Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times.
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.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND. INDICATES A POTENTIALITY HAZARDOUS SITUATION.
SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS For : THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT. JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. JLG INDUSTRIES, INC.
SECTION - REVISION LOG REVISION LOG Original Issue of Manual. . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT • PAGE FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C Outside USA: . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT 4.4 4.5 4.6 4.7 4.8 4.9 ii PAGE Electric Engine Starting Procedure AC Voltage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 Electric Engine Starting Procedure LITHIUM-ION Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . . . . 4-6 TRACKS - DRIVING, STEERING AND TRACK WIDTH ADJUST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 Track width adjust . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE 5.4 SAFETY DEVICES BYPASS KEY USE . . . . . . . . . . . . . .5-13 Using The Emergency Descent In The Case Of An Outrigger Losing Contact With The Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 Machine Realignment Emergency Procedure .5-15 5.5 LITHIUM-ION BATTERY PACK - HANDLING IN DANGEROUS CONDITIONS. . . . . . . . . . . . . . . . . . . . .5-16 Procedure For Handling Hot Cells . . . . . . . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT LIST OF FIGURES 2-1. 2-2. 3-1. 3-2. 4-1. 4-2. 4-3. 4-4. 4-5. 4-6. 4-7. 4-8. 4-9. 4-10. 4-11. 4-12. 4-13. 5-1. 5-2. 5-3. 5-4. 5-5. iv 6-1. Basic Machine Nomenclature . . . . . . . . . . . . . . . . 2-6 Daily Walk-Around Inspection . . . . . . . . . . . . . . . 2-8 Ground Control Station . . . . . . . . . . . . . . . . . . . . . 3-3 Platform/Remote Control Station . . . . . . . . . . . . 3-9 Ground/Emergency Control Box . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIST OF TABLES 1-1 1-2 2-1 3-1 3-2 4-1 4-2 Minimum Approach Distances (M.A.D.) . . . . . . .1-5 Beaufort Scale (For Reference Only). . . . . . . . . . .1-7 Inspection and Maintenance Table . . . . . . . . . . .2-3 LCD Display Icon Descriptions . . . . . . . . . . . . . . 3-13 LCD Display Error Descriptions . . . . . . . . . . . . . 3-15 X600AJ - Decal Installation - Standard. . . . . . .
TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE NOTES: vi – JLG Lift – 3121637
SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS 1.1 GENERAL This section outlines the necessary precautions for proper and safe machine usage and maintenance. It is mandatory that a daily routine is established based on the content of this manual to promote proper machine usage.
SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibilities until adequate training has been given by competent and authorized persons. Workplace Inspection • Allow only those authorized and qualified personnel to operate the machine who have demonstrated that they understand the safe and proper operation and maintenance of the unit. • Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this manual.
SECTION 1 - SAFETY PRECAUTIONS Machine Inspection 1.3 • Do not operate this machine until the inspections and functional checks as specified in Section 2 of this manual have been performed. General • Do not operate this machine until it has been serviced and maintained according to the maintenance and inspection requirements as specified in the machine’s Service and Maintenance Manual. • Ensure all safety devices are operating properly. Modification of these devices is a safety violation.
SECTION 1 - SAFETY PRECAUTIONS • 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. • 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.
SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed and fastened in their proper position. Electrocution Hazards • This machine is not insulated and does not provide protection from contact or proximity to electrical current. • Keep both feet firmly positioned on the platform floor at all times. Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose.
SECTION 1 - SAFETY PRECAUTIONS tional clearance is required for every additional 30,000 volts or less. • Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-1. • 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.
SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • The user must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving. • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis and outriggers of the machine a minimum of 2 ft. (0.6m) from holes, bumps, dropoffs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). Table 1-2. Beaufort Scale (For Reference Only) 1-8 Wind Speed Beaufort Number mph m/s 0 0 0-0.2 Calm Calm. Smoke rises vertically 1 1-3 0.3-1.5 Light air Wind motion visible in smoke 2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle 3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 4 13-18 5.5-7.
SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Approved head gear must be worn by all operating and ground personnel. • Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving. • Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors which may cause collision or injury to personnel.
SECTION 1 - SAFETY PRECAUTIONS 1.4 TOWING, LIFTING, AND HAULING 1.5 • Never allow personnel in platform while towing, lifting, or hauling. MAINTENANCE This sub-section contains general safety precautions which must be observed during maintenance of this machine. Additional precautions to be observed during machine maintenance are inserted at the appropriate points in this manual and in the Service and Maintenance Manual.
SECTION 1 - SAFETY PRECAUTIONS • When performing welding or metal cutting operations, precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. • Always relieve hydraulic pressure from all hydraulic circuits before loosening or removing hydraulic components. • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid.
SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical components or when performing welding on the machine. BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION. • Do not allow smoking, open flame, or sparks near battery during charging or servicing. • Charge batteries only in a well ventilated area.
SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 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. 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.
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.
SECTION 2 - PREPARATION AND INSPECTION Table 2-1.Inspection and Maintenance Table Type Primary Responsibility Frequency Service Qualification Reference Pre-Start Inspection Before using each day; or whenever there’s an Operator change. User or Operator User or Operator Operation and Safety Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.
SECTION 2 - PREPARATION AND INSPECTION Pre-Start Inspection The Pre-Start Inspection should include each of the following: 5. 6. 7. 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. 8. 9. 10. Parent Metal Crack Weld Crack 11. 3.
SECTION 2 - PREPARATION AND INSPECTION b. Check that all guards protecting the function control switches and controllers are in place; 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). c. Operate all functions. Function Check e. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in. d.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-1.
SECTION 2 - PREPARATION AND INSPECTION Basic Machine Nomenclature 1. 2. 3. 4. 5. 6. 7. 8. 9. 3121637 Main Boom Tower Boom Assembly Gas or Diesel Engine Outriggers (4 places) Electric Components Compartment (Left Side of Machine) Ground/Emergency controls (Left Side of Machine) Tracked Undercarriage Turntable Hydraulic Oil tank - (Right Side of Machine) – JLG Lift – 10. Hand Pump - (Right Side of Machine) 11. Electric Motor 12. Track and Outrigger Valves/Manual Controls (Under Cover) 13. Jib 14.
SECTION 2 - PREPARATION AND INSPECTION Figure 2-2.
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.
SECTION 2 - PREPARATION AND INSPECTION NOTES: 2-10 – JLG Lift – 3121637
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION the ground controls are operational. With the switch turned counter clockwise, the platform (remote) control box may be connected to the ground/maintenance cable port located in the electrical components compartment and operated from the ground.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 5. Platform Level Control Provides for positioning the platform up and down to adjust the level of the platform. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/ OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 6. Platform Rotate Control Provides rotating the platform to the right or left. 7. Jib Lift Provides raising and lowering of the jib.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-1.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 3.2 PLATFORM/REMOTE CONTROL STATION Maintenance Control Position On The Ground This control position is for function check and maintenance only. NOTE: Before removing or connecting the platform flex cable connector plug from the control box, depress the emergency stop buttons and the key on the engine must be in the OFF position. Do not operate the machine from this position if anyone is in the platform. 1.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION control station to the ground/remote cable connector. This key switch overrides the footswitch in the platform. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR CONTROL SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. NOTE: Before removing or connecting the special adapter plug, depress the emergency stop buttons and the key on the engine must be in the OFF position.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 2. In the platform, slide the control station assembly into the storage box, on the right side of the control station ensure the attached flexible cable slides into the slot in the box. Now place the rib on the right side of the control station assembly under the metal tab attached to the storage box assembly 4. To remove the control station assembly, reverse the three steps above. 3.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 1. Outrigger - Automatic Retract This control allows the operator to control the retraction of all 4 outriggers at one time. 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.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 8. Override/Selector If the machine is driven into a tilt condition, this button may be pressed to override the drive cutout. Each press of the button will allow the drive function to operate for approximately 8 seconds to back the machine from the tilt condition. This button is also used for selecting an item when in the Service Menu (item 6). 9. Track Width Adjust This control allows the operator to narrow the track. 12.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 15 16 17 18 2 1 20 19 3 4 5 23 11 22 21 6 14 7 8 9 10 12 13 Figure 3-2.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 15. Left Side Track Drive And Steer This control when moved forward or rearward simultaneously with the right side track control (22), allows the operator to move the machine in a straight forward or reverse direction. If each control is moved individually, different amounts or in opposite directions steering the machine occurs. 20. Jib This control allows the operator to raise and lower the jib. 16.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform/Remote Control Station LCD Display Position 1 At machine start-up and during machine operation the main LCD display screen (item 15 - Figure 3-2.) is activated. There are eight (8) display positions which indicate machine status during various stages of operation. 1 2 3 4 5 6 7 8 Not Used. 1 2 3 4 5 6 7 8 Position 2 Not Used.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Position 5 1 2 3 4 5 6 7 8 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. Position 7 1 2 3 4 5 6 7 8 If an overload occurs the main screen goes blank for 3 seconds followed by the overload error display and an alarm. Can indicate any of the following situations: • An emergency stop is pushed in (off). • A low battery.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2.
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION NOTES: 3-16 – JLG Lift – 3121637
SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION 4.1 DESCRIPTION 4.2 This machine is a hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating boom. BOOM OPERATING CHARACTERISTICS AND LIMITATIONS Capacities 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.
