JLG X500AJ Operator Manual

Download

ANSI

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Model(s)

X550AJ

P/N - 3128791

September 26, 2011

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.

3128791 – 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 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.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, 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.

RESULT IN MINOR OR MODERATE INJURY. IT MAY

b – JLG Lift – 3128791

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.

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

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.

Contact :

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA

or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

3128791 – JLG Lift – c

Phone: 240-420-2661 E-mail: ProductSafety@JLG.com

SECTION - REVISION LOG

Original Issue of Manual . . . . . . . . . . . . . . . . . July 22, 2011

Manual Revised . . . . . . . . . . . . . . . . . . September 26, 2011

REVISION LOG

d – JLG Lift – 3128791

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 Display . 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/Diesel Starting Procedure . . . . . . . . . . . . . . 4-2

Gas/Diesel Engine Shutdown Procedure . . . . . . 4-3

Electric Engine Starting Procedure -

AC Voltage Machine. . . . . . . . . . . . . . . . . . . . . . . 4-3

3128791 – 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 . . . . . . . . . . . .4-5

4.5 TRACKS - DRIVING, STEERING AND

TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . .4-6

Track width adjust. . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Travelling (Drive and Steer) . . . . . . . . . . . . . . . . .4-6

Travelling (Grades and Side Slopes) . . . . . . . . . . 4-7

Jib Position for Travelling . . . . . . . . . . . . . . . . . . . 4-9

4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . 4-10

Setting Outriggers From the Platform/

Remote Console . . . . . . . . . . . . . . . . . . . . . . . . .4-12

Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-13

4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . . 4-14

Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . .4-14

Platform Level Adjustment . . . . . . . . . . . . . . . . .4-14

Raise And Lower The Tower Boom . . . . . . . . . .4-16

Raise And Lower The Main Boom . . . . . . . . . . .4-16

Telescope The Main Boom. . . . . . . . . . . . . . . . . 4-16

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-16

Emergency Lowering . . . . . . . . . . . . . . . . . . . . . 4-18

Platform Removal/Installation . . . . . . . . . . . . . . .4-18

4.8 BATTERY CHARGING -

GAS/DIESEL/AC-ELECTRIC . . . . . . . . . . . . . . . . . 4-19

Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-19

4.9 BATTERY CHARGING - LITHIUM-ION MACHINE .4-20

Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-20

Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-22

4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-24

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

4.12 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . 4-27

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

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

ii – JLG Lift – 3128791

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Lithium-Ion Specifications. . . . . . . . . . . . . . . . . . . 6-4

Machine Major Component Weights . . . . . . . . . . 6-4

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

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

Rubber Track Maintenance/Replacement . . . . . 6-13

Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . 6-16

Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-16

Battery Maintenance and Charging -

Gas/Diesel/AC-Electric . . . . . . . . . . . . . . . . . . . . 6-16

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

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

6.5 PLATFORM/REMOTE CONTROL

SERVICE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-20

Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20

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

Cleaning the Machine . . . . . . . . . . . . . . . . . . . . 6-21

Battery Pack System Components and

Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-24

BMS Fault Codes -

(Battery Management System) . . . . . . . . . . . . . 6-27

Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-28

SECTION - 7 - INSPECTION AND REPAIR LOG

3128791 – 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. Swing Control Valve . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Ground Control Station . . . . . . . . . . . . . . . . . . .3-3

3-3. Platform/Remote Control Station . . . . . . . . . . . .3-9

4-1. Ground/Emergency Control Box . . . . . . . . . . . . 4-2

4-2. Grade and Side Slope Definition . . . . . . . . . . . .4-8

4-3. Platform/Remote Control Box. . . . . . . . . . . . . . 4-15

4-4. Platform - Load/Reach Chart . . . . . . . . . . . . . . 4-17

4-5. Lifting Machine - Attach Points . . . . . . . . . . . . . 4-24

4-6. Machine Tie-Down Points. . . . . . . . . . . . . . . . .4-26

4-7. Decal installation - Standard - Right Side . . . .4-27

4-8. Decal Installation - Standard - Left Side. . . . . . 4-28

4-9. Decal installation - Lithium-Ion - Left Side . . . .4-33

4-10. Decal Installation - Lithium-Ion - Right Side . . .4-34

5-1. Platform/Remote Control Station . . . . . . . . . . . .5-3

5-2. Ground Control Station - Boom Control Valves. 5-5

5-3. Main Flow Control Valve Location . . . . . . . . . . .5-6

5-4. Hand Pump - On Top Of Hydraulic Tank . . . . . . 5-7

5-5. Ground Component Valves -

Outriggers/Steer/Tracks - Location . . . . . . . . .5-12

6-1. Lubrication and Maintenance Point Locations. .6-5 6-2. Component Maintenance Intervals -

X550AJ - with Honda Engine . . . . . . . . . . . . . . . 6-7

6-3. Component Maintenance Intervals -

X550AJ - with Hatz Diesel Engine . . . . . . . . . . . 6-8

6-4. Component Maintenance Intervals -

X550AJ - Lithium-ION Machine . . . . . . . . . . . . . 6-9

6-5. Lithium-Ion Battery Pack Components . . . . . . 6-22

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 X550AJ - Decal Installation - Standard . . . . . . . 4-29

4-2 X550AJ - Decal Installation -

Lithium-ION Machine . . . . . . . . . . . . . . . . . . . . 4-35

6-1 Operating Specifications. . . . . . . . . . . . . . . . . . . 6-2

6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Chassis Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-5 Honda iGX440 Specifications . . . . . . . . . . . . . . . 6-3

6-6 Hatz 1B40 Specifications . . . . . . . . . . . . . . . . . . 6-3

6-7 Lithium Ion Specifications. . . . . . . . . . . . . . . . . . 6-4

6-8 Major Component Weights. . . . . . . . . . . . . . . . . 6-4

6-9 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . 6-6

6-10 Inverter Fault Codes . . . . . . . . . . . . . . . . . . . . . 6-24

6-11 Battery Charger Fault Codes . . . . . . . . . . . . . . 6-28

iv – JLG Lift – 3128791

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for towing and also proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. 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 followed to ensure the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should not operate the machine 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.

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.

Operator Training and Knowledge

• Read and understand this manual before towing or operating the machine.

• Do not operate this machine until complete training is performed by authorized persons.

• Only authorized and qualified personnel can operate the machine.

• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.

• Use the machine in a manner which is within the scope of its intended application set by JLG.

3128791 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

• 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 towing and operation of the machine.

1.2 BEFORE OPERATING THE LIFT

Workplace Inspection

• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.

• Before operation, check work area for overhead hazards such as electric lines, bridge cranes, and other potential hazards.

• Check floor surfaces for holes, bumps, drop-offs, obstructions, debris, concealed holes, and other potential hazards.

• Do not operate the machine in hazardous environments unless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.

• This machine can be operated in temperatures of 14

F to 104o F (-10o C to 40o C). Consult JLG for operation outside this range.

