ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X500AJ
P/N - 3121636
05-07-2014
NOTES:
SECTION - FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, 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.
3121636 – JLG Lift – a
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED,
WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A
RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED,
COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE
AN ORANGE BACKGROUND.
b – JLG Lift – 3121636
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 INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS.
CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS
WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND
ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN
SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE
JLG PRODUCT.
For :
• Accident Reporting
•Product Safety Publications
•Current Owner
Updates
• Questions Regarding
Product Safety
• Standards and Regulations Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding
Product Modifications
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)
3121636 – JLG Lift – c
Outside USA:
Phone: 240-420-2661
E-mail: ProductSafety@JLG.com
SECTION - REVISION LOG
Original Issue of Manual. . . . . . . . . . . . . . . . . . . . . 05-07-2014
REVISION LOG
d – JLG Lift – 3121636
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B
Contact: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . .1-1
1.2 BEFORE OPERATING THE LIFT . . . . . . . . . . . . . . . . . . . 1-2
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards. . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
Crushing and Collision Hazards. . . . . . . . . . . . . . . . 1-8
1.4 LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
1.5 ADDITIONAL HAZARDS / SAFETY. . . . . . . . . . . . . . . . 1-9
SECTION - 2 - PREPARATION AND INSPECTION
2.1 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
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND
OPERATION
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . .3-1
3.2 PLATFORM/REMOTE CONTROL STATION . . . . . . . . 3-4
Control Position On The Ground: . . . . . . . . . . . . . . 3-4
Control Position From In The Platform: . . . . . . . .3-5
Platform/Remote Control Station Functions . . .3-6
Platform/Remote Control Station LCD . . . . . . . 3-10
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Gas Starting Procedure. . . . . . . . . . . . . . . . . . . . . . . .4-2
Gas Engine Shutdown Procedure. . . . . . . . . . . . . .4-3
Electric Engine Starting Procedure -
AC Voltage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
3121636 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Electric Engine Starting Procedure -
LITHIUM-ION Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . . . . 4-6
4.5 TRACKS - DRIVING, STEERING AND
TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Track width adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Grades and Side Slopes) . . . . . . . . . . . 4-7
Jib Position for Travelling . . . . . . . . . . . . . . . . . . . . 4-10
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . . . . .4-11
Setting Outriggers From the Platform/
Remote Console. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Retracting The Outriggers . . . . . . . . . . . . . . . . . . .4-14
4.7 BOOM/PLATFORM OPERATION . . . . . . . . . . . . . . . . 4-15
Overload Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Engine Pre-Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
Platform Level 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
4.8 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . . 4-19
4.9 BATTERY CHARGING - GAS/AC-ELECTRIC . . . . . . .4-20
Battery Charging - Daily. . . . . . . . . . . . . . . . . . . . . . 4-20
4.10 BATTERY CHARGING - LITHIUM-ION MACHINE. . 4-21
Charging the Battery Pack . . . . . . . . . . . . . . . . . . . 4-21
Charge Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . .4-23
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . . 4-25
Lifting - Outrigger Lifting Rings . . . . . . . . . . . . . .4-25
Lifting - Fork Lift Pockets . . . . . . . . . . . . . . . . . . . . . 4-26
Loading and Unloading the Machine on
Transport Vehicles Using Ramps . . . . . . . . . . . . .4-27
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28
4.13 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-30
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
Power Main Cut-Off Switch Location . . . . . . . . . . 5-1
Operator Unable to Control Machine . . . . . . . . . . 5-2
Platform or Boom Caught Overhead. . . . . . . . . . . 5-2
Manual Descent with Engine Running and
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Manual Descent with Engine Running but
without Electrical Power(Combustion
Engines Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Manual Descent without Engine and
Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Outrigger/Track Movement
Emergency Procedure: . . . . . . . . . . . . . . . . . . . . . . . . 5-9
ii – JLG Lift – 3121636
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.4 SAFETY DEVICES BYPASS KEY USE . . . . . . . . . . . . . .5-13
Using The Emergency Descent In The Case
Of An Outrigger Losing Contact With The
Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14
Machine Realignment Emergency Procedure .5-15
5.5 LITHIUM-ION BATTERY PACK - HANDLING IN
DANGEROUS CONDITIONS. . . . . . . . . . . . . . . . . . . . .5-16
Procedure For Handling Hot Cells . . . . . . . . . . . .5-16
Procedure For Handling Vented Cells . . . . . . . . .5-17
Procedure For Exploded Cells . . . . . . . . . . . . . . . .5-19
Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . . . . .5-20
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . .6-2
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Lithium-Ion Specifications . . . . . . . . . . . . . . . . . . . .6-4
Machine Major Component Weights . . . . . . . . . . 6-5
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .6-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Rubber Track Maintenance/Replacement. . . . .6-12
Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . .6-15
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . . . 6-15
Battery Maintenance and Charging -
Gas/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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . . . 6-30
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-31
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . . 6-31
Battery Pack System Components and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Lithium-Ion Machine Fault Codes. . . . . . . . . . . . 6-34
BMS Fault Codes - (Battery Management
System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
Battery Charger Fault Codes. . . . . . . . . . . . . . . . . 6-38
SECTION - 7 - INSPECTION AND REPAIR LOG
3121636 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Basic Machine Nomenclature . . . . . . . . . . . . . . . . 2-6
2-2. Daily Walk-Around Inspection . . . . . . . . . . . . . . . 2-8
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Platform/Remote Control Station . . . . . . . . . . . . 3-9
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. Lifting Machine - Lifting Rings Location . . . . .4-25
4-7. Lifting Machine - Fork Lift Pockets Location . 4-26
4-8. Machine Tie-Down Points . . . . . . . . . . . . . . . . . . 4-29
4-9. Decal installation - Standard - Left Side . . . . .4-30
4-10. Decal Installation - Standard - Right Side . . . . 4-31
4-11. Decal installation - Lithium-Ion - Left Side . . .4-35
4-12. Decal Installation - Lithium-Ion - Right Side .4-36
5-1. Platform/Remote Control Station . . . . . . . . . . . . 5-3
5-2. Ground Control Station - Boom
Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
5-3. Hand Pump - On Top Of Hydraulic Tank. . . . . . 5-7
5-4. Hand Pump Decal -
On Top Of Hydraulic Tank . . . . . . . . . . . . . . . . . . . 5-7
5-5. Ground Component Valves -
Outriggers/Track Control - Location. . . . . . . . .5-12
6-1. Lubrication and Maintenance Point
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-2. Component Maintenance Intervals -
with Honda Engine. . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-3. Component Maintenance Intervals -
Lithium-Ion Machine . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-4. Example of Lithium-Ion Battery Pack
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32
iv – JLG Lift – 3121636
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . .1-5
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . .1-7
2-1 Inspection and Maintenance Table . . . . . . . . . . .2-3
3-1 LCD Display Icon Descriptions . . . . . . . . . . . . . . 3-12
3-2 LCD Display Error Descriptions . . . . . . . . . . . . . 3-14
4-1 X500AJ - Decal Installation - Standard. . . . . . . 4-32
4-2 X500AJ - Decal Installation - Lithium Ion . . . . 4-37
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . .6-2
6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
6-3 Chassis Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
6-5 Honda iGX440 Specifications . . . . . . . . . . . . . . . . .6-4
6-6 Lithium Ion Specifications . . . . . . . . . . . . . . . . . . . .6-4
6-7 Major Component Weights. . . . . . . . . . . . . . . . . . .6-5
6-8 Function Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
6-9 Hydraulic Oil Specifications. . . . . . . . . . . . . . . . . . . 6-7
6-10 Inverter Fault Codes. . . . . . . . . . . . . . . . . . . . . . . . 6-34
6-11 Battery Charger Fault Codes . . . . . . . . . . . . . . . . 6-38
3121636 – JLG Lift – v
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
NOTES:
vi – JLG Lift – 3121636
1.1 GENERAL
SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS
This section outlines the necessary precautions for
proper and safe machine usage and maintenance. It is
mandatory that a daily routine is established based on
the content of this manual to promote proper machine
usage. A maintenance program, using the information
provided in this manual and the Service and Maintenance Manual, must also be established by a qualified
person and must be followed to ensure that the
machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine
must not accept operating responsibility until this
manual has been read, training is accomplished, and
operation of the machine has been completed under
the supervision of an experienced and qualified operator.
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 Industries, Inc.
(“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY
DAMAGE, PERSONAL INJURY OR DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• The Operation and Safety Manual must be read and
understood in its entirety before operating the
machine. For clarification, questions, or additional
information regarding any portions of this manual,
contact JLG Industries, Inc.
3121636 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons.
• Allow only those authorized and qualified personnel
to operate the machine who have demonstrated
that they understand the safe and proper operation
and maintenance of the unit.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the
machine and in this manual.
• Ensure that the machine is to be used in a manner
which is within the scope of its intended application
as determined by JLG.
• All operating personnel must be familiar with the
emergency controls and emergency operation of
the machine as specified in this manual.
• Read, understand, and obey all applicable employer,
local, and governmental regulations as 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 operation of the machine.
• Do not operate or raise the platform from a position
on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless the application is
approved in writing by JLG.
• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other
potential overhead obstructions.
• Check operating surfaces for holes, bumps, dropoffs, obstructions, debris, concealed holes, and other
potential hazards.
• Check the work area for hazardous locations. Do not
operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Ensure that the ground conditions are adequate to
support the maximum outrigger load indicated on
the outrigger load decals located on the machine.
Do not travel on unsupported surfaces.
1-2 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS
Machine Inspection
• Do not operate this machine until the inspections
and functional checks as specified in Section 2 of
this manual have been performed.
• Do not operate this machine until it has been serviced and maintained according to the maintenance
and inspection requirements as specified in the
machine’s Service and Maintenance Manual.
• Ensure all safety devices are operating properly.
Modification of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM
THE MANUFACTURER.
• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.
• Check the machine for modifications to original
components. Ensure that any modifications have
been approved by JLG.
• Avoid 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 than
positioning personnel, their tools, and equipment.
• Before operation, the user must be familiar with the
machine capabilities and operating characteristics
of all functions.
• Never operate a malfunctioning machine. If a malfunction occurs, shut down the machine. Remove
the unit from service and notify the proper authorities.
• Do not remove, modify, or disable any safety
devices.
• Never slam a control switch or lever through neutral
to an opposite direction. Always return switch to
neutral and stop before moving the switch to the
next function. Operate controls with slow and even
pressure.
3121636 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Do not allow personnel to tamper with or operate
the machine from the ground with personnel in the
platform, except in an emergency.
• Do not carry materials directly on platform railing
unless approved by JLG.
• When two or more persons are in the platform, the
operator shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed
and never left hanging by their cord from the platform work area.
• When driving, always position boom over rear axle
in line with the direction of travel. Remember, if
boom is over the front axle, steer and drive functions
will be reversed.
• Do not assist a stuck or disabled machine by pushing or pulling except by pulling at the chassis tiedown lugs.
• Fully lower platform and shut off all power before
leaving machine.
• Remove all rings, watches, and jewelry when operating 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 physical control must not operate this machine.
Trip and Fall Hazards
• During operation, occupants in the platform must
wear a full body harness with a lanyard attached to
an authorized lanyard anchorage point. Attach only
one (1) lanyard per lanyard anchorage point..
• Enter and exit only through gate area. Use extreme
caution when entering or leaving platform. Ensure
that the platform assembly is fully lowered. Face the
machine when entering or leaving the platform.
Always maintain “three point contact” with the
machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.
1-4 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all gates
are closed and fastened in their proper position.
• Keep both feet firmly positioned on the platform
floor 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.
3121636 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
• Maintain distance from electrical lines, apparatus, or
any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as
shown in Table 1-1.
• Allow for machine movement and electrical line
swaying.
Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between
any part of the machine and its occupants, their
tools, and their equipment from any electrical line or
apparatus carrying up to 50,000 volts. One foot addi-
MINIMUM APPROACH DISTANCE
in Feet (Meters)
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 to) the machine. The minimum approach
distance shall be reduced to a distance within the
designed working dimensions of the insulating barrier. 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 INSIDE PROHIBITED ZONE
(MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED
UNLESS KNOWN OTHERWISE.
1-6 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS
Tipping Hazards
• The user must be familiar with the surface before
driving. Do not exceed the allowable sideslope and
grade while driving.
• Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. Ensure machine is positioned on a firm, level
and smooth surface before elevating platform or
driving with the platform in the elevated position.
• Before driving on floors, bridges, trucks, and other
surfaces, check allowable capacity of the surfaces.
• Do not raise the platform unless the machine is on
firm surfaces and outriggers are properly set.
• Never exceed the maximum work load as specified
on the platform. Keep all loads within the confines of
the platform, unless authorized by JLG.
• Keep the chassis and outriggers of the machine a
minimum of 2 ft. (0.6m) from holes, bumps, dropoffs, 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 conditions
exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).
• Do not increase the surface area of the platform or
the load. Increase of the area exposed to the wind
will decrease stability.
• Do not increase the platform size with unauthorized
deck extensions or attachments.
• If boom assembly or platform is in a position that
one or more outriggers are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other
appropriate equipment to stabilize machine.
3121636 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28
MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Flags waving near horizontal. Umbrella
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
1-8 – JLG Lift – 3121636
Wind Speed
Description Land Conditions
mph m/s
use becomes difficult.
SECTION 1 - SAFETY PRECAUTIONS
Crushing and Collision Hazards
• Approved head gear must be worn by all operating
and ground personnel.
• Check work area for clearances overhead, on sides,
and bottom of platform when lifting or lowering
platform, and driving.
• During operation, keep all body parts inside platform railing.
• Use the boom functions, not the drive function, to
position the platform close to obstacles.
• Always post a lookout when driving in areas where
vision is obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m)
away from machine during all driving and swing
operations.
• Under all travel conditions, the operator must limit
travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, 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.
• Exercise extreme caution at all times to prevent
obstacles from striking or interfering with operating
controls and persons in the platform.
• Be sure that operators of other overhead and floor
level machines are aware of the aerial work platform’s presence. Disconnect power to overhead
cranes.
• Warn personnel not to work, stand, or walk under a
raised boom or platform. Position barricades on
floor if necessary.
3121636 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
1.4 TOWING, LIFTING, AND HAULING
• Never allow personnel in platform while towing, lifting, or hauling.
• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The
platform must be completely empty of tools.
• When lifting machine, lift only at designated areas of
the machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for lifting information.
1.5 MAINTENANCE
This sub-section contains general safety precautions
which must be observed during maintenance of this
machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual 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 that all
moving parts are secured from inadvertent motion
prior to performing any adjustments or repairs.
• Never work under an elevated platform until it has
been fully lowered to the full down position, if possible, or otherwise supported and restrained from
movement with appropriate safety props, blocking,
or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic
hoses or fittings while the machine is powered on or
when the hydraulic system is under pressure.
1-10 – JLG Lift – 3121636
SECTION 1 - SAFETY PRECAUTIONS
• Always relieve hydraulic pressure from all hydraulic
circuits before loosening or removing hydraulic
components.
• DO NOT use your hand to check for leaks. Use a
piece of cardboard or paper to search for leaks. Wear
gloves to help protect hands from spraying fluid.
• Ensure replacement parts or components are identical or equivalent to original parts or components.
• Never attempt to move heavy parts without the aid
of a mechanical device. Do not allow heavy objects
to rest in an unstable position. Ensure adequate support is provided when 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 cutting 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 batteries or solid tires, with items of different weight or
specification. Do not modify unit in any way to affect
stability.
• Refer to the Service and Maintenance Manual for the
weights of critical stability items.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM
THE MANUFACTURER.
3121636 – JLG Lift – 1-11
SECTION 1 - SAFETY PRECAUTIONS
Battery Hazards
• Always disconnect batteries when servicing electrical components or when performing welding on the
machine.
• Do not allow smoking, open flame, or sparks near
battery during charging or servicing.
• Do not contact tools or other metal objects across
the battery terminals.
• 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 distilled
water to batteries only after the batteries are fully
charged.
1-12 – JLG Lift – 3121636
SECTION 2 - PREPARATION AND INSPECTION
SECTION 2. PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it
is necessary that it be operated and maintained only by
trained personnel.
Persons under the influence of drugs or alcohol or who
are subject to seizures, dizziness or loss of physical control must not operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform
and at the ground, emergency controls and safety
systems.
2. Control labels, instructions, and warnings on the
machine.
3. Rules of the employer and government regulations.
4. Use of approved fall 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 electrical conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until
the trainee has developed the ability to safely control
and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the
responsibility and authority to shut down the machine
in case of a malfunction or other unsafe condition of
either the machine or the job site.
3121636 – JLG Lift – 2-1
SECTION 2 - PREPARATION AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table covers the periodic machine
inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of
inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile 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 TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3121636
SECTION 2 - PREPARATION AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type Frequenc y
Pre-Start Inspec tion Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection (See
Note)
Frequent Inspection In service for 3 months or 150 hours, whichever comes
Annual Machine Inspection Annually, no later than 13 months from the date of
Preventative Maintenance At intervals as specified in the Service and Mainte-
NOTE: Inspection forms are available from JLG. Refer to Section 6 - Operators Maintenance when performing inspections.
Before each sale, lease, or rental delivery. Owner, Dealer, or
first;
or
Out of service for a period of more than 3 months;
or
Purchased used.
prior inspection.
nance Manual.
Primary
Responsibility
User or Operator User or Operator Operation and Safety Manual
User
Owner, Dealer, or
User
Owner, Dealer, or
User
Owner, Dealer, or
User
Service
Qualification
Qualified JLG Mechanic Ser vice and Maintenance Man-
ual and applicable JLG inspection form
Qualified JLG Mechanic Ser vice and Maintenance Man-
ual and applicable JLG inspection form
Factory Trained
Service Technician
(Recommended)
Qualified JLG Mechanic Ser vice and Maintenance Man-
Service and Ma intenance Manual and applicable JLG inspection form
ual
Reference
3121636 – JLG Lift – 2-3
SECTION 2 - PREPARATION AND INSPECTION
Parent Meta l Crac k
Wel d Cr ack
Pre-Start Inspection
The Pre-Start Inspection should include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil,
fuel, or battery fluid) or foreign objects. Report any
leakage to the proper maintenance personnel.
