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Operation and Safety Manual

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

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Model(s)

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X430AJ

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ANSI
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3121773
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June 29, 2018 - Rev C

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

Discount-Equipment.com is your online resource for

commercial and industrial quality parts and equipment sales.
561-964-4949
visit us on line @ www.discount-equipment.com

Select an option below to find your Equipment

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith Surface Prep,Small Line,
Wanco, Yanmar
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WARNING

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Operating, servicing and maintaining this vehicle or equipment

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can expose you to chemicals including engine exhaust, carbon

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monoxide, phthalates, and lead, which are known to the State of

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California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing

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exhaust, do not idle the engine except as necessary, service your
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vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
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information go to www.P65Warnings.ca.gov.
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 SECTION - FOREWORD

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FOREWORD

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This manual is a very important tool! Keep it with the machine at all times.

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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.

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Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without

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prior notification. Contact JLG Industries, Inc. for updated information.

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3121773 – JLG Lift – a

 SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that fol-
low this symbol to avoid possible injury or death.

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INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE
GROUND. Di PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.
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INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR
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RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
BACKGROUND.
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 SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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For :

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THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT • Accident Reporting • Standards and Regulations
JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR Compliance Information

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• Product Safety Publica-
INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN
tions • Questions Regarding Special
ISSUED FOR THIS PRODUCT.

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Product Applications
• Current Owner Updates
• Questions Regarding Prod-
• Questions Regarding

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uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF

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RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT

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Contact :
THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

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Product Safety and Reliability Department
JLG Industries, Inc.

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13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES Hagerstown, MD 21742

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WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING USA
BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS
OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT. Di or Your Local JLG Office
(See addresses on inside of manual cover)
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In USA:
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Toll Free: 877-JLG-SAFE (877-554-7233)

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Outside USA:
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Phone: 240-420-2661
E-mail: [email protected]
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3121773 – JLG Lift – c

SECTION - REVISION LOG

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REVISION LOG

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Original Issue A - March 16, 2017
Revised B - April 3, 2018

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Revised C - June 29, 2018 - Revised Covers, Prop 65

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 TABLE OF CONTENTS

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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-A Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

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SAFETY ALERT SYMBOLS AND SAFETY SIGNAL Training Supervision . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . 2-1

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WORDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c 2.2 PREPARATION, INSPECTION, AND

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In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-c Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . . 2-4

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REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-D Daily Walk-Around Inspection . . . . . . . . . . . . . . . 2-6

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Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
SECTION - 1 - SAFETY PRECAUTIONS
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND

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1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OPERATION
1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . 3-3

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Operator Training and Knowledge . . . . . . . . . . . . 1-1

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Workplace Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2 3.2 PLATFORM/REMOTE CONTROL STATION . . . . . . 3-6
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . 1-3 Control Position On The Ground: . . . . . . . . . . . . 3-6

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1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Control Position From In The Platform: . . . . . . . . 3-7
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Platform/Remote Control Station Functions . . . . 3-9
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Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . 1-5
Platform/Remote Control Station LCD Display . 3-12
SECTION - 4 - MACHINE OPERATION
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Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Crushing and Collision Hazards . . . . . . . . . . . . . . 1-9
4.2 BOOM OPERATING CHARACTERISTICS AND
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1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . 1-10

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LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . 1-10 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
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Battery Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-12

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2
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SECTION - 2 - PREPARATION AND INSPECTION Diesel Starting Procedure . . . . . . . . . . . . . . . . . . 4-2

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . 2-1 Diesel Engine Shutdown Procedure . . . . . . . . . . 4-3
Electric Engine Starting Procedure - AC Voltage
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3121773 – JLG Lift – i

TABLE OF CONTENTS

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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Machine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 4.9 BATTERY CHARGING - LITHIUM-ION MACHINE 4-21

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4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . . 4-5 Charging the Battery Pack . . . . . . . . . . . . . . . . . 4-21
Charge Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

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Platform Rotation Alignment Indicator . . . . . . . . . 4-5
4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH Cold Weather Charging . . . . . . . . . . . . . . . . . . . 4-23

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ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6 Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Track width adjust. . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.10 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-24
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . . 4-7 4.11 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . 4-25

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Travelling (Grades and Side Slopes) . . . . . . . . . . 4-7 Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

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Jib Position for Travelling . . . . . . . . . . . . . . . . . . . 4-9 Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27

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4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . 4-11 SECTION - 5 - EMERGENCY PROCEDURES
Setting Outriggers From the Platform/Remote

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5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

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Retracting The Outriggers . . . . . . . . . . . . . . . . . 4-13 5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . 5-1
4.7 BOOM/PLATFORM OPERATION. . . . . . . . . . . . . . 4-13 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . 5-2

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Overload Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 Power Main Cut-Off Switch Location . . . . . . . . . . 5-2
Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-14 Operator Unable to Control Machine. . . . . . . . . . 5-3
Raise And Lower The Tower Boom . . . . . . . . . . 4-14
Raise And Lower The Main Boom . . . . . . . . . . . 4-14
Di Platform or Boom Caught Overhead . . . . . . . . . . 5-3
Manual Descent with Engine Running and Electrical
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Telescope The Main Boom. . . . . . . . . . . . . . . . . 4-15 Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Using Emergency/Ground Controls from
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Raise And Lower The Jib . . . . . . . . . . . . . . . . . . 4-15 Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

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Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . 4-15 Manual Descent with Engine Running but without
SkyGuard Operation (If Equipped). . . . . . . . . . . 4-18 Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
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Emergency Lowering . . . . . . . . . . . . . . . . . . . . . 4-19 Manual Descent without Engine or Electrical

Platform Removal/Installation . . . . . . . . . . . . . . . 4-19 Power.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
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Outrigger/Track Movement Emergency

4.8 BATTERY CHARGING - DIESEL/AC-ELECTRIC . . 4-20
Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Battery Charging - Daily . . . . . . . . . . . . . . . . . . . 4-20
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 TABLE OF CONTENTS

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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
5.4 SAFETY DEVICES BYPASS KEY USE. . . . . . . . . . 5-13 Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . 6-16

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Using Emergency Descent In Case Of An Outrigger Battery Maintenance and Charging - Diesel/AC-
Losing Contact With The Ground . . . . . . . . . . . . 5-14 Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

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Machine Realignment Emergency Procedure . . 5-15 6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . 6-17

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Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6.5 PLATFORM/REMOTE CONTROL SERVICE

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
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERA- MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

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TOR MAINTENANCE Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

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6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . 6-2 Working Hours Menu . . . . . . . . . . . . . . . . . . . . . 6-21
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.6 LITHIUM-ION MACHINE - MAINTAINANCE . . . . . 6-21

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Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Battery Pack System Components and
Electric Motor Data . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
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Lithium-Ion Battery Pack Specifications . . . . . . . . 6-4
Major Component Weights. . . . . . . . . . . . . . . . . . 6-4
Lithium-Ion Machine Fault Codes . . . . . . . . . . . 6-22
BMS Fault Codes - (Battery Management
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6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . 6-5 System) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-24
Cleaning the Machine . . . . . . . . . . . . . . . . . . . . . . 6-5 Battery Charger Fault Codes . . . . . . . . . . . . . . . 6-26
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Machine Maintenance Locations . . . . . . . . . . . . . 6-6

6.7 LITHIUM-ION BATTERY PACK - HANDLING IN
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Lubrication Types . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . 6-8 DANGEROUS CONDITIONS . . . . . . . . . . . . . . . . 6-28
Procedure For Handling Hot Cells. . . . . . . . . . . 6-28
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Gas Engine Maintenance Procedures . . . . . . . . 6-12

Hydraulic Oil Tank. . . . . . . . . . . . . . . . . . . . . . . . 6-12 Procedure For Handling Vented Cells . . . . . . . . 6-29
Procedure For Exploded Cells. . . . . . . . . . . . . . 6-31
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Hydraulic Oil Filter Cartridge . . . . . . . . . . . . . . . 6-13

Rubber Track Maintenance/Replacement . . . . . 6-13 Lithium Battery Fire . . . . . . . . . . . . . . . . . . . . . . 6-32
Wear Pad Inspection. . . . . . . . . . . . . . . . . . . . . . 6-16
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SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS

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SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-3. Hydraulic Oil Operating Temperatures . . . . . . . 6-9

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LIST OF FIGURES
2-1. Daily Walk-Around Inspection . . . . . . . . . . . . . .2-7

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2-2. SkyGuard™ Sensor and Override Switch
LIST OF TABLES
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9 1-1 Minimum Approach Distances (M.A.D.) . . . . . . . 1-6

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3-1. Basic Machine Component Locations . . . . . . . .3-1 1-2 Beaufort Scale (For Reference Only) . . . . . . . . . 1-8
3-2. Ground Control Station . . . . . . . . . . . . . . . . . . .3-5

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2-1 Inspection and Maintenance Table. . . . . . . . . . . 2-3
3-3. Platform/Remote Control Station . . . . . . . . . . .3-10 3-1 LCD Display Icon Descriptions . . . . . . . . . . . . . 3-15

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4-1. Ground/Emergency Control Box . . . . . . . . . . . .4-2 3-2 LCD Display Error Descriptions . . . . . . . . . . . . 3-17
4-2. Grade and Side Slope Definition . . . . . . . . . . . .4-8 4-1 SkyGuard™ Function Table . . . . . . . . . . . . . . . 4-18

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4-3. Platform/Remote Control Box. . . . . . . . . . . . . .4-16 4-2 X430AJ - Decal Installation - Lithium-Ion
4-4. Platform - Load/Reach Chart - X430AJ . . . . . .4-17 Power Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-36
4-5. SkyGuard™ Sensor and Override Switch 6-1 Operating Specifications. . . . . . . . . . . . . . . . . . . 6-2

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Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-18 6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-2

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4-6. Machine Lifting Points . . . . . . . . . . . . . . . . . . .4-26 6-3 Chassis Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
4-7. Lifting Machine - Attach Points . . . . . . . . . . . . .4-26 6-4 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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4-8. Machine Tie-Down Points. . . . . . . . . . . . . . . . .4-28 6-5 Honda iGX390 Gas Specifications . . . . . . . . . . . 6-3
4-9. Decal installation - Left Side - Machine . . . . . .4-29 6-6 Electric Motor Specifications . . . . . . . . . . . . . . . 6-3
4-10.
4-11.
Decal installation - Left Side - Chassis . . . . . .4-30
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Decal installation - Platform . . . . . . . . . . . . . . .4-31
6-7
6-8
Lithium Ion Specifications . . . . . . . . . . . . . . . . . . 6-4
Major Component Weights . . . . . . . . . . . . . . . . . 6-4
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4-12. Decal Installation - Right Side - Machine . . . . .4-32 6-9 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . 6-7
4-13. Decal installation - Right Side - Chassis. . . . . .4-33 6-10 Component Maintenance Intervals - X430AJ -
4-14. Decal Installation - Right Side- Valve
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with Gas Engine . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Compartments . . . . . . . . . . . . . . . . . . . . . . . . .4-34 6-11 Component Maintenance Intervals - X430AJ -
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4-15. Decal Installation - Machines with Lithium-Ion with Lithium-Ion Battery Pack . . . . . . . . . . . . . . 6-11
Power Only . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35 6-12 Inverter Fault Codes . . . . . . . . . . . . . . . . . . . . . 6-22
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5-1. Platform/Remote Control Station . . . . . . . . . . . .5-5 6-13 Battery Charger Fault Codes . . . . . . . . . . . . . . 6-26
5-2. Ground Control Station . . . . . . . . . . . . . . . . . . .5-7
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5-3. Hand Pump - Chassis Control Valve Tray . . . . .5-8

6-1. Lubrication and Maintenance Point Locations. .6-6
6-2. Hydraulic Oil Specifications . . . . . . . . . . . . . . . .6-8
To

iv – JLG Lift – 3121773

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

Discount-Equipment.com is your online resource for

commercial and industrial quality parts and equipment sales.
561-964-4949
visit us on line @ www.discount-equipment.com

Select an option below to find your Equipment

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith Surface Prep,Small Line,
Wanco, Yanmar
 SECTION 1 - SAFETY PRECAUTIONS

om
SECTION 1. SAFETY PRECAUTIONS

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1.1 GENERAL

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This section outlines the necessary precautions for FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MAN-

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proper and safe machine usage and maintenance. It is UAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL
mandatory that a daily routine is established based on INJURY OR DEATH.

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the content of this manual to promote proper machine
1.2 PRE-OPERATION

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usage. A maintenance program, using the information
provided in this manual and the Service and Mainte-
Operator Training and Knowledge

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nance Manual, must also be established by a qualified
person and must be followed to ensure that the
• The Operation and Safety Manual must be read and

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machine is safe to operate.
understood in its entirety before operating the

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The owner/user/operator/lessor/lessee of the machine machine. For clarification, questions, or additional
must not accept operating responsibility until this information regarding any portions of this manual,

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manual has been read, training is accomplished, and contact JLG Industries, Inc.
operation of the machine has been completed under
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the supervision of an experienced and qualified opera-
tor.
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This section contains the responsibilities of the owner,
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user, operator, lessor, and lessee concerning safety,

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training, inspection, maintenance, application, and

operation. If there are any questions with regard to
safety, training, inspection, maintenance, application,
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and operation, please contact JLG Industries, Inc.

or

(“JLG”).
To

3121773 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

om
• An operator must not accept operating responsibili- Workplace Inspection
ties until adequate training has been given by com-

t.c
petent and authorized persons. • Precautions to avoid all hazards in the work area
must be taken by the user before and during opera-

en
• Allow only those authorized and qualified personnel
tion of the machine.
to operate the machine who have demonstrated

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that they understand the safe and proper operation • Do not operate or raise the platform from a position
and maintenance of the unit. on trucks, trailers, railway cars, floating vessels, scaf-

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folds or other equipment unless the application is
• Read, understand, and obey all DANGERS, WARN-

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approved in writing by JLG.
INGS, CAUTIONS, and operating instructions on the
machine and in this manual. • Before operation, check work area for overhead haz-

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ards such as electric lines, bridge cranes, and other
• Ensure that the machine is to be used in a manner
potential overhead obstructions.

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which is within the scope of its intended application
• Check operating surfaces for holes, bumps, drop-

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as determined by JLG.
offs, obstructions, debris, concealed holes, and other
• All operating personnel must be familiar with the

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potential hazards.
emergency controls and emergency operation of
the machine as specified in this manual. • Check the work area for hazardous locations. Do not
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• Read, understand, and obey all applicable employer,
operate the machine in hazardous environments
unless approved for that purpose by JLG.
to
local, and governmental regulations as they pertain
to your utilization and application of the machine. • Ensure that the ground conditions are adequate to
support the maximum outrigger load indicated on
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the outrigger load decals located on the machine.

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Do not travel on unsupported surfaces.

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1-2 – JLG Lift – 3121773

 SECTION 1 - SAFETY PRECAUTIONS

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Machine Inspection 1.3 OPERATION

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• Do not operate this machine until the inspections
and functional checks as specified in Section 2 of
General

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this manual have been performed. • Machine operation requires your full attention. Bring

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• Do not operate this machine until it has been ser- the machine to a full stop before using any device,
viced and maintained according to the maintenance i.e. cell phones, two-way radios, etc. that will distract

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and inspection requirements as specified in the your attention from safely operating the machine.

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machine’s Service and Maintenance Manual. • Do not use the machine for any purpose other than
• Ensure all safety devices are operating properly. positioning personnel, their tools, and equipment.

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Modification of these devices is a safety violation. • Before operation, the user must be familiar with the
machine capabilities and operating characteristics

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of all functions.

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MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE • Never operate a malfunctioning machine. If a mal-
MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFAC-

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function occurs, shut down the machine. Remove
TURER. the unit from service and notify the proper authori-
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• Do not operate any machine on which the safety or
instruction placards or decals are missing or illegible.
ties.
• Do not remove, modify, or disable any safety
to
• Check the machine for modifications to original devices.
components. Ensure that any modifications have
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• Never slam a control switch or lever through neutral

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been approved by JLG. to an opposite direction. Always return switch to

• Avoid accumulation of debris on platform floor. neutral and stop before moving the switch to the
next function. Operate controls with slow and even
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Keep mud, oil, grease, and other slippery substances

from footwear and platform floor. pressure.
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3121773 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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• Do not allow personnel to tamper with or operate • Persons under the influence of drugs or alcohol or
the machine from the ground with personnel in the who are subject to seizures, dizziness or loss of phys-

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platform, except in an emergency. ical control must not operate this machine.

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• Do not carry materials directly on platform railing
unless approved by JLG.
Trip and Fall Hazards

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• When two or more persons are in the platform, the • During operation, occupants in the platform must

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operator shall be responsible for all machine opera- wear a full body harness with a lanyard attached to
tions. an authorized lanyard anchorage point. Attach only

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one (1) lanyard per lanyard anchorage point..
• Always ensure that power tools are properly stowed

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and never left hanging by their cord from the plat-
form work area.

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• When driving, always position boom over rear axle

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in line with the direction of travel. Remember, if
boom is over the front axle, steer and drive functions

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will be reversed.
• Enter and exit only through gate area. Use extreme
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• Do not assist a stuck or disabled machine by push-
ing or pulling except by pulling at the chassis tie- caution when entering or leaving platform. Ensure
that the platform assembly is fully lowered. Face the
to
down lugs.
machine when entering or leaving the platform.
• Fully lower platform and shut off all power before Always maintain “three point contact” with the
o

leaving machine. machine, using two hands and one foot or two feet
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• Remove all rings, watches, and jewelry when operat- and one hand at all times during entry and exit.
ing machine. Do not wear loose fitting clothing or
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long hair unrestrained which may become caught or

entangled in equipment.
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1-4 – JLG Lift – 3121773

 SECTION 1 - SAFETY PRECAUTIONS

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• Before operating the machine, make sure all gates Electrocution Hazards
are closed and fastened in their proper position.

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

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current.

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• Keep both feet firmly positioned on the platform

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floor at all times. Never position ladders, boxes,

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steps, planks, or similar items on unit to provide
additional reach for any purpose.
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• Keep oil, mud, and slippery substances cleaned from
footwear and the platform floor.
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3121773 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

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• Maintain distance from electrical lines, apparatus, or tional clearance is required for every additional
any energized (exposed or insulated) parts accord- 30,000 volts or less.

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ing to the Minimum Approach Distance (MAD) as
• The minimum approach distance may be reduced if
shown in Table 1-1.

