JLG X430AJ Operation And Safety Manual Download Page 10

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TABLE OF CONTENTS

3121773

– JLG Lift –

iii

SECTION - PARAGRAPH, SUBJECT

PAGE

SECTION - PARAGRAPH, SUBJECT

PAGE

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

Using Emergency Descent In Case Of An Outrigger
Losing Contact With The Ground . . . . . . . . . . . . 5-14
Machine Realignment Emergency Procedure . . 5-15



SECTION - 6 - GENERAL SPECIFICATIONS AND OPERA-
TOR MAINTENANCE

6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . 6-2

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Electric Motor Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Lithium-Ion Battery Pack Specifications . . . . . . . . 6-4
Major Component Weights. . . . . . . . . . . . . . . . . . 6-4

6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-5

Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-16
Battery Maintenance and Charging - Diesel/AC-
Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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

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

6.5 PLATFORM/REMOTE CONTROL SERVICE

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

Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-21
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

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

Battery Pack System Components and
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-22
BMS Fault Codes - (Battery Management
System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-26

6.7 LITHIUM-ION BATTERY PACK - HANDLING IN

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

Procedure For Handling Hot Cells. . . . . . . . . . . 6-28
Procedure For Handling Vented Cells . . . . . . . . 6-29
Procedure For Exploded Cells. . . . . . . . . . . . . . 6-31
Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . 6-32

SECTION - 7 - INSPECTION AND REPAIR LOG

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Summary of Contents for X430AJ

Page 1: ...ation and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times ANSI Model s X430AJ 3121773 June 29 2018 Rev C T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 3: ...California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle or equipment in a well ventilated area and wear gloves or wash your hands frequently when servicing For more information go to www P65Warnings ca gov T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 4: ...ssors and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 5: ...IOUS INJURY OR DEATH THIS DECAL WILL HAVE A RED BACK GROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND INDICATES A POTENTIALITY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND INDICATES INFOR...

Page 6: ...TS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT For Accident Reporting Product Safety Publica tions Current Owner Updates Questions Regarding Product Safety Standards and Regulations Compliance Information Questions Regarding Special Product Applications Questions Regarding Prod uct M...

Page 7: ...N REVISION LOG d JLG Lift 3121773 REVISION LOG Original Issue A March 16 2017 Revised B April 3 2018 Revised C June 29 2018 Revised Covers Prop 65 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 8: ... PERSONNEL TRAINING 2 1 Operator Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Daily Walk Around Inspection 2 6 Function Check 2 8 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 1 GROUND CONTROL STATION 3 3 3 2 PLATFORM REMOTE CONTROL STATION 3 6 Control Position On The Ground 3 6 Control Position Fr...

Page 9: ...ard Operation If Equipped 4 18 Emergency Lowering 4 19 Platform Removal Installation 4 19 4 8 BATTERY CHARGING DIESEL AC ELECTRIC 4 20 Battery Charging Daily 4 20 4 9 BATTERY CHARGING LITHIUM ION MACHINE 4 21 Charging the Battery Pack 4 21 Charge Curve 4 23 Cold Weather Charging 4 23 Cooling Fans 4 24 4 10 SHUT DOWN AND PARK 4 24 4 11 LIFTING AND TIE DOWN 4 25 Lifting 4 25 Tie Down 4 27 SECTION 5 ...

Page 10: ...c Oil Tank 6 12 Hydraulic Oil Filter Cartridge 6 13 Rubber Track Maintenance Replacement 6 13 Wear Pad Inspection 6 16 Turntable Attach Bolts 6 16 Battery Maintenance and Charging Diesel AC Electric 6 16 6 4 ELECTRIC MOTOR MAINTENANCE 6 17 Electric Motor 6 17 6 5 PLATFORM REMOTE CONTROL SERVICE MENU 6 18 Service Button 6 18 Menu Input 6 18 Errors Menu 6 20 Working Hours Menu 6 21 Set up Menu 6 21 ...

Page 11: ...nes with Lithium Ion Power Only 4 35 5 1 Platform Remote Control Station 5 5 5 2 Ground Control Station 5 7 5 3 Hand Pump Chassis Control Valve Tray 5 8 6 1 Lubrication and Maintenance Point Locations 6 6 6 2 Hydraulic Oil Specifications 6 8 6 3 Hydraulic Oil Operating Temperatures 6 9 LIST OF TABLES 1 1 Minimum Approach Distances M A D 1 6 1 2 Beaufort Scale For Reference Only 1 8 2 1 Inspection ...

Page 12: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 13: ...ration of the machine has been completed under the supervision of an experienced and qualified opera tor This section contains the responsibilities of the owner user operator lessor and lessee concerning safety training inspection maintenance application and operation If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Indus...

Page 14: ... they pertain to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before and during opera tion of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaf folds or other equipment unless the application is approved in writing by JLG Before op...

Page 15: ...d accumulation of debris on platform floor Keep mud oil grease and other slippery substances from footwear and platform floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any device i e cell phones two way radios etc that will distract your attention from safely operating the machine Do not use the machine for any purpose other ...

Page 16: ... and shut off all power before leaving machine Remove all rings watches and jewelry when operat ing machine Do not wear loose fitting clothing or long hair unrestrained which may become caught or entangled in equipment Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of phys ical control must not operate this machine Trip and Fall Hazards During oper...

Page 17: ...or at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o...

Page 18: ...their tools and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot addi tional clearance is required for every additional 30 000 volts or less The minimum approach distance may be reduced if insulating barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These barriers shall not be part of or attached...