2. Structure - Inspect the machine structure for
dents, damage, weld or parent metal cracks or
other discrepancies.
3. Decals and Placards – Check all for cleanliness
and legibility. Make sure none of the decals and
placards are missing. Make sure all illegible decals
and placards are cleaned or replaced.
4. Operation and Safety Manuals – Make sure a
copy of the Operation and Safety Manual, AEM
Safety Manual (ANSI markets only), and ANSI Manual of Responsibilities (ANSI markets only) is
enclosed in the weather resistant storage container.
5. Walk-Around Inspection – Refer to Figure 2-2.
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 level.
Ensure hydraulic oil is added as required.
10. Accessories/Attachments - Reference the Operation and Safety Manual of each attachment or
accessory installed upon the machine for specific
inspection, operation, and maintenance instructions.
11. Function Check – Once the “Walk-Around”
Inspection is complete, perform a functional check
of all systems in an area free of overhead and
ground level obstructions. Refer to Section 4 for
more specific operating instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE
MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS
DECLARED SAFE FOR OPERATION.
2-4 – JLG Lift – 3121636
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).
Function Check
MAKE SURE NO FUNCTIONS (EXCEPT TRACK FUNCTIONS) OPERATE WHEN
THE OUTRIGGERS ARE NOT PROPERLY SET.
After properly setting up on outriggers, perform the
function check as follows:
1. From the ground control console with no load in
the platform:
a. Check that all guards protecting the function con-
trol switches and controllers are in place.
b. Operate all functions.
c. Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in.
d. Ensure all boom functions stop when the function
enable switch is released.
2. From the platform control console:
a. Ensure that the control console is firmly secured in
the proper location.
SECTION 2 - PREPARATION AND INSPECTION
b. Check that all guards protecting the function con-
trol switches and controllers are 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 emergency
lowering controls.
3121636 – JLG Lift – 2-5
SECTION 2 - PREPARATION AND INSPECTION
Figure 2-1. Basic Machine Nomenclature (Right Side View)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
2-6 – JLG Lift – 3121636
SECTION 2 - PREPARATION AND INSPECTION
Basic Machine Nomenclature
1. Main Boom
2. Tower Boom Assembly
3. Gas or Diesel Engine
4. Outriggers (4 places)
5. Electric Components Compartment -
(Left Side of Machine)
6. Ground/Emergency controls
7. Tracked Undercarriage
8. Tur ntabl e
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
3121636 – JLG Lift – 2-7
SECTION 2 - PREPARATION AND INSPECTION
2
3
4
4
4
4
5
6
7
8
9
10
11
1
Figure 2-2. Daily Walk-Around Inspection
2-8 – JLG Lift – 3121636
SECTION 2 - PREPARATION AND INSPECTION
General
Begin the "Walk-Around Inspection" at Item 1, as noted
on the diagram. Continue checking each item in
sequence for the conditions listed in the following
checklist.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.
INSPECTION NOTE: On all components, make sure there
are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear
exists in addition to any other criteria mentioned.
1. Platform Assembly, Footswitch, Ladder and
Gate - Footswitch in good working order, not
modified, disabled or blocked. Manuals in storage
container, access bar slides 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
Inspection Note.
6. Boom Sections & Ground Control Station - See
Inspection Note.
7. Drive Tracks - Properly Adjusted. See Inspection
Note.
8. Gas/Diesel Engine & Main Hydraulic Pump, Lithium ION Battery Pack - Free of debris and See
Inspection Note.
9. Swing Drive & Turntable Bearing- Check for
proper lubrication. See Inspection Note.
10. Hydraulic Tank and Hand Pump Assembly Hydraulic oil level correct and See Inspection Note.
11. Electric Motor and Ground Components
Hydraulic Valve Sets - See Inspection Note.
3121636 – JLG Lift – 2-9
SECTION 2 - PREPARATION AND INSPECTION
NOTES:
2-10 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL
LEVERS OR SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT
RETURN TO THE OFF POSITION WHEN RELEASED.
3.1 GROUND CONTROL STATION
See Figure 3-1., Ground Control Station
WHEN THE MACHINE IS SHUT DOWN BOTH EMERGENCY STOP SWITCHES
AND THE KEY SWITCH ON THE ENGINE (IF EQUIPPED) MUST BE SET TO
THE OFF POSITION TO PREVENT DRAINING THE BATTERY. FOR PROLONGED SHUTDOWN OR WHILE PERFORMING MAINTENANCE/REPAIRS,
TURN OFF THE BATTERY DISCONNECT SWITCH.
1. Power/Emergency Stop Switch
A two-position red switch supplies power to PLAT-
FORM/GROUND/REMOTE SELECT switch when
twisted clockwise to be in the out (on) position.
When pushed in (off), power is shut off to the
PLATFORM and GROUND controls.
2. Platform/Ground/Remote Select Switch
A three position, switch that provides power to the
platform when in the center (neutral) position.
With the switch turned clockwise and held, only
the ground controls are operational.
With the switch turned counter clockwise, the platform (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 3-1.)
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 start button
(item 3) must be pushed in until the engine starts.
The button on the RIGHT is for ELECTRIC MOTOR
start, the button on the LEFT is for GAS ENGINE
start.
NOTE: When the machine is not stabilized and the engine is
not running, an alarm will sound to indicate that the
key switch on the engine is ON. Turn OFF the select
switch on the engine when not in operation.
3. Function Enable Indicator (see Figure 3-1.)
In order to operate the boom functions from the
ground controls, item 5 through 11. When the
select switch (item 2) is turned clockwise and held
in that position, this green light will illuminate to
indicate if operation is possible (machine stabi-
lized).
3121636 – JLG Lift – 3-1
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
4. Platform Level Control
Provides for positioning the platform up and down
to adjust the level of the platform.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT
LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/
OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN
DEATH OR SERIOUS INJURY.
5. Platform Rotate Control
Provides rotating the platform to the right or left.
6. Jib Lift
Provides raising and lowering of the jib.
7. Telescope Control
Provides extension and retraction of the main
boom.
8. Main Boom Lift Control
Provides raising and lowering of the main boom.
9. Tower Boom Lift Control
Provides raising and lowering of the tower boom.
10. Swing Control
Provides swing to the left or right of the boom
assembly. Located on the valve set mounted in
front of the electric motor at the platform end of
the machine.
11. Hydraulic Manual Control Valve - (Enable Knob)
This knob used during emergency ground opera-
tion (see Section-5), must be pressed in all the way
before any of the hydraulic valve ground controls
will function.
3-2 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Figure 3-1. Ground Control Station
3121636 – JLG Lift – 3-3
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
1
2
3.2 PLATFORM/REMOTE CONTROL STATION
Maintenance Control Position On The Ground
This control position is for function check and maintenance
only.
Do not operate the machine from this position if anyone is in
the platform.
WHEN OPERATING THE MACHINE FROM THE GROUND POSITION KEEP AT
A DISTANCE OF AT LEAST 3 FT. (1M) FROM THE TRACKS.
Ground maintenance control position for the platform/
remote control is possible by connecting the platform/
remote control station using the (optional) service cable
(item 2) to the service cable connector port (item 1) located
under the small flap opening on the side of the electrical
components box.
NOTE: Before removing or connecting the platform flex cable
connector plug from the control box, depress the
emergency stop buttons and the key on the engine
must be in the OFF position.
1. Disconnect and remove the platform/remote control station from the platform storage box.
2. Disconnect the platform flex cable from the platform/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 to the end of the
platform flexible cable before the platform/remote
control station will operate in the ground maintenance position.
4. Next unscrew the cable connector cover from the
service port connector plug (item 1) on the electri-
cal components box.
5. Attach the (optional) service cable (item 2) to the
platform/remote control box.
6. Attach the other end of the service cable to the
service port connector (item 1).
To enable this position it is necessary to have the select
switch at the ground controls (Item 2 - Figure 3-1.) turned
counterclockwise after connecting the platform/remote
3-4 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
control station to the ground/remote cable connector. This
key switch overrides the footswitch in the platform.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL
LEVERS OR CONTROL SWITCHES CONTROLLING PLATFORM MOVEMENT
DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
NOTE: Before removing or connecting the special adapter
plug, depress the emergency stop buttons and the key
on the engine must be in the OFF position.
Platform/Remote Control Position From The Ground
The machine can also be controlled using the platform/
remote control station from standing outside the platform.
This position can be used for example, while loading the
machine, or moving machine through a doorway with the
platform removed.
To control the machine from this position, 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 BE CERTAIN THE COMPONENT THAT IS BEING MOVED IS COMPLETELY VISIBLE AND CONSTANTLY CHECK ITS TRAJECTORY.
Control Position From In The Platform:
The platform/remote control is connected 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 box.
3121636 – JLG Lift – 3-5
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
2. In the platform, slide the control station assembly
into the storage box, on the right side of the control station ensure the attached flexible cable
slides into the slot in the box. Now place the rib on
the right side of the control station assembly
under the metal tab attached to the storage box
assembly.
