the sloping ramps to the lorry or trailer flatbed position the machine so that none of its parts protrude from the transport vehicle Unload the machine following the same instructions given above ALWAYS lo...

Page 149: ...e completely closed and aligned stabilisers completely lifted and undercarriage exten ded Otherwise the machine would be unbalanced and lifting dangerous Never lift the machine with the operator on board During lifting make sure that no people are in the area affected by the operations and do not move the suspended machine over persons Never lift the machine if it is not secured as shown herein if...

Page 150: ...THE PLATFORM The lifting devices must be in good working order and used according to the specifications supplied by the manufacturer As the weight of the platform is not distributed equally over the four stabilisers the minimum required capacity for the four ropes chains or slings used must not be less than 2000 kg and they must be minimum 3 m long and all identical The slings cannot be more than ...

Page 151: ...ns of the machine and the trailer are compatible with road traffic regulations The fixing system connection points are identified by the sticker Do not make connections in points other than those identified by the sticker This could cause permanent damage to the structure with risk of collapse X17JR0420113 BOOM LIFT MODELS X17J JLG 147 1703814A ...

Page 152: ...ious sensors fitted on the machi ne and from the controls on the remote control Each screen shows the status of the input and options to scroll the menu 1 PREC access the previous input 2 SUCC access the next input 9 ESCI exit the INPUT menu BOOM LIFT MODELS X17J JLG 148 X17JR0420113 ST TERR 1A If both are ON stabiliser 1 is resting on the ground ST TERR 1B ST TERR 2A If both are ON stabiliser 2 i...

Page 153: ...b arm is completely folded MICROJIB B PEDALE If ON the pedal in the basket is pressed pedal version only EMNAV A If both are ON the emergency STOP on the remote control in the basket is NOT pres sed EMNAV B POSM 1A If both are ON stabiliser 1 is lowered stabilisation position POSM 1B POSM 2A If both are ON stabiliser 2 is lowered stabilisation position POSM 2B POSM 3A If both are ON stabiliser 3 i...

Page 154: ...et levelling lever on the distributor in the basket is operated SIIIB If ON the third arm lever on the distributor in the basket is operated SDIB If ON the first arm descent lever on the distributor in the basket is operated SSIB If ON the first arm ascent lever on the distributor in the basket is operated SJIB If ON the jib lever on the distributor in the basket is operated SEXT If ON the extensi...

Page 155: ...ng incongruent information The last page of the error menu describes the error code relating to the battery charger system inverter and battery pack Errors are indicated by the spanner icon in position 7 on the remote control display If there are operating problems with the machine and the spanner icon is shown on the display contact Jlg s service department 9 3 OPERATING HOURS MENU Indicates the ...

Page 156: ... 3 Cause Activated in the event of high inverter current peaks Solution This is generally a temporary problem due to certain working condi tions If problem persists replace inverter 18 Logic Failure 2 Cause Internal fault in the inverter Solution Replace inverter 19 Logic failure 1 Cause Sudden voltage surge or voltage drop Solution This is a temporary problem due to certain working conditions If ...

Page 157: ...verter Solution Check connections and motor phases 61 High temperature Cause High temperature inside the inverter Solution Improve cooling to inverter If fault persists contact Jlg after sales servi ce 65 Motor temperat Cause High motor temperature Solution Temporarily stop machine to allow motor to cool down 67 Can Bus KO Cause Inverter doesn t receive any information from Can Bus line Solution C...

Page 158: ...relay coil is intact 78 VACC not OK Cause Solution This is generally a temporary problem due to certain working condi tions If problem persists replace inverter 79 Incorrect start Cause Incorrect starting procedure Solution Check electrical connections This is generally a temporary problem due to certain working conditions If problem persists replace inverter 86 Pedal wire KO Cause Solution This i...

Page 159: ...partment temperature A99E10 High electronic board temperature A99E11 Incorrect self protection device temperature A99E12 Fault on all temperature sensors A99E13 Temperature sensor fault A99E14 Earth connection fault A99E15 Bootloader error A99E16 Secondary protection A99E17 Control device error A99E18 Power board error A99E19 I2C module not ready A99E20 I2C TX error A99E21 I2C RX error A99E22 I2C ...

Page 160: ...tops working Contact service dept or change product 252 Short circuit in bat tery charger output Battery charger stops working Turn off battery charger and resolve short circuit at output If problem persists contact service dept or change product 246 Stage 1 ended by timeout without reaching control voltage Battery charger stops working Make sure battery capacity is compatible or check that battery...