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insulating barriers are installed to prevent contact,
• Allow for machine movement and electrical line and the barriers are rated for the voltage of the line

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swaying. being guarded. These barriers shall not be part of (or
attached to) the machine. The minimum approach

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Table 1-1. Minimum Approach Distances (M.A.D.) distance shall be reduced to a distance within the

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designed working dimensions of the insulating bar-
Voltage Range MINIMUM APPROACH DISTANCE rier. This determination shall be made by a qualified

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(Phase to Phase) in Feet (Meters) person in accordance with the employer, local, or
0 to 50 KV 10 (3) governmental requirements for work practices near

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energized equipment
Over 50KV to 200 KV 15 (5)

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Over 200 KV to 350 KV 20 (6)

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Over 350 KV to 500 KV 25 (8) DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE
Over 500 KV to 750 KV
Over 750 KV to 1000 KV
35 (11)
45 (14) Di (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED
UNLESS KNOWN OTHERWISE.
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NOTE: This requirement shall apply except where
employer, local or governmental regulations are
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more stringent.
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• Maintain a clearance of at least 10 ft. (3m) between

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any part of the machine and its occupants, their

tools, and their equipment from any electrical line or
or

apparatus carrying up to 50,000 volts. One foot addi-

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1-6 – JLG Lift – 3121773

 SECTION 1 - SAFETY PRECAUTIONS

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Tipping Hazards • Never exceed the maximum work load as specified
on the platform. Keep all loads within the confines of

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• The user must be familiar with the surface before the platform, unless authorized by JLG.
driving. Do not exceed the allowable sideslope and

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• Keep the chassis and outriggers of the machine a
grade while driving.
minimum of 2 ft. (0.6m) from holes, bumps, drop-

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offs, obstructions, debris, concealed holes, and other
potential hazards at the ground level.

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• Do not push or pull any object with the boom.

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• Never attempt to use the machine as a crane. Do not

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tie-off machine to any adjacent structure. Never
attach wire, cable, or any similar items to platform.

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• Do not operate the machine when wind conditions

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exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beau-
fort Scale (For Reference Only).

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• Do not increase the surface area of the platform or
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• Do not elevate platform or drive with platform ele-
vated while on or near a sloping, uneven, or soft sur-
the load. Increase of the area exposed to the wind
will decrease stability.
to
face. Ensure machine is positioned on a firm, level • Do not increase the platform size with unauthorized
and smooth surface before elevating platform or deck extensions or attachments.
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driving with the platform in the elevated position. • If boom assembly or platform is in a position that
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• Before driving on floors, bridges, trucks, and other one or more outriggers are off the ground, all per-
sons must be removed before attempting to stabi-
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surfaces, check allowable capacity of the surfaces.

lize the machine. Use cranes, forklift trucks, or other
• Do not raise the platform unless the machine is on appropriate equipment to stabilize machine.
or

firm surfaces and outriggers are properly set.

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3121773 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

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

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Beaufort Wind Speed
Description Land Conditions

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Number mph m/s
0 0 0-0.2 Calm Calm. Smoke rises vertically

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1 1-3 0.3-1.5 Light air Wind motion visible in smoke

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2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle

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3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion

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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 breezeDi Large branches in motion. Flags waving near horizontal. Umbrella
use becomes difficult.
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7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
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8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
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9 47-54 20.8-24.4 Strong Gale Light structure damage.

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1-8 – JLG Lift – 3121773

 SECTION 1 - SAFETY PRECAUTIONS

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Crushing and Collision Hazards • Under all travel conditions, the operator must limit
travel speed according to conditions of ground sur-

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• Approved head gear must be worn by all operating face, congestion, visibility, slope, location of person-
and ground personnel. nel, and other factors which may cause collision or

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• Check work area for clearances overhead, on sides, injury to personnel.

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and bottom of platform when lifting or lowering • Be aware of stopping distances in all drive speeds.
platform, and driving. When driving in high speed, switch to low speed

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before stopping. Travel grades in low speed only.

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

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• Exercise extreme caution at all times to prevent

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obstacles from striking or interfering with operating

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controls and persons in the platform.
• Be sure that operators of other overhead and floor

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level machines are aware of the aerial work plat-
form’s presence. Disconnect power to overhead
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• During operation, keep all body parts inside plat-
cranes.
to
form railing. • Warn personnel not to work, stand, or walk under a
raised boom or platform. Position barricades on
• Use the boom functions, not the drive function, to
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floor if necessary.
position the platform close to obstacles.
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• Always post a lookout when driving in areas where

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vision is obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m)
or

away from machine during all driving and swing

operations.
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3121773 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

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1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

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• Never allow personnel in platform while towing, lift- This sub-section contains general safety precautions which
ing, or hauling. must be observed during maintenance of this machine.

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Additional precautions to be observed during machine
• Ensure boom is in the stowed position and the turn-
maintenance are inserted at the appropriate points in this

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table locked prior to towing, lifting or hauling. The
manual and in the Service and Maintenance Manual. It is of
platform must be completely empty of tools.
utmost importance that maintenance personnel pay strict

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• When lifting machine, lift only at designated areas of attention to these precautions to avoid possible injury to
the machine. Lift the unit with equipment of ade- personnel or damage to the machine or property. A mainte-

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quate capacity. nance program must be established by a qualified person

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• Refer to the Machine Operation section of this man- and must be followed to ensure that the machine is safe.

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ual for lifting information.
Maintenance Hazards

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• Shut off power to all controls and ensure that all

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moving parts are secured from inadvertent motion
prior to performing any adjustments or repairs.
Di • Never work under an elevated platform until it has
to
been fully lowered to the full down position, if possi-
ble, or otherwise supported and restrained from
movement with appropriate safety props, blocking,
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or overhead supports.
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• DO NOT attempt to repair or tighten any hydraulic

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hoses or fittings while the machine is powered on or

when the hydraulic system is under pressure.
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1-10 – JLG Lift – 3121773

 SECTION 1 - SAFETY PRECAUTIONS

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• Always relieve hydraulic pressure from all hydraulic • Do not use machine as a ground for welding.
circuits before loosening or removing hydraulic

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• When performing welding or metal cutting opera-
components. tions, precautions must be taken to protect the

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• DO NOT use your hand to check for leaks. Use a chassis from direct exposure to weld and metal cut-
piece of cardboard or paper to search for leaks. Wear ting spatter.

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gloves to help protect hands from spraying fluid. • Do not refuel the machine with the engine running.

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• Use only approved non-flammable cleaning sol-

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vents.
• Do not replace items critical to stability, such as bat-

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teries or solid tires, with items of different weight or
specification. Do not modify unit in any way to affect

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stability.

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• Refer to the Service and Maintenance Manual for the

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weights of critical stability items.

Di
• Ensure replacement parts or components are identi-
cal or equivalent to original parts or components. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE
to
MADE ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFAC-
• Never attempt to move heavy parts without the aid TURER.
o

of a mechanical device. Do not allow heavy objects

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to rest in an unstable position. Ensure adequate sup-

port is provided when raising components of the
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machine.
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3121773 – JLG Lift – 1-11

SECTION 1 - SAFETY PRECAUTIONS

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Battery Hazards

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• Always disconnect batteries when servicing electri- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
cal components or when performing welding on the CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH

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machine. CLEAN WATER AND SEEK MEDICAL ATTENTION.

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• Do not allow smoking, open flame, or sparks near • Charge batteries only in a well ventilated area.
battery during charging or servicing.

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• Avoid overfilling the battery fluid level. Add distilled
• Do not contact tools or other metal objects across

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water to batteries only after the batteries are fully
the battery terminals. charged.

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• Always wear hand, eye, and face protection when
servicing batteries. Ensure that battery acid does not

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come in contact with skin or clothing.

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1-12 – JLG Lift – 3121773

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

Discount-Equipment.com is your online resource for

commercial and industrial quality parts and equipment sales.
561-964-4949
visit us on line @ www.discount-equipment.com

Select an option below to find your Equipment

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith Surface Prep,Small Line,
Wanco, Yanmar
SECTION 2 - PREPARATION AND INSPECTION

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SECTION 2. PREPARATION AND INSPECTION

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2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where

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overhead obstructions, other moving equipment,
The aerial platform is a personnel handling device; so it obstacles, depressions, holes, and drop-offs exist.

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is necessary that it be operated and maintained only by 7. Means to avoid the hazards of unprotected electri-
trained personnel.

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cal conductors.
Persons under the influence of drugs or alcohol or who

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8. Specific job requirements or machine application.
are subject to seizures, dizziness or loss of physical con-
trol must not operate this machine. Training Supervision

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Operator Training Training must be done under the supervision of a qual-

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ified person in an open area free of obstructions until
Operator training must cover:

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the trainee has developed the ability to safely control
1. Use and limitations of the controls in the platform and operate the machine.

sc
and at the ground, emergency controls and safety
systems. Operator Responsibility

machine.
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2. Control labels, instructions, and warnings on the The operator must be instructed that he/she has the
responsibility and authority to shut down the machine
to
3. Rules of the employer and government regula- in case of a malfunction or other unsafe condition of
tions. either the machine or the job site.
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4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation
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of the machine to recognize a malfunction or

potential malfunction.
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3121773 – JLG Lift – 2-1

SECTION 2 - PREPARATION AND INSPECTION

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2.2 PREPARATION, INSPECTION, AND MAINTENANCE

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The following table covers periodic machine inspec- JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNI-
tions and maintenance required by JLG Industries, Inc. CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE

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Consult local regulations for further requirements for TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
aerial work platforms. Frequency of inspections and

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maintenance must be increased as necessary when
machine is used in a harsh or hostile environment, if

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machine is used with increased frequency, or if
machine is used in a severe manner.

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2-2 – JLG Lift – 3121773

SECTION 2 - PREPARATION AND INSPECTION

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Table 2-1.Inspection and Maintenance Table

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Primary Service
Type Frequency Reference
Responsibility Qualification

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Pre-Start Inspection Before using each day; or  User or Operator User or Operator Operation and Safety Manual

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whenever there’s an Operator change.
Pre-Delivery Inspection (See Before each sale, lease, or rental delivery. Owner, Dealer, or Qualified JLG Mechanic Service and Maintenance Man-

ui
Note) User ual and applicable JLG inspec-

q
tion form

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Frequent Inspection In service for 3 months or 150 hours, whichever comes Owner, Dealer, or Qualified JLG Mechanic Service and Maintenance Man-
first;  User ual and applicable JLG inspec-

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or tion form

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Out of service for a period of more than 3 months;
or

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Purchased used.
Annual Machine Inspection
prior inspection. Di
Annually, no later than 13 months from the date of Owner, Dealer, or
User
Factory Trained 
Service Technician 
Service and Maintenance Man-
ual and applicable JLG inspec-
to
(Recommended) tion form
Preventative Maintenance At intervals as specified in the Service and Mainte- Owner, Dealer, or Qualified JLG Mechanic Service and Maintenance Man-
o

nance Manual. User ual

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NOTE: Inspection forms are available from JLG. Refer to Section 6 - Operators Maintenance when performing inspections.
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3121773 – JLG Lift – 2-3

SECTION 2 - PREPARATION AND INSPECTION

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Pre-Start Inspection 4. Operation and Safety Manuals – Make sure a
copy of the Operation and Safety Manual, AEM

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The Pre-Start Inspection should include each of the fol-
Safety Manual (ANSI markets only), and ANSI Man-
lowing:
ual of Responsibilities (ANSI markets only) is

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1. Cleanliness – Check all surfaces for leakage (oil, enclosed in the weather resistant storage con-
fuel, or battery fluid) or foreign objects. Report any tainer.

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leakage to the proper maintenance personnel. 5. Walk-Around Inspection – Refer to Figure 2-1.
2. Structure - Inspect the machine structure for 6. Battery – Charge as required.

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dents, damage, weld or parent metal cracks or
7. Fuel (Combustion Engine Powered Machines) –

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other discrepancies.
Add the proper fuel as necessary.

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8. Engine Oil Supply (Combustion Engine Powered

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Machines) - Ensure the engine oil level is at the Full
mark on the dipstick and the filler cap is secure.

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9. Hydraulic Oil – Check the hydraulic oil level.

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Ensure hydraulic oil is added as required.
10. Accessories/Attachments - Reference the Opera-
Parent Metal Crack Weld Crack
Di tion and Safety Manual of each attachment or
accessory installed upon the machine for specific
to
3. Decals and Placards – Check all for cleanliness inspection, operation, and maintenance instruc-
and legibility. Make sure none of the decals and tions.
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placards are missing. Make sure all illegible decals

11. Function Check – Once the “Walk-Around”
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and placards are cleaned or replaced.

Inspection is complete, perform a functional check
of all systems in an area free of overhead and
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ground level obstructions. Refer to Section 4 for

more specific operating instructions.
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2-4 – JLG Lift – 3121773

SECTION 2 - PREPARATION AND INSPECTION

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t.c
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE
IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PER-

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SONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR
OPERATION.

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MAKE SURE THE ENGINE KEY SWITCH IS ON, THE BATTERY DISCONNECT
SWITCH IS TURNED ON, AND THE POWER/EMERGENCY STOP BUTTONS AT

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THE GROUND AND PLATFORM CONTROL BOX IS TURNED CLOCKWISE (ON).

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3121773 – JLG Lift – 2-5

SECTION 2 - PREPARATION AND INSPECTION

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Daily Walk-Around Inspection 4. Electrical & Hydraulic Cover Assemblies - See
Inspection Note.

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General
5. Boom Sections & Turntable - See Inspection
Begin the "Walk-Around Inspection" at Item 1, as noted

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Note.
on the diagram. Continue checking each item in
sequence for the conditions listed in the following 6. Drive Tracks - Properly Adjusted. See Inspection

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checklist. Note.
7. Diesel Engine or Lithium ION Battery Pack - Free

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of debris and See Inspection Note.
TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

q
8. Swing Drive & Turntable Bearing- Check for
DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN COR-

-E
proper lubrication. See Inspection Note.
RECTED. 9. Hydraulic Tank - Hydraulic oil level correct and

nt
INSPECTION NOTE: On all components, make sure there See Inspection Note.

ou
are no loose or missing parts, that they are securely fas- 10. Electric Engine and Hydraulic Pump - See
tened, and no visible damage, leaks or excessive wear Inspection Note.

sc
exists in addition to any other criteria mentioned. 11. Platform Rotator & Machine Bubble Level - See
1. Platform Assembly, Foot Switch, Ladder and
Di
Gate - Foot switch in good working order, not
modified, disabled or blocked. Manuals in storage
Inspection Note.
to
container, access bar slides up and down properly,
platform properly installed and with mounting
o

both caps screwed on tight. Lanyard attach points

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secure and undamaged. See Inspection Note.

2. Platform/Remote & Ground Control Stations -
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Switches and levers return to neutral, decals/plac-

ards secure and legible, control markings legible.
or

3. Outriggers - See Inspection Note; pads pivot

freely.
To

2-6 – JLG Lift – 3121773

SECTION 2 - PREPARATION AND INSPECTION

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Figure 2-1. Daily Walk-Around Inspection

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3121773 – JLG Lift – 2-7

SECTION 2 - PREPARATION AND INSPECTION

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Function Check d. Ensure all boom functions stop when the foot
switch is released.

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e. Ensure that all machine functions are disabled

en
ENSURE NO FUNCTIONS (EXCEPT TRACK FUNCTIONS) OPERATE WHEN OUT- when the Emergency Stop Button is pushed
RIGGERS ARE NOT PROPERLY SET. in.

pm
f. Ensure main lift down, tower lift down, and jib
After properly setting up on outriggers, perform the func- lift down, work properly when using the emer-
tion check as follows: gency lowering controls.

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1. From the ground control console with no load in 3. SkyGuard™ Function Test (If Equipped)

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the platform:

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a. From the platform controls, test the Sky-
a. Check all guards protecting function control Guard ™ feature by setting up machine and

nt
switches and controllers are in place. operating the telescope out functions and
then activating the SkyGuard ™ sensor. The

ou
b. Operate all functions.
telescope out function will stop and the tele-
c. Ensure all machine functions are disabled
scope in function will operate for a short dura-

sc
when Emergency Stop Button is pushed in.
tion, also the ground alarm will sound until
d. Ensure all boom functions stop when function
enable switch is released. Di the SkyGuard™ sensor or footswitch is disen-
gaged.
to
e. Ensure main lift down, tower lift down, and jib b. Disengage the SkyGuard™ sensor, release
lift down, work properly when using the emer- controls, recycle the foot switch, make sure
gency lowering controls.
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normal operation is available.

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2. From the platform control console: c. If SkyGuard™ remains activated after function
a. Ensure that the control console is firmly reversal or cutout, depress and hold the Sky-
de

secured in the proper location. Guard™ Override Switch (button number 8) to

b. Check that all guards protecting the function allow normal use of machine functions until
or

control switches and controllers are in place; the SkyGuard™ sensor is disengaged.
c. Operate all functions.
To

2-8 – JLG Lift – 3121773

SECTION 2 - PREPARATION AND INSPECTION

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2

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1. SkyGuard™ Sensor
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2. SkyGuard™ Override Switch
(button number 8)
to
Figure 2-2. SkyGuard™ Sensor and Override Switch
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Location
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or
To

3121773 – JLG Lift – 2-9

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

Discount-Equipment.com is your online resource for

commercial and industrial quality parts and equipment sales.
561-964-4949
visit us on line @ www.discount-equipment.com

Select an option below to find your Equipment

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith Surface Prep,Small Line,
Wanco, Yanmar
SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION

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1
or

Figure 3-1. Basic Machine Component Locations

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3121773 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Basic Machine Component Locations

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1. Extendible Track Undercarriage 12. SkyGuard™ Sensor (If Equipped)

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2. Ground/Emergency Controls and Boom/Jib 13. Platform/Remote Control Station
Hydraulic Control Compartment
14. Main Boom

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3. Turntable Gear and Motor
15. Electric Components Compartment (same area
4. Track/Outrigger/Drive/Steer/Hand Pump Hydrau- other side of machine)

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lic Control Valve Compartment
16. Electric Motor/Pump Compartment

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5. Hydraulic Oil tank (same area other side of
17. Lithium ION - Battery Charger LED Indicator - on

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machine)
top of battery pack (if equipped)
6. Outriggers

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18. Diesel Engine Compartment OR Lithium ION - Bat-
7. Tower Boom Assembly tery Pack, Inverter, and Battery Charger Compart-

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8. Jib ment (if equipped)
19. Fork Lift Pockets

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9. Platform Fold-Down Entry Ladder
10. Platform 20. Platform Lanyard Attach Points
11. Manuals Compartment Di
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3-2 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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3. Platform/Ground/Remote Select Switch

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This three position selector switch provides power
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL to the platform when in the center (neutral) posi-
LEVERS OR SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT

en
tion.
RETURN TO THE OFF POSITION WHEN RELEASED. With the key switch turned clockwise and held,

pm
only the ground controls are operational.
3.1 GROUND CONTROL STATION With the key switch turned counter-clockwise, the
See Figure 3-2., Ground Control Station ground control electrical connector is enabled and

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the platform (remote) control station can be oper-

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ated from the ground position.