4. To remove the control station assembly, reverse
NOTE: The Platform/Remote control box may also be used to
3. Lower the control station assembly further 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.
the three steps above.
operate the tracks, outriggers and track widening (if
equipped) by removing it from the platform while still
connected to the flex cable. All boom functions will be
disabled when the platform/remote box is operated in
this manner.
3-6 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Platform/Remote Control Station Functions
Footswitch (see photo below)
To operate any function, the footswitch must be
depressed and a function selected within seven seconds.
If a function is not selected within seven seconds, or if a
seven second lapse between ending one function and
beginning the next function, the footswitch must be
released and depressed again to enable the controls.
See Figure 3-2., Platform Control Console for remaining items.
NOTE: Buttons 1, 2, 3, 4, 5, 6, 7, 8, 9, serve a double function,
they can be used to operate a machine function (icon
on button) or used as numerical keys (per number
below the button) when the 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
This button allows the operator to lower the boom
if engine power is not working.
NOTE: Buttons 5 and 6 when pressed simultaneously also
activate the horn.
5. Speed Selector/Horn
This button allows the operator to select the
desired engine speed for operation.
6. Service Menu/Horn
This button allows the operator to access the Ser-
vice Menu.
7. Outrigger - Automatic Set And Level
This control allows the operator to control the
extension of all 4 outriggers at one time.
3121636 – JLG Lift – 3-7
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
8. Override/Selector
If the machine is driven into a tilt condition, this
button may be pressed to override the drive cutout. Each press of the button will allow the drive
function to operate for approximately 8 seconds to
back the machine from the tilt condition.
This button is also used for selecting an item when
in the Service Menu (item 6).
9. Track Width Adjust
This control allows the operator to narrow the
track.
10. Power/Emergency Stop
A two-position red switch supplies power to PLAT-
FORM Controls when turned counterclockwise
(on). When pushed in (off), power is 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
operating information. Wait until a display screen
appears before beginning operation.
NOTE: Controllers (16 through 23), the speed of component
movement is proportional to the controller distance
from the center neutral position.
The movement of a controller without first
pressing the platform footswitch is indicated
by the depress footswitch error icon on the
platform/remote LCD display.
3-8 – JLG Lift – 3121636
1
2
3
456
7
8
9
10
111213
15 16 17 18 19
20212222
23
14
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
3121636 – JLG Lift – 3-9
Figure 3-2. Platform/Remote Control Station
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
15. Left Side Track Drive And Steer
This control when moved forward or rearward
simultaneously with the right side track control
(22), allows the operator to move the machine in a
straight forward or reverse direction. If each control is moved individually, different amounts or in
opposite directions steering the machine occurs.
16. Towe r B oo m L i f t
This control allows the operator to raise and lower
the tower boom.
17. Main Boom Lift
This control allows the operator to raise and lower
the main boom.
18. Main Boom Telescope
This switch allows the operator to extend and
retract 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),
allows the operator to move the machine in a
straight forward or reverse direction or, if each
control is moved individually or in opposite directions, to steer the machine.
23. Engine Pre-Heat
Allows pre-heating of the gasoline engine. One
press on the button sets the engine at 2200 RPM
for 20 seconds, in order to pre-heat the engine and
improve machine operation after initial start.
3-10 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
1
2
3
4
5
6
7
8
12
3
4
5
6
7
8
12
3
4
5
6
7
8
12
3
4
5
6
7
8
12
3
4
5
6
7
8
Platform/Remote Control Station LCD Display
At machine start-up and during machine operation the main
LCD display screen (item 15 - Figure 3-2.) is activated. There
are eight (8) display positions which indicate machine status
during various stages of operation.
Posit ion 1 Not Used.
Posit ion 2 Not Used.
Posit ion 3 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.
Posit ion 4 Displays the selected engine speed.
3121636 – JLG Lift – 3-11
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
12
3
4
5
6
7
8
12
3
4
5
6
7
8
12
3
4
5
6
7
8
CAN
BUS
?
CARD
?
12
3
4
5
6
7
8
Posi tion 5 Displays that the outriggers are properly set
and boom functions are allowed. No display indicates that the outriggers are not
properly set and boom functions are not
allowed.
If an overload occurs the main screen goes
blank for 3 seconds followed by the overload error display and an alarm.
Posi tion 6 Indicates that 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 not
operational. Drive and steer are operational
if all 4 outriggers are not contacting the
ground.
Posi tion 7 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 communication is faulty.
• Electronic fault.
• Lithium ION - Signals an error in the
BMS - Battery Management System
Posi tion 8 • Indicates that emergency lowering has
been selected.
• Lithium ION - Battery Charge Status
• Lithium ION - Battery Charger Plugged
In.
3-12 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Table 3-1. LCD Display Icon Descriptions
3121636 – JLG Lift – 3-13
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Table 3-1. LCD Display Icon Descriptions (Continued)
3-14 – JLG Lift – 3121636
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
Table 3-2. LCD Display Error Descriptions
3121636 – JLG Lift – 3-15
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION
NOTES:
3-16 – JLG Lift – 3121636
SECTION 4. MACHINE OPERATION
SECTION 4 - MACHINE OPERATION
4.1 DESCRIPTION
This machine is a hydraulic personnel lift equipped with a
work platform on the end of an elevating and rotating
boom.
The primary operator control station is in the platform. The
operator can control drive, steer, boom/platform functions
and outriggers. The machine has a Ground Control Station
which will override the Platform Control Station. Ground
Controls operate boom and platform functions. They are to
be used in an emergency to lower the platform to the
ground should the operator in the platform be unable to do
so. The ground control station is to be used for a Pre-Start
Inspection too.
This machine is equipped with an ALL MOTION alarm warning system 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 outriggers
set properly with the outrigger pads on horizontal surfaces.
• Load is within manufacturer's rated capacity.
• All machine systems are functioning properly.
Stability
In addition to the conditions listed above under Capacities,
machine stability also depends on the following:
• A work surface capable of supporting the machine and
a slope within machine leveling specifications.
• Platform is only operated within its work area specification for rated load and boom reach. (See Figure 4-5.)
3121636 – JLG Lift – 4-1
SECTION 4 - MACHINE OPERATION
1
3
2
6
5
4
4.3 ENGINE OPERATION
NOTE: Initial starting must always be performed from the
ground controls.
The gas engine key switch on the engine must be switched
to ON, the battery disconnect switch must be ON (see
Section 4.11 on page 4-23) and power/emergency stop buttons at the platform and ground controls must be ON
(turned clockwise) to start the engine.
Gas Engine Starting Procedure
NOTE: If gas 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 manufacturers engine
maintenance 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.).
4-2 – JLG Lift – 3121636
Figure 4-1. Ground/Emergency Control Box
1. Platform/Remote (Center)
Platform Position
2. Ground Control Position (Turn ClockWise and Hold)
4. Gas Engine Start
Button
(1)
(if equipped)
5. Electric Engine Start Button
6. Function Enable Indicator
3. Platform/Remote Ground
Maintenance Position (Turned CounterClockWise)
NOTE: (1) Switch at engine must be set to ON, main battery disconnect switch must be
ON, and both the ground and platform emergency stop switches must be set to
ON.
(1)
SECTION 4 - MACHINE OPERATION
NOTE: At low temperatures start the motor and let it run for a
few minutes, until the hydraulic oil circulates and
reaches at least 50°F (10°C) before operating the platform.
Gas Engine Shutdown Procedure
1. Remove all load and allow engine to operate at
low speed for 3-5 minutes; this allows further
reduction of internal engine temperature.
2. Turn off the gas engine by using the gas engine
button (item 11, Figure 4-4.) 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 PLATE. USE AN
AC EXTENSION CORD WITH SUFFICIENT AMPERAGE CAPACITY TO PROPERLY POWER THE MACHINE.
CHECK THE EFFICIENCY OF THE GROUND ON THE AC CIRCUIT, IF THE CIRCUIT 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 machine to the electrical
circuit, ensure the key on the gas engine is in the
ON position.
2. Power the machine using a heavy duty AC power
cord with sufficient amperage capacity, through
the connector (item 2) positioned near the electric
engine.
3. Turn on the circuit breaker switch (item 1) posi-
tioned behind the clear cover near the electric
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.
3121636 – JLG Lift – 4-3
SECTION 4 - MACHINE OPERATION
2
3
1
5. When finished operating with the electric engine,
turn off switch (item 1 - opposite side of machine),
unhook the electric AC cord from receptacle (item
2), and disconnect ground discharger cable (item
3), if it was required.
NOTE: At low temperatures start the motor and let it run for a
few minutes, so that the hydraulic oil circulates and
reaches at least 50°F (10°C) before operating the platform.
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 station.
