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JLG X500AJ, Operation And Safety Manual

The JLG X500AJ Operation and Safety Manual is an essential resource for users of this advanced aerial work platform. Available for free download on our website, this comprehensive manual provides detailed instructions and important safety guidelines, ensuring optimal performance and safe operation of the X500AJ.

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SECTION 5 - EMERGENCY PROCEDURES

3121636

– JLG Lift –

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Figure 5-2. Ground Control Station - with Enable Lever

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Summary of Contents for X500AJ

Page 1: ...eration and Safety Manual ANSI Original Instructions Keep this manual with the machine at all times Model s X500AJ 3121636 June 29 2018 Rev F 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: ... 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 BACK GROUND INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTEC TION OF PROPERTY This is the Safety Alert Symbol It is used to alert you to the po...

Page 6: ...S HAVE BEEN INVOLVED IN AN ACCI DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office See addresses on inside of manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside USA...

Page 7: ...REVISION LOG Original Issue A 05 07 2014 Revised B 07 08 2015 Revised C January 22 2016 Revised D July 25 2016 Revised E March 16 2017 Revised F 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 7 Function Check 2 8 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 1 GROUND CONTROL STATION 3 3 Ground Control Station With Enable Lever 3 4 Ground Control Station With Enable Knob 3 7 3 2 PL...

Page 9: ...evel Adjustment 4 15 Raise And Lower The Tower Boom 4 17 Raise And Lower The Main Boom 4 17 Telescope The Main Boom 4 17 Platform Rotation 4 17 Raise And Lower The Jib 4 17 Swinging The Boom 4 17 SkyGuard Operation If Equipped 4 19 4 8 PLATFORM REMOVAL INSTALLATION 4 20 4 9 BATTERY CHARGING GAS AC ELECTRIC 4 21 Battery Charging Daily 4 21 4 10 BATTERY CHARGING LITHIUM ION MACHINE 4 22 Charging the...

Page 10: ...hium Ion Specifications 6 4 Machine Major Component Weights 6 5 Performance 6 5 6 3 SERVICE MAINTENANCE 6 6 Lubrication 6 7 Hydraulic Oil Specifications 6 8 Rubber Track Maintenance Replacement 6 14 Wear Pad Inspection 6 17 Turntable Attach Bolts 6 17 Battery Maintenance and Charging Gas AC Electric 6 18 6 4 ELECTRIC MOTOR MAINTENANCE 6 19 Electric Motor 6 19 6 5 PLATFORM REMOTE CONTROL SERVICE ME...

Page 11: ... with Enable Lever 3 6 3 5 Ground Control Station 3 9 3 6 Platform Remote Control Station 3 15 4 1 Ground Emergency Control Box 4 2 4 2 Ground Emergency Control Box Lithium Ion 4 5 4 3 Grade and Side Slope Definition 4 9 4 4 Platform Remote Control Box 4 16 4 5 Platform Load Reach Chart X500AJ 4 18 4 6 SkyGuard Sensor and Override Switch Location 4 19 4 7 Lifting Machine Lifting Rings Location 4 2...

Page 12: ... X500AJ Lithium Ion Machine 6 11 6 6 Example of Lithium Ion Battery Pack Components 6 34 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 and Maintenance Table 2 3 3 1 LCD Display Icon Descriptions 3 20 3 2 LCD Display Error Descriptions 3 22 4 1 SkyGuard Function Table 4 19 4 2 X500AJ Decal Installation Standard 4 33 4 3 X500AJ Decal...

Page 13: ...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 14: ...eration 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 Indu...

Page 15: ... 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 16: ... 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 t...

Page 17: ... 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 18: ...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 19: ...arded These barriers shall not be part of or attached to the machine The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating bar rier This determination shall be made by a qualified person in accordance with the employer local or governmental requirements for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL I...

Page 20: ... 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 21: ...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 22: ... 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 23: ...anual 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 maintenance 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 24: ... 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 o...

Page 25: ...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 26: ...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 27: ...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 28: ...platforms The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hos tile environment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECH NICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SER VICE TRAINING SCHOOL FOR THE SPECIFIC ...

Page 29: ...rs whichevercomes first or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer or User QualifiedJLGMechanic ServiceandMaintenanceMan ualandapplicableJLGinspec tionform AnnualMachineInspection Annually nolaterthan13monthsfromthedateof priorinspection Owner Dealer or User FactoryTrained ServiceTechnician Recommended ServiceandMaintenanceMan ualandapplicableJLGinspec tionform Preven...

Page 30: ...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 31: ...LEM TO THE PROPER MAIN TENANCE PERSONNEL 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 32: ...SECTION 2 PREPARATION AND INSPECTION 2 6 JLG Lift 3121636 2 3 4 4 4 4 5 6 7 8 9 10 11 1 Figure 2 1 Daily Walk Around Inspection 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: ...lides up and down properly platform properly installed and with both caps screwed on See Inspection Note 2 Platform Remote Control Station Switches and levers return to neutral decals placards secure and legible control markings legible 3 Platform Rotator Machine Bubble Level See Inspection Note 4 Outriggers See Inspection Note pads pivot freely 5 Electrical Components Cover Assembly See Inspectio...

Page 34: ...om 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 emergency lowering controls 3 SkyGuard Function Test If Equipped a From the platform controls test the SkyGuard fea ture by setting up machine and operating the tele sco...