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WHEN THE MACHINE IS SHUT DOWN BOTH EMERGENCY STOP SWITCHES 4. Engine Start Buttons

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AND THE KEY SWITCH ON THE ENGINE MUST BE SET TO THE OFF POSITION TO To start the engine at the ground control, the main
PREVENT DRAINING THE BATTERY. FOR PROLONGED SHUTDOWN OR WHILE power key switch (item 1) must be set to ON, emer-

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PERFORMING MAINTENANCE/REPAIRS, TURN OFF THE BATTERY DISCON- gency stop button (item 2) reset to ON and set the
NECT SWITCH. select switch (item 3) in the center (neutral) posi-

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tion. The engine start button (item 4) must be
1. Main Power Key Switch
Di
This switch must be turned to the ON ( I ) position
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.
to
before power is supplied to the Power/Emergency
Stop switch. When machine is not in use, the key NOTE: When the machine is not stabilized and the engine is
o

can be removed in the OFF (O) position. not running, an alarm will sound to indicate that the
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2. Power/Emergency Stop Switch key switch on the engine is ON. Turn OFF the key
switch on the engine when not in operation.
A two-position red switch supplies power to PLAT-
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FORM/GROUND/REMOTE SELECT switch when

twisted clockwise to be in the out (on) position.
or

When pushed in (off ), power is shut off to the

PLATFORM and GROUND controls.
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3121773 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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5. Function Enable Light 10. Main Boom Telescope Control

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Illuminates when outriggers are properly set and Provides extension and retraction of the main
boom functions are allowed. Not illuminated indi- boom.

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cates outriggers are not properly set and boom
functions are not allowed. 11. Jib Lift

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Provides raising and lowering of the jib.
6. Function Enable Lever
Items 7 through 13. Do not operate the boom con- 12. Platform Rotate Control

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trols unless the green light (item 5) is illuminated to Provides rotating the platform to the right or left.

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indicate if operation is possible (machine stabi-

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lized) from these controls.
7. Swing Control ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEV-

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Provides swing to the left or right of the boom ELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCU-

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assembly. PANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR
SERIOUS INJURY.

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8. Tower Boom Lift Control 13. Platform Level Control
Provides raising and lowering of the tower boom.
9. Main Boom Lift Control Di Provides for positioning the platform up and down
to adjust the level of the platform.
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Provides raising and lowering of the main boom.
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3-4 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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9 10 11 12 13
7 8
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1 4 3

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5 Di
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13
7 12
6 11
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10
9
or

Figure 3-2. Ground Control Station

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3121773 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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3.2 PLATFORM/REMOTE CONTROL STATION

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Control Position On The Ground:

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Using the platform/remote control station from this control
position is for function check and maintenance only.

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Do not operate machine using the platform/remote control
station from this position if anyone is in the platform.

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WHEN OPERATING THE MACHINE FROM THE GROUND POSITION KEEP AT A

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DISTANCE OF AT LEAST 6 FT (1.8 M) FROM THE TRACKS.

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Ground control position for the platform/remote control is

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possible by connecting the platform/remote control station
to the ground/remote control cable located in the electrical

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component compartment, see photo.

Di
NOTE: Before removing or connecting the platform/remote
control station, depress the emergency stop buttons
to
and the key on the engine must be in the OFF position. To enable this position it is necessary to have the selector
switch at the ground controls (Item 3 - Figure 3-2.) turned
Connect the ground/remote control cable on the left side of
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counterclockwise, this selector switch also overrides the

the machine at the electrical components cabinet (see
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footswitch in the platform.

photo), to the platform/remote control station cable connec-
tor.
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TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL

or

LEVERS OR CONTROL SWITCHES CONTROLLING PLATFORM MOVEMENT DO

NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
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3-6 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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NOTE: Before removing or connecting the platform/remote Control Position From In The Platform:
control station, press the emergency stop buttons and

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The platform/remote control is connected to the machine at
place key on the engine in the OFF position. Before
the platform using a flexible cable.
connecting the special adapter plug ensure there is no

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moisture in the electrical connectors at any time. NOTE: Before removing or connecting the flex cable, the
machine must be turned OFF and the key on the

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Re-connect the platform/remote control station at the plat-
form. engine must be in the OFF position.
Installing the Platform/Remote Control Station At The

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Platform

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1. Connect the flexible control cable at the platform

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to the Platform/Remote Control Station box con-

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nector on the right side of the control box.
.

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2. In the platform, slide the remote control station

assembly into the storage box and place the rib on
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the right side of the control station assembly

under the metal tab attached to the storage box
or

assembly.
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3121773 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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4. On the left side of the control station secure the
box by turning the handle on the locking tab

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clockwise locking the rib of the control station
under the rotating metal tab of the handle assem-

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bly.

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5. To remove the control station assembly, reverse
the four steps above.

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NOTE: The Platform/Remote control box may also be used to
operate tracks, outriggers, and track widening (if

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equipped) by removing it from the platform storage

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3. Lower remote control station assembly into the box and plugging in at the ground control position. If
storage box, ensure the attached flexible cable

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outriggers are down, boom function (except jib) can
slides into the slot also on the right side of the box. be operated. The basket must be removed for jib oper-

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ation.

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3-8 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Platform/Remote Control Station Functions 1. Outrigger - Automatic Retract

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Platform Foot Switch (see photo below) This control allows the operator to control the
retraction of all 4 outriggers at one time.
To operate any function, the footswitch must be

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depressed and a function selected within seven 2. Outrigger - Manual
seconds. If a function is not selected within seven This control allows the operator to control the

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seconds, or if a seven second lapse between end- extension or retraction of one outrigger at a time.
ing one function and beginning the next function,
3. Track Width Adjust

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the footswitch must be released and depressed
again to enable the controls. This control allows the operator to widen the track.

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4. Emergency Lowering
This button allows the operator to lower the boom

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if engine power is not working.

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NOTE: Buttons 5 and 6 when pressed simultaneously also
activate the horn.

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5. Speed Selector/Horn
Di This button allows the operator to select the
desired engine speed for operation.
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6. Service Menu/Horn
This button allows the operator to access the Ser-
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See Figure 3-3. on page 3-10, Platform Control Console

vice Menu.
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for remaining items.

7. Outrigger - Automatic Set And Level
NOTE: Buttons 1, 2, 3, 4, 5, 6, 7, 8, 9, serve a double function -
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they can be used to operate a machine function (icon This control allows the operator to control the
on button) or used as numerical keys (per number extension of all 4 outriggers at one time.
or

below the button) when the SERVICE button 6 (item 6)

sub-menus is activated on the LCD display.
To

3121773 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Figure 3-3. Platform/Remote Control Station

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3-10 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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8. Selector Button 14. Platform Level Switch

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Used for selecting an item when the Service Menu The control allows the operator to adjust the level
button is pressed (item 6). of the platform up or down.

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This button is also used as the SkyGuard™ Override
switch. When the SkyGuard™ system is engaged, 15. Display

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press this button to override and disengage Sky- Display shows status of machine and operating
Guard™. information. Wait until a display screen appears
before starting operation.

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9. Track Width Adjust
NOTE: Controllers (16 through 23), the speed of component

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This control allows the operator to narrow the
movement is proportional to the controller distance

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track.
from the center neutral position.
10. Power/Emergency Stop

nt
Movement of a controller without first
A two-position red switch supplies power to PLAT-
pressing the platform footswitch is indi-

ou
FORM Controls when turned counterclockwise
cated by the depress footswitch error
(on). When pushed in (off ), power is shut off to the

sc
icon on the platform/remote LCD dis-
platform and ground controls.
play.
11. Glow Plug (Diesel Engine Only)
Di
This button allows the operator to pre-heat the 16. Left Side Track Drive And Steer
to
diesel engine in cold climates. This control when moved forward or rearward
12. Gas/Diesel Engine Starter simultaneously with the right side track control
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(24), allows the operator to move the machine in a

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This button allows the operator to start or stop the

straight forward or reverse direction. If each con-
gas/diesel engine.
trol is moved individually, different amounts or in
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opposite directions steering the machine occurs.

13. Electric Engine Start
or

This button allows the operator to start or stop the

electric engine.
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3121773 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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17. Tower Boom Lift control is moved individually or in opposite direc-
tions, to steer the machine.

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This control allows the operator to raise and lower
the tower boom.

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18. Main Boom Lift Platform/Remote Control Station LCD Display
At machine start-up and during machine operation the main

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This control allows the operator to raise and lower
the main boom. LCD display screen (item 15 - Figure 3-3.) is activated. There
are eight (8) display positions which indicate machine status

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19. Main Boom Telescope during various stages of operation.
This switch allows the operator to extend and

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retract the main boom.
1 2

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20. Platform Rotate

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This switch allows the operator to rotate the plat-

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3 4
form to the right or left.

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21. Jib
This control allows the operator to raise and lower
the jib.
Di 5 6
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22. Swing

7 8
This control allows the operator to swing the
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boom assembly to the right or left.

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23. Right Side Track Drive And Steer

This control when moved forward or rearward
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simultaneously with the left side track control (17),

allows the operator to move the machine in a
or

straight forward or reverse direction or, if each

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3-12 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Position 1 Currently Unused. Position 5 Displays outriggers are properly set and

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1 2 boom functions are allowed. No display
1 2
3 4 3 4
indicates outriggers are not properly set

en
5 6 5 6 and boom functions are not allowed.
7 8 7 8

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Position 2 Currently Unused.

ui
1 2

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3 4 Position 6 Indicates boom, jib, turntable, and base are

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5 6 aligned. Drive, steer, track width adjustment
7 8 1 2

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3 4
and outrigger functions are operational if
5 6 this symbol below is present. No symbol

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7 8 indicates these functions are not opera-
Position 3 Displays if selected engine (gas/diesel or tional. Drive and steer are operational if all 4

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electric) is on or off. The X on the icon indi- outriggers are not contacting the ground.
1 2
cates the engine is off.
3 4
5 6
7 8
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Position 4 Displays selected engine speed.

1 2
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3 4
5 6
or

7 8
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3121773 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Position 7 Can indicate any of the following situations:

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1 2 • An emergency stop is pushed in (off ).
3 4 • A low battery. Batteries need charging SERV...

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5 6 by running the gas/diesel engine or
7 8 connecting to a power source.
Position 8 • Indicates emergency lowering has been

pm
• Tower boom sensor is faulty. selected.
• Main boom sensor is faulty. Boom func- 1 2
3 4
• Lithium ION - Battery Charge Status and
tions are cut out.

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5 6
Battery Charger Plugged In.
• Swing sensor is faulty.

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7 8
• CANBUS communication is faulty.

-E
• Electronic fault.

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

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• Skyguard System enabled.
• Battery cold/heater activated system is

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enabled.

SEN.3
FAIL
SWING
?
Di
CAN
BUS
?
to
CARD !
o

?
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or:
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• 50 Hr. - 1st Service Interval - See Section

6 - Table 6-10 and Table 6-11, Compo-
or

nent Maintenance Intervals.

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3-14 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Table 3-1. LCD Display Icon Descriptions

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3121773 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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

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3-16 – JLG Lift – 3121773

SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION

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Table 3-2. LCD Display Error Descriptions

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To

3121773 – JLG Lift – 3-17

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

Discount-Equipment.com is your online resource for

commercial and industrial quality parts and equipment sales.
561-964-4949
visit us on line @ www.discount-equipment.com

Select an option below to find your Equipment

We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman,
Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power
Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,
Skytrak, Tsurumi, Husquvarna Target, Stow, Wacker, Sakai, Mi-T-M, Sullair, Basic, Dynapac,
MBW, Weber, Bartell, Bennar Newman, Haulotte, Ditch Runner, Menegotti, Morrison, Contec,
Buddy, Crown, Edco, Wyco, Bomag, Laymor, EZ Trench, Bil-Jax, F.S. Curtis, Gehl Pavers, Heli,
Honda, ICS/PowerGrit, IHI, Partner, Imer, Clipper, MMD, Koshin, Rice, CH&E, General Equip-
ment ,Amida, Coleman, NAC, Gradall, Square Shooter, Kent, Stanley, Tamco, Toku, Hatz,
Kohler, Robin, Wisconsin, Northrock, Oztec, Toker TK, Rol-Air, APT, Wylie, Ingersoll Rand /
Doosan, Innovatech, Con X, Ammann, Mecalac, Makinex, Smith Surface Prep,Small Line,
Wanco, Yanmar
SECTION 4 - MACHINE OPERATION

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SECTION 4. MACHINE OPERATION

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4.1 DESCRIPTION 4.2 BOOM OPERATING CHARACTERISTICS AND

en
This machine is a hydraulic personnel lift equipped with a LIMITATIONS

m
work platform on the end of an elevating and rotating
boom. Capacities

ip
The primary operator control station is in the platform. The The boom can be raised from the transport position with or

qu
without any load in platform, if:
operator can control drive, steer, boom/platform functions
and outriggers. The machine has a Ground Control Station • Machine is positioned on a firm surface and outriggers

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which will override the Platform Control Station. Ground set properly with the outrigger pads on horizontal sur-
Controls operate boom and platform functions. They are to faces.

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be used in an emergency to lower the platform to the • Load is within manufacturer's rated capacity.

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ground should the operator in the platform be unable to do • All machine systems are functioning properly.
so. The ground control station is to be used for a Pre-Start

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Inspection too. Stability

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This machine is equipped with an ALL MOTION alarm warn-
ing system to alert other personnel in the work area of any
In addition to the conditions listed above under Capacities,
machine stability also depends on the following:
to
machine movement during operation. The motion alarm • A work surface capable of supporting the machine and
system is activated during machine function movement a slope within machine leveling specifications.
such as track, boom, or outrigger operation.
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• Platform is only operated within its work area specifica-

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tion for rated load and boom reach. (See Figure 4-4.)
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3121773 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

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4.3 ENGINE OPERATION

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NOTE: Initial starting must always be performed from the
ground controls. 1 2

en
The battery disconnect switch must be ON (see Section 4.10 3

pm
on page 4-24). The main power switch at the ground controls
and power/emergency stop buttons at the platform and
ground controls must be ON (turned clockwise) to start the

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engine.
5

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4
Diesel Starting Procedure

-E
nt
NOTE: If gas/diesel engine fails to start promptly, do not
crank for an extended time. Should engine fail to start

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again, allow starter to cool off for 2-3 minutes. If
engine fails after several attempts, refer to manufac- 6

sc
turers engine maintenance manual.

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NOTE: If engine is diesel, when starting from ground, turn the
start key at the engine to the HEAT (glow plug) posi-
Figure 4-1. Ground/Emergency Control Box
1. Platform/Remote (Center) 4. Gas/Diesel Engine Start
to
tion for 10 to 15 seconds before attempting to start. Platform Position Button (1) (if equipped)
Release the key and start the engine. 2. Ground Control Position - 5. Electric Engine Start Button (1)
o

1. With power on, set the key at the Ground/Emer- (Turn ClockWise and Hold) 6. Enable Light
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gency Control box in the neutral (vertical) position, 3. Platform/Remote Ground

then push the appropriate ENGINE START switch Maintenance Position -
de

(item 4 or 5) until engine starts. (Turned CounterClockWise)

NOTE: Allow gas/diesel engine to warm-up for a few minutes NOTE: (1) Key switch must be set to ON, battery disconnect switch must be ON, and
or

both the ground and platform emergency stop switches must be reset to ON.
at low speed before applying any load.
To

4-2 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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NOTE: At low temperatures start the motor and let it run for a Electric Engine Starting Procedure - AC Voltage Machine
few minutes, so that the hydraulic oil circulates and

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reaches at least 50°F (10°C) before operating the plat-
form.

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ENSURE THE ELECTRICAL CIRCUIT BEING USED IS THE SAME VOLTAGE AND
Diesel Engine Shutdown Procedure FREQUENCY INDICATED ON THE ELECTRIC ENGINE PLATE. USE AN AC EXTEN-

pm
SION CORD WITH SUFFICIENT AMPERAGE CAPACITY TO PROPERLY POWER
1. Remove all load and allow engine to operate at
THE MACHINE.
low speed for 3-5 minutes; this allows further

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reduction of internal engine temperature.

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2. Turn off the gas/diesel engine by using the gas/

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diesel engine button (item 12, Figure 4-3.) on the
platform/remote control box.

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3. The shutdown procedure takes about 1 minute,

ou
wait for complete shut-off (display off ).
4. Push POWER/EMERGENCY STOP switches at the

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platform and ground in, to the off position.
5. Turn engine key to off.
Di 2
to
1
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1. Before connecting the machine to the electrical

circuit, ensure the key on the gas/diesel engine is
or

in the OFF position.

To

3121773 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

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2. Power the machine using a heavy duty AC power 4. Start the electric engine using the engine start
cord with sufficient amperage capacity, through button at the ground/emergency control box.

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the connector (item 1 positioned near the electric (item 5 - Figure 4-1.) and operate machine.
engine.

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5. When finished operating with the electric engine,
3. Turn on the circuit breaker switch (item 2) posi- turn off breaker switch (item 2), and unhook the

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tioned behind the clear plastic cover near the elec- electric AC cord from receptacle (item 1).
tric engine (— symbol is ON - O symbol is OFF).

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to
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or
To

4-4 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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4.4 BASE AND BOOM/JIB ALIGNMENT

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The machine uses a reflector/photocell alignment that
checks if the boom assembly is completely lowered and

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retracted, the jib is lowered, and the turntable is aligned
with the base. (see photos)

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When these conditions are met this symbol
will display in position (6) on the Platform/

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Remote Control LCD display.

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UNLESS THESE CONDITIONS ARE MET, DRIVE,

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STEER, TRACK WIDTH ADJUSTMENT, AND OUTRIGGER

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MOVEMENT IS PREVENTED. Boom/Jib and Base Alignment - Reflectors/Photocells

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Platform Rotation Alignment Indicator

Di There are also platform

alignment indicators on the
to
platform rotator assembly.
When re-aligning the plat-
form straight on the
o

machine, align these indi-

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cators on the platform rota-

tor assembly.
de
or

Base/Boom Alignment - Visual Indicator

To

3121773 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

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4.5 TRACKS - DRIVING, STEERING AND TRACK WIDTH Track width adjust

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ADJUST

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DO NOT WIDEN OR NARROW THE TRACKS WIDTH WHEN PARKED WITH THE
TRACKS ON THE GROUND. THE MACHINE MUST BE TRAVELLING OR RAISED

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KEEP EVERYONE A DISTANCE OF AT LEAST 6 FT. (1.83 M) FROM THE MACHINE ON ITS OUTRIGGERS WHEN OPERATING THIS FUNCTION.
WHEN OPERATING THE TRACKS.

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NOTE: The base and boom/jib must be aligned and retracted Press and hold button 3 for widening or button 9 for narrow-
before this function will operate, see Section 4.4, BASE ing the track.

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AND BOOM/JIB ALIGNMENT.