SECTION 4 - MACHINE OPERATION 4.3 ENGINE OPERATION NOTE: Initial starting must always be performed from the ground controls. The gas engine key switch on the engine must be switched to ON, the battery disconnect switch must be ON (see Section 4.11 on page 4-23) and power/emergency stop buttons at the platform and ground controls must be ON (turned clockwise) to start the engine. 4 5 Gas Engine Starting Procedure NOTE: If gas engine fails to start promptly, do not crank for an extended time.
SECTION 4 - MACHINE OPERATION NOTE: At low temperatures start the motor and let it run for a few minutes, until the hydraulic oil circulates and reaches at least 50°F (10°C) before operating the platform. Gas Engine Shutdown Procedure 1. Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature. 2. Turn off the gas engine by using the gas engine button (item 11, Figure 4-4.) on the platform/ remote control box. 3.
SECTION 4 - MACHINE OPERATION Electric Engine Starting Procedure - LITHIUM-ION Machine 1 1. Set the ON/OFF switch on the lithium-ion battery pack to the ON position, (0 symbol is OFF, 1 is ON). 2 3 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. 2.
SECTION 4 - MACHINE OPERATION 4 2 1 3 Figure 4-2. Ground/Emergency Control Box - Lithium Ion 1. Platform/Remote (Center) Platform Position 2. Ground Control Position - (Turn ClockWise and Hold) 3121637 3. Platform/Remote Ground Maintenance Position (Turned CounterClockWise) 4.
SECTION 4 - MACHINE OPERATION 4.4 BASE AND BOOM/JIB ALIGNMENT The machine has two reflectors/photocells that check if the boom assembly is completely lowered and retracted, the jib is lowered, and the turntable is aligned with the base. (see photos) When these conditions are met this symbol will display in position (6) on the Platform/ Remote Control LCD display. UNLESS THESE CONDITIONS ARE MET, DRIVE, STEER, TRACK WIDTH ADJUSTMENT, AND OUTRIGGER MOVEMENT IS PREVENTED.
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. Travelling (Drive and Steer) USE EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TERRAIN OBSTACLE.
SECTION 4 - MACHINE OPERATION WHEN DRIVING ON SIDE-SLOPES, EXTEND THE LOW SIDE OUTRIGGERS UNTIL THEY ARE CLOSE TO THE GROUND TO HELP PREVENT A TIP-OVER IF A CHANGE IN SURFACE OCCURS. (SEE FIGURE 4-3.) DRIVE ON SIDESLOPES WITH THE BOOM STOWED. DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 10 DEGREES.
SECTION 4 - MACHINE OPERATION Figure 4-3.
SECTION 4 - MACHINE OPERATION Jib Position for Travelling It is necessary to raise the JIB arm when driving up or down slopes that exceed 10° and but less than the max. 15° to prevent the jib from contacting the ground. 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.
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. 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.
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.
SECTION 4 - MACHINE OPERATION Setting Outriggers From the Platform/Remote Console (Reference Figure 4-4. for item numbers) Either - Press and hold the outrigger autoset and level button 7 (item 7) until OK appears on the platform LCD display. AUTO 7 MANUAL SELECT 2 or Operate each outrigger separately by pressing button 2 (item 2) to select which outrigger to control (each outrigger is numbered 1 thru 4, see decal, each press of button 2 displays the outrigger selected on the LCD display).
SECTION 4 - MACHINE OPERATION Retracting The Outriggers IF ONE OF THE ORANGE LIGHTS LOCATED ON EACH OUTRIGGER SHOULD REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE GROUND, STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG SERVICE TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRESPONDING OUTRIGGER MICRO SWITCH. (Reference Figure 4-4. for item numbers) IF THE SLOPE EXCEEDS 12°, THE MACHINE IS NOT CAPABLE OF PROPERLY SETTING THE OUTRIGGERS AND LEVELING ITSELF.
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.
SECTION 4 - MACHINE OPERATION 15 16 17 18 2 1 20 19 3 4 5 23 11 22 21 6 14 7 8 9 10 12 13 Figure 4-4.
SECTION 4 - MACHINE OPERATION • To manually Level Down, turn the select switch counter clockwise and hold until desired position is reached. • To retract the main boom, depress the foot switch and move the controller forward. Platform Rotation (Item 19, Figure 4-4.) 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.
SECTION 4 - MACHINE OPERATION ( Figure 4-5.
SECTION 4 - MACHINE OPERATION 4.8 Platform Installation 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. 1.