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: ...RATION 3121636 JLG Lift 3 1 SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Figure 3 1 Basic Machine Nomenclature Right Side View 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: ...age 8 Turntable 9 Hand Pump Right Side of Machine 10 Hydraulic Oil tank Right Side of Machine 11 Electric Motor 12 Track and Outrigger Valves Manual Controls Under Cover 13 Jib 14 Platform Ladder 15 Platform 16 Manuals Compartment In Platform 17 Platform Remote Control Station 18 Lithium ION Battery Charger LED Indicator 19 Lithium ION Battery Pack Inverter and Battery Charger Compartment 20 SkyGu...

Page 38: ...ion Enable Lever on the left side of the valve set See Ground Control Station With Enable Lever on page 4 If your ground control station looks like this with the BLACK Function Enable Knob on the right side of the valve set See Ground Control Station With Enable Knob on page 7 Figure 3 2 See Ground Control Station With Enable Lever on page 4 Figure 3 3 See Ground Control Station With Enable Knob o...

Page 39: ...hen pushed in off 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 an...

Page 40: ... of the turntable boom assembly 8 Tower Boom Lift Control Provides raising and lowering of the tower boom section 9 Main Boom Lift Control Provides raising and lowering of the main boom section 10 Main Boom Telescope Control Provides extension and retraction of the main boom section 11 Jib Lift Provides raising and lowering of the jib arms 12 Platform Rotate Control Provides rotation of the platfo...

Page 41: ...E CONTROLS INDICATORS AND OPERATION 3 6 JLG Lift 3121636 Figure 3 4 Ground Control Station with Enable Lever 7 8 9 10 11 12 13 6 1 3 2 4 5 7 8 9 10 11 12 13 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 42: ...d controls are operational With the switch turned counter clockwise the plat form remote control box may be connected to the ground maintenance cable port located in the electrical components compartment and operated from the ground Engine Start Buttons see Figure 3 5 To start the engine at the ground control the select switch item 2 must be in place and in the center neutral position The engine s...

Page 43: ... of the jib arms 7 Telescope Control Provides extension and retraction of the main boom section 8 Main Boom Lift Control Provides raising and lowering of the main boom section 9 Tower Boom Lift Control Provides raising and lowering of the tower boom section 10 Swing Control Provides swing to the left or right of the turntable boom assembly 11 Hydraulic Manual Control Valve Enable Knob This knob us...

Page 44: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121636 JLG Lift 3 9 Figure 3 5 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 45: ...gine must be in the OFF position 1 Disconnect and remove the platform remote con trol station from the platform storage box 2 Disconnect the platform flex cable from the plat form remote control station NOTE Before connecting the special adapter plug ensure there is no moisture in the electrical connectors at any time 3 The special adapter supplied with the optional service cable must be attached ...

Page 46: ... there must be no load in the platform and boom must be in the stowed aligned position From this control position walking along side or behind the machine the operator IS NOT enabled to control the aerial part of the machine but only the tracks stabilizers and track extension function WHEN CONTROLLING THE MACHINE FROM THE GROUND POSITION KEEP A DISTANCE OF AT LEAST 3 FT 1 M FROM THE TRACKS ALWAYS ...

Page 47: ...r into the storage box and secure the left side of the control station by turning the thumbscrew on the locking tab clockwise locking the rib of the control station under the rotating metal tab of the thumbscrew 4 To remove the control station assembly reverse the three steps above NOTE The Platform Remote control box may also be used to operate the tracks outriggers and track widening if equipped...

Page 48: ...ton 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 This button ...

Page 49: ...shut off to the platform and ground controls 11 Gas Engine Starter This button allows the operator to start or stop the gas engine 12 Electric Engine Start This button allows the operator to start or stop the electric engine 13 Platform Level Key Switch The control allows the operator to adjust the level of the platform up or down 14 Display The display shows the status of the machine and operatin...

Page 50: ...NTROLS INDICATORS AND OPERATION 3121636 JLG Lift 3 15 Figure 3 6 Platform Remote Control Station 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 22 23 14 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: ...ct the main boom 19 Platform Rotate This switch allows the operator to rotate the plat form to the right or left 20 Jib This control allows the operator to raise and lower the jib 21 Swing This control allows the operator to swing the boom assembly to the right or left 22 Right Side Track Drive And Steer This control when moved forward or rearward simultaneously with the left side track control 15...

Page 52: ...ght 8 display positions which indicate machine status during various stages of operation 1 2 3 4 5 6 7 8 Position1 NotUsed Position2 NotUsed Position3 Displays the selected engine gas or elec tric and whether it is on or off The X on the icon indicates the engine is off Position4 Displays the selected engine speed 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 T o o r d e r g o t ...

Page 53: ...his symbol below is present No symbol indicates these functions are not operational Drive and steer are operational if all 4 outriggers are not contacting the ground 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 Position7 Can indicate any of the following situations An emergency stop is pushed in off A low battery The batteries need charged by running the gas engine or connecting to a power source CANBUS commun...

Page 54: ...OPERATION 3121636 JLG Lift 3 19 Position8 Indicates that emergency lowering has been selected Lithium ION Battery Charge Status Lithium ION Battery Charger Plugged In 1 2 3 4 5 6 7 8 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 55: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 20 JLG Lift 3121636 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 56: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3121636 JLG Lift 3 21 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 57: ...SECTION 3 MACHINE CONTROLS INDICATORS AND OPERATION 3 22 JLG Lift 3121636 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 58: ...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 59: ...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 60: ...tenance manual 1 Set the key at the Ground Emergency Control box in the neutral vertical position then push the appropriate ENGINE START switch until engine starts NOTE Allow gas engine to warm up for a few minutes at low speed before applying any load If starting from the platform press the engine pre heat button Item 23 Figure 4 4 Figure 4 1 Ground Emergency Control Box 1 Platform Remote Center ...