Page 19: ... outriggers of the machine a minimum of 2 ft 0 6m from holes bumps drop offs obstructions debris concealed holes and other potential hazards at the ground level Do not push or pull any object with the boom Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Never attach wire cable or any similar items to platform Do not operate the machine when wind conditi...

Page 20: ...ustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrella usebecomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effortneededtowalkagainstthewind 8 ...

Page 21: ... according to conditions of ground sur face congestion visibility slope location of person nel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in reverse Exerc...

Page 22: ...ual and in the Service and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A mainte nance program must be established by a qualified person and must be followed to ensure that the machine is safe Maintenance Hazards Shut off power to all controls and ensure ...

Page 23: ...raising components of the machine Do not use machine as a ground for welding When performing welding or metal cutting opera tions precautions must be taken to protect the chassis from direct exposure to weld and metal cut ting spatter Do not refuel the machine with the engine running Use only approved non flammable cleaning sol vents Do not replace items critical to stability such as bat teries or...

Page 24: ...s Always wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfilling the battery fluid level Add d...

Page 25: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 26: ...ll protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction 6 The safest means to operate the machine where overhead obstructions other moving equipment obstacles depressions holes and drop offs exist 7 Means to avoid the hazards of unprotected electri cal conductors 8 Specific job requirements or machine application Traini...

Page 27: ... work platforms Frequency of inspections and maintenance must be increased as necessary when machine is used in a harsh or hostile environment if machine is used with increased frequency or if machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECHNI CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT ...

Page 28: ...n3months or Purchasedused Owner Dealer or User QualifiedJLGMechanic ServiceandMaintenanceMan ualandapplicableJLGinspec tionform AnnualMachineInspection Annually nolaterthan13monthsfromthedateof priorinspection Owner Dealer or User FactoryTrained ServiceTechnician Recommended ServiceandMaintenanceMan ualandapplicableJLGinspec tionform PreventativeMaintenance AtintervalsasspecifiedintheServiceandMai...

Page 29: ...s only is enclosed in the weather resistant storage con tainer 5 Walk Around Inspection Refer to Figure 2 1 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine Oil Supply Combustion Engine Powered Machines Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure 9 Hydraulic Oil Check the hydraulic oil ...

Page 30: ...LEM TO THE PROPER MAINTENANCE PER SONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION MAKE SURE THE ENGINE KEY SWITCH IS ON THE BATTERY DISCONNECT SWITCH IS TURNED ON AND THE POWER EMERGENCY STOP BUTTONS AT THE GROUND AND PLATFORM CONTROL BOX IS TURNED CLOCKWISE ON T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 31: ...ss bar slides up and down properly platform properly installed and with mounting both caps screwed on tight Lanyard attach points secure and undamaged See Inspection Note 2 Platform Remote Ground Control Stations Switches and levers return to neutral decals plac ards secure and legible control markings legible 3 Outriggers See Inspection Note pads pivot freely 4 Electrical Hydraulic Cover Assembli...

Page 32: ...1 Figure 2 1 Daily Walk Around Inspection SECTION 2 PREPARATION AND INSPECTION 3121773 JLG Lift 2 7 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 33: ...e in place c Operate all functions d Ensure all boom functions stop when the foot switch is released e Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in f Ensure main lift down tower lift down and jib lift down work properly when using the emer gency lowering controls 3 SkyGuard Function Test If Equipped a From the platform controls test the Sky Guard featu...

Page 34: ...or 2 SkyGuard Override Switch button number 8 SECTION 2 PREPARATION AND INSPECTION 3121773 JLG Lift 2 9 Figure 2 2 SkyGuard Sensor and Override Switch Location T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 35: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 36: ...ic Machine Component Locations SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121773 JLG Lift 3 1 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 37: ...Tower Boom Assembly 8 Jib 9 Platform Fold Down Entry Ladder 10 Platform 11 Manuals Compartment 12 SkyGuard Sensor If Equipped 13 Platform Remote Control Station 14 Main Boom 15 Electric Components Compartment same area other side of machine 16 Electric Motor Pump Compartment 17 Lithium ION Battery Charger LED Indicator on top of battery pack if equipped 18 Diesel Engine Compartment OR Lithium ION ...

Page 38: ...f power is shut off to the PLATFORM and GROUND controls 3 Platform Ground Remote Select Switch This three position selector switch provides power to the platform when in the center neutral posi tion With the key switch turned clockwise and held only the ground controls are operational With the key switch turned counter clockwise the ground control electrical connector is enabled and the platform r...

Page 39: ... 8 Tower Boom Lift Control Provides raising and lowering of the tower boom 9 Main Boom Lift Control Provides raising and lowering of the main boom 10 Main Boom Telescope Control Provides extension and retraction of the main boom 11 Jib Lift Provides raising and lowering of the jib 12 Platform Rotate Control Provides rotating the platform to the right or left ONLY USE THE PLATFORM LEVELING OVERRIDE...

Page 40: ...0 11 12 13 6 1 3 2 4 5 7 8 9 10 11 12 13 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121773 JLG Lift 3 5 Figure 3 2 Ground Control Station T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 41: ...ocated in the electrical component compartment see photo NOTE Before removing or connecting the platform remote control station depress the emergency stop buttons and the key on the engine must be in the OFF position Connect the ground remote control cable on the left side of the machine at the electrical components cabinet see photo to the platform remote control station cable connec tor To enabl...

Page 42: ...onnected to the machine at the platform using a flexible cable NOTE Before removing or connecting the flex cable the machine must be turned OFF and the key on the engine must be in the OFF position Installing the Platform Remote Control Station At The Platform 1 Connect the flexible control cable at the platform to the Platform Remote Control Station box con nector on the right side of the control...