3. Switch the ON/OFF switch on the lithium-ion battery pack to the OFF position when shutting down
at the end of a work period. (0 symbol is OFF, 1 is
ON)
4-4 – JLG Lift – 3121636
Figure 4-2. Ground/Emergency Control Box - Lithium
1
3
2
4
Ion
SECTION 4 - MACHINE OPERATION
1. Platform/Remote (Center)
Platform Position
2. Ground Control Position - (Turn
ClockWise and Hold)
3121636 – JLG Lift – 4-5
3. Platform/Remote Ground
Maintenance Position (Turned CounterClockWise)
4. Function Enable Indicator
SECTION 4 - MACHINE OPERATION
4.4 BASE AND BOOM/JIB ALIGNMENT
The machine has two reflectors/photocells that check if the
boom assembly is completely lowered and retracted, the jib
is lowered, and 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 OUTRIGGER MOVEMENT IS PREVENTED.
Boom/Jib and Base Alignment - Reflectors/Photocells
Base/Boom Alignment - Visual Indicator
4-6 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
3
9
4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH ADJUST
KEEP EVERYONE A DISTANCE OF AT LEAST 3 FT. (1M) FROM THE MACHINE
WHEN OPERATING THE TRACKS.
NOTE: The base and boom/jib must be aligned 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 narrowing the track.
Travelling (Drive and Steer)
USE EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TERRAIN
OBSTACLE. CHECK FOR CURBS, LARGE STONES, OR OTHER TERRAIN
OBSTACLES INCLUDING OVERHEAD OBSTACLES AS THE MACHINE WILL
MAKE UNCONTROLLED PIVOTING MOTIONS WHEN THE CENTER OF GRAVITY (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 controllers for both tracks at the same time, direction and position.
• Always 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)
DO NOT DRIVE MACHINE ON GRADES EXCEEDING 15 DEGREES (26.7%).
USE RAMPS WHEN TRAVELLING ON STEPS OR OTHER SURFACES THAT
ARE NOT SMOOTH OR HAVE GOOD TRACTION.
3121636 – JLG Lift – 4-7
SECTION 4 - MACHINE OPERATION
TRACK ON
8
WHEN DRIVING ON SIDE-SLOPES, EXTEND THE LOW SIDE OUTRIGGERS
UNTIL THEY ARE CLOSE TO THE GROUND TO HELP PREVENT A TIP-OVER
IF A CHANGE IN SURFACE OCCURS. (SEE FIGURE 4-3.) DRIVE ON SIDESLOPES WITH THE BOOM STOWED. DO NOT DRIVE ON SIDESLOPES
WHICH EXCEED 10 DEGREES.
CUT-OUT CONDITION EMPTY BASKET
Longitudinal Limit 16° ( jib closed);
13° (jib open)
Tracks Extended Side
Limit
Tracks Retracted Side
Limit
The machine is equipped with automatic tilt sensing during
driving, the possible driving speeds are adjusted according
to the weight in platform, undercarriage retracted or
extended, position of JIB and inclination of the ground.
In case of approach to dangerous inclinations for machine’s
stability, both lateral and longitudinal, an alarm is activated
and afterwards further movement is prohibited. The only
allowed operation to exit this condition 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
15° 15°
10° 10°
BASKET WITH MORE
THAN 40 Kg
13°
machine as it could cause machine tipping with consequent
danger for operator or people nearby the machine.
It is the operator’s responsibility to run the machine safely,
checking the ground conditions, evaluating the obstacles
and dangers in the working area, and following the rules of
this manual and indications on decals and display of the
machine.
LCD - Showing Maximum Incline Exceeded - While Driving
4-8 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
Figure 4-3. Grade and Side Slope Definition
3121636 – JLG Lift – 4-9
SECTION 4 - MACHINE OPERATION
Jib Position for Travelling
It is necessary to raise the JIB arm when driving up or down
slopes that exceed 10° and but less than the max. 15° to prevent the jib from contacting the ground.
ONLY PERFORM THIS OPERATION WHEN IT IS NECESSARY. IN ALL OTHER
SITUATIONS, DRIVE WITH THE BOOM AND JIB FULLY LOWERED AND
ALIGNED.
The permission to use the JIB is indicated
by the icon in position 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 machine has been
closed and aligned.
If any of these conditions have not been met, the use of the
JIB is not possible and one of the following error displays
appears.
4-10 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
After these conditions have been met, make sure that there
are no obstacles in the Jib working area and operate as follows:
• Activate the joystick for moving the JIB arm. If a different
joystick is activated an error message will appear on the
display.
• After the slope has been passed, for which the jib had to
be raised, fully lower the jib and continue travelling.
• With the JIB raised, ALWAYS travel at minimum speed
and keep the JIB as near as possible to the ground.
4.6 OUTRIGGER OPERATION
BE CERTAIN THAT THE OUTRIGGER PADS ARE SET ON A FIRM AND HORIZONTAL SURFACE. DO NOT SET THE OUTRIGGER PADS ON INCLINED, VERTICAL, 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 turn off or, the selflevelling attempt will stop. This situation may be due to the
slope on which the outriggers are being set up on exceeds
the allowed slope for proper set up at the end of the stabilization phase. If the machine is to be lifted even further from
the ground after the outriggers are properly set, push and
hold the outrigger automatic set and level button.
3121636 – JLG Lift – 4-11
SECTION 4 - MACHINE OPERATION
If the functions are selected when one of the above listed
conditions is missing, an error message will appear on the
platform/remote control display indicating which of the
conditions are OK and which are not. If the condition is that
an outrigger is not set properly, the message will also indicate which outrigger is not set properly.
ST1: if OK outrigger 1 is set 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 stabilizer set button 7, if OK,
stabilizers are set properly.
If NO, button 7 was released before tilt sensor detected
machine was level and stabilizers set properly.
4-12 – JLG Lift – 3121636
AUTO
MANUAL
SELECT
2
Setting Outriggers From the Platform/Remote Console
(Reference Figure 4-4. for item numbers)
Either - Press and hold the outrigger autoset and level button 7 (item 7) until OK
appears on the platform LCD display.
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 button 2 displays the outrigger selected on the
LCD display). Press button 1 (item 1) to
retract or button 7 (item 7) to set that outrigger. The OK will appear on the display
when the 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.
SECTION 4 - MACHINE OPERATION
CHECK THE BUBBLE LEVEL TO CONFIRM UNIT IS LEVEL (BUBBLE IS COMPLETELY 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, AFTER USING THE
AUTO-LEVEL FUNCTION, SHUT DOWN THE MACHINE AND HAVE THE
MACHINE REPAIRED BY A QUALIFIED SERVICE TECHNICIAN.
Each outrigger has a yellow light installed. All lights will be
on steady if the outriggers are positioned to the full operation area. No lights will be on if the outriggers are not set
properly.
3121636 – JLG Lift – 4-13
SECTION 4 - MACHINE OPERATION
AUTO
1
MANUAL
SELECT
2
IF ONE OF THE ORANGE LIGHTS LOCATED ON EACH OUTRIGGER SHOULD
REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE GROUND,
STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG SERVICE
TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRESPONDING OUTRIGGER MICRO SWITCH.
IF THE SLOPE EXCEEDS 15°, THE MACHINE IS NOT CAPABLE OF PROPERLY
SETTING THE OUTRIGGERS AND LEVELING ITSELF. OPERATION OF THE
BOOM AND PLATFORM FUNCTIONS WILL NOT BE ALLOWED IN THIS CONDITION. THE MACHINE IS CONSIDERED STABILIZED WHEN LEVELED TO
LESS THAN 1° AND THE TRACKS ARE LIFTED AT LEAST 2 IN. (5 CM) FROM
THE GROUND.
STABILIZING THE MACHINE WITH AN INCLINATION DEGREE HIGHER
THAN THE ONE ALLOWED COULD CAUSE INSTABILITY OF THE MACHINE
If the platform ladder is higher than 16 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 outriggers will all retract at the same
time and lower the machine.
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 at each outrigger,
each press of button 2 displays the outrigger
selected on the LCD display). Press button 1
(item 1) to retract or button 7 (item 7) to set
that outrigger.
Note: To cycle back to outrigger auto-
retract mode, press button 2 (item 2) until
the LCD display shows the normal operating
icons.
4-14 – JLG Lift – 3121636
4.7 BOOM/PLATFORM OPERATION
THE BOOM WILL NOT OPERATE UNTIL THE OUTRIGGERS ARE PROPERLY
SET AND MACHINE IS LEVELED.
AT PLATFORM/REMOTE CONTROL STATION, TWIST THE EMERGENCY
STOP BUTTON CLOCKWISE TO BE IN THE OUT POSITION, START ENGINE
AND ACTIVATE FOOTSWITCH FOR ALL PLATFORM/ REMOTE CONTROL
FUNCTIONS.
ALWAYS STOW (RAISE) THE LADDER AFTER ENTERING OR EXITING THE
PLATFORM 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 weight
reminder icon appears in the middle of the platform/remote
LCD display and the function stops.
NOTE: At low temperatures start the motor and let it run for a
few minutes, so that the hydraulic oil circulates and
reaches at least 50°F (10°C) before operating the platform.
Overload Alarm
If the platform is overloaded all the boom functions are
stopped, "Overload in Platform" error message appears on
the platform/remote display and the alarm sounds. To
restore the boom functions it is necessary to remove the
extra load.
SECTION 4 - MACHINE OPERATION
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 STOP SWITCH TO STOP THE MACHINE.