Page 61: ...ICAL CIRCUIT BEING USED IS THE SAME VOLTAGE AND FREQUENCY INDICATED ON THE ELECTRIC ENGINE PLATE USE AN AC EXTENSION CORD WITH SUFFICIENT AMPERAGE CAPACITY TO PROP ERLY POWER THE MACHINE CHECK THE EFFICIENCY OF THE GROUND ON THE AC CIRCUIT IF THE CIR CUIT IS NOT GROUNDED INSERT A GROUND DISCHARGER TO GROUND AND CONNECT IT TO THE GROUND CLAMP ON THE MACHINE ITEM 3 SEE PHOTO 1 Before connecting the ...

Page 62: ... oil circulates and reaches at least 50 F 10 C before operating the plat form Electric Engine Starting Procedure LITHIUM ION Machine 1 Set the ON OFF switch on the lithium ion battery pack to the ON position 0 symbol is OFF 1 is ON 2 The electric engine will auto start when a function is activated at the platform or ground control sta tion 3 Switch the ON OFF switch on the lithium ion bat tery pac...

Page 63: ...ntrol Box Lithium Ion 1 Platform Remote Center Platform Position 2 GroundControlPosition Turn ClockWise and Hold 3 Platform Remote Ground Maintenance Position Turned CounterClockWise 4 Function Enable Indicator 1 3 2 4 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 64: ... the turntable is aligned with the base see photos When these conditions are met this symbol will display in position 6 on the Platform Remote Control LCD display UNLESS THESE CONDITIONS ARE MET DRIVE STEER TRACK WIDTH ADJUSTMENT AND OUT RIGGER MOVEMENT IS PREVENTED Base Boom Alignment Visual Indicator Boom Jib and Base Alignment Reflectors Photocells T o o r d e r g o t o D i s c o u n t E q u i ...

Page 65: ...TACLE CHECK FOR CURBS LARGE STONES OR OTHER TERRAIN OBSTACLES INCLUDING OVERHEAD OBSTACLES AS THE MACHINE WILL MAKE UNCONTROLLED PIVOTING MOTIONS WHEN THE CENTER OF GRAV ITY CENTER OF TRACK FRAME SHIFTS OVER AN EDGE SLOW DOWN TO MINIMIZE ACCELERATION DURING PIVOTING MOVEMENT USE EXTREME CAUTION WHEN DRIVING IN REVERSE To drive straight forward or reverse move the control lers for both tracks at th...

Page 66: ...tion is activate the movement override pressing button 8 on platform remote control displays TRACK ON allowing 8 seconds of drive time with each press of the override button and reposition the machine to a safer condition reducing the inclination It is absolutely forbidden to increase the inclination of the machine as it could cause machine tipping with consequent danger for operator or people nea...

Page 67: ...SECTION 4 MACHINE OPERATION 3121636 JLG Lift 4 9 Figure 4 3 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 68: ...sition 5 on the remote control display panel Before lifting the jib arm in the traversing phase the following conditions must be verified All outriggers must be lifted from the ground There must be no operator in the basket 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...

Page 69: ...IGGER PADS ON INCLINED VER TICAL OR SLIPPERY SURFACES THE OUTRIGGERS WILL NOT OPERATE UNLESS THE BOOM AND JIB ARE COMPLETELY LOWERED RETRACTED AND ALIGNED WITH THE BASE NOTE The base and boom jib must be aligned and stowed before this function will operate see Section 4 4 BASE AND BOOM JIB ALIGNMENT If one of the outriggers does not come into contact with the ground while being set the engine will...

Page 70: ...properly ST2 if OK outrigger 2 is set properly ST3 if OK outrigger 3 is set properly ST4 if OK outrigger 4 is set properly INCL if OK the machine is set up on an accepted slope LOAD if OK the load in the platform is acceptable PLATFORM if OK the platform remote control box is in the proper location in the platform PEDAL If OK the footswitch is correctly depressed AUTOST when using the auto stabili...

Page 71: ... outriggers are set properly and the unit is level Note To cycle back to outrigger auto set mode press button 2 item 2 until the LCD display shows the normal operating icons CHECK THE BUBBLE LEVEL TO CONFIRM UNIT IS LEVEL BUBBLE IS COM PLETELY IN THE 1 GREEN CENTER AREA AND THAT THE TRACKS ARE OFF THE GROUND BEFORE OPERATING THE BOOM FUNCTIONS IF THE BUBBLE IN THE LEVEL IS NOT IN THE GREEN AREA AF...

Page 72: ...6 in 40 cm off the ground when the ladder is lowered when setting the machine on outriggers from the ground position lower the outriggers until the ladder is less than 16 in 40 cm off the ground Then enter the platform to properly set the machine up on outriggers Retracting The Outriggers Reference Figure 4 4 for item numbers Either Press and hold button no 1 item 1 of the remote control The 4 out...

Page 73: ...isplay and the alarm sounds To restore the boom functions it is necessary to remove the extra load TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE YOUR FOOT FROM THE FOOT SWITCH AND OR USE EMERGENCY ...

Page 74: ...N 4 MACHINE OPERATION 4 16 JLG Lift 3121636 Figure 4 4 Platform Remote Control Box 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 22 23 14 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 75: ...ch and move the controller backward To retract the main boom depress the foot switch and move the controller forward Platform Rotation Item19 Figure4 4 To rotate the platform to the right depress the foot switch and move the controller forward To rotate the platform to the left depress the footswitch and move the controller backwards Raise And Lower The Jib Item20 Figure4 4 To raise the jib depres...