1-2 – JLG Lift – 3128791

SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection

• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.

• Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.

• Be sure 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 WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which 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 any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1.3 OPERATION

General

• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine.

• 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.

• 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.

• Supplies or tools which extend outside the platform are prohibited unless approved by JLG.

3128791 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

• Do not assist a stuck or disabled machine by pushing, pulling, or by using extending structure functions.

• Do not place boom or platform against any structure to steady the platform or to support the structure.

• Stow boom and shut off all power before leaving 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.

• 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. Do not climb on platform rails. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach.

• Never use the boom assembly to enter or leave the platform.

• Always use the intended access gate to enter or leave the platform.

• Use extreme caution when entering or leaving platform. Be sure that the platform is fully lowered. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.

1-4 – JLG Lift – 3128791

SECTION 1 - SAFETY PRECAUTIONS

Electrocution Hazards

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

• Maintain safe 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 additional clearance is required for every additional 30,000 volts or less.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3128791 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• 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.

Tipping Hazards

• The user should be familiar with the surface before operating. Do not exceed the allowable sideslope and grade while operating.

•

• Do not elevate platform while on a soft surface.

• Before operating on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces.

• Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.

• Do not raise the platform unless the machine is on firm surfaces and outriggers are properly set.

• Keep the chassis and outriggers of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs,

1-6 – JLG Lift – 3128791

obstructions, debris, concealed holes, and other potential hazards on the floor/surface.

• 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.

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

SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises ver tically.

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. Whistling heard in overhead wires.

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.

Wind Speed

Description Land Conditions

mph m/s

Umbrella use becomes difficult.

3128791 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability and could result in a tip-over.

• Do not increase the platform size with unauthorized platform 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.

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.

• 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 operations.

1-8 – JLG Lift – 3128791

SECTION 1 - SAFETY PRECAUTIONS

• Be aware of stopping distances in all drive speeds. When driving in high speed, slow down the machine using the controllers before stopping.

• Do not use high speed drive in restricted or close quarters or when driving in reverse.

• 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 causing hazards of collision or injury to personnel.

• 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.

1.4 LIFTING, AND HAULING

• Never allow personnel in platform while lifting or hauling the machine.

• Ensure boom is in the stowed position prior to lifting or hauling. The platform must be completely empty.

• 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 ADDITIONAL HAZARDS / SAFETY

• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations, 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.

• Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times.

• Charge batteries only in a well ventilated area.

3128791 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-10 – JLG Lift – 3128791

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.

3128791 – 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 – 3128791

SECTION 2 - PREPARATION AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection 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 ho urs, whichever

Annual Machine Inspection Annually, no later than 13 months from the date

Preventative Maintenance At intervals as specified in the Service and Main-

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

comes first; o r Out of service for a p eriod of more than 3 months; o r Purchased used.

of prior inspection.

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operation and Safety Manual

User

Owner, Dealer, or User

Service

Qualification

Qualified JLG Mechanic

Fact ory Train ed Service Technician (Recommended)

Qualified JLG Mechanic

Reference

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

3128791 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

Pare nt Met al Cra ck

Weld Crack

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 Opera-

tion 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” Inspec-

tion 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 – 3128791

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

control 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 func-

tion enable switch is released.

SECTION 2 - PREPARATION AND INSPECTION

2. From the platform control console:

a. Ensure that the control console is firmly secured

in the proper location.

b. Check that all guards protecting the function

control 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.

3128791 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-1. Basic Machine Nomenclature (Right Side View)

2-6 – JLG Lift – 3128791

SECTION 2 - PREPARATION AND INSPECTION

Basic Machine Nomenclature

1. Main Boom

2. Tower Boom Assembly

3. Gas or Diesel Engine

4. Outrigger

5. Electric Components Compartment -

(Left Side of Machine)

6. Ground/Emergency controls

7. Tracked Undercarriage

8. Tur nt ab le

9. Hand Pump - (Right Side of Machine)

10. Hydraulic Oil tank - (Right Side of Machine)

11. Electric Engine

12. Track and Outrigger Valves/Manual Controls -

(Under Cover)

13. Jib

14. Ladder

15. Platform

16. Manuals Compartment

17. Platform/Remote Control Station

18. Lithium ION - Battery Charger LED Indicator

19. Lithium ION - Battery Pack, Inverter, and Battery

Charger Compartment

3128791 – JLG Lift – 2-7

SECTION 2 - PREPARATION AND INSPECTION

Figure 2-2. Daily Walk-Around Inspection

2-8 – JLG Lift – 3128791

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 Engine and Ground Components Hydraulic Valve Sets - See Inspection Note.

3128791 – JLG Lift – 2-9

SECTION 2 - PREPARATION AND INSPECTION

NOTES:

2-10 – JLG Lift – 3128791

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 3-2., Ground Control Station

WHEN THE MACHINE IS SHUT DOWN BOTH EMERGENCY STOP SWITCHES AND THE KEY SWITCH ON THE ENGINE 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 PLATFORM/ 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 Key Switch

A three position, key operated switch that provides power to the platform when in the center (neutral) posi-

tion. With the key switch turned clockwise and held, only the ground controls are operational. With the key switch turned counter clockwise, the platform (remote) control box may be removed from the platform and connected to the cable located in the electrical components compartment, located below the ground controls and operated from the ground.

3. Engine Start Buttons (see Figure 3-2.)

To start the engine at the ground control, the select key 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/DIESEL 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 key switch on the engine when not in operation.

4. Function Enable (see Figure 3-2.)

The key switch must be turned clockwise and held in that position in order to operate the boom functions from the ground controls, item 5 through 10. A green light will illuminate to indicate if operation is possible (machine stabi-

lized) from these controls.

3128791 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

5. Tower Boom Lift Control (located up under cover)

Provides raising and lowering of the tower boom.

6. Main Boom Lift Control (located up under cover)

Provides raising and lowering of the main boom.

7. Tel es c o p e C on tr ol (located up under cover)

Provides extension and retraction of the main boom.

8. Jib Lift (located up under cover)

Provides raising and lowering of the jib.

9. Platform Rotate Control

Provides rotating the platform to the right or left.

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.

10. Platform Level Control

Provides for positioning the platform up and down to adjust the level of the platform.

11. Swing Control (See Figure 3-1.)

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.

Figure 3-1. Swing Control Valve

3-2 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Figure 3-2. Ground Control Station

3128791 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

3.2 Platform/Remote Control Station

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 control position for the platform/remote control is possible by connecting the platform/remote control station to the ground/remote control cable connector (item 1) located near the battery in the rear of the electrical components box. Machine electrical panel cover removed - See photo below.

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.

Unscrew the special adapter plug (item 2) from the ground/ remote cable connector (item 1) and attach to the platform/ remote flex cable in the platform when operating the platform/ remote control station at the ground position.