If the platform is lifted from the proper mounting position
during the use of the machine, an alarm will sound and all
the movements of the machine will stop. An error message
will appear on the LCD display of the platform/remote control.
Engine Pre-Heat
(Item 23, Figure 4-4.)
Allows pre-heating of the gasoline engine. One press on the
button sets the engine at 2200 RPM for 20 seconds, in order
to pre-heat the engine and improve machine operation after
initial start.
Platform Level Adjustment
(Item 13, Figure 4-4.)
NOTE: During normal operation of the machine, the plat-
form will automatically maintain its position.
• To manually Level Up, turn the select switch clockwise
and hold until desired position is reached.
3121636 – JLG Lift – 4-15
SECTION 4 - MACHINE OPERATION
1
2
3
4
5
6
7
8
9
10
111213
15 16 17 18 19
20212222
23
14
Figure 4-4. Platform/Remote Control Box
4-16 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
• To manually Level Down, turn the select switch counter
clockwise and hold until desired position is reached.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT
LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/
OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN
DEATH OR SERIOUS INJURY.
Raise And Lower The Tower Boom
(Item 16, Figure 4-4.)
• To raise the tower boom, depress the foot switch and
move the controller forward.
• To lower the tower boom, depress the foot switch and
move the controller backwards.
Raise And Lower The Main Boom
(Item 17, Figure 4-4.)
• To raise the main boom, depress the foot switch and
move the controller forward.
• To lower the main boom, depress the foot switch and
move the controller backwards.
Telescope The Main Boom
(Item 18, Figure 4-4.)
• To extend the main boom, depress the foot switch and
move the controller backward.
• To retract the main boom, depress the foot switch and
move the controller forward.
Platform Rotation (Item 19, Figure 4-4.)
• To rotate the platform to the right, depress the footswitch 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 (Item 20, Figure 4-4.)
• 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 21, Figure 4-4.)
WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR
THE BOOM AND UPRIGHT TO CLEAR SURROUNDING WALLS, PARTITIONS
AND EQUIPMENT.
ALSO WHEN SWINGING THE BOOM WITH WHEN THE BOOM IS LOWERED
BE CERTAIN THE BOOM/JIB/PLATFORM ARE HIGH ENOUGH TO AVOID
CONTACT WITH THE OUTRIGGERS.
• To swing the boom to the right, depress the foot switch
and move the controller forward.
• To swing the boom to the left, depress the foot switch
and move the controller backwards.
3121636 – JLG Lift – 4-17
SECTION 4 - MACHINE OPERATION
(
Figure 4-5. Platform - Load/Reach Chart - X500AJ
4-18 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
4.8 Platform Removal/Installation
The platform may only be removed to allow passage
through areas measuring a minimum of 39 in. (99cm).
NOTE: If the platform is removed only track movement is
allowed.
Platform Removal
1. Remove the platform/remote control box from the
mounting support.
2. Loosen and remove the 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 overtighten.
3. Re-install the platform/remote control box into the
mounting support on the platform.
3121636 – JLG Lift – 4-19
SECTION 4 - MACHINE OPERATION
4.9 BATTERY CHARGING - GAS/AC-ELECTRIC
NOTE: Be sure that the machine is parked in a well ventilated
area free of flames and sparks.
• Only plug the charger into 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 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 appropriately grounded
AC receptacle and activate the charging switch behind the
clear plastic door. (See photo) Verify the battery disconnect
switch is on.
4-20 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
4.10 BATTERY CHARGING - LITHIUM-ION MACHINE
To check the battery condition on the lithium
ION equipped machine, power up the
machine and use the special indicator shown
at position 8 on the platform control station
LCD display.
or;
Check the charge indicator (item 2) on
the side of the Lithium-Ion battery pack.
This indicator shows the current charge
state of the lithium-ion battery pack as
follows;
Red Steady: first phase of recharging.
Red flashing: second phase of recharging.
Orange/yellow steady: third phase of recharging.
Orange/yellow flashing (4s ON - 1s OFF): equalization/
standby phase. When you're in this phase, batteries can be
considered charged. The charger is doing the batteries voltage equalization at first and then it's in standby maintaining
batteries at max charge. The time for equalization can be of
some hours but it's not necessary to complete it in order to
consider the recharge phase completed.
If the machine is powered on while charging,
the LCD display on the platform control station also shows the machine charge indicator.
Charging the Battery Pack
Approximate time required to fully recharge the battery
pack:
• Full Recharge - 4 hrs. - 120V AC
• 80% Recharge - 2 hrs. - 120V AC
• The batteries can be charged during machine opera-
tion, (obviously the charging times in this case will be longer).
• The batteries can be charged when they are not fully
depleted.
• If the charge is less than 20% an audible warning signal
will be activated whenever the electric motor is started,
to alert the user to charge the machine.
• If the charge is less than 10%, in addition to the audible
warning signal, reduced speed is activated and an icon
comes on in position 4 on the platform station LCD display.
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 righthand side of the machine on the lithiumion battery pack turns red, meaning the battery has started
charging.
3121636 – JLG Lift – 4-21
SECTION 4 - MACHINE OPERATION
1
2
THE BATTERY CHARGER SUPPLIED WITH THE LIFT WAS DESIGNED TO
ENSURE SAFE AND RELIABLE PERFORMANCE. IT IS ALREADY FITTED ON
THE MACHINE AND DOES NOT NEED ANY ADJUSTMENT OR CONFIGURATION BY THE USER; NONETHELESS, TO AVOID INJURY AND DAMAGE TO
THE BATTERY CHARGER, THE FOLLOWING ESSENTIAL PRECAUTIONS
MUST BE OBSERVED:
• Carefully read the installation instructions contained in
this manual. For future reference, keep the manual in a
safe place.
• Do not place the battery charger near sources of heat.
• As the battery charger is sealed and without forced ven-
tilation, its performance depends on the ambient temperature and the type of installation.
• Be certain the type of power supply available corresponds to the voltage specified and indicated on the
battery charger rating plate or in this Operation/Maintenance Manual. If any questions, contact your local JLG
Service Center or the local electrical company.
• An AC class circuit breaker can be used as protection
device for the battery charger power supply, however it
is recommended to use a class A or even better class B
device.
• In regard to safety and electromagnetic compatibility,
the battery charger features a three pin plug with
ground, 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
4-22 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
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 are used, make sure
that these support the total rated current.
• Disconnect the power supply before connecting or disconnecting the battery.
• Do not use the battery charger to charge the batteries
of other vehicles; the battery charger installed was specially designed to charge the type of lithium batteries
used on this machine. Do not attempt to charge any
other type of batteries.
• Do not attempt to repair the battery charger. Opening
the cover may expose the user to the risk of electric
shock.
• Do not open the battery charger, opening it may affect
the index of protection (IP) even after it has been closed
again.
• If the battery charger is not working correctly or is damaged, disconnect it immediately from the 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.
4.11 SHUT DOWN AND PARK
WHEN PARKING THE MACHINE ON A SLOPE OR UNEVEN GROUND WITH
THE OUTRIGGERS RETRACTED, PARK WITH THE TRACKS IN THE FULLY
WIDENED POSITION AND BLOCK THE TRACKS USING WEDGES TO PREVENT MACHINE MOVEMENTS.
1. Drive machine to a reasonably well protected area.
2. Ensure the 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 the gas/electric engine with the same
button on the platform/remote 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 environment,
place a cover over this area.
3121636 – JLG Lift – 4-23
SECTION 4 - MACHINE OPERATION
7. If machine is to be shut down for long periods of
time, turn the battery disconnect switch, RED handle located on the electrical/battery tray housing,
to the POWER OFF position. (photos below and
next page)
POWER ON
Clockwise
POWER OFF
Counte rClockwise
POWER ON
Clockwise
POWER OFF
Counte rClockwise
BATTERY DISCONNECT - LITHIUM-ION - ELECTRIC
(Mounted Inside Left-Side Electrical Component Compartment)
BATTERY DISCONNECT - GAS/AC-ELECTRIC
4-24 – JLG Lift – 3121636
4.12 LIFTING AND TIE DOWN
1
1
SECTION 4 - MACHINE OPERATION
Lifting - Outrigger Lifting Rings
1. Determine gross weight of machine, refer to the
serial number tag, or weigh the individual unit to
find out the gross vehicle weight.
2. 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. 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 4-6. OTHERWISE THE
MACHINE MAY NOT BALANCE PROPERLY AND MOVE UNEXPECTEDLY.
THE USE OF ROPES, CHAINS OR SLINGS WITH LENGTH LESS THAN 10 ft.
(3m) COULD CAUSE PERMANENT DAMAGE TO THE MACHINE OUTRIGGERS.
As the weight of the machine is not spread equally over the
four outriggers, the minimum required capacity of the four
ropes, chains or slings used must be: no less than 4,409 lb.
(2000 kg) and their length no less than 10 ft. (3m) and all
identical.
Figure 4-6. Lifting Machine - Lifting Rings Location
1. Lifting Rings (4 - 1 Each Outrigger)
3121636 – JLG Lift – 4-25
SECTION 4 - MACHINE OPERATION
Lifting - Fork Lift Pockets
The machine is equipped with two tubular fork lift pockets
designed to lift the machine using a forklift of suitable
capacity.