Page 76: ...SECTION 4 MACHINE OPERATION 4 18 JLG Lift 3121636 Figure 4 5 Platform Load Reach Chart X500AJ 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 77: ... 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 SkyGuard Sensor 2 SkyGuard Override Switch button number 8 Figure 4 6 SkyGuard Sensor and Override Switch Location 1 2 Table 4 1 SkyGuard Function Table Main Lift Up Main Lift Dn Main Tele In M...

Page 78: ...aluminum caps that secure the platform to the jib platform mounting posts 3 Lift the platform off the mounting posts in an upward direction Place platform aside for later installation Platform Installation 1 Lift the platform and align the platform mounts with the jib mounting posts and lower until seated 2 Secure the platform to the jib mounting posts with the aluminum threaded caps Do not overti...

Page 79: ...reaking 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 Charging Daily BEFORE CONNECTING THE BUILT IN CHARGER TO THE RECEPTACLE ENSURE THE KEY ON THE ENGINE IS POSITIONED TO OFF The machine has a built in battery charger To activate this feature connect the machine to an...

Page 80: ...it in order to consider the recharge phase completed If the machine is powered on while charging the LCD display on the platform control sta tion also shows the machine charge indica tor Charging the Battery Pack DO NOT LEAVE THE MACHINE IN CONTINUOUS CHARGING FOR TIME PERIODS EXCEEDING 24 HOURS REMEMBER THE CHARGE WORKS EVEN IF THE ELECTRONIC BOARD OF THE MACHINE IS TURNED OFF SO THE BATTERIES CA...

Page 81: ... play To start charging the battery connect the main AC power supply to the AC socket item 1 photo located on the right rear of the machine next to the electric engine After a few seconds the charge indicator item 2 photo located on the right hand side of the machine on the lith ium ion battery pack turns red meaning the battery has started charging 1 2 T o o r d e r g o t o D i s c o u n t E q u ...

Page 82: ...d which can only be plugged into an grounded socket If the plug does not go into the socket most probably the socket is old and not grounded In this case contact an electrician to have the socket replaced Do not use adapters to resolve ungrounded circuit plug problems Ensure the power cable is undamaged If the cable is worn or damaged have it replaced immediately If extensions or multiple sockets ...

Page 83: ...mote control station used to start it Complete machine shut down will take approximately 1 minute LCD display OFF 5 At ground and platform controls push in the emergency stop buttons and remove the key at the ground controls Turn off the engine and remove the key 6 Close the platform control console lid If necessary to protect instruction placards warning decals and operating controls from hostile...

Page 84: ...ine 3 Lift machine using only the lifting rings provided on the end of the outrigger arm at the outrigger pad 4 Properly adjust the rigging to prevent damage to the machine and so the machine remains level and balanced TO LIFT THE MACHINE A SEPARATE WIRE ROPE CHAIN SLING MUST BE ATTACHED TO EACH OF THE 4 LIFTING RINGS USING THE APPROPRIATE LIFTING POINTS AS INDICATED IN FIGURE 4 7 OTHERWISE THE MA...

Page 85: ...ight of machine refer to the serial number tag or weigh the individual unit to find out the gross vehicle weight 2 Configure the machine in the transport position a place the booms in the stowed position and properly aligned b all outriggers are fully retracted c tracks are fully widened d Remove all loose items from the machine 3 Adjust forks of fork lift to the proper width for the lifting pocke...

Page 86: ... a truck trailer It is recommended to load unload the machine using the remote control while keeping away from the machine keeping a MINIMUM distance of 3 feet 1m Park the truck trailer on a flat surface Make sure that the ramps do not exceed the maximum inclination of 15 Make sure that the ramps and the trailer have the capac ity to support the machine and are free from debris or slippery materia...

Page 87: ... WHEN TRANSPORTING THE MACHINE THE BOOM MUST BE FULLY LOW ERED INTO THE BOOM REST Travel up ramps with the platform behind the machine Do not contact the ground with the jib or bottom of platform when loading unloading Operate the machine from the ground remote position and raise the jib to prevent contact with the ground See Jib Position for Travelling on page 4 10 ALWAYS load unload the machine ...

Page 88: ...RATION 4 30 JLG Lift 3121636 Figure 4 9 Machine Tie Down Points both sides of machine 1 Tie Down Loop 2 Tie Down Decal 1 1 2 2 1703814A 1703814A 1701499 1701499 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: ...SECTION 4 MACHINE OPERATION 3121636 JLG Lift 4 31 4 13 MACHINE DECALS Figure 4 10 Decal installation Standard Left Side 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 90: ...SECTION 4 MACHINE OPERATION 4 32 JLG Lift 3121636 Figure 4 11 Decal Installation Standard Right Side 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 91: ...p 7 06040500 Decal ForwardDirectArrow 8 1701640 Decal ReadTheManual 9 1703814 Decal Tie DownAnchor 10 07071200 Decal LiftingLug 11 1704277 Decal PlatformLanyardAttachPoint 12 07506500 Decal EmergencyStop 13 07056700 Decal NotALiftingPoint 14 1701499 Decal DoNotLiftFromThisAnchorPoint 15 06706500 Decal PlatformAlignment 16 06998800 Decal PlatformManualDiverterPump 17 07242000 Decal RemoteControl 3 ...

Page 92: ...cal CrushingDanger 30 1706387 Decal CrushingDanger 31 1706099 Decal CrushingDanger 32 1702868 Decal CrushingDanger Hand 33 07056200 Decal CrushingDanger LowerLimb 34 1706386 Decal DangerWhileLowering 35 07051100 Decal DangerofFalling ReplacePin 36 07051000 Decal DangerofFalling UnlockOnlyWhenAllowed 37 1706133 Decal DangerofTilting 38 07058600 Decal StabilizerPositioning 39 07045300 Decal GroundCo...