To enable this position it is necessary to have the key at the ground controls (Item 2 - Figure 3-2.) turned counterclockwise after connecting the platform/remote control box 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. Before connecting the special adapter plug ensure there is no moisture in the electrical connectors at any time.

Re-connect the special adapter plug (item 2) on the ground/ remote cable connector (item 1) as shown in photo, when using the platform/remote control station at the platform.

3-4 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Control Position From In The Platform:

The platform/remote control is connected to the machine at the platform using a flexible cable.

Always remember to close the platform/remote control station lid when not in use.

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 connector on the right side of the control box.

3. Lower 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. Secure this side of the control station by turning the thumbscrew on the locking tab counterclockwise locking the rib of the control station under the rotating metal tab of the thumbscrew.

2. In the platform, slide the control station assembly into the

storage box and place the rib on the left side of the control station assembly under the metal tab attached to the storage box assembly.

3128791 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

4. To remove the control station assembly, reverse the three

steps above.

NOTE: The Platform/Remote control box may also be used to

operate the tracks, outriggers and track widening (if equipped) 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.

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.

3-6 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

See Figure 3-3., Platform Control Console for remaining items.

NOTE: Buttons 1, 2, 3, 4, 5, 6, 7, 8, 9, serve a double func-

tion, 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. Tra c k W id t h A d j u s t

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 Service Menu.

7. Outrigger - Automatic Set And Level

This control allows the operator to control the extension of all 4 outriggers at one time.

8. Selector

Used only 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 PLATFORM Controls when turned counterclockwise (on). When pushed in (off), power is shut off to the platform and ground controls.

11. Gas/Diesel Engine Starter

This button allows the operator to start or stop the gas/ diesel engine.

12. Electric Engine Start

This button allows the operator to start or stop the electric engine.

3128791 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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.

15. Left Side Track Drive And Steer

This control when moved forward or rearward simultaneously with the right side track control (24), 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. Tower Boom Lift

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 platform 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 (17), allows the operator to move the machine in a straight forward or reverse direction or, if each control is moved individually or in opposite directions, to steer the machine.

3-8 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Figure 3-3. Platform/Remote Control Station

3128791 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

12 3

MAX

300

LB.

MAX

440

LB.

12 3

Platform/Remote Control Station LCD Display

At machine start-up and during machine operation the main LCD display screen (item 15 - Figure 3-3.) is activated. There are eight (8) display positions which indicate machine status during various stages of operation.

Position 1 Not Used.

Position 2 Displays the capacity based on jib position.

Position 3 Displays the selected engine (gas/diesel or

electric) and whether it is on or off. The X on the icon indicates the engine is off.

Position 4 Displays the selected engine speed.

3-10 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

12 3

MAX

300

LB.

MAX

440

LB.

12 3

CAN BUS

CARD

12 3

Position 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.

Position 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.

Position 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/diesel engine or connecting to a power source.

• CANBUS communication is faulty.

• Electronic fault.

• Lithium ION - Signals an error in the BMS - Battery Management System

Position 8 • Indicates that emergency lowering has

been selected.

• Lithium ION - Battery Charge Status

• Lithium ION - Battery Charger Plugged In.

3128791 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Table 3-1. LCD Display Icon Descriptions

3-12 – JLG Lift – 3128791

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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

3128791 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

Table 3-2. LCD Display Error Descriptions

3-14 – JLG Lift – 3128791

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 4-4.)

3128791 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION

NOTE: Initial starting must always be performed from the

ground controls.

The gas/diesel engine key switch on the engine must be switched to ON, the battery disconnect switch must be ON (see Section 4.10 on page 4-22) and power/emergency stop buttons at the platform and ground controls must be ON (turned clockwise) to start the engine.

Gas/Diesel Starting Procedure

NOTE: If gas/diesel engine fails to start promptly, do not

crank for an extended time. Should engine fail to start again, allow starter to cool off for 2-3 minutes. If engine fails after several attempts, refer to manufacturers engine maintenance manual.

NOTE: If engine is diesel, when starting from ground, turn the

start key at the engine to the HEAT (glow plug) position for 10 to 15 seconds before attempting to start. Release the key and start the engine.

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/diesel engine to warm-up for a few minutes

at low speed before applying any load.

Figure 4-1. Ground/Emergency Control Box

1. Platform/Remote (Center) Platform Position

2. Ground Control Position (Turn ClockWise and Hold)

3. Platform/Remote Ground Maintenance Position (Turned CounterClockWise)

NOTE: (1) Switch at engine must be set to ON, battery disconnect

switch must be ON, and both the ground and platform emergency stop switches must be set to ON.

4. Gas/Diesel Engine Start

5. Electric Engine Start Button

6. Enable Light

Button

(1)

(if equipped)

4-2 – JLG Lift – 3128791

(1)

SECTION 4 - MACHINE OPERATION

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.

Gas/Diesel 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/diesel engine by using the gas/die-

sel engine button (item 11, Figure 4-3.) on the plat- form/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 cir-

cuit, ensure the key on the gas/diesel engine is in the OFF 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) positioned 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.

3128791 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

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 - LITHIUMION 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. 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).

3. Start the electric engine using the engine start but-

ton at the ground/emergency control box. (item 5 - Figure 4-1. on page 4-2) and operate machine.

4. When finished operating the electric engine turn off

the electric engine at either the platform or ground control station.

5. Switch the circuit breaker switch (item 1) positioned

behind the clear cover on the breaker box, opposite

4-4 – JLG Lift – 3128791

side of machine, near the electric engine to the OFF position. (— symbol is ON - O symbol is OFF).

6. 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)

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.

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 pho-

tos)

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.

Base/Boom Alignment - Visual Indicator

Boom/Jib and Base Alignment - Reflectors/Photocells

3128791 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

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.

4-6 – JLG Lift – 3128791

Travelling (Grades and Side Slopes)

DO NOT DRIVE MACHINE ON GRADES EXCEEDING 21 DEGREES (38.4%).

USE RAMPS WHEN TRAVELLING ON STEPS OR OTHER SURFACES THAT ARE NOT SMOOTH OR HAVE GOOD TRACTION.

WHEN DRIVING ON SIDE-SLOPES, EXTEND THE LOW SIDE OUTRIGGERS UNTIL THEY ARE CLOSE TO THE GROUND TO HELP PEVENT A TIP-OVER IF A CHANGE IN SURFACE OCCURS. (SEE FIGURE 4-2.) DRIVE ON SIDE-SLOPES WITH THE BOOM STOWED. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 11 DEGREES.

SECTION 4 - MACHINE OPERATION

3128791 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Figure 4-2. Grade and Side Slope Definition

4-8 – JLG Lift – 3128791

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. 21° 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.

3128791 – JLG Lift – 4-9

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 self-levelling 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.

4-10 – JLG Lift – 3128791

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.