Page 43: ...king the rib of the control station under the rotating metal tab of the handle assem bly 5 To remove the control station assembly reverse the four steps above NOTE The Platform Remote control box may also be used to operate tracks outriggers and track widening if equipped by removing it from the platform storage box and plugging in at the ground control position If outriggers are down boom functio...

Page 44: ...SERVICE button 6 item 6 sub menus is activated on the LCD display 1 Outrigger Automatic Retract This control allows the operator to control the retraction of all 4 outriggers at one time 2 Outrigger Manual This control allows the operator to control the extension or retraction of one outrigger at a time 3 Track Width Adjust This control allows the operator to widen the track 4 Emergency Lowering T...

Page 45: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 10 JLG Lift 3121773 Figure 3 3 Platform Remote Control Station T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 46: ... to pre heat the diesel engine in cold climates 12 Gas Diesel Engine Starter This button allows the operator to start or stop the gas diesel engine 13 Electric Engine Start This button allows the operator to start or stop the electric engine 14 Platform Level Switch The control allows the operator to adjust the level of the platform up or down 15 Display Display shows status of machine and operati...

Page 47: ...s control allows the operator to swing the boom assembly to the right or left 23 Right Side Track Drive And Steer This control when moved forward or rearward simultaneously with the left side track control 17 allows the operator to move the machine in a straight forward or reverse direction or if each control is moved individually or in opposite direc tions to steer the machine Platform Remote Con...

Page 48: ...on5 1 2 3 4 5 6 7 8 Displays outriggers are properly set and boom functions are allowed No display indicates outriggers are not properly set and boom functions are not allowed Position6 1 2 3 4 5 6 7 8 Indicates boom jib turntable and base are aligned Drive steer track width adjustment and outrigger functions are operational if this symbol below is present No symbol indicates these functions are n...

Page 49: ...re cut out Swing sensor is faulty CANBUS communication is faulty Electronic fault Lithium ION Signals an error in the BMS Battery Management System Skyguard System enabled Battery cold heater activated system is enabled SEN 3 FAIL SWING CAN BUS CARD or 50 Hr 1st Service Interval See Section 6 Table 6 10 and Table 6 11 Compo nent Maintenance Intervals SERV Position8 1 2 3 4 5 6 7 8 Indicates emerge...

Page 50: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121773 JLG Lift 3 15 Table 3 1 LCD Display Icon Descriptions T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 51: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 16 JLG Lift 3121773 Table 3 1 LCD Display Icon Descriptions Continued T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 52: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121773 JLG Lift 3 17 Table 3 2 LCD Display Error Descriptions T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 53: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 54: ...ystem to alert other personnel in the work area of any machine movement during operation The motion alarm system is activated during machine function movement such as track boom or outrigger operation 4 2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities The boom can be raised from the transport position with or without any load in platform if Machine is positioned on a firm surface and ou...

Page 55: ...N and boththegroundandplatformemergencystopswitchesmustberesettoON Diesel Starting Procedure NOTE If gas diesel engine fails to start promptly do not crank for an extended time Should engine fail to start again allow starter to cool off for 2 3 minutes If engine fails after several attempts refer to manufac turers engine maintenance manual NOTE If engine is diesel when starting from ground turn th...

Page 56: ...re 4 3 on the platform remote control box 3 The shutdown procedure takes about 1 minute wait for complete shut off display off 4 Push POWER EMERGENCY STOP switches at the platform and ground in to the off position 5 Turn engine key to off Electric Engine Starting Procedure AC Voltage Machine ENSURE THE ELECTRICAL CIRCUIT BEING USED IS THE SAME VOLTAGE AND FREQUENCY INDICATED ON THE ELECTRIC ENGINE...

Page 57: ...h item 2 posi tioned behind the clear plastic cover near the elec tric engine symbol is ON O symbol is OFF 4 Start the electric engine using the engine start button at the ground emergency control box item 5 Figure 4 1 and operate machine 5 When finished operating with the electric engine turn off breaker switch item 2 and unhook the electric AC cord from receptacle item 1 T o o r d e r g o t o D ...

Page 58: ...osition 6 on the Platform Remote Control LCD display UNLESS THESE CONDITIONS ARE MET DRIVE STEER TRACK WIDTH ADJUSTMENT AND OUTRIGGER MOVEMENT IS PREVENTED Base Boom Alignment Visual Indicator Boom Jib and Base Alignment Reflectors Photocells Platform Rotation Alignment Indicator There are also platform alignment indicators on the platform rotator assembly When re aligning the plat form straight o...

Page 59: ...ned and retracted before this function will operate see Section 4 4 BASE AND BOOM JIB ALIGNMENT Track width adjust DO NOT WIDEN OR NARROW THE TRACKS WIDTH WHEN PARKED WITH THE TRACKS ON THE GROUND THE MACHINE MUST BE TRAVELLING OR RAISED ON ITS OUTRIGGERS WHEN OPERATING THIS FUNCTION Press and hold button 3 for widening or button 9 for narrow ing the track 3 9 T o o r d e r g o t o D i s c o u n t...

Page 60: ...s fully widen the track prior to driving if possible for easier steering and increased stability Always travel in the slow speed setting unless the travel path is firm level and uniform Travelling Grades and Side Slopes TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER FULLY WIDEN TRACKS AND DO NOT DRIVE MACHINE ON GRADES EXCEEDING 25 DEGREES 40 USE RAMPS WHEN TRAVELLING ON STEPS OR OTHER SURFACES THAT ...