-E
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3 9
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to
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or
To

4-6 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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Travelling (Drive and Steer) Travelling (Grades and Side Slopes)

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en
USE EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TERRAIN TO AVOID LOSS OF TRAVEL CONTROL OR "TIP OVER", FULLY WIDEN TRACKS,
OBSTACLE. CHECK FOR CURBS, LARGE STONES, OR OTHER TERRAIN OBSTA- AND DO NOT DRIVE MACHINE ON GRADES EXCEEDING 25 DEGREES (40%).

pm
CLES INCLUDING OVERHEAD OBSTACLES AS THE MACHINE WILL MAKE 
UNCONTROLLED PIVOTING MOTIONS WHEN THE CENTER OF GRAVITY (CEN- USE RAMPS WHEN TRAVELLING ON STEPS OR OTHER SURFACES THAT ARE
TER OF TRACK FRAME) SHIFTS OVER AN EDGE. SLOW DOWN TO MINIMIZE NOT SMOOTH OR HAVE GOOD TRACTION.

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ACCELERATION DURING PIVOTING MOVEMENT. 

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 WHEN DRIVING ON SIDESLOPES, FULLY WIDEN THE TRACKS AND EXTEND

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USE EXTREME CAUTION WHEN DRIVING IN REVERSE. 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

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4-2.)

ou
• To drive straight forward or reverse, move the control- DRIVE ON SIDESLOPES WITH THE BOOM STOWED. DO NOT DRIVE ON SIDES-
lers for both tracks at the same time, direction and posi- LOPES WHICH EXCEED 14 DEGREES.

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tion.
• Always fully widen the track prior to driving, if possible,
Di
for easier steering and increased stability.
• Always travel in the slow speed setting unless the travel
to
path is firm, level and uniform.
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or
To

3121773 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

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Figure 4-2. Grade and Side Slope Definition

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To

4-8 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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Jib Position for Travelling If any of these conditions have not been met, the use of the
JIB is not possible and one of the following error displays

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It is necessary to raise the JIB arm when driving up or down
appears.
slopes that exceed 10° and but less than the max. 25° to pre-

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vent the jib from contacting the ground.

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ONLY PERFORM THIS OPERATION WHEN IT IS NECESSARY. IN ALL OTHER SIT-

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UATIONS, DRIVE WITH THE BOOM AND JIB FULLY LOWERED AND ALIGNED.
IN SOME CASES AND FOR SOME MACHINE MODELS TO BE ABLE TO RAISE THE

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JIB, IN ADDITION TO THE ABOVE CONDITIONS IT IS NECESSARY TO REMOVE

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THE PLATFORM.

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The permission to use the JIB is indicated

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by the icon in position 5 on the remote
control display panel.

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Before lifting the jib arm in the traversing
Di
phase, the following conditions must be
verified:
to
• All outriggers must be lifted from the ground
• The platform must be removed from the jib arm.
o
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• The platform/remote control box must be removed After these conditions have been met, make sure that there
from the platform and used from the ground. are no obstacles in the Jib working area and operate as fol-
de

NOTE: The aerial part safety device by-pass key must not lows:
have been activated after the machine has been • Activate joystick for moving the JIB arm. If a different
or

closed and aligned. joystick is activated an error message will appear on the
display.
To

3121773 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

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In this case if you try to move the JIB without first removing
the basket, the use of the JIB arm will not be possible and

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will display the following error screen.

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pm
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• After slope has been passed, for which the jib had to be
raised, fully lower jib and continue travelling.
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• With JIB raised, ALWAYS travel at minimum speed and
keep JIB as near as possible to the ground.
o

• DO NOT travel downhill if the JIB is not completely

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stowed.
ERROR - Remove the Platform
Before Proceeding
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TO BE ABLE TO RAISE THE JIB, IN ADDITION TO THE ABOVE CONDITIONS, IT

IS NECESSARY TO REMOVE THE PLATFORM. TO DO THIS FOLLOW THE ADVICE
or

IN THE FOLLOWING PARAGRAPH.

To

4-10 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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4.6 OUTRIGGER OPERATION Operate each outrigger separately by
MANUAL pressing button 2 (item 2) to select which

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outrigger to control (each outrigger is num-
bered 1 thru 4, see decal, each press of but-

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BE CERTAIN OUTRIGGER PADS ARE SET ON A FIRM AND HORIZONTAL SUR-
ton 2 displays the outrigger selected on the
FACE. DO NOT SET OUTRIGGER PADS ON INCLINED, VERTICAL, OR SLIPPERY SELECT
LCD display). Press button 1 (item 1) to

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SURFACES.
retract or button 7 (item 7) to set that out-
2 rigger. The OK will appear on the display

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when the outriggers are set properly and
the unit is level.

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THE OUTRIGGERS WILL NOT OPERATE UNLESS THE BOOM AND JIB ARE COM-

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PLETELY LOWERED, RETRACTED AND ALIGNED WITH THE BASE.

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NOTE: Base and boom/jib must be aligned and stowed Note: To cycle back to outrigger auto-set
before this function will operate, see Section 4.4, BASE mode, press button 2 (item 2) until the

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AND BOOM/JIB ALIGNMENT. LCD display shows the normal operating
icons.

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Setting Outriggers From the Platform/Remote Console

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(Reference Figure 4-3. on page 4-16 for item number location)
Either - Press and hold the outrigger auto-
to
set and level button 7 (item 7) until OK
appears on the platform LCD display;
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AUTO
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or
7
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or
To

3121773 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

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t.c
CHECK BUBBLE LEVEL INDICATOR TO CONFIRM UNIT IS LEVEL (BUBBLE IS IN IF ONE OF THE ORANGE LIGHTS LOCATED ON EACH OUTRIGGER SHOULD
THE 1° GREEN (CENTER) AREA) AND TRACKS ARE OFF THE GROUND BEFORE FLASH OR REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE

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OPERATING THE BOOM FUNCTIONS. IF BUBBLE IN THE LEVEL INDICATOR IS GROUND, STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG
NOT IN THE GREEN AREA, AFTER USING THE AUTO-LEVEL FUNCTION, SHUT SERVICE TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRE-

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DOWN THE MACHINE AND HAVE THE MACHINE REPAIRED BY A QUALIFIED SPONDING OUTRIGGER MICRO SWITCH.
SERVICE TECHNICIAN.

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IF SLOPE EXCEEDS 13°, THE MACHINE IS NOT CAPABLE OF PROPERLY SET-

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TING OUTRIGGERS AND LEVELING ITSELF. OPERATION OF BOOM AND PLAT-
FORM FUNCTIONS WILL NOT BE ALLOWED IN THIS CONDITION. THE

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MACHINE IS CONSIDERED STABILIZED WHEN LEVELED TO LESS THAN 1° AND

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TRACKS ARE LIFTED AT LEAST 2 IN. (5 CM) FROM THE GROUND.
STABILIZING MACHINE WITH AN INCLINATION DEGREE HIGHER THAN THE

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ONE ALLOWED COULD CAUSE INSTABILITY OF THE MACHINE

Di If the platform ladder is higher than 16 in. (40 cm) off the
ground when the ladder is lowered, when setting the
to
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
o

up on outriggers.
rg

Each outrigger has a orange light installed. All lights will be

on steady when outriggers are properly set and machine is
de

leveled. No lights will be on if the outriggers are not set

properly.
or
To

4-12 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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Retracting The Outriggers 4.7 BOOM/PLATFORM OPERATION

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(Reference Figure 4-3. on page 4-16 for item number location)
Either - Press and hold button no. 1 (item

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THE BOOM WILL NOT OPERATE UNTIL THE OUTRIGGERS ARE PROPERLY SET
1) of the remote control.
AND MACHINE IS LEVELED.

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The 4 outriggers will all retract at the same AT PLATFORM/REMOTE CONTROL STATION, TWIST EMERGENCY STOP BUT-
AUTO
time and lower the machine. TON CLOCKWISE TO THE OUT POSITION, START ENGINE, AND ACTIVATE
FOOTSWITCH FOR ALL PLATFORM/ REMOTE CONTROL FUNCTIONS.

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1 or ALWAYS STOW (RAISE) THE LADDER AFTER ENTERING OR EXITING THE PLAT-

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FORM TO PREVENT IT BEING DAMAGED WHEN OPERATING THE MACHINE.

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Operate each outrigger separately by
MANUAL pressing button 2 (item 2) to select which If the operator attempts to raise the JIB with more than the

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outrigger to control (each outrigger is num- allowed capacity in the platform a maximum weight
bered 1 thru 4, see decal at each outrigger, reminder icon appears in the middle of the platform/remote

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each press of button 2 displays the outrigger LCD display and the function stops.
SELECT
selected on the LCD display). Press button 1

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If the machine is set up on outriggers for the reduced oper-
(item 1) to retract or button 7 (item 7) to set ating area, the swing function will be stopped if and when
2 that outrigger.
Di you try to go outside the allowed working area. A message
on the platform/remote control LCD display will appear
Note: To cycle back to outrigger auto-
to
retract mode, press button 2 (item 2) until informing that it is necessary to swing in the opposite direc-
the LCD display shows the normal operat- tion to continue operation.
o

ing icons. NOTE: At low temperatures start the motor and let it run for a
rg

few minutes, so that the hydraulic oil circulates and

reaches at least 50°F (10°C) before operating the plat-
de

form.
or
To

3121773 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

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Overload Alarm Platform Level Adjustment (Item 14, Figure 4-3.)

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If the platform is overloaded all the boom functions are NOTE: During normal operation of the machine, the plat-
stopped, the overload icon appears on the platform/remote form will automatically maintain its position.

en
LCD display and the alarm sounds. To restore the boom
functions it is necessary to remove the extra load. • To manually Level Up, turn select switch clockwise and

pm
hold until desired position is reached.
• To manually Level Down, turn the select switch counter
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL clockwise and hold until desired position is reached.

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LEVER OR SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN

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TO THE 'OFF' OR NEUTRAL POSITION WHEN RELEASED.

-E
IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS
RELEASED, REMOVE YOUR FOOT FROM THE FOOT SWITCH AND/OR USE ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEV-

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EMERGENCY STOP SWITCH TO STOP THE MACHINE. ELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCU-
PANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR

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If platform is lifted from the proper mounting position dur- SERIOUS IN.JURY.
ing the use of the machine, an alarm will sound and all the

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movements of the machine will stop. An error message will
zz
Raise And Lower The Tower Boom (Item 17, Figure 4-3.)
Di
appear on the LCD display of the platform/remote control.
• To raise the tower boom, depress the foot switch and
move the controller forward.
to
• To lower the tower boom, depress the foot switch and
move the controller backwards.
o

Raise And Lower The Main Boom (Item 18, Figure 4-3.)
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• To raise the main boom, depress the foot switch and

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move the controller forward.

• To lower the main boom, depress the foot switch and
or

move the controller backwards.

To

4-14 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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Telescope The Main Boom (Item 19, Figure 4-3.) Swinging The Boom (Item 22, Figure 4-3.)

t.c
• To extend the main boom, depress foot switch and
move controller backward.

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• To retract the main boom, depress foot switch and WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE
move controller forward. BOOM AND UPRIGHT TO CLEAR SURROUNDING WALLS, PARTITIONS AND

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EQUIPMENT.
Platform Rotation (Item 20, Figure 4-3.)
• To rotate the platform to the right, depress the foot-

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switch and move the controller forward.

q
IF THE TURNTABLE IS ROTATED WITH TOWER BOOM TOO LOW OR TOWER
• To rotate the platform to the left, depress the footswitch

-E
BOOM IS LOWERED NEAR AN OUTRIGGER, THE TOWER BOOM MAY CONTACT
and move the controller backwards. THE OUTRIGGERS CAUSING MACHINE DAMAGE.

nt
Raise And Lower The Jib (Item 21, Figure 4-3.) • To swing the boom to the right, depress the foot switch

ou
• To raise the jib, depress the foot switch and move the and move the controller forward.
controller forward. • To swing boom to the left, depress foot switch and

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

3121773 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

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t.c
en
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qui
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Figure 4-3. Platform/Remote Control Box

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4-16 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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(

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sc500 lb.
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Figure 4-4. Platform - Load/Reach Chart - X430AJ

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(Full 360° Rotation and Jib Extend ONLY with Outriggers Set to Full Work Area Position)

3121773 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

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SkyGuard Operation (If Equipped)

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The SkyGuard™ feature is used to provide
enhanced control panel protection. When !

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the SkyGuard™ sensor is activated, functions
that were in use at the time of actuation will

pm
reverse or cutout and the ground alarm will
beep. The table below outlines these func-
tions.

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NOTE: Reverse motion can be stopped by the operator by 1

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releasing the footswitch, depressing the emergency

-E
stop button, or by releasing pressure on the Sky-

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Guard™ sensor.

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If SkyGuard™ remains activated after function reversal or
2
cutout, depress and hold the SkyGuard™ Override Switch

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(button number 8) to allow normal use of machine functions 1. SkyGuard™ Sensor 2. SkyGuard™ Override Switch
until the SkyGuard™ sensor is disengaged. (button number 8)
Di Figure 4-5. SkyGuard™ Sensor and Override Switch
Location
to
Table 4-1. SkyGuard™ Function Table
o
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Main Main Main Main Drive Tower Tower

Lift Tele Tele Swing Drive Platform Platform Jib
Lift Lift Lift
Up Dn Forward Reverse Level Rotate Lift
In Out Up Down
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R C C R R C C R C C C C
R = Indicates Reversal is Activated
or

C = Indicates Cutout is Activated

N/A Indicates the function does not exist for this model
To

4-18 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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Emergency Lowering Platform Removal/Installation

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The main function of the emergency lowering is to lower the The platform may only be removed to allow passage
platform in the event of primary power failure. through areas measuring a minimum of 39 in. (99cm).

en
Some functions will not operate since this is a gravity lower- NOTE: If the platform is removed, only track movement and
ing system and a symbol will appear on the display if one of jib functions are allowed.

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those functions are selected.
Platform Removal
Operate as follows:

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1. Remove the platform/remote control box from the
1. Ensure the emergency stop button is in mounting support.

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the ON position by turning it clockwise.

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2. Loosen and remove the aluminum caps that
2. Push and hold down button 4 (item 4) secure the platform to the jib platform mounting

nt
on the platform/remote control box. posts.
The LCD display will show the symbol

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3. Disconnect SkyGuard™ connection.
shown on button 4 in position 8 on the
LCD display. (Items 4 and 15, Figure 4-3.)

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3. Select a boom function to operate by moving the
Di
paddle controller in the direction for lowering -
(items 18, and 21 in Figure 4-3.)
to
4. When finished, release the emergency lowering
switch, controller and foot switch.
o
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5. Position the emergency stop switch to the off posi-

tion.
de

Determine the reason for the primary power failure and

have the problem corrected by a qualified JLG service tech-
or

nician.
To

3121773 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

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4. Lift the platform off the mounting posts in an Battery Charging - Daily
upward direction. Place platform aside for later

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installation.

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Platform Installation BEFORE CONNECTING THE BUILT-IN CHARGER TO THE RECEPTACLE, ENSURE
1. Lift the platform and align the platform mounts THE KEY ON THE ENGINE IS POSITIONED TO OFF.

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with the jib mounting posts and lower until The machine has a built-in battery charger. To activate this
seated. feature connect the machine to an appropriately grounded

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2. Secure the platform to the jib mounting posts with AC receptacle and activate the charging switch behind the
the aluminum threaded caps. Do not overtighten. clear plastic door. (See photo) Verify the battery disconnect

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-E
3. Re-install the platform/remote control box into the switch is on.
mounting support on the platform.

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4.8 BATTERY CHARGING - DIESEL/AC-ELECTRIC

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NOTE: Be sure that the machine is parked in a well ventilated
area free of flames and sparks.
Di
• Only plug the charger into a properly grounded outlet.
to
• Do not use ground adaptors or modify plug. Do not
touch non-insulated portion of output connector or
o

non-insulated battery terminal.

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• Always disconnect the AC supply before making or

breaking the connections to the battery.
de

• Do not open or disassemble charger.

• Do not operate charger if the AC supply cord is dam-
or

aged or if the charger has been damaged in any way.

To

4-20 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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4.9 BATTERY CHARGING - LITHIUM-ION MACHINE Charging the Battery Pack

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To check the battery condition on the lithium
ION equipped machine, power up the

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machine and use the special indicator shown DO NOT LEAVE THE MACHINE IN CONTINUOUS CHARGING FOR TIME PERIODS
at position 8 on the platform control station EXCEEDING 24 HOURS.

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LCD display. REMEMBER, THE CHARGE WORKS EVEN IF THE ELECTRONIC BOARD OF THE
MACHINE IS TURNED OFF. SO THE BATTERIES CAN BE CHARGING EVEN IF THE
or;

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REMOTE CONTROL IS OFF.
Check charge indicator (item 2) on CHARGE THE MACHINE USING ONLY THE BATTERY CHARGER INSTALLED ON

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top right side of the Lithium-Ion bat- IT. THE USE OF A CHARGER OTHER THAN THAT PROVIDED VOIDS ANY KIND

-E
tery pack. While charging, this indi- OF WARRANTY ON BATTERIES.
cator shows the current charge state

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of the lithium-ion battery pack as fol- Approximate time required to fully recharge the battery

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lows; pack:
RED LED: shows that the battery is in • Full Recharge -8 hrs. - 120V AC or 4 hrs. - 220V AC

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the initial charging phase.
• 80% Recharge -4 hrs. - 120V AC or 2 hrs. - 220V AC

charge. Di
YELLOW LED: shows that the battery has reached 80% • The batteries can be charged during machine opera-
tion, (obviously the charging times in this case will be lon-
to
GREEN LED: shows that the battery has reached 100% of ger).
charge. • The batteries can be charged when they are not fully
o

If machine is powered on while charging, the depleted.

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LCD display on the platform control station • If the charge is less than 20% an audible
also shows the machine charge indicator. warning signal and an icon will be acti-
de

vated whenever the electric motor is

started, to alert the user to charge the
or

machine.
To

3121773 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

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• If the charge is less than 10%, in addition
to the audible warning signal, reduced

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speed is activated and an icon comes on THE BATTERY CHARGER SUPPLIED WITH THE LIFT WAS DESIGNED TO
in position 4 on the platform station LCD ENSURE SAFE AND RELIABLE PERFORMANCE. IT IS ALREADY FITTED ON THE

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display. MACHINE AND DOES NOT NEED ANY ADJUSTMENT OR CONFIGURATION BY
THE USER; NONETHELESS, TO AVOID INJURY AND DAMAGE TO THE BATTERY

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To start charging the battery connect the main AC power
supply to the AC socket (item 1 - photo) located on the CHARGER, THE FOLLOWING ESSENTIAL PRECAUTIONS MUST BE OBSERVED:
right rear of the machine next to the electric engine. • Carefully read installation instructions contained in this

ui
After a few seconds the charge indicator (item 2 - photo) manual. For future reference, keep manual in a safe

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located on the right hand side of the machine on top of the place.