SECTION 4 - MACHINE OPERATION 4.9 BATTERY CHARGING - GAS/AC-ELECTRIC Battery Charging - Daily NOTE: Be sure that the machine is parked in a well ventilated area free of flames and sparks. • Only plug the charger into a properly grounded outlet. • Do not use ground adaptors or modify plug. Do not touch non-insulated portion of output connector or non-insulated battery terminal. • Always disconnect the AC supply before making or breaking the connections to the battery.
SECTION 4 - MACHINE OPERATION 4.10 BATTERY CHARGING - LITHIUM-ION MACHINE Charging the Battery Pack 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 three (3) phase 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: first phase of recharging.
SECTION 4 - MACHINE OPERATION 1 2 4-22 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.
SECTION 4 - MACHINE OPERATION • • • • • • • case, contact an electrician to have the socket replaced. Do not use adapters to resolve ungrounded circuit plug problems. Ensure the power cable is undamaged. If the cable is worn or damaged, have it replaced immediately. If extensions or multiple sockets are used, make sure that these support the total rated current. Disconnect the power supply before connecting or disconnecting the battery.
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.
SECTION 4 - MACHINE OPERATION 4.12 LIFTING AND TIE DOWN LIFTING POINTS AS INDICATED IN FIGURE 4-6. OTHERWISE THE MACHINE MAY NOT BALANCE PROPERLY AND MOVE UNEXPECTEDLY. Lifting - Outrigger Lifting Rings 1. Determine gross weight of machine, refer to the serial number tag, or weigh the individual unit to find out the gross vehicle weight. 2. Configure the machine in the transport position; a. place the booms in the stowed position and properly aligned b. all outriggers are fully retracted c.
SECTION 4 - MACHINE OPERATION Figure 4-7.
SECTION 4 - MACHINE OPERATION Lifting - Fork Lift Pockets The machine is equipped with two tubular fork lift pockets designed to lift the machine using a forklift of suitable capacity. 1. Determine gross weight of machine, refer to the serial number tag, or weigh the individual unit to find out the gross vehicle weight. 2. Configure the machine in the transport position; a. place the booms in the stowed position and properly aligned b. all outriggers are fully retracted c. tracks are fully widened d.
SECTION 4 - MACHINE OPERATION • Make sure that the ramps do not exceed the maximum inclination of 15°; Loading and Unloading the Machine on Transport Vehicles Using Ramps • Make sure that the ramps and the trailer have the capacity to support the machine and are free from debris or slippery material; • Position the ramps parallel to each other at a distance equal to the space between the drive tracks; The JLG platform offers high maneuverability and stability even in travelling (stowed) configuration.
SECTION 4 - MACHINE OPERATION 1. Configure the machine to the transport position; a. place the booms in the stowed position and properly aligned b. all outriggers are fully retracted c. tracks are fully widened d. remove all loose items from the machine 2. Secure the chassis using straps or chains of adequate strength. Tie Down (See Figure 4-9.) WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. • Travel up ramps with the platform behind the machine.
SECTION 4 - MACHINE OPERATION 2 1 1 2 1703814A 1703814A 1701499 1701499 Figure 4-9. Machine Tie-Down Points (both sides of machine) 1. Tie-Down Loop 4-30 2.
SECTION 4 - MACHINE OPERATION 4.13 MACHINE DECALS 32 32 13 32 32 9 28 14 10 17 6 58 28 10 5 19 32 16 15 32 32 5 9 14 1 26 36 42 7 47 21 23 57 53 52 12 57 2 26 36 31 8 37 33 41 47 40 48 34 35 39 11 47 35 60 20 51 55 59 Figure 4-10.
SECTION 4 - MACHINE OPERATION 5 9 14 13 32 32 32 32 14 9 43 44 54 5 56 32 32 32 27 4 3 26 36 26 36 47 38 46 54 11 5 39 7 18 45 10 28 10 28 29 25 47 30 22 47 5 23 GASOLINE 24 49 22 21 54 Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1. X600AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1. X600AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.
SECTION 4 - MACHINE OPERATION Table 4-1. X600AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.
SECTION 4 - MACHINE OPERATION 6 4 1 3 2 2 Figure 4-12.
SECTION 4 - MACHINE OPERATION 4 5 1 2 7 2 Figure 4-13.
SECTION 4 - MACHINE OPERATION Table 4-2. X600AJ - Decal Installation - Lithium Machine (See Figure 4-12. and Figure 4-13.
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 5.3 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.
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.
SECTION 5 - EMERGENCY PROCEDURES 15 16 17 18 2 1 20 19 3 4 5 23 11 22 21 6 14 7 8 9 10 12 13 Figure 5-1.
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. 5-4 – JLG Lift – 4.
SECTION 5 - EMERGENCY PROCEDURES Figure 5-2.