Page 61: ...SECTION 4 MACHINE OPERATION 4 8 JLG Lift 3121773 Figure 4 2 Grade and Side Slope Definition T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 62: ...ifting the jib arm in the traversing phase the following conditions must be verified All outriggers must be lifted from the ground The platform must be removed from the jib arm The platform remote control box must be removed from the platform and used from the ground NOTE The aerial part safety device by pass key must not have been activated after the machine has been closed and aligned If any of ...

Page 63: ...nhill if the JIB is not completely stowed TO BE ABLE TO RAISE THE JIB IN ADDITION TO THE ABOVE CONDITIONS IT IS NECESSARY TO REMOVE THE PLATFORM TO DO THIS FOLLOW THE ADVICE IN THE FOLLOWING PARAGRAPH In this case if you try to move the JIB without first removing the basket the use of the JIB arm will not be possible and will display the following error screen ERROR RemovethePlatform BeforeProceed...

Page 64: ... for item number location Either Press and hold the outrigger auto set and level button 7 item 7 until OK appears on the platform LCD display AUTO 7 or Operate each outrigger separately by pressing button 2 item 2 to select which outrigger to control each outrigger is num bered 1 thru 4 see decal each press of but ton 2 displays the outrigger selected on the LCD display Press button 1 item 1 to re...

Page 65: ...HINE IMMEDIATELY AND CALL A QUALIFIED JLG SERVICE TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRE SPONDING OUTRIGGER MICRO SWITCH IF SLOPE EXCEEDS 13 THE MACHINE IS NOT CAPABLE OF PROPERLY SET TING OUTRIGGERS AND LEVELING ITSELF OPERATION OF BOOM AND PLAT FORM FUNCTIONS WILL NOT BE ALLOWED IN THIS CONDITION THE MACHINE IS CONSIDERED STABILIZED WHEN LEVELED TO LESS THAN 1 AND TRACKS ARE LIFTE...

Page 66: ...T PLATFORM REMOTE CONTROL STATION TWIST EMERGENCY STOP BUT TON CLOCKWISE TO THE OUT POSITION START ENGINE AND ACTIVATE FOOTSWITCH FOR ALL PLATFORM REMOTE CONTROL FUNCTIONS ALWAYS STOW RAISE THE LADDER AFTER ENTERING OR EXITING THE PLAT FORM TO PREVENT IT BEING DAMAGED WHEN OPERATING THE MACHINE If the operator attempts to raise the JIB with more than the allowed capacity in the platform a maximum ...

Page 67: ...e control Platform Level Adjustment Item 14 Figure 4 3 NOTE During normal operation of the machine the plat form will automatically maintain its position To manually Level Up turn select switch clockwise and hold until desired position is reached To manually Level Down turn the select switch counter clockwise and hold until desired position is reached ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTI...

Page 68: ... 3 To raise the jib depress the foot switch and move the controller forward To lower the jib depress the foot switch and move the controller backwards Swinging The Boom Item 22 Figure 4 3 WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM AND UPRIGHT TO CLEAR SURROUNDING WALLS PARTITIONS AND EQUIPMENT IF THE TURNTABLE IS ROTATED WITH TOWER BOOM TOO LOW OR TOWER BOOM IS LOWERED NEAR ...

Page 69: ...SECTION 4 MACHINE OPERATION 4 16 JLG Lift 3121773 Figure 4 3 Platform Remote Control Box T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 70: ...otationandJibExtendONLYwithOutriggersSettoFullWorkAreaPosition SECTION 4 MACHINE OPERATION 3121773 JLG Lift 4 17 Figure 4 4 Platform Load Reach Chart X430AJ T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 71: ... SkyGuard remains activated after function reversal or cutout depress and hold the SkyGuard Override Switch button number 8 to allow normal use of machine functions until the SkyGuard sensor is disengaged 1 2 1 SkyGuard Sensor 2 SkyGuard Override Switch button number 8 Table 4 1 SkyGuard Function Table Main Lift Up Main Lift Dn Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lif...

Page 72: ...perate by moving the paddle controller in the direction for lowering items 18 and 21 in Figure 4 3 4 When finished release the emergency lowering switch controller and foot switch 5 Position the emergency stop switch to the off posi tion Determine the reason for the primary power failure and have the problem corrected by a qualified JLG service tech nician Platform Removal Installation The platfor...

Page 73: ...to a properly grounded outlet Do not use ground adaptors or modify plug Do not touch non insulated portion of output connector or non insulated battery terminal Always disconnect the AC supply before making or breaking the connections to the battery Do not open or disassemble charger Do not operate charger if the AC supply cord is dam aged or if the charger has been damaged in any way Battery Char...

Page 74: ...rge indicator Charging the Battery Pack DONOTLEAVETHEMACHINEINCONTINUOUSCHARGING FORTIMEPERIODS EXCEEDING 24 HOURS REMEMBER THE CHARGE WORKS EVEN IF THE ELECTRONIC BOARD OF THE MACHINEISTURNEDOFF SOTHEBATTERIESCANBECHARGINGEVENIFTHE REMOTE CONTROL IS OFF CHARGE THE MACHINE USING ONLY THE BATTERY CHARGER INSTALLED ON IT THE USE OF A CHARGER OTHER THAN THAT PROVIDED VOIDS ANY KIND OF WARRANTY ON BAT...