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lithium-ion battery pack turns red, meaning the battery has • Do not place battery pack near heat sources.
started charging.

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• As battery charger is sealed without forced ventilation,
its performance depends on ambient temperature and

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type of installation.

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2 • Be certain type of power supply available corresponds
to voltage specified and indicated on the battery char-
Di ger rating plate or in this Operation/Maintenance Man-
ual. If any questions, contact your local JLG Service
to
Center or the local electrical company.
• An AC class circuit breaker can be used as a protection
o

device for the battery charger power supply, however it

rg

is recommended to use a class A or even better class B

device.
1
de

• In regard to safety and electromagnetic compatibility,

the battery charger features a three pin plug with
or

ground, which can only be plugged into an grounded

socket. If the plug does not go into the socket, most
To

probably the socket is old and not grounded. In this

4-22 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
case, contact an electrician to have the socket replaced. Charge Curve
Do not use adapters to resolve ungrounded circuit plug

t.c
The battery charger features just one charge curve (IUIa)
problems.
plus balancing and maintenance, designed specifically for

en
• Ensure power cable is undamaged. If cable is worn or charging the lithium-ion battery pack on this machine.
damaged, have it replaced immediately.
Cold Weather Charging

pm
• If extensions or multiple sockets are used, make sure
these support total rated current. Lithium battery pack discharge and/or recharge with posi-
tive lithium battery level (SOC>0) is possible over 14°F

ui
• Disconnect power supply before connecting or discon-
necting battery. (-10°C).

q
• Do not use the battery charger to charge the batteries

-E
of other vehicles; the battery charger installed was spe- In cold environmental temperature (not lower than -13°F
(-25°C), the on-board electric heaters automatically warm

nt
cially designed to charge the type of lithium batteries
used on this machine. Do not attempt to charge any up the cells. The heaters are activated by the BMS when the

ou
other type of batteries. minimum cell temperature is 32°F (0°C). The heaters are
• Do not attempt to repair the battery charger. Opening automatically switched off when the minimum cell tempera-

sc
the cover may expose the user to the risk of electric ture raises over 35.6°F (2°C).

•
shock.
Di
Do not open battery charger, opening it may affect the
In cases where the battery charger is connected, when the
minimum cell temperature is 32°F (0°C), the charger only
to
index of protection (IP) even after it has been closed
again. supplies 3A to supply power to the heaters until a positive
minimum cell temperature is reached.
o

• If battery charger is not working correctly or is dam-

rg

aged, disconnect it immediately from power outlet and From -13°F (-25°C) to 32°F (0°C) with null lithium battery
the battery socket and contact your local JLG Service level (SOC=0) the heaters will only work while the battery
de

Center. charger is connected to the machine.

or
To

3121773 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

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The battery cold/heater activated icon will be 4. Shut down gas/diesel/electric engine with the
shown on the display when the heaters are same button on the platform/remote control sta-

t.c
enabled. The machine can only be moved in tion used to start it. Complete machine shut down
the lower speed while the heater system is takes approximately 1 minute, LCD display OFF.

en
active. 5. At ground and platform controls, push-in emer-

pm
Cooling Fans gency stop buttons and remove key at the ground
controls. Turn off engine and remove the key.
In hot environmental temperatures, the cooling fans sys-
6. Close platform control console lid if necessary to

ui
tems becomes active to cool down the battery cells. This sys-
tem is automatically activated by the BMS when cell protect instruction placards, warning decals and

q
operating controls from hostile environment,
temperature raises over 98.6 °F (37°C). The cooling fans sys-

-E
place a cover over this area.
tem will automatically shut off when cell temperature cools

nt
7. If machine is to be shut down for long periods of
down to 95°F (35°C). time, turn battery disconnect switch, RED handle

ou
located on the front of the hydraulic tank/battery
4.10 SHUT DOWN AND PARK tray housing, to the POWER OFF position. (see

sc
photo below)

Di
WHEN PARKING THE MACHINE ON A SLOPE OR UNEVEN GROUND WITH THE
to
OUTRIGGERS RETRACTED, PARK WITH THE TRACKS IN THE FULLY WIDENED
POSITION AND BLOCK THE TRACKS USING WEDGES TO PREVENT MACHINE
o

MOVEMENTS.
rg

1. Drive machine to a reasonably well protected area.

2. Ensure boom and jib are in the stowed (aligned)
de

position.
or

3. Remove all load and allow engine to operate 3-5

minutes at LOW setting to permit reduction of
internal engine temperatures.
To

4-24 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
POWER ON
4.11 LIFTING AND TIE DOWN

t.c
Clockwise Lifting
(As Shown) ON

en
1. Determine gross weight of machine, refer to the
serial number tag, or weigh the individual unit to
POWER OFF

pm
find out the gross vehicle weight.
Counter-
2. Place the booms in the stowed position and prop-
Clockwise

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

q
3. Remove all loose items from the machine.

-E
4. Properly adjust the rigging to prevent damage to

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the machine and so the machine remains level.

ou
5. Width of slings must not exceed 2.36 in (60 mm),
OFF the width of the chains must not exceed .984 in (25

sc
mm), the diameter of the ropes must not exceed
.984 in (25 mm) in order not to exert a pressure in
Di
1702155A
an abnormal direction on the outrigger plate.
to
BATTERY DISCONNECT SWITCH - GAS/DIESEL/AC-ELECTRIC
USE OF ROPES, CHAINS OR SLINGS WITH LENGTH LESS THAN 10 ft (3m)
o

COULD CAUSE PERMANENT DAMAGE TO MACHINE OUTRIGGERS.

rg

To lift machine, a separate sling must be attached to each

de

outrigger using the appropriate lifting points as indicated in

Figure 4-6..
or

Weight of machine is not spread equally over the four out-

riggers (See Figure 4-7.). Minimum required capacity of the
To

3121773 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

om
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

t.c
identical.

en
pm
1
1

q ui
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nt
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sc
1
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Figure 4-6. Machine Lifting Points

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1. Outrigger Lifting Lug (4 corners) Figure 4-7. Lifting Machine - Attach Points
or

1. Lifting Slings
To

4-26 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
Tie Down (See Figure 4-8.)

t.c
en
WHEN TRANSPORTING MACHINE, BOOM MUST BE FULLY LOWERED INTO
THE BOOM REST.

pm
• Travel up ramps with platform behind machine.

ui
• Do not contact ground with jib or bottom of platform
when loading/unloading. Operate machine from

q
ground remote position and raise jib to prevent contact

-E
with the ground. See “Jib Position for Travelling” on

nt
page 4-9.
• ALWAYS load/unload the machine with track fully wid-

ou
ened.

sc
1. Place booms in the stowed position.
2. Remove all loose items from machine.
Di
3. Secure chassis using straps or chains of adequate
strength.
to
o
rg

DO NOT MAKE CONNECTIONS AT POINTS DIFFERENT THAN THOSE IDENTI-

FIED BY THE TIE DOWN LOCATION DECAL SHOWN. THIS COULD CAUSE PER-
MANENT DAMAGE RESULTING IN COLLAPSE OF THE PRODUCT.
de
or
To

3121773 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

om
t.c
1

en
2

pm
1

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1703814A

q
-E
nt
ou
sc
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to
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1
rg
de
or

Figure 4-8. Machine Tie-Down Points (both sides of machine)

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

4-28 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
MACHINE DECALS

t.c
en
pm
q ui
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nt
ou
sc
Di
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or

Figure 4-9. Decal installation - Left Side - Machine

To

3121773 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

om
t.c
en
pm
q ui
-E
nt
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sc
Di
to
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or

Figure 4-10. Decal installation - Left Side - Chassis

To

4-30 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
t.c
en
pm
q ui
-E
nt
ou
sc
Di
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or

Figure 4-11. Decal installation - Platform

To

3121773 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

om
t.c
en
pm
q ui
-E
nt
ou
sc
Di
to
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or

Figure 4-12. Decal Installation - Right Side - Machine

To

4-32 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

om
t.c
en
pm
q ui
-E
nt
ou
sc
Di
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or

Figure 4-13. Decal installation - Right Side - Chassis

To

3121773 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

om
t.c
en
pm
q ui
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ou
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Di
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or

Figure 4-14. Decal Installation - Right Side- Valve Compartments

To

4-34 – JLG Lift – 3121773

SECTION 4 - MACHINE OPERATION

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t.c
en
pm
q ui
-E
nt
ou
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Di
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de
or

Figure 4-15. Decal Installation - Machines with Lithium-Ion Power Only

To

3121773 – JLG Lift – 4-35

SECTION 4 - MACHINE OPERATION

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Table 4-2. X430AJ - Decal Installation - Lithium-Ion Power Only

t.c
(See Figure 4-15.)

en
ITEM # PART NUMBER DESCRIPTION
17107300 DECAL INSTALLATION

m
1 07107200 Decal, Danger - Batteries

ip
4 1001125483 Decal, No Pressure Washing At This Location

qu
9 06520600 Decal, 88 dB Sound Level Warning

t-E
13 07107100 Decal, Recharge Batteries After Each Use or At Least Every 3 Months
16 07110300 Decal, Emergency Lowering Procedure - Lithium-Ion

n
18 07264800 Decal, Battery Charge Level Indicator

ou
19 1701644 Decal, Battery Charger AC Plug
20 1703813 Decal, Battery Charging Ventilation Warning

sc
Di
to
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or
To

4-36 – JLG Lift – 3121773

 TO PURCHASE THIS PRODUCT PLEASE CONTACT US

Equipment Financing and

Extended Warranties Available

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Wanco, Yanmar
SECTION 5 - EMERGENCY PROCEDURES

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SECTION 5. EMERGENCY PROCEDURES

t.c
5.1 GENERAL 5.2 INCIDENT NOTIFICATION

en
This section explains the steps to be taken in case of an JLG Industries, Inc. must be notified immediately of any

m
emergency situation while operating. incident involving a JLG product. Even if no injury or
property damage is evident, the factory should be con-

ip
tacted by telephone and provided with all necessary

qu
details.
In USA -

t-E
JLG Phone: 877-JLG-SAFE (554-7233)
(8am till 4:45pm EST)

n
Outside USA: 240-420-2661

ou
E-mail: [email protected]

sc
Failure to notify the manufacturer of an incident involv-
ing a JLG Industries product within 48 hours of such an
Di occurrence may void any warranty consideration on
that particular machine.
to
o
rg

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT MACHINE AND TEST ALL

FUNCTIONS FIRST FROM GROUND CONTROLS, THEN FROM PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 10 FT (3 M) UNTIL YOU ARE SURE ALL DAMAGE
de

HAS BEEN REPAIRED, IF REQUIRED, AND ALL CONTROLS ARE OPERATING

CORRECTLY.
or
To

3121773 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES

om
5.3 EMERGENCY OPERATION
POWER ON

t.c
Power Main Cut-Off Switch Location Clockwise
ON

en
A battery cut-off switch - RED handle (photo shows power (As Shown)
ON) is located on the inside of the battery/electrical box tray

m
at the left front of the machine just behind the outrigger POWER OFF
mount. When switched off - handle turn all the way counter- Counter-

ip
clockwise - all electrical power to the machine is shut down. Clockwise

qu
n t-E
ou
OFF

sc
Di 1702155A
to
BATTERY DISCONNECT SWITCH - GAS/DIESEL/AC-ELECTRIC
o
rg
de
or
To

5-2 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

om
Operator Unable to Control Machine Platform or Boom Caught Overhead

t.c
IF PLATFORM OPERATOR IS PINNED, TRAPPED OR If platform or boom becomes jammed or snagged in
UNABLE TO OPERATE OR CONTROL MACHINE: overhead structures or equipment, rescue platform

en
1. Other personnel should operate the machine from occupants prior to freeing the machine.
ground controls only as required. NOTE: The engine runs the hydraulic pump which provides

pm
2. Other qualified personnel on the platform may use hydraulic pressure for the hydraulic system.
the platform controls. DO NOT CONTINUE OPERA- The electric power provides power for the hydraulic

ui
TION IF CONTROLS DO NOT FUNCTION PROPERLY. proportional valve solenoids to open and close which
operate various solenoids and relays on the hydraulic

q
3. Cranes, forklift trucks or other equipment can be
system. In the event either/or both are not operating

-E
used to remove platform occupants and stabilize
machine motion. properly, the following procedures will allow the low-

nt
ering of the boom and platform.

ou
sc
Di
to
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de
or
To

3121773 – JLG Lift – 5-3

SECTION 5 - EMERGENCY PROCEDURES

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Manual Descent with Engine Running and Electrical 2. Press and hold down button 4 (item 4)
with hazard symbol on platform/remote

t.c
Power
control box. The LCD display (item 15)
will indicate the triangle symbol seen

en
on the button in LCD position 8.
ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD

pm
OF PERSONNEL BEFORE LOWERING. 3. Select a boom function to operate by
moving it’s controller in the direction for lowering.
Using Platform/Remote Control Box from Platform (items 17, 18, and 21)

ui
(See Figure 5-1.) 4. Position (press) the emergency stop switch to the

q
OFF position.

-E
The manual descent system is provided as an emergency
means to lower personnel in the platform.

nt
1. Check emergency stop button (item 10) is in the

ou
ON position by turning it clockwise.


sc




Di
to


o


rg


de
or
To

5-4 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

om
t.c
en
pm
q ui
-E
nt
ou
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Di
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or

Figure 5-1. Platform/Remote Control Station

To

3121773 – JLG Lift – 5-5

SECTION 5 - EMERGENCY PROCEDURES

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Using Emergency/Ground Controls from Ground Manual Descent with Engine Running but without

t.c
(See Figure 5-2.) Electrical Power
(See Figure 5-2.)

en
ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD

pm
OF PERSONNEL BEFORE LOWERING. ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVERHEAD
OF PERSONNEL BEFORE LOWERING.
1. Check that the main power key switch (item 1) is

ui
set to the ON ( I ) position. 1. Open the Ground Control valve distributor cover.

q
2. Be certain emergency stop button (item 2) is in the 2. Locate the RED Enable valve lever (item 6). The

-E
ON position by turning it clockwise. RED Enable valve lever must be held open while
operating any of the other boom control valves on

nt
3. Start engine, if not already running (item 4).
the valve distributor.
4. At Emergency/Ground Control box, turn mode

ou
selector switch (item 3) all the way clockwise and 3. At the ground control valve distributor operate the
hold. boom control valves as needed. (see Figure 5-2.)

sc
5. Check that the green (machine stabilized) indicator 4. Make boom movements in the following

Di
light (item 5) on the Emergency/Ground Control
box is on.
sequence:
• fully retract main boom (item 10, Figure 5-2.)
to
6. Operate the appropriate manual control lever • fully lower jib (item 11, Figure 5-2.)
(item 7 thru 13) next to it’s control valve under the • fully lower tower boom (item 8, Figure 5-2.)
o

cover of the valve distributor. See decal on valve • fully lower main boom (item 9, Figure 5-2.)
rg

distributor cover for boom component and direc-

tion to operate lever for desired movement. 5. When emergency operation is complete, return all
control levers to the neutral position and shut
de

7. When finished, release mode selector switch (item machine down.

3) back to the neutral position.
or

8. Position (press) emergency stop switch (item 1) to

the OFF position.
To

5-6 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

om
t.c
en
pm
9 10 11 12 13
7 8
2

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1 4 3

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5 Di
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13
7 12
6 11
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9 10
8
or

Figure 5-2. Ground Control Station

To

3121773 – JLG Lift – 5-7

SECTION 5 - EMERGENCY PROCEDURES

om
t.c
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6 5

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3

-E
4 3

nt
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1
Di 7
to
2
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Figure 5-3. Hand Pump - Chassis Control Valve Tray

To

5-8 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

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Manual Descent without Engine or Electrical Power.
5

t.c
Using Hand Pump in Hydraulic Compartment on Right
side of Machine

en
(See Figure 5-3.) 3

pm
1. Platform retrieval sequence.
Ensure the machine is level and all outriggers are
properly deployed on a firm surface.

ui
a. Remove the hydraulic panel cover on the right

q
front side of the machine.

-E
b. Locate the pump handle (item 3) secured to 4

nt
the underside of the Ground Control Box.

ou
c. Install the pump handle on the pump (item 4)
and secure in place with the provided screw.

sc
The lever (item 5) on the pump must be set to
the left, check decal above pump. NEVER REACH THROUGH, UNDER, OR OVER THE BOOM'S PATH OF TRAVEL TO

Di
NOTE: Always swing turntable inline with the chassis first so
THE GROUND CONTROL PANEL. IF NO ASSISTANT IS AVAILABLE, PROCEED
WITH THE FOLLOWING STEPS.
to
that the turntable and base indicator arrows are
aligned. This will eliminate possibility of an elevated or
extended boom being positioned overhead of person-
o

nel at the pump and eliminate the risk of lowering the TO AVOID CONTACT BETWEEN JIB AND OUTRIGERS. DO NOT ATTEMPT MAN-
rg

jib onto an outrigger. UAL SWING WITH BOOMS AND JIB FULLY LOWERED.
2. Lift the function enable lever UP and hold (item 6 -
de

Figure 5-2.), While pumping the hand pump (item

4) and activating the swing control lever (item 7 -
or

Figure 5-2.) in the desired direction of travel, until

the turntable is aligned with the chassis.
To

3121773 – JLG Lift – 5-9

SECTION 5 - EMERGENCY PROCEDURES

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3. Retract the main boom (if necessary). vate the appropriate platform rotate function lever
(item 12, Figure 5-2.) to rotate the platform.

t.c
Lift the function enable lever UP and hold (item 6 -
Figure 5-2.). While pumping the hand pump, acti- 8. Level the platform (if necessary).

en
vate telescope function lever (Item 7, Figure 5-2.) in
Lift the function enable lever UP and hold (item 6 -
the appropriate direction to retract the main
Figure 5-2.), while pumping the handpump, acti-

pm
boom.
vate the appropriate platform level function lever
4. Lower the jib. (item 13, Figure 5-2.) to level the platform.

ui
Lift the function enable lever UP and hold (item 6 - 9. Remove the manual pump handle from the pump

q
Figure 5-2.), while pumping the handpump, acti- and secure to turntable in its original position.