SECTION 5 - EMERGENCY PROCEDURES NOTE: The distributor enable valve (item 12) adjusts the speed of the boom movements (pressure flow) when using the boom control valves at the valve distributor on the left side of the machine in Figure 5-2. Without electrical power you must manually open this valve by pressing it in before operating the boom controls. Manual Descent with Engine Running but without Electrical Power (Combustion Engines Only) (See Figure 5-2.
SECTION 5 - EMERGENCY PROCEDURES Manual Descent without Engine and Electrical Power Using Hand Pump Mounted to Hydraulic Tank on Right side of Machine Platform Retrieval Sequence 1. Ensure the machine is level and all outriggers are properly deployed on a firm surface. If outrigger movement is required first, See “Outrigger/Track Movement Emergency Procedure:” on page 5-9. 2.
SECTION 5 - EMERGENCY PROCEDURES nel at the pump and eliminate the risk of lowering the jib onto an outrigger. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING. a. Depress the enable valve button (item 12 Figure 5-2. on page 5-5). b. Activate the swing control lever (item 11 Figure 5-2. on page 5-5), in the desired direction of travel while pumping the hand pump until the turntable is aligned with the chassis.
SECTION 5 - EMERGENCY PROCEDURES 5. Lowering the Tower Boom (if necessary). While pumping the handpump, activate the tower boom lift function lever (item 9, Figure 5-2.) in the appropriate direction to lower the tower boom. 6. Lowering the Main Boom (if necessary). With the aid of an assistant, activate the main boom lift function lever (item 10, Figure 5-2. on page 5-5) in the appropriate direction to lower the main boom. 7. Rotating the platform (if necessary).
SECTION 5 - EMERGENCY PROCEDURES machine, secure in place with the provided screw. (item 3 - Figure 5-3.) 4. Set the lever on the hydraulic hand pump (item 2 Figure 5-3.), it must be positioned up to provide hydraulic pressure to operate right side outrigger, track functions, and boom components. When positioned down hydraulic pressure is provided to the left side outrigger, and track functions. (See following decal). 7.
For right side (operator's (platform) perspective) Outrigger and Track Functions: 8. Locate the proportional flow valve on the right side of the chassis attached to the group of three valves (item 6 - Figure 5-5.). Push and hold the black knob before activating any function lever. 9. The lever on the hydraulic hand pump (item 2 - Figure 5-3.) must be positioned up to manually provide pressure to operate right side outrigger and track functions. 10.
SECTION 5 - EMERGENCY PROCEDURES 2 2 3 4 5 7 1 1 8 9 6 3 Figure 5-5.
SECTION 5 - EMERGENCY PROCEDURES 5.4 Remove the key and insert it into the bypass key switch (item 2 - photo). 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 requires a key for bypassing the platform safety systems. To activate the safety device bypass switch (item 2 - photo), locate the key set.
SECTION 5 - EMERGENCY PROCEDURES 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.
SECTION 5 - EMERGENCY PROCEDURES Machine Realignment Emergency Procedure Movement Of The Tracks With The Machine Not Aligned: THIS OPERATION MUST ONLY BE PERFORMED WITH THE BOOMS AND JIB FULLY LOWERED AND RETRACTED. OPERATION ONLY ALLOWED TO GO TO A CONDITION SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN "MACHINE REALIGNMENT" ABOVE. ALL OTHER USE IS PROHIBITED. During transport, the turntable may swing and become out of alignment with the base.
SECTION 5 - EMERGENCY PROCEDURES 5.5 LITHIUM-ION BATTERY PACK - HANDLING IN DANGEROUS CONDITIONS Procedure For Handling Hot Cells 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.
SECTION 5 - EMERGENCY PROCEDURES Start Procedure; Procedure For Handling Vented Cells 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.
SECTION 5 - EMERGENCY PROCEDURES Start Procedure; First Aid In The Event Of Contact With The Electrolyte In the event of electrolyte release from the cells, proceed as follows: EYES 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 temperature before handling it (see “Procedure For Handling Hot Cells” on page 16). 4.
SECTION 5 - EMERGENCY PROCEDURES Start Procedure; 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.
SECTION 5 - EMERGENCY PROCEDURES 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.
SECTION 5 - EMERGENCY PROCEDURES cells. Larger fires have to be managed only by professionally trained personnel. Finally, it should be noted that in the presence of combustible materials other than lithium it is advisable to use different types of extinguishers in conjunction to better ensure the extinguishing action of each on the appropriate material, however do not use water or CO2 extinguishers directly on lithium fires. Minimum Equipment Required; NOTE: Lithium melts at 356° F (180° C).