Page 75: ...CAUTIONS MUST BE OBSERVED Carefully read installation instructions contained in this manual For future reference keep manual in a safe place Do not place battery pack near heat sources As battery charger is sealed without forced ventilation its performance depends on ambient temperature and type of installation Be certain type of power supply available corresponds to voltage specified and indicate...

Page 76: ...connect it immediately from power outlet and the battery socket and contact your local JLG Service Center Charge Curve The battery charger features just one charge curve IUIa plus balancing and maintenance designed specifically for charging the lithium ion battery pack on this machine Cold Weather Charging Lithium battery pack discharge and or recharge with posi tive lithium battery level SOC 0 is...

Page 77: ...o a reasonably well protected area 2 Ensure boom and jib are in the stowed aligned position 3 Remove all load and allow engine to operate 3 5 minutes at LOW setting to permit reduction of internal engine temperatures 4 Shut down gas diesel electric engine with the same button on the platform remote control sta tion used to start it Complete machine shut down takes approximately 1 minute LCD displa...

Page 78: ... 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 USE OF ROPES CHAINS OR SLINGS WITH LENGTH LESS THAN 10 ft 3m COULD CAUSE PERMANENT DAMAG...

Page 79: ...st be no less than 4 409 lb 2000 kg and their length no less than 10 ft 3m and all identical 1 1 Outrigger Lifting Lug 4 corners 1 1 1 Lifting Slings Figure 4 6 Machine Lifting Points Figure 4 7 Lifting Machine Attach Points T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 80: ...aise jib to prevent contact with the ground See Jib Position for Travelling on page 4 9 ALWAYS load unload the machine with track fully wid ened 1 Place booms in the stowed position 2 Remove all loose items from machine 3 Secure chassis using straps or chains of adequate strength DO NOT MAKE CONNECTIONS AT POINTS DIFFERENT THAN THOSE IDENTI FIED BY THE TIE DOWN LOCATION DECAL SHOWN THIS COULD CAUS...

Page 81: ...1703814A both sides of machine 1 Tie Down Loop 2 Tie Down Decal SECTION 4 MACHINE OPERATION 4 28 JLG Lift 3121773 Figure 4 8 Machine Tie Down Points T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 82: ...SECTION 4 MACHINE OPERATION 3121773 JLG Lift 4 29 MACHINE DECALS Figure 4 9 Decal installation Left Side Machine T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 83: ...SECTION 4 MACHINE OPERATION 4 30 JLG Lift 3121773 Figure 4 10 Decal installation Left Side Chassis T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 84: ...SECTION 4 MACHINE OPERATION 3121773 JLG Lift 4 31 Figure 4 11 Decal installation Platform T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 85: ...SECTION 4 MACHINE OPERATION 4 32 JLG Lift 3121773 Figure 4 12 Decal Installation Right Side Machine T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 86: ...SECTION 4 MACHINE OPERATION 3121773 JLG Lift 4 33 Figure 4 13 Decal installation Right Side Chassis T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 87: ...SECTION 4 MACHINE OPERATION 4 34 JLG Lift 3121773 Figure 4 14 Decal Installation Right Side Valve Compartments T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 88: ...SECTION 4 MACHINE OPERATION 3121773 JLG Lift 4 35 Figure 4 15 Decal Installation Machines with Lithium Ion Power Only T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 89: ...on 9 06520600 Decal 88dBSoundLevelWarning 13 07107100 Decal RechargeBatteriesAfterEachUseorAtLeastEvery3Months 16 07110300 Decal EmergencyLoweringProcedure Lithium Ion 18 07264800 Decal BatteryChargeLevelIndicator 19 1701644 Decal BatteryChargerACPlug 20 1703813 Decal BatteryChargingVentilationWarning SECTION 4 MACHINE OPERATION 4 36 JLG Lift 3121773 T o o r d e r g o t o D i s c o u n t E q u i p...

Page 90: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 91: ...y details In USA JLG Phone 877 JLG SAFE 554 7233 8am till 4 45pm EST Outside USA 240 420 2661 E mail ProductSafety JLG com Failure to notify the manufacturer of an incident involv ing a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT MACHINE AND TEST ALL FUNCTIONS FIRST FROM GROUND...

Page 92: ...de of the battery electrical box tray at the left front of the machine just behind the outrigger mount When switched off handle turn all the way counter clockwise all electrical power to the machine is shut down POWERON Clockwise AsShown POWEROFF Counter Clockwise 1702155A ON OFF BATTERY DISCONNECT SWITCH GAS DIESEL AC ELECTRIC T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 93: ...ccupants and stabilize machine motion Platform or Boom Caught Overhead If platform or boom becomes jammed or snagged in overhead structures or equipment rescue platform occupants prior to freeing the machine NOTE The engine runs the hydraulic pump which provides hydraulic pressure for the hydraulic system The electric power provides power for the hydraulic proportional valve solenoids to open and ...

Page 94: ...r personnel in the platform 1 Check emergency stop button item 10 is in the ON position by turning it clockwise 2 Press and hold down button 4 item 4 with hazard symbol on platform remote control box The LCD display item 15 will indicate the triangle symbol seen on the button in LCD position 8 3 Select a boom function to operate by moving it s controller in the direction for lowering items 17 18 a...

Page 95: ...SECTION 5 EMERGENCY PROCEDURES 3121773 JLG Lift 5 5 Figure 5 1 Platform Remote Control Station T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 96: ... for desired movement 7 When finished release mode selector switch item 3 back to the neutral position 8 Position press emergency stop switch item 1 to the OFF position Manual Descent with Engine Running but without Electrical Power See Figure 5 2 ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD OF PERSONNEL BEFORE LOWERING 1 Open the Ground Control valve distributor cover 2 Locate th...