Page 161: ...ion resu mes as soon as alarm condi tions are no longer present If problem persists check battery charger mains power supply 242 Error when reading internal memory on microcontroller Battery charger stops working Contact service dept or change product 18 Extended shutdown or power failure Battery charger stops sup plying power Operation resu mes as soon as alarm condi tions are no longer present o...

Page 162: ...ipment has been stabilised it is not pos sible to detach the aerial part from the supports in the rest position See point 2 The outriggers micro swit ches do not close the contact The machine is not levelled with the tolerance of 1 The emergency stop button in the basket is not correctly inserted See point 2 Adjust the outriggers microswitches Level the machine with tolerance of 1 Check the key fo...

Page 163: ... putting the aerial part of the machine to rest and check the correct signal from the photocells During use of the aerial part vibrations and unsteadiness in the extension manoeuvre and work arm retraction speed are detected Telescopic arm and slide blocks are sparsely lubricated Slide blocks worn Lubricate arm and slide blocks Adjust slide blocks The work platform does not remain level during mov...

Page 164: ...65bar 5 b a B A 3 8 G 3 8 G 13 ALLARGAMENTO CINGOLI SFILO CESTO CILINDRO BRACCI ROTAZIONE CILINDRO 3 BRACCIO 2 BRACCIO CILINDRO CILINDRO 1 BRACCIO JIB CILINDRO 180 Bar A B A B A B B A T V1 V2 210 Bar T A A B B B A A B A B V2 V1 V1 V2 V2 V1 V2 V1 V1 V2 V2 V1 M M M P 16 17 18 19 20 21 21 22 21 23 24 25 29 32 30 28 CESTO SU CESTO LIVELLAMENTO CILINDRO LIVELLAMENTO CESTO SU RINVIO CILINDRO B A CESTO R...

Page 165: ...rack gauge extension cylinder 14 Directional solenoid valve 15 Aerial part safety device solenoid valve 16 Switch 17 Hydraulic distributor 18 Rotation motor 19 First arm cylinder 20 Second arm cylinder 21 Arm balance valve 22 Third arm cylinder 23 Extension arm cylinder 24 Extension arm balance valve 25 Jib arm cylinder 26 Double balance valve 27 Basket levelling cylinder on the basket 28 Basket l...

Page 166: ...12 2 HYDRAULIC SYSTEM DIAGRAM LITHIUM VERSION X17JR0420113 162 BOOM LIFT MODELS X17J JLG ...

Page 167: ...nder 14 Directional solenoid valve 15 Aerial part safety device solenoid valve 16 Switch 17 Hydraulic distributor 18 Rotation motor 19 First arm cylinder 20 Second arm cylinder 21 Arm balance valve 22 Third arm cylinder 23 Extension arm cylinder 24 Extension arm balance valve 25 Jib arm cylinder 26 Double balance valve 27 Basket levelling cylinder on the basket 28 Basket levelling cylinder on the ...

Page 168: ...ecomando Caricabatterie Link di sicurezza B Link di sicurezza A Alimentazione positiva Alimentazione negativa CAN H CAN L Telecomando Ricevente Chiave quadro Scheda condizionamento celle di carico Negativo batteria Micro jib A Micro jib B Disc emer I II Spia Mk stabilizzata Stab 1 basso Stab 2 basso Stab 3 basso Stab 4 basso Cella A Cella B Celle di carico bianco nero verde bianco nero verde B1 MO...

Page 169: ...mico Alimentazione sottosistemi Telecomando Caricabatterie Link di sicurezza B Link di sicurezza A Alimentazione positiva Alimentazione negativa CAN H CAN L Telecomando Ricevente Chiave quadro Scheda condizionamento celle di carico Negativo batteria Micro jib A Micro jib B Disc emer I II Spia Mk stabilizzata Stab 1 basso Stab 2 basso Stab 3 basso Stab 4 basso Cella A Cella B Celle di carico bianco...

Page 170: ... LITHIUM VERSION X17JR0420113 166 BOOM LIFT MODELS X17J JLG ...

Page 171: ...3 NOTE Leased or rented units should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Previous Owner ___________________________________________________________ Address _________________________________________________________________ ____________________________________...

Page 172: ...na Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North ...