3128791 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

AUTO

MANUAL

SELECT

Setting Outriggers From the Platform/Remote Console

(Reference Figure 4-3. for item numbers)

Either - Press and hold the outrigger autoset and level button 7 (item 7) until OK appears on the platform LCD display.

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.

CHECK THE BUBBLE LEVEL TO CONFIRM UNIT IS LEVEL (BUBBLE IS 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.

4-12 – JLG Lift – 3128791

IF ONE OF THE ORANGE LIGHTS LOCATED ON EACH OUTRIGGER

AUTO

MANUAL

SELECT

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.

SECTION 4 - MACHINE OPERATION

Retracting The Outriggers

(Reference Figure 4-3. 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.

IF THE SLOPE EXCEEDS 11°, 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.

3128791 – JLG Lift – 4-13

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 but-

ton 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.

SECTION 4 - MACHINE OPERATION

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.

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.

Platform Level Adjustment

(Item 13, Figure 4-3.)

NOTE: During normal operation of the machine, the platform

will automatically maintain its position.

• To manually Level Up, turn the select switch clockwise and hold until desired position is reached.

4-14 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Figure 4-3. Platform/Remote Control Box

3128791 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

• To manually Level Down, turn the select switch counter clockwise and hold until desired position is reached.

Raise And Lower The Tower Boom

(Item 16, Figure 4-3.)

• 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 4-3.)

• 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.

Te l e s c o p e T h e M a i n B o o m

(Item 18, Figure 4-3.)

• 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 4-3.)

• 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 4-3.)

• To raise the jib, depress the foot switch and move the controller forward.

• To lower the jib, depress the foot switch and move the controller backwards.

Swinging The Boom (Item 21, Figure 4-3.)

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM AND UPRIGHT TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT. 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.

4-16 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

(

Figure 4-4. Platform - Load/Reach Chart

3128791 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Emergency Lowering

The main function of the emergency lowering is to lower the platform in the event of primary power failure.

Some functions will not operate since this is a gravity lowering system and a symbol will appear on the display if one of those functions are selected.

Operate as follows:

1. Ensure the emergency stop button is in the ON posi-

tion by turning it clockwise.

2. Depress the foot switch.

3. Push and hold down button 4 (item 4) on

the platform/remote control box. The LCD display will show the symbol shown on button 4 in position 8 on the LCD display.

(Items 4 and 15, Figure 4-3.)

4. Select a boom function to operate by moving the

paddle controller in the direction for lowering - (items

18, and 21 in Figure 4-3.)

5. When finished, release the emergency lowering

switch, controller and foot switch.

6. Position the emergency stop switch to the off posi-

tion.

Determine the reason for the primary power failure and have the problem corrected by a qualified JLG service technician.

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.

4-18 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

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.

4.8 BATTERY CHARGING - GAS/DIESEL/ACELECTRIC

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 noninsulated 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 damaged 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.

3128791 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

4.9 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 -8 hrs. - 120V AC 4 hrs. - 220V AC

• 80% Recharge - 4 hrs. - 120V AC

2 hrs. - 220V AC

• The batteries can be charged during machine operation,

(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 lithium-ion battery pack turns red, meaning the battery has started charging.

4-20 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

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 ventilation, 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

3128791 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

socket is old and not grounded. In this case, contact an electrician to have the socket replaced. Do not use adapters to resolve ungrounded circuit plug problems.

• Ensure the power cable is undamaged. If the cable is worn or damaged, have it replaced immediately.

• If extensions or multiple sockets 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.

4.10 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/diesel/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 emer-

gency stop buttons. remove the key at the ground controls, and turn off the key at the engine.

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.

4-22 – JLG Lift – 3128791

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

CounterClockwise

POWER ON

Clockwise

POWER OFF

CounterClockwise

BATTERY DISCONNECT - LITHIUM-ION - ELECTRIC

(Mounted Inside Left-Side Electrical Component Compartment)

BATTERY DISCONNECT - GAS/DIESEL/AC-ELECTRIC

3128791 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

4.11 LIFTING AND TIE DOWN

Lifting

1. Determine gross weight of machine, refer to the

serial number tag, or weigh the individual unit to find out the gross vehicle weight.

2. Place the booms in the stowed position and properly

aligned. All outriggers are fully retracted and the tracks are fully widened.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to the

machine and so the machine remains level.

5. The width of the slings must not exceed 2.36 in. (60

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

THE USE OF ROPES, CHAINS OR SLINGS WITH LENGTH LESS THAN 10 ft. (3m) COULD CAUSE PERMANENT DAMAGE TO THE MACHINE OUTRIGGERS.

To lift the machine a separate sling must be attached to each outrigger using the appropriate lifting points as indicated in the photo.

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 iden-

tical.

Figure 4-5. Lifting Machine - Attach Points

1. Lifting Slings

4-24 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Tie Down

(See Figure 4-6.)

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 4-9.

• ALWAYS load/unload the machine with the track fully widened.

1. Place the booms in the stowed position.

2. Remove all loose items from the machine.

3. 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. THIS COULD CAUSE PERMANENT DAMAGE RESULTING IN THE COLLAPSE OF THE PRODUCT.

3128791 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Figure 4-6. Machine Tie-Down Points (both sides of machine)

1. Tie-Down Loop 2. Tie-Down Decal

4-26 – JLG Lift – 3128791

4.12 MACHINE DECALS

SECTION 4 - MACHINE OPERATION

Figure 4-7. Decal installation - Standard - Right Side

3128791 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Figure 4-8. Decal Installation - Standard - Left Side

4-28 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Table 4-1. X550AJ - Decal Installation - Standard (See Figure 4-7. and Figure 4-8.)

ITEM # PART NUMBER DESCRIPTION

DECAL INSTALLATION

1 1706128 Decal, Danger - Electrocution Hazard - Maintain Distance From Electric Lines 2 1001125483 Decal, No Pressure Washing At This Location 3 07050300 Decal, Machine Maximum Capacity/Side Force - Jib Extended/Retracted 4 WIP Decal, Hand Pump Manual Descent Instructions 5 07042000 Decal, Machine Gross Weight 6 07042400 Decal, Outrigger Pad - Ground Pressure 7 07042600 Decal, 1m/3.3 ft. - Safe Working Distance When Operating M ach ine From Ground 8 06942200 Decal, Ground Key Switch Mode Selector

9 07045200 Decal, Ground Control Station - Control Valve - Manual Operation 10 07045100 Decal, Left Side - Outrigger/Drive/Steer - Manual Control Valve Operation 11 07045000 Decal, Right Side - Outrigger/Drive/Steer/Track Width - Manual Control Valve Operation 12 — Not Used 13 06555500 Decal, Outrigger Number 1 14 06555600 Decal, Outrigger Number 2 15 1701640 Decal, Manual 16 07056100 Decal, Warning - Boom Crushing Hazard 17 1702901 Decal, Manual Descent Instructions Inside 18 07056200 Decal, Warning - Crushing Hazard - Outrigge Pad 19 07056400 Decal, 120V - 50/60HZ - Electrical 20 07071200 Decal, Machine Lifting Point 21 06040500 Decal, Forward Travel Direction 22 1704277 Decal, Lanyard Attach Point

3128791 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

Table 4-1. X550AJ - Decal Installation - Standard (See Figure 4-7. and Figure 4-8.)