Page 97: ...7 8 9 10 11 12 13 6 1 3 2 4 5 7 8 9 10 11 12 13 SECTION 5 EMERGENCY PROCEDURES 3121773 JLG Lift 5 7 Figure 5 2 Ground Control Station T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 98: ...SECTION 5 EMERGENCY PROCEDURES 5 8 JLG Lift 3121773 3 4 5 6 7 1 2 3 Figure 5 3 Hand Pump Chassis Control Valve Tray T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 99: ...s swing turntable inline with the chassis first so that the turntable and base indicator arrows are aligned This will eliminate possibility of an elevated or extended boom being positioned overhead of person nel at the pump and eliminate the risk of lowering the jib onto an outrigger NEVER REACH THROUGH UNDER OR OVER THE BOOM S PATH OF TRAVEL TO THE GROUND CONTROL PANEL IF NO ASSISTANT IS AVAILABL...

Page 100: ...e appropriate direction to lower the tower boom 6 Lower the Main Boom Lift the function enable lever UP and hold item 6 Figure 5 2 while pumping the handpump acti vate the main boom lift function lever item 6 Fig ure 5 2 in the appropriate direction to lower the main boom 7 Rotate the platform if necessary Lift the function enable lever UP and hold item 6 Figure 5 2 while pumping the handpump acti...

Page 101: ...rigger and right and left track function solenoids 2 Locate and remove the pump handle item 3 secured to the bottom of the Ground Control com partment 3 Install pump handle item 3 on the pump item 4 and secure in place with the provided screw The lever item 5 on the pump must be set to the left to manually operate right side outrigger and track functions item 7 For right side operator s perspectiv...

Page 102: ...d direction on the appropriate valve solenoid valve description below while pumping the handle to achieve the desired function movement Item 6 Figure 5 3 1st valve far left toward front of machine in the group of four operates Left Rear Outrigger 2nd valve from the left in the group of four oper ates Left Front Outrigger 3rd valve from the left in the group of four oper ates the Left Track Drive f...

Page 103: ...tch item 1 photo After using the safety device bypass a qualified JLG mechanic must be contacted to determine the reason for needing to use this feature Return the key to the where you found it and secure it in that location The safety device circuit board records every time the safety device bypass key is activated along with the movements made during these operations NOTE In case of machine with...

Page 104: ...nd 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 con trol 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 lower...

Page 105: ...In case of machine with restricted work area the bypass of the safety devices does not allow the boom assembly to go out of the working area related to that outrigger configuration Movement Of Tracks With Machine Not Aligned OPERATION ONLY ALLOWED TO GO TO A CONDITION SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN MACHINE RE ALIGNMENT ABOVE ALL OTHER USE IS PROHIBITED 1 Open the electric compone...

Page 106: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 107: ...h Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual 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 UTI LIZED TO WASH AREAS CONTAINING ELECTRICAL ELECTRONIC COMPO NENTS JLG INDUSTRIES INC RECOMMENDS A MAXIMUM PRESSURE OF 750 PS...

Page 108: ...ch Departangle 20 36 Table 6 3 Chassis Data Model X430AJ MaximumTravelGradew boominstowedposition gradeability 16 28 MaximumTravelSideSlopew boominstowed position 15 26 Turningradius 0 Maximumgroundpressurepertrack psi 8 2psi 0 58kg cm2 Maximumgroundpressureperoutrigger 34 1psi 2 40kg cm2 Outriggerpaddiameter 11 5in 292mm Maxdrivespeed withstd 2ndspeed GasEngine Lithium Ion ElectricEngine 1 62mph ...

Page 109: ... 5Nm 2500RPM Weight 80 0lb 36 4Kg IgnitionSystem CDITypeMagneto AlternatorOutput 10A 3600RPM ShaftRotation CounterClockWise Table 6 6 Electric Motor Specifications Model X430AJ 12VSystemBattery 60Ah 680A 12V MotorRatedInputVoltage 230V 110V 120V MotorRatedFrequency 50Hz 50Hz 60Hz MotorRatedPower 2 2Kw 2 2Kw 1 2Kw SECTION 6 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3121773 JLG Lift 6 3 Capaci...

Page 110: ...8 Major Component Weights Model X430AJ Engine DryWeight HondaiGX390Gas 81 6lb 37Kg BoomSections Tower LowerTowerBoom LowerBoomLink LowerUpright UpperTowerBoom Upper BoomLink Qty 2 WeightEach UpperUpright MainBoom FlyBoom 202 8lb 92kg 114 6lb 52kg 79 3lb 36kg 99 2lb 45kg 172lb 78kg 48 5lb 22kg 114 6lb 52kg 141lb 64kg 110 2lb 50kg LiftCylinders PlatformLevelCylinder PlatformSwingActuator JibCylinder...

Page 111: ...ore it will need to be re greased see lubrication chart Do not wet the electric motors and the other elec trical components directly Do not aim the spray directly onto decals and rat ing plates Cleaning the electrical system NEVER CLEAN THE INVERTER OR THE ELECTRIC MOTOR WITH WATER AS THIS MAY CAUSE DAMAGE TO THE ELECTRICAL SYSTEM ONLY USE DRY DETERGENTS IN ACCORDANCE WITH THE MANUFACTURERS INSTRU...