Page 93: ...706135 Decal PlatformUse 51 07056400 Decal Danger 120V 60Hz 52 07056300 Decal Danger 220V 50 60Hz 53 072422GB Decal EmergencyDescentInstructions 54 072423GB Decal MaximumPlatformCapacity X500AJ 55 072424GB Decal DistributorValveGroundControl Side 56 072425GB Decal DistributorValveGroundControls Rear LeftSide 57 072426GB Decal DistributorValveGroundControls Rear RightSide Table 4 2 X500AJ Decal Ins...

Page 94: ...SECTION 4 MACHINE OPERATION 4 36 JLG Lift 3121636 Figure 4 12 Decal installation Lithium Ion Left Side 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 95: ...SECTION 4 MACHINE OPERATION 3121636 JLG Lift 4 37 Figure 4 13 Decal Installation Lithium Ion Right Side 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: ...0 Decal Danger Batteries 2 1001125483 Decal DoNotPressureWash 3 06506400 Decal On OffPowerSwitch LithiumIonEngine 4 06520600 Decal Sound 88dB 5 07107100 Decal RechargeBatteriesAfterEachUseorAtLeastEvery3Months 6 172241GB Decal EmergencyDescentInstructions X500AJ Lithium Ion 7 07394800 Decal BatteryChargingLEDIndicator 48VBattery 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 97: ...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 98: ...in 48 hours of such an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 10 FT 3M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 5 3 EMERGENCY OPERATION P...

Page 99: ... and close which operate various solenoids and relays on the hydraulic system In the event either or both are not operating properly the following procedures will allow the low ering of the boom and platform Manual Descent with Engine Running and Electrical Power ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVER HEAD OF PERSONNEL BEFORE LOWERING Using Platform Remote Control Box from Platf...

Page 100: ... EMERGENCY PROCEDURES 3121636 JLG Lift 5 3 Figure 5 1 Platform Remote Control Station 1 2 3 4 5 6 7 8 9 10 11 12 13 15 16 17 18 19 20 21 22 22 23 14 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 101: ...mergency Ground Control box turn the key switch item 2 all the way clockwise and hold 4 Check that the green machine stabilized indicator light item 4 on the Emergency Ground Control box is on 5 Operate the appropriate manual control lever item 5 6 7 or 8 next to it s proportional valve under the cover of the valve distributor See decal on valve distributor cover for boom component and direction t...

Page 102: ...N 5 EMERGENCY PROCEDURES 3121636 JLG Lift 5 5 Figure 5 2 Ground Control Station with Enable Lever 7 8 9 10 11 12 13 6 1 3 2 4 5 7 8 9 10 11 12 13 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 103: ...SECTION 5 EMERGENCY PROCEDURES 5 6 JLG Lift 3121636 Figure 5 3 Ground Control Station Boom Control Valves 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 104: ...gency Procedure on page 5 10 NOTE The distributor enable valve item 12 adjusts the speed of the boom movements pressure flow when using the boom control valves at the valve distributor on the left side of the machine in Figure 5 3 Without electrical power you must manually open this valve by pressing it in before operating the boom controls 3 Always carry out movement at the slowest possi ble spee...

Page 105: ... hydraulic pump handle secured to the top cover above the outrig ger track ground control proportional valve groups at the rear of the machine 3 Install the pump handle on the hydraulic pump item 1 Figure 5 4 and secure in place with the provided screw 4 The manual pump lever item 2 Figure 5 4 on the pump must be Turned to the left for right side outrigger track and boom functions See Figure 5 5 T...

Page 106: ... and eliminate the risk of lowering the jib onto an outrigger a Depress the enable valve lever button See Fig ure 5 2 or Figure 5 3 b Activate the swing control lever item 11 Figure 5 3 on page 5 6 in the desired direction of travel while pumping the hand pump until the turntable is aligned with the chassis c Activating the lever up while pumping will swing the platform to the clockwise d Activati...

Page 107: ...he outrigger track valve cover at the rear of the machine Outrigger Track Movement Emergency Procedure Outrigger Track Movement Using the Hydraulic Hand Pump on Right Side of Machine PLACE THE MACHINE INTO TRANSPORT CONFIGURATION ONLY AFTER HAVING ALIGNED AND FULLY LOWERED AND RETRACTED THE BOOM AND JIB WHEN RETRACTING THE OUTRIGGERS THE MACHINE CAN BECOME UNBALANCED IF ONE OR MORE OUTRIGGERS ARE ...

Page 108: ...alves item 1 Figure 5 6 Push and hold the black knob before activating any function lever 6 The lever on the hydraulic hand pump item 2 Fig ure 5 4 must be turned to right to manually pro vide pressure to operate left side outrigger and track functions 7 With the aid of an assistant activate the lever up or down for the desired direction on the appropriate valve solenoid while pumping the handle t...

Page 109: ...to operate right side outrigger and track functions 10 With the aid of an assistant activate the lever for the desired direction on the appropriate valve solenoid valve description below while pumping the pump handle to achieve the desired function movement 1st valve item 7 Figure 5 6 far right right side of machine in the group of three operates Right Rear Outrigger 2nd valve item 8 Figure 5 6 fr...

Page 110: ...TION 5 EMERGENCY PROCEDURES 3121636 JLG Lift 5 13 Figure 5 6 Ground Component Valves Outriggers Track Control Location 1 2 3 1 2 3 4 5 7 8 9 6 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 111: ...witch item 2 photo Turn the key to the LEFT for boom operations Turn the key to the right for TRACK operations After using the safety device bypass a qualified JLG mechanic must be contacted to determine the reason required 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 a...