ITEM # PART NUMBER DESCRIPTION

23 — Not Used 24 1702155 Decal, Batter y Disconnect 25 06555700 Decal, Outrigger Number 3 26 06555800 Decal, Outrigger Number 4 27 — Not Used 28 — Not Used 29 07061900 Decal, X550AJ - Model Designation 30 06039700 Decal, Outrigger - Hazard Stripe 31 06086700 Decal, Platform Hazard Stripe 32 06039900 Decal, Outrigger - Hazard Stripe 33 06087400 Decal, Platform Hazard Stripe

1701505 Decal, Diesel Fuel Only 34 07060500 Decal, JLG Logo 35 — Not Used 36 06040200 Decal, Hydraulic Pump - Left/Right Side - Diverter Valve 37 — Not Used 38 06087700 Decal, Tower Boom End - Hazard Stripe 39 06087600 Decal, Tower Boom End - Hazard Stripe 40 06087500 Decal, Tower Boom End - Hazard Stripe 41 06087900 Decal, Tower Boom End - Hazard Stripe 42 1701504 Decal, Warning - Hydraulic Fluid Under Pressure 43 07042100 Decal, Boom Functions Safety System Bypass (Key Switch) 44 07042200 Decal, Drive Functions Safety System Bypass (Key Switch) 45 1703814 Decal, Machine Tie Down Location

4-30 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Table 4-1. X550AJ - Decal Installation - Standard (See Figure 4-7. and Figure 4-8.)

ITEM # PART NUMBER DESCRIPTION

46 — Not Used 47 1701499 Decal, Not A Machine Lif ting Point 48 07060700 Decal, JLG Lift Logo 49 — Not Used 50 — Not Used 51 1701499 Decal, Not A Machine Lif ting Point 52 — Not Used 53 06706500 Decals, Boom/Base Alignment Arrow 54 — Not Used 55 — Not Used 56 07051100 Decal, Warning - Fall Hazard - Platform Mounting Caps 57 07051000 Decal, Warning - Fall Hazard - Platform Mounting Caps 58 06165000 Decal, Hydraulic Oil Tank - Fluid Level Check 59 06056300 Decal, Danger - Hot Surface 60 — Not Used 61 — Not Used 62 1706898 Decal, Ground Control Emergency Stop Button 63 07045300 Decal, Ground Control Key Switch 64 — Not Used 65 1701542 Decal, Gasoline Fuel Only

1701505 Decal, Diesel Fuel Only 66 06232100 Decal, Warning - Gasoline - Flammable/Explosive 67 06060000 Decal, Check Motor Oil Level 68 — Not Used

3128791 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

Table 4-1. X550AJ - Decal Installation - Standard (See Figure 4-7. and Figure 4-8.)

ITEM # PART NUMBER DESCRIPTION

69 1706386 Decal, Warning - Fall Hazard - Platform 70 1706387 Decal, Warning - Crushing Hazard - Platform 71 1706133 Decal, Warning - Tip-Over Hazard - Platform 72 07058600 Decal, Warning - Tip-Over Hazard - Platfor m 73 1706385 Decal, Warning - Fall Hazard - Platform Gate 74 1706135 Decal, Warning - Ground Control Instructions 75 706099 Decal, Warning - Boom Crushing Hazard - Ground Controls 76 3252347 Decal, Warning - Platform Foot Switch 77 1702868 Decal, Caution - No Hands or Lanyard - Platform Rail 78 1703813 Decal, Warning - Battery Charging Ventilation - Explosion/Fire Hazard 79 1704972 Decal, Warning - Diesel Engine - Explosion/Fire Hazard - Glow Plugs/Star ting Fluid 80 1702961 Decal, Warning - Engine Exhaust Hazard

1702962 Decal, Califor nia Prop 65 Warning 81 1705514 Decal, CSA B354.4-02 82 07050700 Decal, NOT A Lanyard Attach Point 83 07071000 Decal, Platform Horn

4-32 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal installation - Lithium-Ion - Left Side

3128791 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Installation - Lithium-Ion - Right Side

4-34 – JLG Lift – 3128791

SECTION 4 - MACHINE OPERATION

Table 4-2. X550AJ - Decal Installation - Lithium Machine (See Figure 4-9. and Figure 4-10.)

ITEM # PART NUMBER DESCRIPTION

DECAL INSTALLATION

1 06520600 Decal, Operating Decibel Level 2 07110200 Decal, Emergency Descent Instructions 3 07107200 Decal, Warning - Batter y Hazard 4 1001125483 Decal, Do Not Pressure Wash 5 06506400 Decal, Power ON/OFF Key Switch 6 07107100 Decal, Recharge Batteries After Each Use or At Least Every 3 Months

3128791 – JLG Lift – 4-35

SECTION 4 - MACHINE OPERATION

NOTES:

4-36 – JLG Lift – 3128791

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

3128791 – 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 is in the ON posi-

tion by turning it clockwise.

2. Depress the platform foot switch.

3. 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.

4. Select a boom function to operate by moving it’s con-

troller in the direction for lowering. (items 16, 17, and 20)

5. When finished, release the emergency lowering switch

(item 4), and foot switch.

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

position.

5-2 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

Figure 5-1. Platform/Remote Control Station

3128791 – JLG Lift – 5-3

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.

5-4 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

Figure 5-2. Ground Control Station - Boom Control Valves

3128791 – JLG Lift – 5-5

SECTION 5 - EMERGENCY PROCEDURES

Manual Descent with Engine Running but without Electrical Power (Combustion Engines Only)

(See Figure 5-3.)

ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD OF PERSONNEL BEFORE LOWERING.

1. Remove the cover from the electrical components tray

on the left side of the machine.

2. Locate and remove the proportional valve adjustment

knob from the protective plastic bag,

3. Slide the adjustment knob assembly onto the propor-

tional valve stem (item 1) located next to the electric engine.

NOTE: The proportional valve 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 with the adjustment knob before operating the boom controls.

4. Turn the proportional valve adjustment knob clockwise

approximately four turns, the more turns the valve is open the faster the movement of the boom component.

Always carry out movement at the slowest possible speed.

5. Operate the boom control valves at the ground control

valve distributor. (see Figure 5-2.)

6. Make boom movements in the following sequence:

• fully retract main boom

• fully lower jib

• fully lower tower boom

• fully lower main boom

Figure 5-3. Main Flow Control Valve Location

7. When emergency operation is complete, loosen knob

on the proportional valve completely, remove it and place it back in the protective bag.