1. Determine gross weight of machine, refer to the
serial number tag, or weigh the individual unit to
find out the gross vehicle weight.
2. 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 pockets on machine.
4. Carefully approach the machine with fork lift truck
being careful not to damage any machine components. Insert the forks into the lifting pockets on
the machine and carefully lift machine.
5. Move machine to new location.
Figure 4-7. Lifting Machine - Fork Lift Pockets
Location
4-26 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
Loading and Unloading the Machine on Transport Vehicles Using Ramps
The JLG platform offers high maneuverability and stability
even in travelling (stowed) configuration.
Despite this, the operator is to take safety measures even
when carrying out the simplest operations.
ALWAYS LOAD/UNLOAD THE MACHINE WITH UNDERCARRIAGE (TRACKS)
EXTENDED TO WIDEST WIDTH.
Loading
For example, follow the procedure below to load the
machine onto 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 capacity to support the machine and are free from debris or
slippery material;
• Position the ramps parallel to each other at a distance
equal to the space between the tracks;
• Climb the ramps, proceeding with the basket facing
backwards;
• When approaching the loading surface, before the
change in inclination, ALWAYS check that the JIB arm is
COMPLETELY RETRACTED. Then proceed with great care
in order to prevent sudden jolts when passing from the
sloping ramps to the truck/trailer flatbed;
• Position the machine so that none of its parts protrude
from the transport vehicle.
UnLoading
Unload the machine following the same instructions given
above.
• During travel and when changing slope, make sure not
to damage the safety devices positioned under the basket.
• If the change in inclination is excessive, adjust the angle
of the ramps or, if this is not possible, use longer ramps.
It is also possible to use the jib arm as described earlier.
3121636 – JLG Lift – 4-27
SECTION 4 - MACHINE OPERATION
Tie Down
(See Figure 4-8.)
WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED 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 with the track fully
widened.
1. Configure the machine to 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
2. Secure the chassis using straps or chains of ade-
quate strength.
DO NOT MAKE CONNECTIONS AT POINTS DIFFERENT THAN THOSE IDENTIFIED BY THE TIE DOWN LOCATION DECAL SHOWN - SEE FIGURE 4-8.
THIS COULD CAUSE PERMANENT DAMAGE RESULTING IN THE COLLAPSE
OF THE PRODUCT.
4-28 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
1
1
2
2
1703814A 1703814A
1701499 1701499
Figure 4-8. Machine Tie-Down Points (both sides of machine)
1. Tie-Down Loop 2. Tie-Down Decal
3121636 – JLG Lift – 4-29
SECTION 4 - MACHINE OPERATION
4.13 MACHINE DECALS
Figure 4-9. Decal installation - Standard - Left Side
4-30 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
Figure 4-10. Decal Installation - Standard - Right Side
3121636 – JLG Lift – 4-31
SECTION 4 - MACHINE OPERATION
Table 4-1. X500AJ - Decal Installation - Standard (See Figure 4-9. and Figure 4-10.)
ITEM # PART NUMBER DESCRIPTION
1 06555500 Decal, Outrigger Number 1
2 06555600 Decal, Outrigger Number 2
3 06555700 Decal, Outrigger Number 3
4 06555800 Decal, Outrigger Number 4
5 1001125483 Decal, Do Not High Pressure Wash
6 1706898 Decal, Emergency Stop
7 06040500 Decal, Forward Direct Arrow
8 1701640 Decal, Read The Manual
9 1703814 Decal, Tie-Down Anchor
10 07071200 Decal, Lifting Lug
11 1704277 Decal, Platform Lanyard Attach Point
12 07506500 Decal, Emergency Stop
13 07056700 Decal, Not A Lifting Point
14 1701499 Decal, Do Not Lift From This Anchor Point
15 06706500 Decal, Platform Alignment
16 06998800 Decal, Platform Manual Diverter Pump
17 07242000 Decal, Remote Control, 3-Position Selector
18 1702155 Decal, Battery Master Switch
19 1701504 Decal, Hydraulic Oil
20 06165000 Decal, Hydraulic Oil Level
DECAL INSTALLATION
4-32 – JLG Lift – 3121636
Table 4-1. X500AJ - Decal Installation - Standard (See Figure 4-9. and Figure 4-10.)
ITEM # PART NUMBER DESCRIPTION
21 06060000 Decal, Engine Oil Level
22 1701542 Decal, Gasoline Fuel Only
22 1701505 Decal, Fuel Only
23 06056300 Decal, Burn Hazard
24 06232100 Decal, Danger - Flammable - Gasoline
25 07240300 Decal, Keep 3 ft./1m Away When Operating WithTele/Radio Commands
26 07242100 Decal, Stabilizer Load - Lower On A Firm/Stable Surface Only
27 07071000 Decal, Lower Onto A Firm/Stable Surface Only
28 07350300 Decal, Fork Truck Lifting Pocket
29 07056100 Decal, Crushing Danger
30 1706387 Decal, Crushing Danger
31 1706099 Decal, Crushing Danger
32 1702868 Decal, Crushing Danger - Hand
33 07056200 Decal, Crushing Danger - Lower Limb
34 1706386 Decal, Danger While Lowering
35 07051100 Decal, Danger of Falling - Replace Pin
36 07051000 Decal, Danger of Falling - Unlock Only When Allowed
37 1706133 Decal, Danger of Tilting
38 07058600 Decal, Stabilizer Positioning
39 07045300 Decal, Ground Control - Engine Start
40 07042100 Decal, Boom Bypass System
41 07042200 Decal, Track Bypass System
SECTION 4 - MACHINE OPERATION
3121636 – JLG Lift – 4-33
SECTION 4 - MACHINE OPERATION
Table 4-1. X500AJ - Decal Installation - Standard (See Figure 4-9. and Figure 4-10.)
ITEM # PART NUMBER DESCRIPTION
42 1702901 Decal, Instructions For Emergency Manual Pump
43 3252347 Decal, Pedal
44 1706128 Decal, Danger of Electrocution
45 1703813 Decal, Explosion Hazard - Battery
46 1704972 Decal, Explosion Hazard
47 — Not Used
48 1706385 Decal, Lower Sliding Bar After Entering Platform
49 1705514 Decal, CSA Conformation
50 1706135 Decal, Platform Use
51 07056400 Decal, Danger - 120V - 60Hz
52 07056300 Decal, Danger - 220V - 50/60Hz
53 072422GB Decal, Emergency Descent Instructions
54 072423GB Decal, Maximum Platform Capacity - X500AJ
55 072424GB Decal, Distributor Valve Ground Control - Side
56 072425GB Decal, Distributor Valve Ground Controls - Rear - Left Side
57 072426GB Decal, Distributor Valve Ground Controls - Rear - Right Side
4-34 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
Figure 4-11. Decal installation - Lithium-Ion - Left Side
3121636 – JLG Lift – 4-35
SECTION 4 - MACHINE OPERATION
Figure 4-12. Decal Installation - Lithium-Ion - Right Side
4-36 – JLG Lift – 3121636
SECTION 4 - MACHINE OPERATION
Table 4-2. X500AJ - Decal Installation - Lithium Machine (See Figure 4-11. and Figure 4-12.)
ITEM # PART NUMBER DESCRIPTION
DECAL INSTALLATION
1 07107200 Decal, Danger - B atteries
2 1001125483 Decal, Do Not Pressure Wash
3 06506400 De cal, On/Off Power Switch - Lithium Ion Engine
4 06520600 Decal, Sound - 88 dB
5 07107100 Decal, Recharge Batteries After Each Use or At Least Every 3 Months
6 172241GB Decal, Emergency Descent Instructions - X500AJ - Lithium-Ion
7 07394800 Decal, Battery Charging LED Indicator, 48V Battery
3121636 – JLG Lift – 4-37
SECTION 4 - MACHINE OPERATION
NOTES:
4-38 – JLG Lift – 3121636
SECTION 5 - EMERGENCY PROCEDURES
SECTION 5. EMERGENCY PROCEDURES
5.1 GENERAL
This section explains the steps to be taken in case of an
emergency situation while operating.
5.2 INCIDENT NOTIFICATION
JLG Industries, Inc. must be notified immediately of any
incident involving a JLG product. Even if no injury or
property damage is evident, the factory should be contacted by telephone and provided with all necessary
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 involving 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 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
Power Main Cut-Off Switch Location
A battery cut-off switch - RED handle (photo shows power
OFF) is located on the outside 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 in direction of arrow - all electrical power to the machine is shut
down.
Gas/Diesel/AC-Electric Lithium-Ion-Electric
3121636 – JLG Lift – 5-1
SECTION 5 - EMERGENCY PROCEDURES
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from
ground controls only as required.
2. Other qualified personnel on the platform may use
the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.
3. Cranes, forklift trucks or other equipment can be
used to remove platform occupants and stabilize
motion of the machine.
Platform or Boom Caught Overhead
If the 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
the hydraulic pressure for the hydraulic system.
The electric power provides power for the hydraulic
proportional valve solenoids to open 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 lowering of the boom and platform.
Manual Descent with Engine Running and Electrical Power
ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD OF PERSONNEL BEFORE LOWERING.