Page 112: ...emergency manual operations to bring the platform back to the ground 1 Locate and use the safety device bypass key as stated above 2 Activate the safety device bypass by turning the 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...

Page 113: ...con trol box 6 Once the machine is aligned release the key and store it as stated above Movement Of The Tracks With The Machine Not Aligned OPERATION ONLY ALLOWED TO GO TO A CONDITION SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN MACHINE REALIGNMENT ABOVE ALL OTHER USE IS PROHIBITED 1 Open the electric components compartment 2 Locate and use the safety device bypass key as described above 3 Act...

Page 114: ...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 115: ...Maintenance and Inspection Schedule included in the Service and Maintenance Manual IT IS GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELEC TRONIC COMPONENTS IN THE EVENT PRESSURE WASHING THE MACHINE IS NEEDED ENSURE MACHINE IS SHUT DOWN BEFORE PRES SURE WASHING IF PRESSURE WASHING IS USED TO WASH AREAS CON TAINING ELECTRICAL ELECTRONIC COMPONENTS JLG INDUSTRIES INC RECOMMENDS A MAXIMUM PRESS...

Page 116: ... 230kg Max VerticalPlatformHeight 49 08ft 14 96m Max HorizontalPlatformReach 24 60ft 7 5m Table 6 2 Dimensional Data Model X500AJ OverallWidth Platformremoved tracksretracted 31 41in 7 98cm OutriggersDeployedWidth 9 47ftx9 46ft 2 88mx2 88m StowedHeight 6ft5in 1 99m StowedLength 14ft85in 4 53m ApproachanglewithJiblowered 20 Departureangle 21 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...

Page 117: ... 1 8km hr Maxdrivespeed GasEngine w Opt 2ndSpeed 0 43mph 0 7km hr 1 11mph 1 8km hr 2 23mph 3 6km hr Maxhydraulicsystempressure Track Outrigger Boom 2 393psi 165bar 2 683psi 185bar Maximumwindspeed 28mph 12 5m s Maximummanualforce 90lb 400N Electricalsystemvoltage Charger PlatformReceptacle AC GasolineEngine StarterBattery System DC Lithium IonBatteryPack ElectricMotor 120V 12V 48V Grossmachineweig...

Page 118: ...rypack Ratedvoltageofeachcell Max cellvoltage Min cellvoltage Featuresofcompletepack Chargecycles Cathode Anode Memoryeffect 15cells 3 2volt 3 65volt 2 5volt 48volt 90Amp hr 2000cycles LithiumIonPhosphate LiFePO4 Graphite NO BatteryCharger Type Necessarytimetorecharge 120V 10 50 60Hz 8hrstoBalance 4hrsto80 ofrecharge ElectricSystem 48voltforthebatteries 12voltfor machine ElectricMotor 48volt three...

Page 119: ...inder Liftcylinder Upperliftcylinder SwingActuator Telescopecylinder 16 5lb 7 5kg 24 3lb 11kg 16 5lb 7 5kg 77lb 35kg 77lb 35kg 144lb 20kg 88lb 40kg Platforms 2occupant 110 2lb 50kg Chassis 2 368lb 1074kg Table 6 8 Function Speeds FUNCTION X500AJ TIME SECONDS Telescope Extend Retract 15 20 16 22 TowerBoom Up Down 21 24 19 22 UpperBoom Up Down 25 29 24 30 BasketRotate Right Left 7 10 7 10 Swing Left...

Page 120: ...ICE MAINTENANCE Figure 6 1 Lubrication and Maintenance Point Locations 500 h 250 h 100 h 50 h 10 h G M M I I G T I I M ENGINE OIL TRANSMISSION OIL T I HYDRAULIC OIL G GREASE OR BEFORE WORK SHIFT OR EVERY WEEK WHICH COMES FIRST 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 121: ...cants Contact Grease EP blue in color be used to grease the turn table and cylinder pins on the chassis GR MU EP1 Grease be used to grease the expansion guide of the chassis the track tension valve and basket support pins White EP NLGI 2 Grease be used on the boom extensions Either MU EP1 or Esso Beacon EP2 be used to grease the coupler and belt tensioner Greasing Locations See Figure 6 1 NOTE Use...

Page 122: ...ne 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 46 145 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 123: ...SECTION 6 GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3121636 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 124: ...TED JOINT POINTS GREASE BATTERY CHECK ELECTROLYTE LEVEL REDUCTION GEAR OIL CHECK LEVEL CHANGE MACHINE GENERAL PERIODICAL CHECKS EXTENSION ARM INTERNAL SLIDING RING CHECK WEAR CHANGE TURNTABLE BOLT TIGHTENING CHECK First time service interval then per chart thereafter Every 3 months or 1000 hrs of operation Every 5 years or 2000 hrs of operation Check every year If the torque is not correct replace...

Page 125: ...EDUCTION GEAR OIL CHECK LEVEL CHANGE MACHINE GENERAL PERIODICAL CHECKS EXTENSION ARM INTERNAL SLIDING RING CHECK WEAR REPLACE TURNTABLE BOLT TIGHTENING CHECK LITHIUM ION MACHINE First time service interval then per chart thereafter Every 3 months or 1000 hrs of operation Every 5 years or 2000 hrs of operation Check every year If the torque is not correct replace the nuts with two new nuts of the s...