-E
vate the jib lift function lever (item 8, Figure 5-2.) in
the appropriate direction to lower the jib.

nt
5. Lower Tower Boom

ou
Lift the function enable lever UP and hold (item 6 -
Figure 5-2.), while pumping the handpump, acti-

sc
vate the tower boom lift function lever (item 5, Fig-

Di
ure 5-2.) in the appropriate direction to lower the
tower boom.
to
6. Lower the Main Boom
Lift the function enable lever UP and hold (item 6 -
o

Figure 5-2.), while pumping the handpump, acti-

rg

vate the main boom lift function lever (item 6, Fig-

ure 5-2.) in the appropriate direction to lower the
de

main boom.
7. Rotate the platform (if necessary).
or

Lift the function enable lever UP and hold (item 6 -

To

Figure 5-2.), while pumping the handpump, acti-

5-10 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

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Outrigger/Track Movement Emergency Procedure: 3. Install pump handle (item 3) on the pump (item 4)
and secure in place with the provided screw.

t.c
Outrigger/Track Movement Using the Hand Pump in
The lever (item 5) on the pump must be set to the
Hydraulic Compartment on Right side of Machine
left to manually operate right side outrigger and

en
track functions (item 7).

pm
PLACE THE MACHINE INTO TRANSPORT CONFIGURATION ONLY AFTER HAV- For right side (operator's perspective) Outrigger and
ING ALIGNED AND FULLY LOWERED AND RETRACTED THE BOOM AND JIB. Track Functions:

ui
4. Locate the proportional flow valve attached to the
group of three valves (item 7 - Figure 5-3.). Press the

q
knob on the valve in until it stops.

-E
WHEN RETRACTING THE OUTRIGGERS, THE MACHINE CAN BECOME UNBAL-
ANCED IF ONE OR MORE OUTRIGGERS ARE OFF OF THE GROUND AT ANY ONE 5. While holding the flow valve in, activate the lever

nt
TIME. RETRACT OUTRIGGERS EQUALLY, TO KEEP MACHINE BALANCED. in the desired direction on the appropriate valve
solenoid (valve description below) while pumping

ou
NOTE: When performing ANY manual operation of outrig- the pump handle to achieve the desired function
ger/track functions with hand pump, if available, movement.

sc
machine electrical power can be powered ON.
(Item 7 - Figure 5-3.)

Outrigger Functions: (See Figure 5-3.) Di • 1st valve, far left in the group of three operates
Right Rear Outrigger.
to
1. Remove the hydraulic valve compartment cover • 2nd valve, from the left in the group of three
on the right - side of the chassis by removing the operates Right Front Outrigger
o

thumbscrews. This will provide access to the man-

• 3rd valve, from the left in the group of three
rg

ual override levers for the right side (item 7) and

left side (item 6) outrigger and right and left track operates the Right Track Drive functions.
de

function solenoids.
2. Locate and remove the pump handle (item 3)
or

secured to the bottom of the Ground Control com-

partment.
To

3121773 – JLG Lift – 5-11

SECTION 5 - EMERGENCY PROCEDURES

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For left side (operator's perspective) Outrigger and 5. When finished release the flow valve button and
Track Functions re-install the flow valve cap (item 1 - Figure 5-3.).

t.c
1. Locate the proportional flow valve attached to the 6. Remove manual pump handle from the pump and

en
group of four valves (item 6 - Figure 5-3.). Press the secure it in its original position under the ground
enable lever on the valve in until it stops. control station cover.

pm
2. The lever on the pump must be set to the right to 7. Replace any access panels that were previously
manually operate left side outrigger and track removed.

ui
functions.
3. If operating with NO power, remove the valve stem

q
cover (item 1 - Figure 5-3.) from the flow valve,

-E
depress the button and hold while operating left

nt
side functions (item 2 - Figure 5-3.)
4. While also holding the enable lever, activate a

ou
function lever in the desired direction on the
appropriate valve solenoid (valve description

sc
below), while pumping the handle to achieve the
desired function movement.
(Item 6 - Figure 5-3.) Di
to
• 1st valve, far left - toward front of machine in the
group of four, operates Left Rear Outrigger.
o

• 2nd valve from the left in the group of four, oper-

rg

ates Left Front Outrigger.

• 3rd valve from the left in the group of four, oper-
de

ates the Left Track Drive functions.

• 4th valve from the left in the group of four, oper-
or

ates track extension and retraction.

To

5-12 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

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5.4 SAFETY DEVICES BYPASS KEY USE Remove key and insert it into the bypass key
switch (item 1 - photo). After using the safety

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device bypass, a qualified JLG mechanic must be
contacted to determine the reason for needing

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THIS FEATURE MUST ONLY BE USED AS DESCRIBED BELOW. THE MACHINE
to use this feature. Return the key to the where you found it
COULD TIP OVER IF THESE DIRECTIONS ARE NOT FOLLOWED.
and secure it in that location.

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The machine has a key for bypassing the platform safety sys- The safety device circuit board records every time the safety
tems. The safety device bypass switch is located at the left device bypass key is activated along with the movements

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rear in the electronics cabinet inside the access hatch. The made during these operations.

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key used to activate the safety device bypass switch, is fas-
NOTE: In case of machine with restricted area of operation,

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tened to the cover attach screw mounting tab from the fac-
tory, on the right side - hand pump/valve components the bypass of the safety devices does not allow the

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compartment - near the platform. boom assembly to go out of the safe working area.

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SAFETY DEVICE BYPASS ALLOWS OPERATION OF MACHINE WITH AN OVER-
LOAD IN THE PLATFORM. THE OVERLOAD ALARM WILL SOUND AND THE
Di OVERLOAD ICON WILL BE ON THE PLATFORM/REMOTE CONTROL BOX DIS-
PLAY. REMOVE OVERLOAD FROM THE PLATFORM BEFORE OPERATION.
to
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3121773 – JLG Lift – 5-13

SECTION 5 - EMERGENCY PROCEDURES

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Using Emergency Descent In Case Of An Outrigger Losing 4. Operate the machine from the platform/remote
control ONLY carrying out operations that allow

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Contact With The Ground
the tower boom lowering, main boom retract and
One or more of the outriggers may loose contact with the jib lowering. The main boom must be fully

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ground which will result in the platform/remote control box retracted prior to operating swing and main boom
functions being inoperable except for emergency lowering. lowering functions.

pm
To restore platform/remote control box functions, lower and
retract the booms and then reposition the machine and

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properly set the outriggers. NEVER PERFORM OPERATIONS DIFFERENT TO THOSE LISTED OR THAT CAN

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Use the emergency descent from the platform if possible by IN SOME WAY REDUCE THE STABILITY OF THE MACHINE. THE ORDER OF THE

-E
using the following sequence, fully retract main boom, fully BOOM MOVEMENTS MUST BE DONE IN A WAY TO PREVENT ANY OPERATION
lower jib, fully lower tower boom, and fully lower main THAT REDUCES THE STABILITY OF THE MACHINE.

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

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If this is not possible, have a properly trained person on the release the key and follow instructions above to
ground bypass the platform safety devices and allow the secure the key.

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operator in the platform to lower and retract the booms or If machine is set up in the reduced stabilization area, bypass-
allow emergence manual operations to bring the platform
back to the ground. Di ing the safety devices does not allow the boom to go out of
the working area related to that outrigger configuration.
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1. Locate and use safety device bypass key as stated
above.
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2. Activate safety device bypass by turning key in a

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counterclockwise direction and hold it in position

(see decal).
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3. The safety devices BYPASS icon will

appear on the platform/remote con-
or

trol box display.

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5-14 – JLG Lift – 3121773

SECTION 5 - EMERGENCY PROCEDURES

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Machine Realignment Emergency Procedure Movement Of Tracks With Machine Not Aligned:

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THIS OPERATION MUST ONLY BE PERFORMED WITH THE OPERATION ONLY ALLOWED TO GO TO A CONDITION
BOOMS AND JIB FULLY LOWERED AND RETRACTED. SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN

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"MACHINE RE-ALIGNMENT" ABOVE. ALL OTHER USE IS
During transport, the turntable may swing and become out
PROHIBITED.
of alignment with the base. If this occurs, one of the two

pm
EMERGENCY PROCEDURES given below can be used: 1. Open the electric components compartment;
Machine Realignment: 2. Locate and use the safety device bypass key as

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described above;
1. Open the electric components compartment;

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3. Activate the safety device bypass key by turning it
2. Locate and use the safety device bypass key as

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

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3. Activate the safety device bypass by turning the
4. The safety devices BYPASS icon will
key in a counterclockwise direction and holding it

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appear on the platform/remote con-
in position (see sticker);
trol box display.

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4. The safety devices BYPASS icon will
5. Operate drive/steer controls with
appear on the platform/remote con-
trol box LCD display.
5. Realign the machine while operating
Di extreme caution.
6. Move machine to a proper location to perform
to
"Machine Realignment" procedure to realign the
the swing function from the platform/remote con-
machine.
trol box.
o

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

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

store it as is described above.
store it as stated above.
The control circuit board records every activation of the
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NOTE: In case of machine with restricted work area, the safety device bypass key.
bypass of the safety devices does not allow the boom
or

assembly to go out of the working area related to that

outrigger configuration.
To

3121773 – JLG Lift – 5-15

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Wanco, Yanmar
SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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6.1 INTRODUCTION

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This section of the manual provides additional necessary AVOID PRESSURE-WASHING ELECTRICAL/ELECTRONIC COMPONENTS. IF

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information to the operator for proper operation and main- PRESSURE-WASHING THE MACHINE IS NEEDED, ENSURE MACHINE IS SHUT
tenance of this machine. DOWN BEFORE PRESSURE-WASHING. SHOULD PRESSURE WASHING BE UTI-

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The maintenance portion of this section is intended as infor- LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPO-

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mation to assist the machine operator to perform daily NENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750
maintenance tasks only, and does not replace the more PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 IN (30.5 CM) AWAY FROM

t-E
thorough Preventive Maintenance and Inspection Schedule THESE COMPONENTS. IF ELECTRICAL/ELECTRONIC COMPONENTS ARE
included in the Service and Maintenance Manual. SPRAYED, SPRAYING MUST NOT BE DIRECT AND ONLY FOR BRIEF TIME PERI-

n
ODS TO AVOID HEAVY SATURATION.

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3121773 – JLG Lift – 6-1

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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6.2 OPERATING SPECIFICATIONS Chassis

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Table 6-3. Chassis Data
Table 6-1. Operating Specifications

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Model X430AJ
Model X430AJ
Maximum Travel Grade w/ boom in stowed position 16° (28%)

pm
Maximum work load (capacity) 500 lbs (230 kg) (gradeability)
Max. Vertical Platform Height 43 ft. 7 in. (13.3 m) Maximum Travel Side Slope w/ boom in stowed 15° (26%)

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Max. Horizontal Platform Reach 21 ft. 7 in. (6.6 m) position

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Turning radius 0°

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Dimensional Data Maximum ground pressure per track (psi) 8.2 psi (0.58 kg/cm2)

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Table 6-2. Dimensional Data Maximum ground pressure per outrigger 34.1 psi (2.40 kg/cm2)

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Outrigger pad diameter 11.5 in (292 mm)
Model X430AJ
Max drive speed (with std. 2nd speed)

sc
Overall Width without Platform: 29 in (0.75 m) Gas Engine: 1.62 mph (2,6 km/hr)
with 2 Person Platform: 52 in. (1.34 m) (Lithium-Ion) Electric Engine: 0.87 mph (1,4 km/hr)
with 1 person platform: 31 in. (0.78 m) Di Max hydraulic system pressure Drive/Stablizer: 2,610 psi (180 bar)
to
Outriggers Deployed Width 9 ft 2 in x 9 ft 2 in Boom: 2,593 psi (165 bar)
(2.80 m x 2.80 m) Maximum wind speed 28 mph (12.5m/s)
o

Stowed Height (with Platform 13 ft 2 in (4.02m) Maximum manual force 90 lb (400 N)

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Stowed Length (without Platform) 11 ft. 2 in. (3.40 m) Electrical system voltage 12V
Gross machine weight (platform empty)
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Approach/Depart angle 20° / 36°

Gas: 4,277 lbs (1,940 kg)
Lithium-Ion: 4,932 lbs (1,992 kg)
or
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6-2 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Capacities Table 6-5. Honda iGX390 Gas Specifications

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Table 6-4. Capacities Model X430AJ

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Model X430AJ Shaft Rotation CounterClockWise

Hydraulic Tank 6.34 gal (24 L)

pm
Electric Motor Data
Fuel Tank Gasoline: 1.4 gal (5,3 L) Table 6-6. Electric Motor Specifications

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Engine Oil Gasoline: 1.2 qt. (1.1L)
Model X430AJ

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Engine Data 12V System Battery 60Ah - 680A - 12V

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Table 6-5. Honda iGX390 Gas Specifications Motor Rated Input Voltage 230V - 110V - 120V
Motor Rated Frequency 50Hz - 50Hz - 60Hz

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Model X430AJ
Type Air cooled Motor Rated Power 2.2 Kw - 2.2 Kw - 1.2 Kw

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Fuel Unleaded - 86 Octane or

Number of cylinders 1 Di
better - Max. 10% Ethanol
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Displacement 23.74 cu. in. (389 cm3)
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Output 11.66 hp (8.7 kW)

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High engine speed 3600 RPM

Torque 19.5 ft. lb. (26.5 Nm) @
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2500RPM
Weight 80.0 lb. (36.4 Kg)
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Ignition System CDI Type Magneto

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Alternator Output 10 A @ 3600 RPM

3121773 – JLG Lift – 6-3

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Lithium-Ion Battery Pack Specifications Major Component Weights

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Table 6-7. Lithium Ion Specifications Table 6-8. Major Component Weights

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Model X430AJ Model X430AJ

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Battery Pack Engine (Dry Weight) Honda iGX390 Gas: 81.6 lb. (37 Kg)
No. of cells in the battery pack: 24 cells

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Boom Sections
Rated voltage of each cell: 3.2 volt
Tower: 202.8 lb. (92 kg)

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Max. cell voltage: 3.65 volt
Lower Tower Boom: 114.6 lb. (52 kg)
Min. cell voltage: 2.5 volt 79.3 lb. (36 kg)
Lower Boom Link:

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Features of complete pack: 36 volt - 100 ampere/h
Lower Upright: 99.2 lb. (45 kg)
*Charge cycles: 2000 cycles
Upper Tower Boom: 172 lb. (78 kg)

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Cathode: Lithium Ion Phosphate (LiFePO4) 48.5 lb. (22 kg)
Upper Boom Link (Qty=2). Weight Each:

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Anode: Graphite
Upper Upright: 114.6 lb. (52 kg)
Memory effect: NO
Main Boom: 141 lb. (64 kg)

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Battery Charger Fly Boom: 110.2 lb. (50 kg)
Type: 120 V (+/– 30V) - 50/60 Hz
Necessary time to recharge: 4 hrs to 80% of recharge Di Lift Cylinders
Platform Level Cylinder: 17.6 lb. (8 kg)
to
Electric System 36 volt for the batteries - 12 volt for the Platform Swing Actuator: 35.3 lb. (16 kg)
machine Jib Cylinder: 26.5 lb. (12 kg)
Main Boom Lift Cylinder: 57.3 lb. (26 kg
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Electric Motor 36 volt - three phase - 2000 watt

Main Boom Telescope Cylinder: 88.2 lb. (40 kg)
rg

* The charge cycles have to be considered based on the fact that there is not mem- Main Boom Tower Cylinder: 14.5 lb. (6.6 kg)
ory effect in the lithium batteries, i.e. 2000 charges at 100% or 4000 charges at Lower Boom Lift Cylinder: 61.7 lb. (28 kg)
de

50%, etc..
Platform Assembled: 132.3 lb (60 kg)
or

Chassis Gas: 4,718 lb. (2,140 kg)

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6-4 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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6.3 SERVICE/MAINTENANCE • Cleaning the electrical system;

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Cleaning the Machine

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NEVER CLEAN THE INVERTER OR THE ELECTRIC MOTOR WITH WATER, AS
THIS MAY CAUSE DAMAGE TO THE ELECTRICAL SYSTEM.

pm
WHEN WASHING THE MACHINE, THE MAIN POWER SWITCH MUST BE DISEN-
GAGED, THE KEY REMOVED AND THE EMERGENCY STOP BUTTON PRESSED.

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• Washing the outside of the machine; ONLY USE DRY DETERGENTS, IN ACCORDANCE WITH THE MANUFACTURERS’
INSTRUCTIONS. NEVER REMOVE COVERS, GUARDS AND THE LIKE.

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Never use flammable liquids. Adopt the above

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safety measures to prevent sparks due to short-cir-
cuits. Clean the electrical system using a dry, non-metal-

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lic brush and low pressure air.
If washing the track with a cleaning solution, care-

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fully cover all the vital parts and above all the elec- • After cleaning
trical components. Follow the instruc tions Dry the machine carefully before starting it again

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provided by the manufacturer of the cleaning (for example using compressed air).
solution.
Di
Clean the machine using only water-soluble deter-
to
gents. IF, DESPITE ALL THE PRECAUTIONS, MOISTURE HAS PENETRATED INTO THE
ELECTRIC MOTOR OR OTHER PARTS OF THE ELECTRIC SYSTEM, THESE MUST
The more often the machine is cleaned, the more it
o

BE DRIED USING COMPRESSED AIR TO AVOID THE RISK OF SHORT CIRCUITS.

will need to be re-greased (see lubrication chart).
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Do not wet the electric motors and the other elec-

trical components directly.
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Do not aim the spray directly onto decals and rat-

or

ing plates.
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3121773 – JLG Lift – 6-5

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Machine Maintenance Locations

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en
pm
q ui
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M = ENGINE OIL
T = TRANSMISSION OIL
I = HYDRAULIC OIL AND FILTER

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G = GREASE

Di
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Figure 6-1. Lubrication and Maintenance Point Locations

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6-6 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Lubrication Types Engine Oil

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(See Figure 6-1.) SAE 10W30
Greasing and Lubrication

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Hydraulic Oil
Recommended lubricants

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Table 6-9. Hydraulic Oil Specifications Contact Grease EP (blue in color) is used to grease the turn-
table and cylinder pins on the chassis
Hydraulic System
Viscosity

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Operating GR MU EP1 Grease is used to grease the expansion guide of
Grade the chassis, the track tension valve, and basket support pins

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Temperature Range

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White EP NLGI 2 Grease is used on the boom extensions
14deg F (-10 deg C) and ISO VG 46
Either MU EP1 or Esso Beacon EP2 is used to grease the cou-

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104deg F (+40deg C)
pler and belt tensioner

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14deg F (-10 deg C) or ISO 68
Greasing Locations (See Figure 6-1.)
above 104deg F (+40deg C)

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NOTE: Use a brush to spread grease onto telescopic boom
NOTE: When adding or replacing hydraulic oil only use JLG wear pad areas.
Di
approved hydraulic oil. Do not mix oils unless directed
by JLG.
to
Recommended Gearbox Oils
o

600 XP 150
rg

EP 150
Blasia 150
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Spartan EP150
or
To

3121773 – JLG Lift – 6-7

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Hydraulic Oil Specifications

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en
m
ip
qu
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sc
Di
46 145
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Figure 6-2. Hydraulic Oil Specifications

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* Readily biodegradable classification indicates one of the following: CO2 Conversion > 60% per EPA 560/6-82-003 / CO2
de

Conversion > 80% per CEC-L-33-A-93.

