JLG X500AJ Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X500AJ
3121636
June 29, 2018 - Rev F
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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SECTION - FOREWORD
3121636 – JLG Lift – a
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
b– JLG Lift – 3121636
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED,
WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A
RED BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED,
COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE
AN ORANGE BACKGROUND.
INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED,
MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT
AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACK-
GROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTEC-
TION OF PROPERTY.
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety mes-
sages that follow this symbol to avoid possible injury or death.
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SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
3121636 – JLG Lift – c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS.
CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRE-
SENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS
WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC.
TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND
ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCI-
DENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN
SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE
JLG PRODUCT.
Contact :
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: [phone]
E-mail: [e-mail]
For :
• Accident Reporting
• Product Safety Publi-
cations
• Current Owner
Updates
• Questions Regarding
Product Safety
• Standards and Regula-
tions Compliance Infor-
mation
• Questions Regarding Spe-
cial Product Applications
• Questions Regarding
Product Modifications
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SECTION - REVISION LOG
d– JLG Lift – 3121636
REVISION LOG
Original Issue A - 05-07-2014
Revised B - 07-08-2015
Revised C - January 22, 2016
Revised D - July 25, 2016
Revised E - March 16, 2017
Revised F - June 29, 2018 - Revised Covers, Prop 65
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TABLE OF CONTENTS
3121636 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL
WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B
Contact : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
In USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
Outside USA: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
REVISION LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . .1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards. . . . . . . . . . . . . . . . . . . . . . . . .1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-7
Crushing and Collision Hazards. . . . . . . . . . . . . . . . 1-9
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . .1-10
1.5 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . .1-10
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
SECTION - 2 - PREPARATION AND INSPECTION
2.1 PERSONNEL TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training. . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . .2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . .2-1
2.2 PREPARATION, INSPECTION, AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .2-4
Daily Walk-Around Inspection . . . . . . . . . . . . . . . . .2-7
Function Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8
SECTION - 3 - MACHINE CONTROLS, INDICATORS AND
OPERATION
3.1 GROUND CONTROL STATION . . . . . . . . . . . . . . . . . . .3-3
Ground Control Station - With Enable Lever. . . .3-4
Ground Control Station - With Enable Knob. . . .3-7
3.2 PLATFORM/REMOTE CONTROL STATION . . . . . . 3-10
Maintenance Control Position On The
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Platform/Remote Control Position From The
Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Control Position From In The Platform: . . . . . . 3-11
Platform/Remote Control Station Functions . 3-13
Platform/Remote Control Station LCD Display 3-17
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
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TABLE OF CONTENTS
ii – JLG Lift – 3121636
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Gas Engine Starting Procedure . . . . . . . . . . . . . . . . 4-2
Gas Engine Shutdown Procedure . . . . . . . . . . . . . 4-3
Electric Engine Starting Procedure -
AC Voltage Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Electric Engine Starting Procedure -
LITHIUM-ION Machine . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.4 BASE AND BOOM/JIB ALIGNMENT . . . . . . . . . . . . . . 4-6
4.5 TRACKS - DRIVING, STEERING AND
TRACK WIDTH ADJUST . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Track width adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Drive and Steer) . . . . . . . . . . . . . . . . . . . 4-7