5-6 – JLG Lift – 3128791

Manual Descent without Engine and Electrical

Power

Using Hand Pump in Hydraulic Compartment on Right side of Machine

1. Platform retrieval sequence.

Ensure the machine is level and all outriggers are properly deployed on a firm surface.

a. Remove the cover from the electrical components

tray on the left side of the machine.

b. Locate and remove the proportional valve adjust-

ment knob from the protective plastic bag,

c. Slide the adjustment knob assembly onto the pro-

portional valve stem (item 1 - Figure 5-3.) located next to the electric engine.

d. Open the flow valve by turning the thumbwheel in

the clockwise direction until it stops.

e. Locate the pump handle secured to the side of the

boom assembly directly behind the hand pump.

f. Install the pump handle on the pump (item 1 - Figure

5-4.) and secure in place with the provided screw.

The lever (item 2 - Figure 5-4.) on the pump must be set to the left.

SECTION 5 - EMERGENCY PROCEDURES

Figure 5-4. Hand Pump - On Top Of Hydraulic Tank

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.

3128791 – JLG Lift – 5-7

SECTION 5 - EMERGENCY PROCEDURES

TO AVOID CONTACT BETWEEN THE JIB AND OUTRIGERS, DO NOT ATTEMPT TO MANUAL SWING WITH THE BOOMS AND JIB FULLY LOWERED.

2. Swing turntable inline with the chassis so that the turnta-

ble 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. Activate the swing control lever located next to the

main flow control valve (see photo below - item 1), in the desired direction of travel while pumping the hand pump until the turntable is aligned with the chassis.

b. Activating the lever rearward while pumping will

swing the platform to the left. Activating the lever forward while pumping will swing the platform to the right.

3. Retract the main boom (if necessary).

With the aid of an assistant, while pumping the hand pump, activate the telescope function lever (Item 7, Fig- ure 5-2.) at the ground controls, to retract the main boom.

4. Lower the jib.

While pumping the handpump, activate the jib lift function lever (item 8, Figure 5-2.) in the appropriate direction to lower the jib.

5. Lower the Tower Boom

While pumping the handpump, activate the tower boom lift function lever (item 5, Figure 5-2.) in the appropriate direction to lower the tower boom.

6. Lower the Main Boom

With the aid of an assistant, activate the main boom lift function lever (item 6, Figure 5-2.) in the appropriate direction to lower the main boom.

7. Rotate the platform (if necessary).

Activate the appropriate platform rotate function button to rotate the platform.

5-8 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

8. Level the platform (if necessary).

Activate the appropriate platform level function button to level the platform.

9. Completely unscrew (counterclockwise) the black thum-

bwheel from the diverter valve until it stops. Remove the thumbwheel from the shaft of the diverter valve.

10. Remove the manual pump handle from the pump and

secure to turntable in its original position.

Outrigger/Track Movement Emergency Procedure:

Outrigger/Track Movement Using the 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 chassis, locate the three valve and four

valve group of manual override buttons. The manual override buttons on these valves provide access to the right and left side outrigger and right and left track functions.

2. Locate the pump handle secured to the side of the

boom assembly directly behind the hand pump.

3. Install the pump handle on the pump and secure in

place with the provided screw. (item 3 - Figure 5-4.) The lever on the pump must be set to the right to manually operate right side outrigger and track functions.

3128791 – JLG Lift – 5-9

SECTION 5 - EMERGENCY PROCEDURES

For right side (operator's perspective) Outrigger and Track Functions:

4. Locate the proportional flow valve on the right side of

the chassis attached to the group of four valves (item 1 Figure 5-5.). Turn the black knob on the valve clockwise

(tighten) until it stops.

5. With the aid of an assistant, activate the pushbutton for

the desired direction on the appropriate valve solenoid (valve description below) while pumping the pump handle to achieve the desired function movement.

NOTE: If no assistant is available, the black pushbuttons on

the solenoids may be unscrewed to allow installation of the valve tool on the solenoids.

•1st valve (item 2 - Figure 5-5.) (far right - right side of machine in the group of four) operates Right Rear Outrigger

• 2nd valve (item 3 - Figure 5-5.) from the right in the group of four operates Right Front Outrigger

•3rd valve (item 4 - Figure 5-5.) from the right in the group operates the Right Track Drive functions.

•4th valve (item 5 - Figure 5-5.) from right in the group of four, operates track extension and retraction.

For left side (operator's perspective) Outrigger and Track Functions

6. Locate the proportional flow valve on the left side of the

chassis attached to the group of three valves (item 6 Figure 5-5.). Turn the black knob on the valve clockwise

(tighten) until it stops.

7. Install valve tool on diverter solenoid on left side near

rear outrigger.

8. The lever on the pump (item 2 - Figure 5-4.) must be set

to the left to manually operate left side outrigger and track functions.

9. With the aid of an assistant, activate the pushbutton for

the desired direction on the appropriate valve solenoid

5-10 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

while pumping the handle to achieve the desired function movement.

NOTE: If no assistant is available, the black thumbscrews on

the solenoids may be unscrewed to allow installation of a second valve tool on the solenoids.

•1st valve (item 7 - Figure 5-5.) (far right (at rear of machine) in the group of three) operates Left Front Outrigger.

• 2nd valve (item 8 - Figure 5-5.) from the right in the group of three operates Left Rear Outrigger.

•3rd valve (item 9 - Figure 5-5.) from the right in the group of three valves operates the Left Track Drive functions.

1. When manual operation is complete, remove (if neces-

sary) the valve tool(s), unscrew the proportional flow valve black knob and reinstall any valve solenoid retaining thumbscrews or pushbuttons.

2. Remove the manual pump handle from the pump and

secure it in its original position.

3128791 – JLG Lift – 5-11

SECTION 5 - EMERGENCY PROCEDURES

5-12 – JLG Lift – 3128791

Figure 5-5. Ground Component Valves - Outriggers/Steer/Tracks - Location

SECTION 5 - EMERGENCY PROCEDURES

5.4 SAFETY DEVICES BYPASS KEY USE

THIS FEATURE MUST ONLY BE USED AS DESCRIBED BELOW. THE MACHINE COULD TIP OVER IF THESE DIRECTIONS ARE NOT FOLLOWED.

The machine has a key for bypassing the platform safety systems. The key used to activate the safety device bypass switch (item 2 - photo), is fastened to the cover attach screw mounting tab from the factory (item 1 - photo), on the left side of the electrical components compartment near the battery.

Remove the key and insert it into the bypass key switch (item 2 - photo). After using the safety device bypass, a qualified JLG mechanic must be contacted to determine the reason for

needing to use this feature. Return the key to the where you found it and secure it in that location.

The safety device circuit board records every time the safety device bypass key is activated along with the movements made during these operations.