Page 112: ...OR MAINTENANCE 6 6 JLG Lift 3121773 Machine Maintenance Locations Figure 6 1 Lubrication and Maintenance Point Locations M ENGINEOIL T TRANSMISSIONOIL I HYDRAULICOILANDFILTER G GREASE T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 113: ...Gearbox Oils 600 XP 150 EP 150 Blasia 150 Spartan EP150 Engine Oil SAE 10W30 Greasing and Lubrication Recommended lubricants Contact Grease EP blue in color is used to grease the turn table and cylinder pins on the chassis GR MU EP1 Grease is used to grease the expansion guide of the chassis the track tension valve and basket support pins White EP NLGI 2 Grease is used on the boom extensions Eithe...

Page 114: ...cates one of the following CO2 Conversion 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 classification indicates Factory Mutual Research Corp FMRC Approval Figure 6 2 Hydraulic Oil Specifications T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 115: ...SECTION 6 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3121773 JLG Lift 6 9 Figure 6 3 Hydraulic Oil Operating Temperatures T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 116: ...il CheckLevel Replace Machine GeneralPeriodicCheck ExtensionArmInternalSlidingRing ifequipped CheckWear Replace TurntableBoltTightening Check PlatformMountPinNuts Checktorque148ft lb 200Nm SERV 1sttimeintervalthenperchartthereafter Atleastevery3monthsor1000hrs ofoperation Atleaseevery5yearsor2000hrsofoperation Checkevery year Iftorqueisnotcorrect replacethenutswithnewnutsofsamespecification Instal...

Page 117: ...eck ExtensionArmInternalSlidingRing ifequipped CheckWear Replace TurntableBoltTightening Check PlatformMountPinNuts Checktorque148ft lb 200Nm SERV 1sttimeintervalthenperchartthereafter Atleastevery3monthsor1000hrs ofoperation Atleaseevery5yearsor2000hrsofoperation Checkevery year Iftorqueisnotcorrect replacethenutswithnewnutsofsamespecification Installdrywithoutusinggreaseoroiltospecifiedtorque SE...

Page 118: ...emove Fill Cap B slowly tank is pressurized at 2 1 PSI 15 bar l A B Lube Point s Fill Cap Capacity 6 34 gallons 24 liters Interval Check level daily Change every two years or 1200 hours of operation NOTE Hydraulic oil levels are to be checked with the machine in transport position while on a firm level and uniform surface Oil level must be half way in the level indicator Indicator A To add hydraul...

Page 119: ...achine on a firm level and uniform surface Raise the machine off the surface using the outriggers Measure distance A from the bottom of the roller to the inside of the rubber belt The rubber track tension is to be between 0 4inches 10mm and 0 6 inches 15mm A NOTE If the track is out of tolerance immediately discontinue use of the machine THE GREASE CONTAINED WITHIN THE HYDRAULIC TRACK IS PRESSURIZ...

Page 120: ...valve 7 Clean area of all trace grease Tightening of the track Connect a grease gun to grease valve 2 and add grease until belt tension is within the specified values NOTE If the track does not return to the specified values by following the above procedure immediately discon tinue use and contact service personnel Checking the rubber tracks If broken steel ropes are noted discontinue use until da...

Page 121: ...E TRACK BROKEN STUDS AND POS SIBLE DANGEROUS SEPARATION OF THE TRACK FROM THE TEETH Replacing Rubber Tracks 1 Elevate the machine on firm level and uniform sur face utilizing the outriggers 2 Remove the screws and remove cover 3 as shown in figure 3 To loosen the track slowly unscrew valve 1 in a counter clockwise direction Do NOT exceed one 1 rotation 4 Allow grease to drain If grease does not dr...

Page 122: ...and boom sections Distance is to be no more than 1 32nd inch Turntable Attach Bolts Ensure the bolts of the coupling elements turntable are torqued to 183 ft lb 248 Nm Battery Maintenance and Charging Diesel AC Electric NOTE The battery is a maintenance free battery Do NOT attempt to open a maintenance free sealed battery External Battery Charger Use WHEN AN EXTERNAL BATTERY CHARGER IS TO BE USED ...

Page 123: ...ENDS A MAXIMUM PRESSURE OF 750 PSI 52 BAR AT A MINIMUM DISTANCE OF 12 INCHES 30 5 CM AWAY FROM THESE COMPONENTS IF ELECTRICAL ELECTRONIC COMPONENTS ARE SPRAYED SPRAYING MUST NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURA TION 6 4 ELECTRIC MOTOR MAINTENANCE Periodically check the condition of the following electric motor components Electric Motor The electric motor is located ins...

Page 124: ...SSED Menu Input The signals that arrive at the board from the various sensors mounted on the machine and from the platform remote control commands are displayed The status of the input and the following selection to scroll the menu appears for each screen 1 PREV access the previous input 2 NEXT access the successive input 9 ESC escape from the INPUT menu LIGHTLIFTSELF PROPELLEDAERIALPLATFORM X700A...

Page 125: ...d onlyRussianversion TEMPALRM B GENERATOR ONorOFFdependingonwhether theengineisONorOFF EMERG COMM ONpositionindicatestheemergencybuttonsareactivated MICROROPES ONpositionindicatesbothcablesareworking STARTM TE ONpositionindicatestheenginestartbutton fromground is pressed MOTORTEMP OFFpositionwiththeenginerunningindicatesthealarmis activated MOTORPRESS ONpositionwiththeenginerunningindicatesthealar...

Page 126: ...e remote control display See Platform Remote Control Station Functions on page 3 9 If there are operating problems with the machine and the spanner icon is shown on the display do not operate machine until repaired by a JLG factory trained technician R C PLATFORM ONpositionindicatestheremotecontrolisinitsmount inthe platform INCLIN X IndicatestheinclinationofXaxisintenthsofadegree INCLIN Y Indicat...