** Virtually Non-toxic classification indicates an LC50 > 5000 per OECD 203.
or

*** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval.
To

6-8 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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t.c
en
pm
q ui
-E
nt
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Di
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Figure 6-3. Hydraulic Oil Operating Temperatures

To

3121773 – JLG Lift – 6-9

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Table 6-10. Component Maintenance Intervals - X430AJ - with Gas Engine

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Hours
Component Operation Pre-Start As Needed

en
10 50 100 250 500 1000 2000
Dry Air Filter(Diesel Engine) Check/Clean •

pm
Replace •
Engine Oil (Gas Engine) Check Level •

ui
Replace •* •

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FuelTank and Filter (Gas Engine) Clean •

-E
Hydraulic Oil Check Level •
Replace •

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Hydraulic Oil Filter Replace Cartridge •* •

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Articulated Joint Points Grease •* •
Battery Check •

sc
Reduction Gear Oil Check Level •

Machine
Replace
Di
General Periodic Check
•* •
• •*
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Extension Arm Internal Sliding Ring (if equipped) Check Wear •
Replace •
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Turntable Bolt Tightening Check •* •

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Platform Mount Pin Nuts Check torque 148 ft. lb. (200 Nm) •
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* 1st time interval then per chart thereafter

** At least every 3 months or 1000 hrs. of operation
or

SERV... *** At lease every 5 years or 2000 hrs of operation. Check every year. If torque is not correct, replace the nuts with new nuts of same specification.
Install dry without using grease or oil to specified torque.
To

6-10 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Table 6-11. Component Maintenance Intervals - X430AJ - with Lithium-Ion Battery Pack

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Hours
Component Operation Pre-Start As Needed

en
10 50 100 250 500 1000 2000
Hydraulic Oil Check Level •

pm
Replace •
Hydraulic Oil Filter Replace Cartridge •* •

ui
Articulated Joint Points Grease •* •

q
-E
Battery (Auxiliary) Check •
Reduction Gear Oil Check Level •

nt
Replace •* •

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Machine General Periodic Check • •*
Extension Arm Internal Sliding Ring (if equipped) Check Wear •

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Replace •
Turntable Bolt Tightening
Platform Mount Pin Nuts
Check Di
Check torque 148 ft. lb. (200 Nm)
•* •
•
to
* 1st time interval then per chart thereafter
o

** At least every 3 months or 1000 hrs. of operation

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*** At lease every 5 years or 2000 hrs of operation. Check every year. If torque is not correct, replace the nuts with new nuts of same specification. SERV...
Install dry without using grease or oil to specified torque.
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or
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3121773 – JLG Lift – 6-11

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Gas Engine Maintenance Procedures Hydraulic Oil Tank

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For engine maintenance service, see the manual supplied NOTE: Remove Fill Cap (B) slowly, tank is pressurized at 2.1
by the engine manufacturer or download it from the web- PSI (.15 bar).

en
site: l

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• www.engines.honda.com

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B

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A

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Di
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Lube Point(s) - Fill Cap
Capacity - 6.34 gallons (24 liters)
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Interval - Check level daily. Change every two years or 1200

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hours of operation
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NOTE: Hydraulic oil levels are to be checked with the

machine in transport position while on a firm, level
or

and uniform surface. Oil level must be half-way in the

level indicator (Indicator-A). To add hydraulic oil use
(cap-B).
To

6-12 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Hydraulic Oil Filter Cartridge Rubber Track Maintenance/Replacement

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Check track tension
Stop the machine on a firm, level, and uniform surface. Raise

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the machine off the surface using the outriggers. Measure
distance A from the bottom of the roller to the inside of the

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rubber belt. The rubber track tension is to be between

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0.4inches (10mm) and 0.6 inches (15mm).

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A

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Lube Point(s) - Filter Cap (Indicator A) A
Interval - Replace after first 50 hours of use. Replace thereaf-

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ter every 250 hours and every time the hydraulic oil is NOTE: If the track is out of tolerance immediately discontinue
replaced.
Di use of the machine
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THE GREASE CONTAINED WITHIN THE HYDRAULIC TRACK IS PRESSURIZED.

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NEVER LOOSEN GREASING VALVE 1 MORE THAN ONE (1) TURN. NEVER
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LOOSEN GREASE VALVE 2.

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3121773 – JLG Lift – 6-13

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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1. Ensure all debris has been removed between the Tightening of the track
wheel teeth and track links.

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• Connect a grease gun to grease valve 2 and add grease
2. Remove the screws from the adjustment access lid until belt tension is within the specified values.

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3.
NOTE: If the track does not return to the specified values by
following the above procedure immediately discon-

pm
2 tinue use and contact service personnel.
Checking the rubber tracks

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• If broken steel ropes are noted discontinue use until

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damaged components are replaced

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1
CARVED
-&./0.(% PROFILE

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DANGER
PERICOLO

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3

3. Loosening of the track.

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SPROKET
'('$(.'0%
4. Slowly unscrew valve 1 in the counterclockwise STEEL
&'()* ROPES HOLE
)*10%0%
direction. Do not exceed one (1) screw rotation. )+%&&,%,'
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WHEEL SIDE
/%0'$(.'0%
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5. If the grease does not begin to drain, slowly rotate METAL CORE
%1,2%$2*0%//,&%
the track.
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6. Once correct track tension has been achieved, turn • If broken metal cores are noted discontinue use until
grease valve 1 clockwise to tighten valve. damaged components are replaced
or

7. Clean area of all trace grease.

To

6-14 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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• If metal cores are separating discontinue use of the Replacing Rubber Tracks
machine until the damaged components are replaced.

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1. Elevate the machine on firm, level and uniform sur-
face utilizing the outriggers.

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2. Remove the screws and remove cover 3 as shown
in figure.

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Worn Parts 2

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• If abrasive or fatigue cracks are noted it is recom-
mended the machine be removed from service until the

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components are replaced. 1

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3

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3. To loosen the track, slowly unscrew valve 1 in a

Di counter-clockwise direction. Do NOT exceed one

(1) rotation.
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4. Allow grease to drain. If grease does not drain,
Track Torque slowly rotate the track.
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It is extremely important to apply and maintain proper track 5. Insert three steel pipes 4 between the rollers of the
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mounting torque. track. Turn the driving wheel backwards 5 to

engage the track tensioning wheel. Apply an out-
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ward force 6 to lift the track from the track tension-

TRACK NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER ing wheel.
or

TORQUE TO PREVENT LOOSENING OF THE TRACK, BROKEN STUDS, AND POS-

SIBLE DANGEROUS SEPARATION OF THE TRACK FROM THE TEETH.
To

3121773 – JLG Lift – 6-15

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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5
Wear Pad Inspection

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Check for distance between wear pads and boom sections.
Distance is to be no more than 1/32nd inch.

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Turntable Attach Bolts

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Ensure the bolts of the coupling elements (turntable) are
torqued to 183 ft-lb. (248 Nm)

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Battery Maintenance and Charging - Diesel/AC-Electric

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-E
4 NOTE: The battery is a maintenance free battery. Do NOT
6 attempt to open a maintenance-free sealed battery.

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Installation of Rubber Track External Battery Charger Use

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1. Ensure all hydraulic cylinder grease have been
removed

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2. Align the track links with the wheel teeth. Position WHEN AN EXTERNAL BATTERY CHARGER IS TO BE USED, CHARGING HAR-

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the other end of the track on the track tensioning
wheel
NESS MUST BE PLUGGED INTO A GROUNDED RECEPTACLE. IF RECEPTACLE IS
NOT GROUNDED AND A MALFUNCTION SHOULD OCCUR, THE MACHINE
to
COULD CAUSE SERIOUS ELECTRICAL SHOCK.
3. Slowly rotate the drive wheel in reverse while,
using one steel pipe, pushing the track plate inside 1. Open battery cover.
o

the frame. 2. Disconnect the terminal clamps from the battery

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4. Verify the track links have engaged the wheel poles.

teeth in the track tensioning wheel 3. Connect the cables of the charger to the battery
de

5. Adjust track tension (see Loosening/Tightening poles. and turn on the battery charger
track section).
or
To

6-16 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
NOTE: Re-charge voltage should never exceed 14.7 volts and 6.4 ELECTRIC MOTOR MAINTENANCE
the load intensity shall be 0.2% of the value indicated

t.c
below and on the lid of the battery. Periodically check the condition of the following electric
motor components.

en
4. When charging is completed turn off the battery
charger before disconnecting the cables from the Electric Motor

pm
battery poles The electric motor is located inside of the rear hydraulic
5. Return the terminal clamps to the battery poles valve distributor support cover.

ui
and lubricate with the appropriate product
• POWER SUPPLY TERMINALS
6. Close battery cover.

q
Check tightness of the nuts on the power supply

-E
terminals and make sure the insulation is intact.

nt
• FAN
IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC-
Keep air intakes clean and make sure the fan can

ou
TRONIC COMPONENTS. IN THE EVENT PRESSURE-WASHING THE MACHINE IS
NEEDED, ENSURE THE MACHINE IS SHUT DOWN BEFORE PRESSURE-WASH- rotate freely.

sc
ING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAIN- • BEARINGS
ING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC.
Di
RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM
DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF
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
to
ELECTRICAL/ELECTRONIC COMPONENTS ARE SPRAYED, SPRAYING MUST
operating conditions.
NOT BE DIRECT AND BE FOR BRIEF TIME PERIODS TO AVOID HEAVY SATURA-
o

TION. NOTE: This motor is "brushless" therefore no brushes need to

rg

be checked or replaced.
de
or
To

3121773 – JLG Lift – 6-17

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
6.5 PLATFORM/REMOTE CONTROL SERVICE MENU Menu Input

t.c
The signals that arrive at the board from the various sensors
Service Button mounted on the machine and from the platform/remote

en
(See Figure 3-3. on page 3-10) control commands are displayed. The status of the input and
A SERVICE button (item 6) is present on the remote control the following selection to scroll the menu appears for each

m
which allows to view the status of the machine parameters screen:

ip
and is an aid in the safety checks of the machine. 1 - PREV - access the previous input

qu
By pressing the SERVICE button a numerical menu is dis- 2 - NEXT - access the successive input
played on the LCD display (item 15), each of these menu 9 - ESC - escape from the INPUT menu

t-E
items can be accessed by pressing the corresponding plat-
form/remote control buttons (numbered 1 thru 9) below the
LIGHTLIFT SELF-PROPELLED AERIAL PLATFORM - X700AJ

n
buttons.
ST1 GND A Both ON indicate the stabilizer 1 rests on the ground.

ou
1 - INPUT ST1 GND B

sc
2 - LANGUAGE ST2 GND A Both ON indicate the stabilizer 2 rests on the ground.
3 - ERRORS
4 - RAMPS Di ST2 GND B
ST3 GND A Both ON indicate the stabilizer 3 rests on the ground.
to
5 - CURRENT ST3 GND B
6 - W. HOURS
o

ST4 GND A Both ON indicate the stabilizer 4 rests on the ground.

rg

7 - SETUP ST4 GND B

8 - JOYSTICK ST1 OPEN A Both ON indicate the stabilizer 1 is completely open, TOTAL
de

9 - EXIT ST1 OPEN B AREA.

or

MENUS 4; 5; CANNOT BE ACCESSED ST2 OPEN A Both ON indicate the stabilizer 2 is completely open, TOTAL
ST2 OPEN B AREA
To

6-18 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
ST3 OPEN A Both ON indicate the stabilizer 3 is completely open, TOTAL MICROROPES ON position indicates both cables are working.

t.c
ST3 OPEN B AREA START M. TE ON position indicates the engine start button (from ground) is
ST4 OPEN A Both ON indicate the stabilizer 4 is completely open, TOTAL pressed.

en
ST4 OPEN B AREA MOTOR TEMP. OFF position with the engine running indicates the alarm is

pm
activated.
BYPASAE A Both ON indicate aerial part safety devices have been discon-
nected by the specially provided key. MOTOR PRESS. ON position with the engine running indicates the alarm is
BYPASAE B activated.

ui
BYPASCB A Both ON indicate undercarriage part safety devices have been START M. EL ON position indicates the remote control from ground is acti-

q
BYPASCB B disconnected by the specially provided key. vated by the provided key.

-E
EM. GRND A Both ON indicate that emergency stop button isn't pressed MICROJIB A Both ON indicates the JIB arm is completely closed.

nt
EM. GRND B (from ground). MICROJIB B

ou
FOTO A Both ON indicate that the photocells are aligned. PEDALE ON position indicates the pedal within the basket is pressed.
(only pedal version)

sc
FOTO B
EM BASK. A Both ON indicates the emergency STOP (of the remote control)
EM R.C. GND Both ON indicate that the remote control button isn't pressed
(from ground). Di EM BASK. B
POSM 1 A
within the basket isn't pressed
Both ON indicates the stabilizer 1 is in stabilization position.
to
ST12 CLOSED ON status indicates the stabilizers 1-2 are completely up and
pressurized. POSM 1 B
o

ST34 CLOSED ON status indicates the stabilizers 3-4 are completely up and POSM 2 A Both ON indicates the stabilizer 2 is in stabilization position.
rg

pressurized.
POSM 2 B
TEMP ALRM A Both ON indicate the external temperature probe is activated
de

(only Russian version). POSM 3A Both ON indicates the stabilizer 3 is in stabilization position.
TEMP ALRM B
POSM 3B
or

GENERATOR ON or OFF depending on whether, the engine is ON or OFF.

POSM 4A Both ON indicates the stabilizer 4 is in stabilization position.
EMERG. COMM ON position indicates the emergency buttons are activated.
To

POSM 4B

3121773 – JLG Lift – 6-19

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
R.C. PLATFORM ON position indicates the remote control is in its mount. (in the Errors Menu

t.c
platform). Indicates the agreement (OK) or not (FAULT) status of the
INCLIN. X Indicates the inclination of X axis in tenths of a degree. sensors that have a double control.

en
INCLIN. Y Indicates the inclination of Y axis in tenths of a degree. The sensors are listed on different screens use:

pm
LOAD Indicates the weight in the platform in pounds. 1 - PREV - access the previous input
POS. 1E2 Indicates 1° and 2° arm cylinder stroke in tenths of a millime- 2 - NEXT - access the successive input

ui
ter. 9 - ESC - escape from the INPUT menu

q
POS. 3 Indicates 3° arm cylinder stroke in tenths of a millimeter. If the OK symbol appears at the side of the sensor it means

-E
ROTATION A Indicates the angular position of the aerial part in degrees that the two elements of the same sensor sent identical
(180° - aligned photocells). information.

nt
MOTOR RPM Indicates the engine speed. If the FAULT symbol appears at the side of the sensor it

ou
means that the two elements of the same sensor sent incon-
CURRENT A Indicates the power to proportional valve.
sistent information.

sc
CURRENT B Indicates the power to proportional valve.
The last page of the error menu describes the error code
CURRENT C
TEMPERAT.
Indicates the power to proportional valve.
Di
Indicates the temperature measured by the electrical probe.
relating to the battery charger system, inverter or battery
pack. (See “Lithium-Ion Machine Fault Codes” on page 6-22.)
to
SUPPLY (V) Indicate the voltage (In volts). Errors are indicated by the “spanner” icon in
position 7 on the remote control display (See
o

“Platform/Remote Control Station Functions”

rg

on page 3-9.).
If there are operating problems with the machine and the
de

“spanner” icon is shown on the display, do not operate

machine until repaired by a JLG factory trained technician.
or
To

6-20 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Working Hours Menu 6.6 LITHIUM-ION MACHINE - MAINTAINANCE

t.c
Indicates the number of machine working hours. Battery Pack System Components and Maintenance

en
Set-up Menu
The items in this menu cannot normally be accessed.

pm
WHEN RECHARGING THE BATTERY PACK AND DURING ANY OTHER MAINTE-
Joystick Menu NANCE OPERATION ON THE BATTERY PACK, IT IS NECESSARY TO USE AT
LEAST THE PERSONAL PROTECTIVE EQUIPMENT (PPE) LISTED BELOW.

ui
Displays the signal that each individual Joystick sends to the
main board. • Eye protection devices

q
-E
Protective glasses, for protection against sprays of
hazardous materials.

nt
• Hand protection devices

ou
Hand protection gloves, for protection and insula-
tion during work on live parts.

sc
• Foot protection devices
Di Shoes with antistatic coating able to insulate the
worker during work on the electrical parts of the
to
system.
o
rg
de
or
To

3121773 – JLG Lift – 6-21

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Lithium-Ion Machine Fault Codes Table 6-12. Inverter Fault Codes

t.c
(See “Errors Menu” on page 20 info for display information)
CODE DESCRIPTION
Table 6-12. Inverter Fault Codes

en
Logic failure #1
CODE DESCRIPTION Cause – Sudden voltage surge or voltage drop.
19

m
Solution – This is a temporary problem due to certain working condi-
Wrong Config tions. If problem persists, replace inverter.

ip
1 Cause - EEPROM memory not configured.
Solution - Contact Hinowa after.sales service. VMN low

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Cause – Inverter power supply voltage is lower than battery voltage, or
Watch Dog 30 alternatively incorrect connection to positive battery pole.

t-E
Cause - Inverter cannot start or stop electric motor.
8 Solution – Check connection to positive battery pole. If problem persists,
Solution - Check connections and continuity of electric motor. If OK,
replace inverter.
replace inverter.

n
VMN High

ou
Eeprom KO
31 Cause – One motor phase not connected correctly or faulty.
13 Cause – EEPROM hardware or software problem. Solution – Check motor phases. If problem persists, replace inverter.

sc
Solution – Replace inverter.
Contactor closed
Aux output KO
16
Cause – Problem with electromechanical brake.
Di
Solution – This is generally a temporary problem due to certain working
37 Cause – Relay remains closed when power to coil is disconnected.
Solution – Check relay.
to
conditions. If problem persists, replace inverter. Contactor Open
38 Cause – Inverter supplies power to relay coil but contact doesnft close.
Logic failure #3
o

Solution – Check relay and power supply to coil.

Cause – Activated in the event of high inverter current peaks.
rg

17 I=0 Ever
Solution – This is generally a temporary problem due to certain working
conditions. If problem persists, replace inverter. 49 Cause – Feedback current from motor sensor not constantly at 0.
de

Solution – Check connection to motor.

Logic Failure #2
18 Cause – Internal fault in the inverter.
or

Solution – Replace inverter.