SECTION 5 - EMERGENCY PROCEDURES 11. Wear safety equipment: coat, gloves, mask and filters. 12. The area around the cell will be covered by a black carbonaceous deposit which contains metallic parts of the cell. Cover the carbonaceous residue with a 50/50 mixture of baking soda and vermiculite or other absorbent material. Avoid contact between the metallic residue and charged cells as this condition may cause a short.circuit. 13.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.1 INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.2 OPERATING SPECIFICATIONS Dimensional Data Table 6-2. Dimensional Data Table 6-1. Operating Specifications Model Model X600AJ X600AJ Maximum work load (capacity) 500 lb. (230 kg) Overall Width (with platform removed-tracks retracted) 31.29 in. (80cm) Max. Vertical Platform Height 59.22 ft. (18.05 m) Outriggers Deployed Width Max. Horizontal Platform Reach 31.82 ft. (9.70m) 9.58 ft. x 9.58 ft. (2.92 m x 2.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-3. Chassis Data Chassis Table 6-3.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Data Lithium-Ion Specifications Table 6-5. Honda iGX440 Specifications Model Type Number of cylinders Displacement Output High engine speed Torque (Max.) Table 6-6. Lithium Ion Specifications X600AJ Gasoline/Air cooled 1 27 cu. in. (440 cm3) 12.74 hp (9.5 kW) 3600 RPM 22 ft. lb. / 29.8 Nm @ 2500 RPM Model Battery Pack No. of cells in the battery pack: Rated voltage of each cell: Max. cell voltage: Min.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Machine Major Component Weights Performance Table 6-7. Major Component Weights Model Table 6-8. Function Speeds X600AJ X600AJ TIME (SECONDS) FUNCTION Engine (tank full) Gasoline: 86 lb. (39 kg) Telescope Extend: Retract: 21 - 28 16 - 20 Lithium Ion Battery Pack (72V) 401 lb. (182kg) Boom Sections Combined 3,104 lb. (1408 kg) Tower Boom Up: Down: 30 - 35 30 - 35 17.6 lb. (8 kg) 26.4 lb. (12 kg) 117.5 lb. (53.3 kg) 15.4 lb.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.3 SERVICE/MAINTENANCE G 1 C 5,0 1 C 5,0 5,0 A 5,0 M= ENGINE OIL TM=OLIO = TRANSMISSION OIL MOTORE TRASMISSIONE I T=OLIO = HYDRAULIC OIL I=OLIO IDRAULICO GG=GRASSO = GREASE M M I I I ** aWHICHEVER seconda di quello piu corto IS SHORTER I G )* 10 h (( OR o un ONE periodoWORK di lavoro SHIFT a squadra)* T 50 h ((OR o unaONE settimana)* WEEK )* 100 h 250 h 500 h Figure 6-1.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Recommended Gearbox Oils FOLLOW THE LUBRICATION INTERVALS INDICATED AND USE ONLY THE RECOMMENDED LUBRICANTS IN ORDER TO PROTECT PINS AND CONNECTIONS FROM WEAR. 600 XP 150 EP 150 Blasia 150 Lubrication Spartan EP150 (See Figure 6-1.) Engine Oil Hydraulic Oil SAE 10W30 Greasing and Lubrication Table 6-9.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE HONDA GAS ENGINE PART INTERVENTION CHECK, CLEAN DRY AIR FILTER BEFORE STARTING AS NEEDED INTERVAL (HOURS) 10 50 100 250 • • CHANGE CHECK LEVEL ENGINE OIL • • •* CHANGE OIL SUMP FUEL TANK AND NET • • CLEAN • CLEAN CHECK LEVEL HYDRAULIC OIL 500 1000 • • CHANGE •* HYDRAULIC OIL CHANGE CARTRIDGE FILTER ARTICULATED JOINT GREASE POINTS BATTERY REDUCTION GEAR OIL MACHINE EXTENSION ARM INTERNAL SLIDING RING CHECK ELECTROLYTE LEVE
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE LITHIUM-ION MACHINE PART MAINTENANCE WORK CHECK LEVEL BEFORE STARTING INTERVAL (HOURS) AS NEEDED 10 50 100 250 500 1000 • HYDRAULIC OIL • CHANGE HYDRAULIC OIL FILTER REPLACE CARTRIDGE •* ARTICULATE JOINT POINTS GREASING •* REDUCTION GEAR OIL MACHINE EXTENSION ARM INTERNAL SLIDING RING TURNTABLE BOLT TIGHTENING • • • CHECK LEVEL •* CHANGE • GENERAL PERIODICAL CHECKS • * First time service interval then per chart thereaf
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Oil Engine Air Filter Honda Gas Honda Gas DIPSTICK UPPER LIMIT Lube Point(s) - Replaceable Paper Element, or Foam Filter Element Interval - Check daily. Replace paper element after 500 hrs of operation, sooner if operating in a dusty environment. The foam element can be washed out in warm soapy water, then rinse and let dry, Dip in clean engine oil and squeeze out the excess oil.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Fuel Filter/Sediment Bowl (if equipped) Hydraulic Oil l Honda Gas B A Interval - Clean or replace every 500 hours Lube Point(s) - Fill Cap Capacity - 6.6 gallons (25 liters) Interval - Check level daily. Change every two years or 1200 hours of operation NOTE: Hydraulic oil levels are to be checked with the machine in transport position while on a firm, level and uniform surface.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Hydraulic Oil Filter Cartridge Rubber Track Maintenance/Replacement Check track tension Stop the machine on a firm, level, and uniform surface. Raise the machine off the surface using the outriggers. Measure distance A from the bottom of the roller to the inside of the rubber belt. The rubber track tension is to be between 0.4inches (10mm) and 0.6 inches (15mm).