THE SAFETY DEVICE BYPASS ALLOWS OPERATION OF THE MACHINE WITH AN OVERLOAD IN THE PLATFORM. THE OVERLOAD ALARM WILL SOUND AND THE OVERLOAD ICON WILL BE ON THE PLATFORM/REMOTE CONTROL BOX DISPLAY. REMOVE THE OVERLOAD FROM THE PLATFORM BEFORE OPERATION.

3128791 – JLG Lift – 5-13

SECTION 5 - EMERGENCY PROCEDURES

Using The Emergency Descent In The Case Of An Outrigger Losing Contact With The Ground

One or more of the outriggers may loose contact with the ground which will result in the platform/remote control box functions being inoperable except for emergency lowering.

To restore platform/remote control box functions, lower and retract the booms and then reposition the machine and properly set the outriggers.

Use the emergency descent from the platform if possible by using the following sequence, fully retract main boom, fully lower jib, fully lower tower boom, and fully lower main boom.

If this is not possible, have a properly trained person on the ground bypass the platform safety devices and allow the operator in the platform to lower and retract the booms or allow emergency manual operations to bring the platform back to the ground.

1. Locate and use the safety device bypass key as stated

above.

2. Activate the safety device bypass by turning the key in a

counterclockwise direction and hold it in position (see decal).

3. The safety devices BYPASS icon will appear

on the platform/remote control box display.

4. Operate the machine from the platform/remote control

ONLY carrying out operations that allow the tower boom lowering, main boom retract and jib lowering. The main boom must be fully retracted prior to operating swing and main boom lowering functions.

NEVER PERFORM OPERATIONS DIFFERENT TO THOSE LISTED OR THAT CAN IN SOME WAY REDUCE THE STABILITY OF THE MACHINE. THE ORDER OF THE BOOM MOVEMENTS MUST BE DONE IN A WAY TO PREVENT ANY OPERATION THAT REDUCES THE STABILITY OF THE MACHINE.

5. Once the booms and jib are fully lowered and aligned,

release the key and follow the instructions above to secure the key.

5-14 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

Machine Realignment Emergency Procedure

THIS OPERATION MUST ONLY BE PERFORMED WITH THE BOOMS AND JIB FULLY LOWERED AND RETRACTED.

During transport, the turntable may swing and become out of alignment with the base. If this occurs, one of the two EMERGENCY PROCEDURES given below can be used:

Machine Realignment:

1. Open the electric components compartment;

2. Locate and use the safety device bypass key as

described above;

3. Activate the safety device bypass by turning the key in a

counterclockwise direction and holding it in position (see decal beside keyswitch);

4. The safety devices BYPASS icon will appear

on the platform/remote control box LCD display.

5. Realign the machine while operating the

swing function from the platform/remote control box.

6. Once the machine is aligned, release the key and store

it as stated above.

Movement Of The Tracks With The Machine Not Aligned:

OPERATION ONLY ALLOWED TO GO TO A CONDITION SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN "MACHINE REALIGNMENT" ABOVE. ALL OTHER USE IS PROHIBITED.

1. Open the electric components compartment;

2. Locate and use the safety device bypass key as

described above;

3. Activate the safety device bypass key by turning it in a

clockwise direction and holding it in position (see decal);

4. The safety devices BYPASS icon will appear

on the platform/remote control box display.

5. Operate the drive/steer controls with

extreme caution.

6. Move the machine to a proper location to perform

"Machine Realignment" procedure to realign the machine.

7. At the end of the operation release the key and store it

as is described above.

The control circuit board records every activation of the safety device bypass key.

3128791 – JLG Lift – 5-15

SECTION 5 - EMERGENCY PROCEDURES

5.5 LITHIUM-ION BATTERY PACK - HANDLING IN DANGEROUS CONDITIONS

The battery cells must be handled correctly in order to ensure proper and safe use. However, if mistakes are made in handling the cells, causing explosion or venting, the user has to be equipped so as to be able to face this emergency. The aim of this section is to adequately train the user on safe handling of the cells that have been subjected to extreme conditions.

These Conditions Are As Follows:

1. Hot cells

2. Cells that have released substances or vented

3. Exploded cells

4. Fire enveloping the lithium batteries

Procedure For Handling Hot Cells

As soon as it has been established that the temperature of a cell has risen considerably, the first action is the evacuation of personnel from the affected area. The area has to be isolated and nobody can enter if not strictly necessary.

If possible, before leaving the area, the person who first identified the problem has to check if there is an external short-circuit and resolve it as soon as possible. After the short-circuit has been resolved, the cell will start to cool down. However, the area has to remain isolated until the cell reaches ambient temperature and is removed from the area. The temperature of the cell has to be checked periodically using a remote sensor such as an infrared sensor. If the cell remains hot the following actions must be assessed.

Minimum Equipment Required:

• Infrared temperature probe

• Safety glasses

• Hard hat with impact resistant face visor

• Non-conductive pliers

• Hand, arm and body protection

5-16 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

Start Procedure;

1. Evacuate the area as soon as abnormal cell temperature

has been established.

2. Periodically check the temperature of the cell using a

remote sensor for the first two hours or until one of the following cases occur:

• The cell starts to cool down

• The cell vents

• The cell explodes

3. If the cell starts cooling, check the temperature every

hour until ambient temperature has been reached.

4. If a temperature sensor is not available, do not handle

the cell for a minimum of 24 hours.

5. Remove the cell from the work area when ambient tem-

perature has been reached and return to normal operations.

6. Dispose of the cell in accordance with existing legislation

(in the country in question) on hazardous materials.

The procedures in cases of venting or explosion are examined in the following paragraphs.

Procedure For Handling Vented Cells

In normal conditions a cell does not show leaks or venting, however a cell may vent or release substances if the critical temperature is reached or if the protective glass.metal seal breaks due to severe mechanical conditions.

The severity of the leak consequent to venting ranges from slight leak around the seal to a violent leak of substances through the vent. In some cases, if the cell is not plugged, it may behave as a projectile.

The electrolyte inside the cell may cause very serious irritation to the respiratory tract, eyes and skin. In addition, venting may cause the emission of highly corrosive vapors in the work environment. In this case, all protective equipment suited to limit exposure to toxic fumes must be available.

Minimum Equipment Required;

• Class D fire extinguisher

• Eye protection or face shield

• Respirator with filter for hydrochloric acid and sulphur dioxide

• Neoprene gloves

• Acid.resistant lab coats

• Baking soda, calcium oxide or acid absorbent in kit form

•Vermiculite

•Plastic bags

3128791 – JLG Lift – 5-17

SECTION 5 - EMERGENCY PROCEDURES

Start Procedure;

In the event of electrolyte release from the cells, proceed as follows:

1. Evacuate the people exposed to fumes from the area.

2. Air the environment until the complete removal of the cell

and until the characteristic pungent odour has disappeared.

3. If the cell is too hot, allow it to cool to ambient tempera-

ture before handling it (see “Procedure For Handling Hot Cells” on page 16).

4. Wear safety equipment: coat, gloves, mask and filters,

and move the cell to a well-ventilated area.