To

6-22 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Table 6-12. Inverter Fault Codes Table 6-12. Inverter Fault Codes

t.c
CODE DESCRIPTION CODE DESCRIPTION

en
STBY I high Thermis sensor KO
Cause – Internal fault detected in the inverter. Cause – Signal from temperature sensor greater than 4.95 Volts or less
53

pm
Solution – This is generally a temporary problem due to certain working 73 than 0.1 Volt.
conditions. If problem persists, replace inverter. Solution – This is generally a temporary problem due to certain working
Capacitor Charge conditions. If problem persists, replace inverter.

ui
60 Cause – Internal fault in the inverter. Driver shorted

q
Solution – Check connections and motor phases. Cause – Relay power supply fault.

-E
High temperature 74 Solution – Check relay power supply. This is generally a temporary prob-
lem due to certain working conditions. If problem persists, replace

nt
Cause – High temperature inside the inverter.
61 inverter.
Solution – Improve cooling to inverter. If fault persists, contact JLG after-

ou
sales service. Driver shorted
Motor temperature Cause – Relay power supply fault.

sc
65 Cause – High motor temperature. 75 Solution – Check relay power supply. This is generally a temporary prob-
lem due to certain working conditions. If problem persists, replace
Can Bus KO Di
Solution – Temporarily stop machine to allow motor to cool down.
inverter.
Coil shorted
to
67 Cause – Inverter doesn’t receive any information from Can Bus line.
Solution – Check connections using multifunction tester. 76 Cause – Problem detected with relay coil.
Solution – Make sure relay coil is intact.
o

Encoder Error
rg

Cause – Problem detected with encoder (=motor speed sensor). VACC not OK
70 Cause –
Solution – Check speed sensor connection. Anomaly may also have been 78
Solution – This is generally a temporary problem due to certain working
de

caused by fault with bearing.

conditions. If problem persists, replace inverter.
or
To

3121773 – JLG Lift – 6-23

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Table 6-12. Inverter Fault Codes BMS Fault Codes - (Battery Management System)

t.c
CODE DESCRIPTION (See “Errors Menu” on page 20 info for display information)
NOTE: The CODE column indicates the CAN CODE in the mes-

en
Incorrect start
Cause – Incorrect starting procedure. sage sent by the battery charger. The normal mains
voltage tolerance is the rated value ±15%.

pm
79 Solution – Check electrical connections. This is generally a temporary
problem due to certain working conditions. If problem persists, replace CODE – TYPE OF ERROR
inverter.

ui
A99E01 – Configuration error
Pedal wire KO

q
Cause – A99E02 – Incorrect voltage
86

-E
Solution – This is generally a temporary problem due to certain working A99E03 – Incorrect temperature
conditions. If problem persists, replace inverter.

nt
A99E04 – Excess discharge current
Wrong set batt
A99E05 – Excess charge current

ou
Cause – With power connected, battery test detected incorrect batteries
93 fitted. A99E06 – Pre.charge error

sc
Solution – Replace batteries with the original ones supplied directly by A99E07 – No 12 V power supply
JLG.

94
Current sensor KO
Cause – Set up procedure for maximum current in progress.
Di A99E08 – No 12 V power supply
A99E09 – High battery compartment temperature
to
Solution – Contact JLG after-sales service. A99E10 – High electronic board temperature
o

Check up needed A99E11 – Incorrect self.protection device temperature

rg

99 Cause –
Solution – Contact Hinowa after.sales service. A99E12 – Fault on all temperature sensors
A99E13 – Temperature sensor fault
de

A99E14 – Earth connection fault

or

A99E01 – Incorrect system configuration

A99E02 – Incorrect voltage
To

6-24 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
A99E03 – Incorrect temperature

t.c
A99E04 – Excess discharge current
A99E05 – Excess charge current

en
A99E06 – Pre.charge error

pm
A99E07 – No 12 V power supply
A99E08 – No 12 V power supply

ui
A99E09 – High battery compartment temperature

q
A99E15 – Boot loader error

-E
A99E16 – Secondary protection

nt
A99E17 – Control device error

ou
A99E18 – Power board error
A99E19 – I2C module not ready

sc
A99E20 – I2C TX error
A99E21 – I2C RX error Di
to
A99E22 – I2C RX error 2
A99E23 – AD error
o

A99E99 – General error

rg
de
or
To

3121773 – JLG Lift – 6-25

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Battery Charger Fault Codes

t.c
(See “Errors Menu” on page 20 info for display information)

en
Table 6-13. Battery Charger Fault Codes

pm
CODE DESCRIPTION STATUS ACTION
8 Internal logic fault. Battery charger stops working. Contact service dept. or change product.

ui
13 Communication problem with external memory. Battery charger stops working. Contact service dept. or change product.

q
-E
Extended shutdown or power failure. Battery charger stops supplying power. Operation If problem is a power failure, check battery charger
18 resumes as soon as alarm conditions are no longer mains power supply.

nt
present or after restarting.

ou
19 Internal logic fault. Battery charger stops working. Contact service dept. or change product.

sc
Digital input is open and managed as hardware Battery charger stops charging until digital input Close digital input.
240
start-stop. closes.

241
tems in the network.
Di
Problem in CANBUS communication with other sys- The way this is managed may change based on dif-
ferent firmware releases.
Check correct operation of CANBUS system.
to
Error when reading internal memory on micro con- Battery charger stops working. Contact service dept. or change product.
242
troller.
o
rg

Mains voltage lower than maximum operating Battery charger won’t start charging until mains Make sure mains voltage is within correct operating
244
range tolerance. voltage returns within normal operating range. parameters.
de

Abnormal current draw in primary section. Battery charger stops supplying power. Operation If problem persists, contact service dept. or change
245 resumes as soon as alarm conditions are no longer product.
or

present.
To

6-26 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Table 6-13. Battery Charger Fault Codes

t.c
CODE DESCRIPTION STATUS ACTION

en
Stage 1 ended by timeout without reaching control Battery charger stops working. Make sure battery capacity is compatible or check
voltage. that battery is compliant with battery charger. If bat-
246

pm
tery is correct and problem persi.sts, contact service
dept.

ui
Temperature inside battery charger too high. If internal temperature exceeds 80° C, battery char-
ger reduces power to 80%, while it stops operating

q
248 altogether if internal temperature exceeds 90° C.

-E
Battery charger starts at full power again when

nt
internal temperatu.re falls below 70° C.

ou
Battery temperature too high. If temperature exceeds 55° C or is less than
–20° C, battery charger stops working. When battery
249

sc
temperature falls below 45° C or exceeds –10° C bat-
tery charger resumes normal operation.

251
Power failure detected. Di Battery charger stops supplying power. Operation
resumes as soon as alarm conditions are no longer
If problem persists, check battery charger mains
power supply.
to
present.
o

Short-circuit in battery charger output. Battery charger stops working. Turn off battery charger and resolve short.circuit at
rg

252 output. If problem persists, contact service dept. or

change product.
de

Mains voltage higher than maximum operating Battery charger won’t start charging until mains Make sure mains voltage is within correct operating
253
range tolerance. voltage returns within normal operating range. parameters.
or
To

3121773 – JLG Lift – 6-27

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
6.7 LITHIUM-ION BATTERY PACK - HANDLING IN Procedure For Handling Hot Cells

t.c
DANGEROUS CONDITIONS As soon as it has been established the temperature of a cell
has risen considerably, the first action is evacuation of per-

en
Battery cells must be handled correctly in order to ensure sonnel from the affected area. The area has to be isolated
proper and safe use. However, if mistakes are made in han- and nobody can enter if not strictly necessary.

m
dling the cells, causing explosion or venting, the user has to
If possible, before leaving the area, the person who first
be equipped so as to be able to face this emergency.

ip
identified the problem has to check if there is an external
The purpose of this section is to train the user on safe han- short-circuit and resolve it as soon as possible. After the

qu
dling of cells that have been subjected to extreme condi- short-circuit has been resolved, the cell will start to cool
tions. down. However, the area has to remain isolated until the cell

t-E
These Conditions Are As Follows: reaches ambient temperature and is removed from the area.
The temperature of the cell has to be checked periodically

n
1. Hot cells using a remote sensor such as an infrared sensor. If the cell

ou
2. Cells that have released substances or vented remains hot the following actions must be assessed.
3. Exploded cells Minimum Equipment Required:

sc
4. Fire enveloping the lithium batteries • Infrared temperature probe
Di •
•
Safety glasses
Hard hat with impact resistant face visor
to
• Non-conductive pliers
o

• Hand, arm and body protection

rg
de
or
To

6-28 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Start Procedure; Procedure For Handling Vented Cells

t.c
1. Evacuate the area as soon as abnormal cell tem- In normal conditions a cell does not show leaks or venting,
perature has been established. however a cell may vent or release substances if the critical

en
2. Periodically check temperature of the cell using a temperature is reached or if the protective glass metal seal
remote sensor for the first two hours or until one of breaks due to severe mechanical conditions.

pm
the following cases occur: The severity of the leak consequent to venting ranges from
• The cell starts to cool down slight leak around the seal to a violent leak of substances

ui
through the vent. In some cases, if the cell is not plugged, it
• The cell vents may behave as a projectile.

q
• The cell explodes

-E
Electrolyte inside the cell may cause very serious irritation to
3. If the cell starts cooling, check the temperature the respiratory tract, eyes and skin. In addition, venting may

nt
every hour until ambient temperature has been cause emission of highly corrosive vapors in the work envi-
ronment. In this case, all protective equipment suited to

ou
reached.
limit exposure to toxic fumes must be available.
4. If a temperature sensor is not available, do not

sc
handle the cell for a minimum of 24 hours. Minimum Equipment Required;

Di
5. Remove cell from the work area when ambient
temperature has been reached and return to nor-
• Class D fire extinguisher
• Eye protection or face shield
to
mal operations.
• Respirator with filter for hydrochloric acid and sulphur
6. Dispose of the cell in accordance with existing leg- dioxide
o

islation (in the country in question) on hazardous

• Neoprene gloves
rg

materials.
Procedures in cases of venting or explosion are examined in the • Acid.resistant lab coats
de

following paragraphs. • Baking soda, calcium oxide or acid absorbent in kit form
• Vermiculite
or

• Plastic bags
To

3121773 – JLG Lift – 6-29

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Start Procedure; First Aid In The Event Of Contact With The Electrolyte

t.c
In the event of electrolyte release from the cells, proceed as EYES
follows: Immediately wash the eyes in abundant running water for at

en
1. Evacuate the people exposed to fumes from the least 15 minutes, keeping the eyelids open and flushing the
area. eye and back of the eyelid. Immediately seek medical help.

pm
2. Air the environment until the complete removal of SKIN
the cell and until the characteristic pungent odor
Wash in cold water under a shower, remove contaminated

ui
has disappeared. garments. Continue washing for at least 15 minutes. Seek

q
3. If the cell is too hot, allow it to cool to ambient medical help where necessary.

-E
temperature before handling it (see “Procedure
RESPIRATORY TRACT
For Handling Hot Cells” on page 28).

nt
4. Wear safety equipment: coat, gloves, mask and fil- Move person(s) outdoors into the open air. If person(s) has
difficulty breathing, have oxygen administered by trained

ou
ters, and move the cell to a well-ventilated area.
personnel. If breathing stops, apply mouth-to-mouth resus-
5. Place every cell in a sealable plastic bag and citation and immediately seek emergency medical help.

sc
remove the excess air, then seal the bag.

Di
6. Place a cup of vermiculite in a second bag, place
first bag in the second and seal it.
to
7. Place everything in a third bag with some baking
soda and seal the bag.
o

8. Absorb and collect the leaked electrolyte with

rg

absorbent material or baking soda.

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

10. Clean area with plenty of water.

or

11. Dispose of hazardous material in accordance with

the local legislation in force.
To

6-30 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
Procedure For Exploded Cells Start Procedure;

t.c
Explosion of lithium batteries is not likely, it is a rare event In the event of cell explosion, proceed as follows:
that only occurs when an abnormal condition causes the 1. Evacuate personnel from the areas contaminated

en
temperature to rise and reach a critical point. However, in by smoke.
the event of lithium battery explosion the environment will
2. Ventilate the rooms until the cell has been

pm
quickly be filled with dense white smoke which will cause
serious irritation to the respiratory tract, eyes and skin. Pre- removed from the area and until the characteristic
pungent odor has disappeared.
cautions must be taken to limit exposure to these fumes.

ui
3. Even if this is quite unlikely, there may be fires as a
Minimum Equipment Required;

q
consequence of the explosion. The ways these

-E
• Class D fire extinguisher emergencies are faced are described in the follow-
• Class ABC extinguisher for any secondary fires ing paragraph.

nt
• Eye protection or face shield 4. The exploded cell may be hot. Allow it to cool

ou
• Respirator with filter for hydrochloric acid and sulphur down to ambient temperature before handling it
dioxide (see Procedure for handling hot cells).

sc
• Neoprene gloves 5. Wear safety equipment: coat, gloves, mask and fil-
ters.
•
•
Acid.resistant lab coats
Di
Baking soda, calcium oxide or acid absorbent in kit form
6. In case of explosion the area around the cell will be
to
covered by a black carbonaceous material which
• Vermiculite contains metallic parts of the cell. Cover the carbo-
• Plastic bags naceous residues with a 50/50 mixture of baking
o

soda and vermiculite or other absorbent material.

rg

Avoid contact between the metallic residues and

charged cells, as this condition may cause a
de

short.circuit.
or

7. Place contaminated material in a sealable plastic

bag and remove excess air.
To

8. Seal the bag.

3121773 – JLG Lift – 6-31

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

om
9. Place a cup of vermiculite in a second bag, place Lithium Battery Fire
the first bag in the second and seal it.

t.c
All metals may burn in certain conditions, which depend on
10. Clean area with plenty of water and keep cleaning certain factors such as: physical state, presence of oxidizing

en
with water and soap. atmospheres and severity of the source of ignition. Alkali
11. Dispose of hazardous material in accordance with metals such as lithium may burn in normal atmospheres. In

pm
the local legislation in force. addition, lithium reacts explosively with water to form
First Aid In The Event Of Contact With The Electrolyte; hydrogen and the presence of small quantities of water may
set fire to the material and the hydrogen gas that is released.

ui
EYES Once metal fires start they are very hard to extinguish with

q
Immediately wash eyes in abundant running water for at ordinary equipment. This is partly due to the strong heat

-E
least 15 minutes, keeping the eyelids open and flushing the produced by the burning metal, whose temperature may
eye and back of the eyelid. Immediately seek medical help. reach 1832° F (1000° C). In addition, lithium may react with

nt
certain materials commonly used in fire extinguishers, like
SKIN

ou
water and CO2. Special extinguishers are required, designed
Wash in cold water under a shower, remove contaminated for controlling and extinguishing lithium fires.

sc
garments. Continue washing for at least 15 minutes. Seek
In particular, graphite-based extinguishers (Lith-x) are used.
medical help where necessary.
Usually these extinguishers work by forming a crust or a
RESPIRATORY TRACT Di
Move casualty outdoors into the open air. If person(s) has
layer of material on the surface of the burning metal. Lith-x,
which is a common graphite-based agent, may be used with
to
difficulty breathing, have oxygen administered by trained an extinguisher or spread over the fire. In the event of lith-
personnel. If breathing stops, apply mouth-to-mouth resus- ium fire, the room may fill with a dense white smoke, mostly
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citation and immediately seek emergency medical help. formed by lithium oxide and other metal oxides. This condi-
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tion may cause serious damage to the respiratory tract, skin

and eyes. All precautions needed to limit exposure to these
de

fumes must be adopted. It should be noted that this proce-

dure is applicable only to fires on individual cells. Larger fires
or

have to be managed only by professionally trained person-

nel.
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6-32 – JLG Lift – 3121773

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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Finally, it should be noted that in the presence of combusti- 4. Quarantine the area. Air the rooms until the burn-
ble materials other than lithium it is advisable to use differ- ing material has been removed from the area and

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ent types of extinguishers in conjunction to better ensure the characteristic pungent odor has disappeared.
the extinguishing action of each on the appropriate mate-

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5. Two members of the team enter the area with
rial, however do not use water or CO2 extinguishers directly appropriate safety equipment.
on lithium fires.

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NOTE: Lithium melts at 356° F (180° C). It becomes highly
Minimum Equipment Required;

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reactive and when it catches fire it may eject molten
• Class D fire extinguisher lithium particles. For this reason the surrounding cells

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• Class ABC extinguisher for any secondary fires may overheat and cause a violent explosion. The fire-
fighting personnel must pay attention to any danger-

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• Breathing apparatus
ous materials located near the fire.
• Fireproof clothing

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• Fireproof gloves 6. Completely cover fire with extinguishing material.
Never leave fire unattended as it may develop

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• Mask or protective glasses again.
• Non-conductive pliers

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7. If necessary, extinguish secondary fires with suit-
• Dustpan, mineral oil able extinguishers.
Start Procedure;
Di
1. In the event of fire on one cell, a team of experi-
8. After all material has burned and cooled down,
carefully mix residual material to prevent resump-
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enced fire-fighting personnel has to be contacted. tion of the fire.
The personnel must be properly trained to fight 9. Put the material in a metal drum, cover the surface
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lithium battery fires. with plenty of extinguishing material.

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2. Evacuate personnel from all areas and sound the 10. Residual material may contain un-reacted lithium,
fire alarm. therefore limit exposure to rain by covering, for
de

3. The fire-fighting personnel go to the area where example, with mineral oil.
or

the fire is located and gather all the information 11. Wear safety equipment: coat, gloves, mask and fil-
regarding the situation and the person who gave ters.
the alarm.
To

3121773 – JLG Lift – 6-33

SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE

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12. The area around the cell will be covered by a black First Aid In The Event Of Contact With The Electrolyte;
carbonaceous deposit which contains metallic

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EYES
parts of the cell. Cover the carbonaceous residue
with a 50/50 mixture of baking soda and vermicu- Immediately wash the eyes in abundant running water for at

en
lite or other absorbent material. Avoid contact least 15 minutes, keeping the eyelids open and flushing the
between the metallic residue and charged cells as eye and back of the eyelid. Immediately seek medical help.

m
this condition may cause a short.circuit. SKIN

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13. Place the contaminated material in a sealable plas- Wash in cold water under a shower, remove contaminated

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tic bag and remove the excess air. garments. Continue washing for at least 15 minutes. Seek
14. Seal the bag. medical help where necessary.

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15. Place a cup of vermiculite in a second bag, place RESPIRATORY TRACT
the first bag in the second and seal it. Move person(s) outdoors into the open air. If person(s) has

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16. Clean the area with plenty of water and keep difficulty breathing, have oxygen administered by trained

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cleaning with water and soap. personnel. If breathing stops apply mouth-to-mouth resus-
citation and immediately seek emergency medical help.

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17. Dispose of hazardous material in accordance with
the local legislation in force.
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6-34 – JLG Lift – 3121773

 SECTION 7 - INSPECTION AND REPAIR LOG

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SECTION 7. INSPECTION AND REPAIR LOG

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Machine Serial Number _________________________________

en
Date Comments

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3121773 – JLG Lift – 7-1

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