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 1. Ensure all debris has been removed between the wheel teeth and track links. 2. Remove the screws from the adjustment access lid 3. 2 Tightening of the track • Connect a grease gun to grease valve (2) and add grease until belt tension is within the specified values. NOTE: If the track does not return to the specified values by following the above procedure immediately discontinue use and contact service personnel.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE • If metal cores are separating discontinue use of the machine until the damaged components are replaced. 1. Elevate the machine on firm, level and uniform surface utilizing the outriggers. 2. Remove the screws and remove cover 3 as shown in figure. 2 Worn Parts • If abrasive or fatigue cracks are noted it is recommended the machine be removed from service until the components are replaced.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Wear Pad Inspection 5 Check for distance between wear pads and boom sections. Distance is to be no more than 1/32nd inch. Turntable Attach Bolts Ensure the bolts of the coupling elements (turntable) are torqued to 183 ft-lb. (248 Nm) 4 6 Installation of Rubber Track 1. Ensure all hydraulic cylinder grease have been removed 2. Align the track links with the wheel teeth. Position the other end of the track on the track tensioning wheel 3.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 4. When charging is completed turn off the battery charger before disconnecting the cables from the battery poles 5. Return the terminal clamps to the battery poles and lubricate with the appropriate product 6. Close battery cover. Battery Maintenance and Charging - Gas/AC-Electric NOTE: The battery is a maintenance free battery. Do NOT attempt to open a maintenance-free sealed battery.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.4 • FAN ELECTRIC MOTOR MAINTENANCE Keep air intakes clean and make sure the fan can rotate freely. Periodically check the condition of the following electric motor components. • BEARINGS Electric Motor Check the condition of the bearings, in the event of noise contact JLG for replacement, the life of the bearings is reduced significantly in heavy duty operating conditions.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.5 1 - INPUT PLATFORM/REMOTE CONTROL SERVICE MENU Service Button 2 - LANGUAGE A SERVICE button is present on the remote control which allows to view the status of the machine parameters and is an aid in the safety checks of the machine.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Menu Input 1 - PREV - access the previous input The signals that arrive at the board from the various sensors mounted on the machine and from the platform/remote control commands are displayed.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE gg ST2 OPEN A ST2 OPEN B ST3 GND A ST3 GND B ST3 OPEN A ST3 OPEN B ST4 GND A ST4 GND B 6-20 p p ON Do not consider OFF Do not consider ON Do not consider OFF Do not consider ON Outrigger N° 3 on the ground – the switch is released and A line is closed OFF Outrigger N° 3 lifted – the switch is pressed and A line is opened ON Outrigger N° 3 on the ground – the switch is released and B line is closed OFF Outrigger N° 3 lifted –
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ST4 OPEN A ST4 OPEN B OFF Outrigger N 4 lifted ON Do not consider OFF Do not consider ON Do not consider OFF Do not consider ON The aerial part safeties are disconnected through the key button (emergency condition) – “A” line of the aerial part safeties by-pass button is closed.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ON The ground part safeties are disconnected through the key button (emergency condition)– “B” line of the ground part safeties by-pass button is closed.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ON Turret is not almost completely rotated, contact is close, the 1 st-2nd arm is not above the engine OFF Turret is almost completely rotated, contact is open, the 1st-2nd arm is above the engine ON The stop button on ground remote control is released.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE p TEMP ALRM B Option reserved for some markets POS.1 ARM OFF The temperature external probe hasn’t reached the maximum value – “B” line of the temperature probe is open ON The switch of 1-2 arm position is released, contact is close, the 1st-2nd arm is open OFF The switch of 1-2 arm position is pressed, contact is open, the 1st-2nd arm is closed ON Tracks are in wide position.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE p START M.TE MOTOR TEMP To consider only for X20JP - X600AJ MOTOR PRES To consider only for X20JP - X600 AJ START M.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE PEDAL ON The pedal is pressed– the pedal electric line is closed OFF The pedal is released – the pedal electric line is open FREE B EM.BASK.A EM.BASK.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE POSM2 B POSM3 A POSM3 B POSM4 A POSM4 B R.C.