5. Place every cell in a sealable plastic bag and remove the

excess air, then seal the bag.

6. Place a cup of vermiculite in a second bag, place the first

bag in the second and seal it.

7. Place everything in a third bag with some baking soda

and seal the bag.

8. Absorb and collect the leaked electrolyte with absorbent

material or baking soda.

9. Place the absorbent material in a bag and seal it.

10. Clean the area with plenty of water.

11. Dispose of the hazardous material in accordance with

the local legislation in force.

First Aid In The Event Of Contact With The Electrolyte

EYES

Immediately wash the eyes in abundant running water for at least 15 minutes, keeping the eyelids open and flushing the eye and back of the eyelid. Immediately seek medical help.

SKIN

Wash in cold water under a shower, remove contaminated garments. Continue washing for at least 15 minutes. Seek medical help where necessary.

RESPIRATORY TRACT

Move the person(s) outdoors into the open air. If the person(s) has difficulty breathing, have oxygen administered by trained personnel. If breathing stops, apply mouth-to-mouth resuscitation and immediately seek emergency medical help.

5-18 – JLG Lift – 3128791

SECTION 5 - EMERGENCY PROCEDURES

Procedure For Exploded Cells

The explosion of lithium batteries is not likely, it is a rare event that only occurs when an abnormal condition causes the temperature to rise and reach a critical point. However, in the event of lithium battery explosion the environment will quickly be filled with dense white smoke which will cause serious irritation to the respiratory tract, eyes and skin. Precautions must be taken to limit exposure to these fumes.

Minimum Equipment Required;

• Class D fire extinguisher

• Class ABC extinguisher for any secondary fires

• Eye protection or face shield

• Respirator with filter for hydrochloric acid and sulphur dioxide

• Neoprene gloves

• Acid.resistant lab coats

• Baking soda, calcium oxide or acid absorbent in kit form

•Vermiculite

•Plastic bags

Start Procedure;

In the event of cell explosion, proceed as follows:

1. Evacuate personnel from the areas contaminated by

smoke.

2. Ventilate the rooms until the cell has been removed from

the area and until the characteristic pungent odour has disappeared.

3. Even if this is quite unlikely, there may be fires as a con-

sequence of the explosion. The ways these emergencies are faced are described in the following paragraph.

4. The exploded cell may be hot. Allow it to cool down to

ambient temperature before handling it (see Procedure for handling hot cells).

5. Wear safety equipment: coat, gloves, mask and filters.

6. In case of explosion the area around the cell will be cov-

ered by a black carbonaceous material which contains metallic parts of the cell. Cover the carbonaceous residues with a 50/50 mixture of baking soda and vermiculite or other absorbent material. Avoid contact between the metallic residues and charged cells, as this condition may cause a short.circuit.

7. Place the contaminated material in a sealable plastic bag

and remove the excess air.

8. Seal the bag.

3128791 – JLG Lift – 5-19

SECTION 5 - EMERGENCY PROCEDURES

9. Place a cup of vermiculite in a second bag, place the first

bag in the second and seal it.

10. Clean the area with plenty of water and keep cleaning

with water and soap.

11. Dispose of the hazardous material in accordance with

the local legislation in force.

First Aid In The Event Of Contact With The Electrolyte;

EYES

Immediately wash the eyes in abundant running water for at least 15 minutes, keeping the eyelids open and flushing the eye and back of the eyelid. Immediately seek medical help.

SKIN

Wash in cold water under a shower, remove contaminated garments. Continue washing for at least 15 minutes. Seek medical help where necessary.

RESPIRATORY TRACT

Move the casualty outdoors into the open air. If the person(s) has difficulty breathing, have oxygen administered by trained personnel. If breathing stops, apply mouth-to-mouth resuscitation and immediately seek emergency medical help.

Lithium Battery Fire

All metals may burn in certain conditions, which depend on certain factors such as: physical state, presence of oxidising atmospheres and severity of the source of ignition. Alkali metals such as lithium may burn in normal atmospheres. In addition, lithium reacts explosively with water to form hydrogen and the presence of small quantities of water may set fire to the material and the hydrogen gas that is released. Once metal fires start they are very hard to extinguish with ordinary equipment. This is partly due to the strong heat produced by the burning metal, whose temperature may reach 1832° F (1000° C). In addition, lithium may react with certain materials commonly used in fire extinguishers, like water and CO2. Special extinguishers are required, designed for controlling and extinguishing lithium fires.

In particular, graphite-based extinguishers (Lith-x) are used. Usually these extinguishers work by forming a crust or a layer of material on the surface of the burning metal. Lith-x, which is a common graphite-based agent, may be used with an extinguisher or spread over the fire. In the event of lithium fire, the room may fill with a dense white smoke, mostly formed by lithium oxide and other metal oxides. This condition may cause serious damage to the respiratory tract, skin and eyes. All precautions needed to limit exposure to these fumes must be adopted. It should be noted that this procedure is applicable only to fires on individual cells. Larger fires have to be managed only by professionally trained personnel.

5-20 – JLG Lift – 3128791

JLG X500AJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

Contact :

In USA:

Outside USA:

REVISION LOG

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

Operator Training and Knowledge

1.2 BEFORE OPERATING THE LIFT

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 LIFTING, AND HAULING

1.5 ADDITIONAL HAZARDS / SAFETY

SECTION 2. PREPARATION AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

Function Check

General

SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION

3.1 Ground Control Station

3.2 Platform/Remote Control Station

Control Position On The Ground:

Control Position From In The Platform:

Platform/Remote Control Station Functions

Platform/Remote Control Station LCD Display

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 BOOM OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 ENGINE OPERATION

Gas/Diesel Starting Procedure

Gas/Diesel Engine Shutdown Procedure

Electric Engine Starting Procedure - AC Voltage Machine

4.4 BASE AND BOOM/JIB ALIGNMENT

4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH ADJUST

Track width adjust

Travelling (Drive and Steer)

Travelling (Grades and Side Slopes)

Jib Position for Travelling

4.6 OUTRIGGER OPERATION

Setting Outriggers From the Platform/Remote Console

4.7 BOOM/PLATFORM OPERATION

Overload Alarm

Platform Level Adjustment

Raise And Lower The Tower Boom

Raise And Lower The Main Boom

Te l e s c o p e T h e M a i n B o o m

Platform Rotation (Item 19, Figure 4-3.)

Raise And Lower The Jib (Item 20, Figure 4-3.)

Emergency Lowering

Platform Removal/Installation

Battery Charging - Daily

4.9 BATTERY CHARGING - LITHIUM-ION MACHINE

Charging the Battery Pack

Charge Curve

4.10 SHUT DOWN AND PARK

4.11 LIFTING AND TIE DOWN

Lifting

Tie Down

4.12 MACHINE DECALS

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL

5.2 INCIDENT NOTIFICATION

5.3 EMERGENCY OPERATION