Travelling (Grades and Side Slopes) . . . . . . . . . . . 4-7
Jib Position for Travelling . . . . . . . . . . . . . . . . . . . .4-10
4.6 OUTRIGGER OPERATION. . . . . . . . . . . . . . . . . . . . . . .4-11
Setting Outriggers From the
Platform/Remote Console . . . . . . . . . . . . . . . . . . . 4-13
Retracting The Outriggers . . . . . . . . . . . . . . . . . . . 4-14
4.7 BOOM/PLATFORM OPERATION . . . . . . . . . . . . . . . . 4-15
Overload Alarm. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Engine Pre-Heat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Platform Level Adjustment. . . . . . . . . . . . . . . . . . .4-15
Raise And Lower The Tower Boom . . . . . . . . . . . 4-17
Raise And Lower The Main Boom. . . . . . . . . . . . . 4-17
Telescope The Main Boom . . . . . . . . . . . . . . . . . . .4-17
Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17
Raise And Lower The Jib . . . . . . . . . . . . . . . . . . . . .4-17
Swinging The Boom . . . . . . . . . . . . . . . . . . . . . . . . .4-17
SkyGuard Operation (If Equipped). . . . . . . . . . . .4-19
4.8 PLATFORM REMOVAL/INSTALLATION . . . . . . . . . .4-20
4.9 BATTERY CHARGING - GAS/AC-ELECTRIC . . . . . . .4-21
Battery Charging - Daily. . . . . . . . . . . . . . . . . . . . . .4-21
4.10 BATTERY CHARGING - LITHIUM-ION MACHINE. .4-22
Charging the Battery Pack . . . . . . . . . . . . . . . . . . .4-22
Charge Curve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-24
4.11 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . . . .4-25
4.12 LIFTING AND TIE DOWN . . . . . . . . . . . . . . . . . . . . . . .4-26
Lifting - Outrigger Lifting Rings . . . . . . . . . . . . . .4-26
Lifting - Fork Lift Pockets . . . . . . . . . . . . . . . . . . . . .4-27
Loading and Unloading the Machine on
Transport Vehicles Using Ramps . . . . . . . . . . . . .4-28
Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4.13 MACHINE DECALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-31
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . 5-1
Power Main Cut-Off Switch Location . . . . . . . . . . 5-1
Operator Unable to Control Machine . . . . . . . . . . 5-2
Platform or Boom Caught Overhead. . . . . . . . . . . 5-2
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TABLE OF CONTENTS
3121636 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Manual Descent with Engine Running and
Electrical Power. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
Manual Descent with Engine Running but
without Electrical Power (Combustion
Engines Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
Manual Descent without Engine and Electrical
Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
Outrigger/Track Movement Emergency
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5.4 SAFETY DEVICES BYPASS KEY USE . . . . . . . . . . . . . .5-14
Using The Emergency Descent In The Case
Of An Outrigger Losing Contact With The
Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
Machine Realignment Emergency Procedure .5-16
SECTION - 6 - GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . 6-2
Dimensional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Lithium-Ion Specifications . . . . . . . . . . . . . . . . . . . . 6-4
Machine Major Component Weights . . . . . . . . . .6-5
Performance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.3 SERVICE/MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . .6-6
Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7
Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . .6-8
Rubber Track Maintenance/Replacement . . . . 6-14
Wear Pad Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Turntable Attach Bolts . . . . . . . . . . . . . . . . . . . . . . 6-17
Battery Maintenance and Charging -
Gas/AC-Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4 ELECTRIC MOTOR MAINTENANCE . . . . . . . . . . . . . 6-19
Electric Motor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
6.5 PLATFORM/REMOTE CONTROL SERVICE MENU 6-20
Service Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Menu Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Errors Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Working Hours Menu . . . . . . . . . . . . . . . . . . . . . . . 6-32
Set-up Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
Joystick Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.6 LITHIUM-ION MACHINE ONLY - ADDITIONAL
MAINTAINANCE INFORMATION . . . . . . . . . . . . . . . 6-33
Cleaning the Machine. . . . . . . . . . . . . . . . . . . . . . . 6-33
Battery Pack System Components and
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Lithium-Ion Machine Fault Codes. . . . . . . . . . . . 6-36
BMS Fault Codes -
(Battery Management System) . . . . . . . . . . . . . . 6-39
Battery Charger Fault Codes. . . . . . . . . . . . . . . . . 6-40
6.7 LITHIUM-ION BATTERY PACK - HANDLING IN
DANGEROUS CONDITIONS. . . . . . . . . . . . . . . . . . . . 6-42
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