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE INCLIN. X INCLIN. Y 0 Indicates the inclination of the machine on the X axis in tenth of degrees (accelerometer A) 0 0 Indicates the inclination of the machine on the X axis in tenth of degrees (accel B) Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerometer A) 0 Indicates the inclination of the machine on the Y axis in tenth of degrees (accel B) LOAD 94 POS.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 3121637 CURRENT A 2,5 Indicates (in tenth of mA) the current ECM1-2 is sending to the aerial part proportional valve or to the left-side undercarriage proportional valve (values less that 5 not relevant) CURRENT B 45,3 Indicates (in tenth of mA) the current ECM1-2 is sending to the right-side undercarriage proportional valve (values less that 5 not relevant) CURRENT C 0 Do not consider TEMPERAT.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Errors Menu Working Hours Menu Indicates the agreement (OK) or not (FAULT) status of the sensors that have a double control. Indicates the number of machine working hours. The sensors are listed on different screens use: Set-up Menu The items in this menu cannot normally be accessed.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 6.6 • Cleaning the electrical system; LITHIUM-ION MACHINE - MAINTAINANCE Cleaning the Machine NEVER CLEAN THE INVERTER OR THE ELECTRIC MOTOR WITH WATER, AS THIS MAY CAUSE DAMAGE TO THE ELECTRICAL SYSTEM. WHEN WASHING THE MACHINE, THE MAIN POWER SWITCH MUST BE DISENGAGED, THE KEY REMOVED AND THE EMERGENCY STOP BUTTON PRESSED. • Washing the outside of the machine; Never use flammable liquids.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Battery Pack System Components and Maintenance Figure 6-4.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-10. Inverter Fault Codes Lithium-Ion Machine Fault Codes (See “Errors Menu” on page 6-30 info for display information) Table 6-10. Inverter Fault Codes CODE 1 DESCRIPTION 8 13 Eeprom KO Cause – EEPROM hardware or software problem. Solution – Replace inverter. 16 Aux output KO Cause – Problem with electromechanical brake. Solution – This is generally a temporary problem due to certain working conditions.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-10. Inverter Fault Codes Table 6-10. Inverter Fault Codes CODE DESCRIPTION 53 STBY I high Cause – Internal fault detected in the inverter. Solution – This is generally a temporary problem due to certainworking conditions. If problem persists, replace inverter. 60 Capacitor Charge Cause – Internal fault in the inverter. Solution – Check connections and motor phases. 61 High temperature Cause – High temperature inside the inverter.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-10. Inverter Fault Codes CODE DESCRIPTION 79 Incorrect start Cause – Incorrect starting procedure. Solution – Check electrical connections. This is generally a temporary problem due to certain working conditions. If problem persists, replace inverter. 86 Pedal wire KO Cause – Solution – This is generally a temporary problem due to certain working conditions. If problem persists, replace inverter.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE BMS Fault Codes - (Battery Management System) A99E03 – Incorrect temperature (See “Errors Menu” on page 6-30 info for display information) A99E04 – Excess discharge current NOTE: The CODE column indicates the CAN CODE in the message sent by the battery charger. The normal mains voltage tolerance is the rated value ±15%.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Battery Charger Fault Codes (See “Errors Menu” on page 6-30 info for display information) Table 6-11. Battery Charger Fault Codes CODE DESCRIPTION STATUS ACTION 8 Internal logic fault. Battery charger stops working. Contact service dept. or change product. 13 Communication pro.blem with external memory. Battery charger stops working. Contact service dept. or change product. Extended shutdown or power failure.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-11. Battery Charger Fault Codes CODE 246 DESCRIPTION STATUS Stage 1 ended by timeout without reaching control Battery charger stops working. voltage. If internal temperature exceeds 80° C, battery charger reduces power to 80%, while it stops operating altogether if internal temperature exceeds 90° C. Battery charger starts at full power again when internal temperatu.re falls below 70° C. Battery temperature too high.
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE NOTES: 6-40 – JLG Lift – 3121637
SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7.
SECTION 7 - INSPECTION AND REPAIR LOG DATE 7-2 COMMENTS – JLG Lift – 3121637
JLG Industries, Inc. 1 JLG Drive McConnellsburg PA. 172339533 USA (717) 485-5161 (717) 485-6417 3121637 JLG Worldwide Locations JLG Industries (Australia) P.O. Box 5119 11 Bolwarra Road Port Macquarie N.S.W. 2444 Australia +61 2 65 811111 +61 2 65 810122 JLG Latino Americana Ltda. Rua Eng.