Page 126: ... washed out in warm soapy water then rinse and let dry Dip in clean engine oil and squeeze out the excess oil If too much oil is left in the foam the engine will smoke when started Engine Oil Lube Point s Fill Cap Dip Stick Tube Capacity Gasoline 0 3 gal 1 1L Diesel 0 39 gal 1 5 L Interval Check fill level on dipstick daily Do not overfill Change oil per maintenance interval chart Figure 6 4 Honda...

Page 127: ...ap Capacity 6 6 gallons 25 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 hydraulic oil use cap B Honda Gas A B 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...

Page 128: ...ine 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 NOTE If the track is out of tolerance immediately discontinue use of the machine THE GREASE CONTAINED WITHIN THE HYDRAULIC TRACK IS PRESSUR IZED N...

Page 129: ...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 130: ...KEN STUDS AND POSSIBLE 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 drain slowly r...

Page 131: ...e while using one steel pipe pushing the track plate inside the frame 4 Verify track links have engaged wheel teeth on the track tensioning wheel 5 Adjust track tension see Loosening Tightening track section Wear Pad Inspection Check distance between wear pads and boom sections Dis tance is to be no more than 1 32nd inch Turntable Attach Bolts Ensure bolts of the coupling elements turntable are to...

Page 132: ...hall be 0 2 of the value indicated below and on the lid of the battery 4 When charging is completed turn off the battery charger before disconnecting the cables from the battery poles 5 Return the terminal clamps to the battery poles and lubricate with the appropriate product 6 Close battery cover IT IS GOOD PRACTICE TO AVOID PRESSURE WASHING ELECTRICAL ELEC TRONIC COMPONENTS IN THE EVENT PRESSURE...

Page 133: ...over POWER SUPPLY TERMINALS Check tightness of the nuts on the power supply termi nals and make sure the insulation is intact FAN Keep air intakes clean and make sure fan can rotate freely BEARINGS Check condition of the bearings In the event of noise contact JLG for replacement Bearing life is reduced sig nificantly in heavy duty operating conditions NOTE This motor is brushless No brushes need t...

Page 134: ...s and is an aid in the safety checks of the machine By pressing the SERVICE button a numerical menu is dis played on the LCD display each of these menu items can be accessed by pressing the corresponding platform remote control buttons numbered 1 thru 9 below the buttons 1 INPUT 2 LANGUAGE 3 ERRORS 4 RAMPS 5 CURRENT 6 W HOURS 7 SETUP 8 JOYSTICK 9 EXIT MENUS 4 5 CANNOT BE ACCESSED T o o r d e r g o...

Page 135: ...line is closed OFF Outrigger N 1 lifted the switch is pressed and A line is opened ST1 GND B ON Outrigger N 1 on the ground the switch is released and B line is closed OFF Outrigger N 1 lifted the switch is pressed and B line is opened ST1 OPEN A ON Do not consider OFF Do not consider ST1 OPEN B ON Do not consider OFF Do not consider ST2 GND A ON Outrigger N 2 on the ground the switch is released ...

Page 136: ...d the switch is released and B line is closed OFF Outrigger N 3 lifted the switch is pressed and B line is opened ST3 OPEN A ON Do not consider OFF Do not consider ST3 OPEN B ON Do not consider OFF Do not consider ST4 GND A ON Outrigger N 4 on the ground the switch is released and A line is closed OFF Outrigger N 4 lifted the switch is pressed and A line is opened ST4 GND B ON Outrigger N 4 on the...

Page 137: ... the aerial part safeties by pass button is opened BYPASAE B ON The aerial part safeties are disconnected through the key button emergency condition B line of the aerial part safeties by pass button is closed OFF The aerial part safeties are connected normal working condition B line of the aerial part safeties by pass button is opened BYPASCB A ON The ground part safeties are disconnected through ...

Page 138: ...D B ON Emergency stop on the ground is released B line of the emergency stop is closed OFF Emergency stop on the ground is pressed B line of the emergency stop is opened FOTO A ON Photocell A receives the signal from the reflector Aerial part closed and aligned OFF Photocell A does not receive the signal from the reflector Aerial part opened FOTO B ON Photocell B receives the signal from the reflecto...

Page 139: ...t end run and the max pressure valve is opened OFF The pressure switch contact of outriggers 1 and 2 is opened the outriggers are open partially open or already closed ST34 CLOSED ON The pressure switch of outriggers 3 and 4 closes the contact the outriggers are at end run and the max pressure valve is opened OFF The pressure switch contact of outriggers 3 and 4 is opened the outriggers are open p...

Page 140: ...ches are pressed contact is closed OFF Tracks are not in full wide position Widening cylinders switches are released contact is open FREE Do not consider this signal EMRG COMM ON The control position key selector for aerial part operation from the ground is activated emergency condition OFF The control position key selector for aerial part operation is released normal working condition MICROROPES ...

Page 141: ...nadequate emergency condition engine turns off OFF The engine oil pressure is OK START M EL ON The ground button for electric motor start is pressed OFF The ground button for electric motor start is released GND BASKET ON The control position key selector is positioned on basket OFF The control position key selector is positioned on ground MICROJIB A ON The JIB is closed the control switch is rele...

Page 142: ...FF The stop button on remote control in basket is pressed or the ground remote control is disconnected A line is open EM BASK B ON The stop button on remote control in basket is released B line is closed OFF The stop button on remote control in basket is pressed or the ground remote control is disconnected B line is open POSM1 A ON Do not consider OFF Do not consider POSM1 B ON Do not consider OFF...