Using Platform/Remote Control Box from Platform
(See Figure 5-1.)
The manual descent system is provided as an emergency
means to lower personnel in the platform.
1. Check that the emergency stop button (item 10) is
in the ON position by turning it clockwise.
2. Press and hold down button 4 (item 4)
with the hazard symbol on the platform/remote control box. The LCD display (item 14) 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.
4. When finished, release the emergency lowering
switch (item 4).
5. Position (press) the emergency stop switch to the
OFF position.
5-2 – JLG Lift – 3121636
1
2
3
4
5
6
7
8
9
10
111213
15 16 17 18 19
20212222
23
14
SECTION 5 - EMERGENCY PROCEDURES
3121636 – JLG Lift – 5-3
Figure 5-1. Platform/Remote Control Station
SECTION 5 - EMERGENCY PROCEDURES
Using Emergency/Ground Controls from Ground
(See Figure 5-2.)
ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD OF PERSONNEL BEFORE LOWERING.
1. Be certain the emergency stop button (item 1) is in
the ON position by turning it clockwise.
2. Start the engine, if not already running.
3. At the Emergency/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 to operate lever for desired movement.
6. When finished, release the key switch (item 2) back
to the neutral position.
7. Position (press) the emergency stop switch (item 1)
to the OFF position to shut machine down.
5-4 – JLG Lift – 3121636
SECTION 5 - EMERGENCY PROCEDURES
Figure 5-2. Ground Control Station - Boom Control Valves
3121636 – JLG Lift – 5-5
SECTION 5 - EMERGENCY PROCEDURES
Manual Descent with Engine Running but without Electrical Power (Combustion Engines Only)
(See Figure 5-2.)
ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD OF PERSONNEL BEFORE LOWERING.
1. Operate the boom control valves at the ground
control valve distributor. (see Figure 5-2.)
2. Ensure the machine is level and all outriggers are
properly deployed on a firm surface. If outrigger
movement is required first, See “Outrigger/Track
Movement Emergency Procedure:” on page 5-9.
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 5-2. 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 possible speed.
4. Make boom movements in the following
sequence:
• fully lower jib
• fully lower tower boom
• fully lower main boom
5. When emergency operation is complete, release
the proportional valve to the closed position.
6. At the engine, turn the key to the off position.
5-6 – JLG Lift – 3121636
Manual Descent without Engine and Electrical Power
1
2
Using Hand Pump Mounted to Hydraulic Tank on Right
side of Machine
Platform Retrieval Sequence
1. Ensure the machine is level and all outriggers are
properly deployed on a firm surface. If outrigger
movement is required first, See “Outrigger/Track
Movement Emergency Procedure:” on page 5-9.
2. Locate and remove the manual hydraulic pump
handle secured to the top cover above the outrigger/track ground control proportional valve
groups at the rear of the machine.
3. Install the pump handle on the hydraulic pump
(item 1 - Figure 5-3.) and secure in place with the
provided screw.
4. The manual pump lever (item 2 - Figure 5-3.) on the
pump must be;
Turned to the left - for right side outrigger, track
and boom functions. (See - Figure 5-4.)
Turn to right - for left side outrigger and track
functions.
SECTION 5 - EMERGENCY PROCEDURES
Figure 5-3. Hand Pump - On Top Of Hydraulic Tank
3121636 – JLG Lift – 5-7
Figure 5-4. Hand Pump Decal - On Top Of Hydraulic
Tank
SECTION 5 - EMERGENCY PROCEDURES
NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS
BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR
OVERHEAD SLING.
NEVER REACH THROUGH, UNDER, OR OVER THE BOOM'S PATH OF
TRAVEL TO THE GROUND CONTROL PANEL. IF NO ASSISTANT IS AVAILABLE, PROCEED WITH THE FOLLOWING STEPS.
TO AVOID CONTACT BETWEEN THE JIB AND OUTRIGERS, DO NOT ATTEMPT TO
MANUAL SWING WITH THE BOOMS AND JIB FULLY LOWERED.
1. Open the cover on the Ground Control Station (see
Figure 5-2. on page 5-5), located on the hydraulic
tank side of the machine.
At the ground control valve distributor perform the following steps as required;
2. If not already aligned, first swing the turntable
inline with the chassis so that the turntable and
base indicator arrows are aligned.
NOTE: This will eliminate the possibility of an elevated or
extended boom being positioned overhead of personnel at the pump and eliminate the risk of lowering the
jib onto an outrigger.
a. Depress the enable valve button (item 12 - Figure 5-
2. on page 5-5).
b. Activate the swing control lever (item 11 -
Figure 5-2. on page5-5), 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. Activating the lever down while pumping will
swing the platform to the counterclockwise.
NOTE: All of the following functions require the enable but-
ton (item 12 - Figure 5-2. on page 5-5) to be depressed
while pumping the hydraulic hand pump and operating the function lever.
3. Retracting the main boom (if necessary).
With the aid of an assistant, while pumping the
hand pump, activate the telescope function lever
(Item 8, Figure 5-2. on page 5-5) at the ground controls, to retract the main boom.
4. Lowering the jib (if necessary).
While pumping the hand pump, activate the jib lift
function lever (item 7, Figure 5-2. on page 5-5) in the
appropriate direction to lower the jib.
5-8 – JLG Lift – 3121636
SECTION 5 - EMERGENCY PROCEDURES
5. Lowering the Tower Boom (if necessary).
While pumping the handpump, activate the tower
boom lift function lever (item 9, Figure 5-2.) in the
appropriate direction to lower the tower boom.
6. Lowering the Main Boom (if necessary).
With the aid of an assistant, activate the main
boom lift function lever (item 10, Figure 5-2. on
page 5-5) in the appropriate direction to lower the
main boom.
7. Rotating the platform (if necessary).
Activate the appropriate platform rotate function
lever (item 6, Figure 5-2. on page 5-5) to rotate the
platform.
8. Leveling the platform (if necessary).
Activate the appropriate platform level function
lever (item 5, Figure 5-2. on page 5-5) to level the
platform.
9. Release the enable button when finished all boom
functions.
10. Remove the manual pump handle from the pump
and secure back to its original position on top of
the 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 OFF OF THE GROUND
AT ANY ONE TIME. RETRACT OUTRIGGERS EQUALLY, TO KEEP MACHINE
BALANCED.
Outrigger Functions:
1. At the rear of the machine, locate the three and
four ground control proportional valve groups
with manual override levers. The manual override
levers on these proportional valves provide function to the right and left side outriggers and right
and left track functions.
2. Locate and remove the manual pump handle
secured to the top cover above the ground control
proportional valve groups at the rear of the
machine.
3. Install the pump handle on the manual hydraulic
pump on top of the hydraulic tank on right side of
3121636 – JLG Lift – 5-9
SECTION 5 - EMERGENCY PROCEDURES
machine, secure in place with the provided screw.
(item 3 - Figure 5-3.)
4. Set the lever on the hydraulic hand pump (item 2 -
Figure 5-3.), it must be turned to the left to pro-
vide hydraulic pressure to operate right side out-
rigger, track functions, and boom components.
When turned to right hydraulic pressure is provided to the left side outrigger, and track functions. (See following decal).
For left side (operator's (platform) perspective) Outrigger and Track Functions
5. Locate the proportional flow valve on the left side
of the chassis attached to the group of four valves
(item 1 - Figure 5-5.). Push and hold the black knob
before activating any function lever.
6. The lever on the hydraulic hand pump (item 2 - Fig-
ure 5-3.) 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 to
achieve the desired function movement.
• 1st valve (item 2 - Figure 5-5.) (far
left (at rear of machine) in the
group of four) operates Left
Front Outrigger.
• 2nd valve (item 3 - Figure 5-5.)
from the left in the group of four
operates Left Rear Outrigger.
• 3rd valve (item 4 - Figure 5-5.)
from the left in the group of four
valves operates the Left Track
Drive functions.
5-10 – JLG Lift – 3121636
SECTION 5 - EMERGENCY PROCEDURES
1608710001C
1608710002C
• 4th valve (item 5 - Figure 5-5.)
from left in the group of four,
operates track extension and
retraction.
For right side (operator's (platform) perspective) Outrigger and Track Functions:
8. Locate the proportional flow valve on the right
side of the chassis attached to the group of three
valves (item 6 - Figure 5-5.). Push and hold the black
knob before activating any function lever.
9. The lever on the hydraulic hand pump (item 2 - Fig-
ure 5-3.) must be turned to left to manually pro-
vide pressure 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 5-5.) (far
right-right side of machine in
the group of three) operates
Right Rear Outrigger
• 2nd valve (item 8 - Figure 5-5.)
from the right in the group of
three operates Right Front Outrigger
• 3rd valve (item 9 - Figure 5-5.)
from the right in the group
operates the Right Track Drive
functions.
11. Remove the manual pump handle from the pump
and secure it in its original position.
3121636 – JLG Lift – 5-11
SECTION 5 - EMERGENCY PROCEDURES
1
2
3
1
2
3
4
5
7
89
6
Figure 5-5. Ground Component Valves - Outriggers/Track Control - Location
5-12 – JLG Lift – 3121636
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