Page 127: ...ance WHEN RECHARGING THE BATTERY PACK AND DURING ANY OTHER MAINTE NANCE OPERATION ON THE BATTERY PACK IT IS NECESSARY TO USE AT LEAST THE PERSONAL PROTECTIVE EQUIPMENT PPE LISTED BELOW Eye protection devices Protective glasses for protection against sprays of hazardous materials Hand protection devices Hand protection gloves for protection and insula tion during work on live parts Foot protection ...

Page 128: ...ions Ifproblempersists replaceinverter 18 LogicFailure 2 Cause Internalfaultintheinverter Solution Replaceinverter 19 Logicfailure 1 Cause Suddenvoltagesurgeorvoltagedrop Solution Thisisatemporaryproblemduetocertainworkingcondi tions Ifproblempersists replaceinverter 30 VMNlow Cause Inverterpowersupplyvoltageislowerthanbatteryvoltage or alternativelyincorrectconnectiontopositivebatterypole Solutio...

Page 129: ...nsorconnection Anomalymayalsohavebeen causedbyfaultwithbearing Table 6 12 Inverter Fault Codes CODE DESCRIPTION 73 ThermissensorKO Cause Signalfromtemperaturesensorgreaterthan4 95Voltsorless than0 1Volt Solution Thisisgenerallyatemporaryproblemduetocertainworking conditions Ifproblempersists replaceinverter 74 Drivershorted Cause Relaypowersupplyfault Solution Checkrelaypowersupply Thisisgenerally...

Page 130: ...E12 Fault on all temperature sensors A99E13 Temperature sensor fault A99E14 Earth connection fault A99E01 Incorrect system configuration A99E02 Incorrect voltage 79 Incorrectstart Cause Incorrectstartingprocedure Solution Checkelectricalconnections Thisisgenerallyatemporary problemduetocertainworkingconditions Ifproblempersists replace inverter 86 PedalwireKO Cause Solution Thisisgenerallyatempora...

Page 131: ... A99E07 No 12 V power supply A99E08 No 12 V power supply A99E09 High battery compartment temperature A99E15 Boot loader 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 RX error 2 A99E23 AD error A99E99 General error T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 132: ...Contactservicedept orchangeproduct 240 Digitalinputisopenandmanagedashardware start stop Batterychargerstopscharginguntildigitalinput closes Closedigitalinput 241 ProbleminCANBUScommunicationwithothersys temsinthenetwork Thewaythisismanagedmaychangebasedondif ferentfirmwarereleases CheckcorrectoperationofCANBUSsystem 242 Errorwhenreadinginternalmemoryonmicrocon troller Batterychargerstopsworking C...

Page 133: ...rislessthan 20 C batterychargerstopsworking Whenbattery temperaturefallsbelow45 Corexceeds 10 Cbat terychargerresumesnormaloperation 251 Powerfailuredetected Batterychargerstopssupplyingpower Operation resumesassoonasalarmconditionsarenolonger present Ifproblempersists checkbatterychargermains powersupply 252 Short circuitinbatterychargeroutput Batterychargerstopsworking Turnoffbatterychargerandre...

Page 134: ...re of a cell has risen considerably the first action is evacuation of per sonnel from the affected area The area has to be isolated and nobody can enter if not strictly necessary If possible before leaving the area the person who first identified the problem has to check if there is an external short circuit and resolve it as soon as possible After the short circuit has been resolved the cell will...

Page 135: ...ure For Handling Vented Cells In normal conditions a cell does not show leaks or venting however a cell may vent or release substances if the critical temperature is reached or if the protective glass metal seal breaks due to severe mechanical conditions The severity of the leak consequent to venting ranges from slight leak around the seal to a violent leak of substances through the vent In some c...

Page 136: ...bag with some baking soda and seal the bag 8 Absorb and collect the leaked electrolyte with absorbent material or baking soda 9 Place the absorbent material in a bag and seal it 10 Clean area with plenty of water 11 Dispose of hazardous material in accordance with the local legislation in force First Aid In The Event Of Contact With The Electrolyte EYES Immediately wash the eyes in abundant runnin...

Page 137: ... explosion proceed as follows 1 Evacuate personnel from the areas contaminated by smoke 2 Ventilate the rooms until the cell has been removed from the area and until the characteristic pungent odor has disappeared 3 Even if this is quite unlikely there may be fires as a consequence of the explosion The ways these emergencies are faced are described in the follow ing paragraph 4 The exploded cell m...

Page 138: ...rn in normal atmospheres In addition lithium reacts explosively with water to form hydrogen and the presence of small quantities 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 1832 F 1000 C In ad...

Page 139: ...tuation and the person who gave the alarm 4 Quarantine the area Air the rooms until the burn ing material has been removed from the area and the characteristic pungent odor has disappeared 5 Two members of the team enter the area with appropriate safety equipment NOTE Lithium melts at 356 F 180 C It becomes highly reactive and when it catches fire it may eject molten lithium particles For this rea...

Page 140: ...rea with plenty of water and keep cleaning with water and soap 17 Dispose of hazardous material in accordance with the local legislation in force First Aid In The Event Of Contact With The Electrolyte EYES Immediately wash the eyes in abundant running water for at least 15 minutes keeping the eyelids open and flushing the eye and back of the eyelid Immediately seek medical help SKIN Wash in cold w...

Page 141: ...INSPECTION AND REPAIR LOG 3121773 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerialNumber_________________________________ Date Comments T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 142: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 143: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

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