Page 143: ...consider OFF Do not consider POSM3 B ON Do not consider OFF Do not consider POSM4 A ON Do not consider OFF Do not consider POSM4 B ON Do not consider OFF Do not consider R C BASKET ON The remote control is in the support in basket OFF The remote control is not in the support in basket 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 144: ...tion of the machine on the Y axis in tenth of degrees accelerom eter A 0 Indicates the inclination of the machine on the Y axis in tenth of degrees accel B LOAD 94 Indicates the weight in Kg in the basket POS 1E2 0 Do not consider POS 3 2398 Indicates the opening of the 3 arm cylinder in tenths of a millimetre ROTATION A 180 Do not consider MOTOR RPM Diesel Only 2200 Indicate the engine RPM I di t...

Page 145: ...ENT B 45 3 Indicates in tenth of mA the current ECM1 2 is sending to the right side undercarriage proportional valve values less that 5 not relevant CURRENT C 0 Do not consider TEMPERAT 37 6 Indicates the temperature of the control module in C SUPPLY V 12 1 Indicates the batteries voltage or the output voltage from the battery charger BATTERY 100 Only for Lithium version indicates the level of cha...

Page 146: ...ent information The last page of the error menu describes the error code relating to the battery charger system inverter or battery pack See Lithium Ion Machine Fault Codes on page 6 36 Errors are indicated by the spanner icon in position 7 on the remote control display See Platform Remote Control Station LCD Dis play on page 3 17 If there are operating problems with the machine and the spanner ic...

Page 147: ... cleaned the more it will need to be re greased see lubrication chart Do not wet electric motors and other electrical compo nents directly Do not aim spray directly onto decals and rating plates Cleaning the electrical system NEVER CLEAN INVERTER OR ELECTRIC MOTOR WITH WATER THIS MAY DAMAGE THE ELECTRICAL SYSTEM Only use dry detergents in accordance with the manufacturers instructions Never remove...

Page 148: ...IFICATIONS AND OPERATOR MAINTENANCE 6 34 JLG Lift 3121636 Battery Pack System Components and Maintenance Figure 6 6 Example of Lithium Ion Battery Pack Components 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 149: ...ING 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 haz ardous materials Hand protection devices Hand protection gloves for protection and insulation during work on live parts Foot protection devices Shoes with an...

Page 150: ...erallyatemporaryproblemduetocertainworking conditions Ifproblempersists replaceinverter 18 LogicFailure 2 Cause Internalfaultintheinverter Solution Replaceinverter 19 Logicfailure 1 Cause Suddenvoltagesurgeorvoltagedrop Solution Thisisatemporaryproblemduetocertainworkingcondi tions Ifproblempersists replaceinverter 30 VMNlow Cause Inverterpowersupplyvoltageislowerthanbatteryvoltage or alternativel...

Page 151: ...singmultifunctiontester Table 6 10 Inverter Fault Codes CODE DESCRIPTION 70 EncoderError Cause Problemdetectedwithencoder motorspeedsensor Solution Checkspeedsensorconnection Anomalymayalsohavebeen causedbyfaultwithbearing 73 ThermissensorKO Cause Signalfromtemperaturesensorgreaterthan4 95Voltsorless than0 1Volt Solution Thisisgenerallyatemporaryproblemduetocertainworking conditions Ifproblempersi...

Page 152: ...wireKO Cause Solution Thisisgenerallyatemporaryproblemduetocertainworking conditions Ifproblempersists replaceinverter 93 Wrongsetbatt Cause Withpowerconnected batterytestdetectedincorrectbatteries fitted Solution Replacebatterieswiththeoriginalonessupplieddirectlyby JLG 94 CurrentsensorKO Cause Setupprocedureformaximumcurrentinprogress Solution ContactJLGafter salesservice Table 6 10 Inverter Fau...

Page 153: ...ompartment 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 A99E01 Incorrect system configuration A99E02 Incorrect voltage A99E03 Incorrect temperature A99E04 Excess discharge current A99E05 Excess charge current A99E06 Pre charge error A99E0...

Page 154: ... Contactservicedept orchangeproduct 240 Digitalinputisopenandmanagedashardware start stop Batterychargerstopscharginguntildigitalinput closes Closedigitalinput 241 ProbleminCANBUScommunicationwithothersys temsinthenetwork Thewaythisismanagedmaychangebasedondif ferentfirmwarereleases CheckcorrectoperationofCANBUSsystem 242 Errorwhenreadinginternalmemoryonmicrocon troller Batterychargerstopsworking ...

Page 155: ...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 156: ...perature of a cell has risen considerably the first action is the evacuation of personnel from the affected area The area has to be iso lated 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...

Page 157: ...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 158: ...ith some baking soda and seal the bag 8 Absorb and collect the leaked electrolyte with absor bent material or baking soda 9 Place the absorbent material in a bag and seal it 10 Clean the area with plenty of water 11 Dispose of the 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 ru...

Page 159: ...l 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 con sequence of the explosion The ways these emergen cies are faced are described in the following paragraph 4 The exploded cell may be hot Allow it to cool down to ambient tempe...

Page 160: ...y burn 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 extin guish with ordinary equipment This is partly due to the strong heat produced by the burning metal whose tem perature may reach 1832 F 1000 C...

Page 161: ... located and gather all the information regarding the situation and the person who gave the alarm 4 Quarantine the area Air the rooms until the burning material has been removed from the area and the char acteristic pungent odor has disappeared 5 Two members of the team enter the area with appro priate safety equipment NOTE Lithium melts at 356 F 180 C It becomes highly reactive and when it catche...

Page 162: ... seal it 16 Clean the area 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 h...

Page 163: ...INSPECTION AND REPAIR LOG 3121636 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 164: ...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 165: ...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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