JLG X430AJ Operation And Safety Manual
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JLG X430AJ Operation And Safety Manual

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ANSI
ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X430AJ
3121773
June 29, 2018 - Rev C

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Summary of Contents for JLG X430AJ

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) X430AJ ANSI ANSI 3121773 ® June 29, 2018 - Rev C...
  • Page 2 @ 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,...
  • Page 3 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.
  • Page 4 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.

  • Page 5: Safety Alert Symbols And Safety Signal Words

    INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY. RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. – JLG Lift – 3121773...

  • Page 6: Contact

    • Questions Regarding Prod- • Questions Regarding uct Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT Contact : THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

  • Page 7: Revision Log

    SECTION - REVISION LOG REVISION LOG Original Issue A - March 16, 2017 Revised B - April 3, 2018 Revised C - June 29, 2018 - Revised Covers, Prop 65 – JLG Lift – 3121773...

  • Page 8: Table Of Contents

    Diesel Engine Shutdown Procedure ..4-3 2.1 PERSONNEL TRAINING ..... 2-1 Electric Engine Starting Procedure - AC Voltage 3121773 – JLG Lift –...
  • Page 9 Procedure: ......5-11 Battery Charging - Daily ....4-20 – JLG Lift – 3121773...
  • Page 10 Rubber Track Maintenance/Replacement ..6-13 Wear Pad Inspection..... . 6-16 SECTION - 7 - INSPECTION AND REPAIR LOG 3121773 – JLG Lift –...
  • Page 11 4-4. Platform - Load/Reach Chart - X430AJ ..4-17 Power Only ......4-36 4-5.
  • Page 12 @ 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,...

  • Page 13: Section 1 - Safety Precautions

    This section contains the responsibilities of the owner, user, operator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”). 3121773 – JLG Lift –...

  • Page 14: Workplace Inspection

    • Read, understand, and obey all applicable employer, unless approved for that purpose by JLG. local, and governmental regulations as they pertain • Ensure that the ground conditions are adequate to to your utilization and application of the machine.

  • Page 15: Machine Inspection

    • Check the machine for modifications to original components. Ensure that any modifications have • Never slam a control switch or lever through neutral been approved by JLG. to an opposite direction. Always return switch to neutral and stop before moving the switch to the •...

  • Page 16: Trip And Fall Hazards

    • Do not carry materials directly on platform railing Trip and Fall Hazards unless approved by JLG. • During operation, occupants in the platform must • When two or more persons are in the platform, the...

  • Page 17: Electrocution Hazards

    Never position ladders, boxes, steps, planks, or similar items on unit to provide additional reach for any purpose. • Keep oil, mud, and slippery substances cleaned from footwear and the platform floor. 3121773 – JLG Lift –...

  • Page 18: Minimum Approach Distances (M.a.d.)

    • Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot addi- – JLG Lift – 3121773...

  • Page 19: Tipping Hazards

    Keep all loads within the confines of • The user must be familiar with the surface before the platform, unless authorized by JLG. driving. Do not exceed the allowable sideslope and • Keep the chassis and outriggers of the machine a grade while driving.

  • Page 20: Beaufort Scale (For Reference Only)

    32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. – JLG Lift – 3121773...

  • Page 21: Crushing And Collision Hazards

    • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. 3121773 – JLG Lift –...

  • Page 22: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. 1-10 – JLG Lift – 3121773...
  • Page 23 • Never attempt to move heavy parts without the aid TURER. of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate sup- port is provided when raising components of the machine. 3121773 – JLG Lift – 1-11...

  • Page 24: Battery Hazards

    • Always wear hand, eye, and face protection when servicing batteries. Ensure that battery acid does not come in contact with skin or clothing. 1-12 – JLG Lift – 3121773...
  • Page 25 @ 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,...

  • Page 26: Section 2 - Preparation And Inspection

    3. Rules of the employer and government regula- either the machine or the job site. tions. 4. Use of approved fall protection device. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunction. 3121773 – JLG Lift –...

  • Page 27: 2.2 Preparation, Inspection, And Maintenance

    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 Consult local regulations for further requirements for TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

  • Page 28: Inspection And Maintenance Table

    At intervals as specified in the Service and Mainte- Owner, Dealer, or Qualified JLG Mechanic Service and Maintenance Man- nance Manual. User NOTE: Inspection forms are available from JLG. Refer to Section 6 - Operators Maintenance when performing inspections. 3121773 – JLG Lift –...

  • Page 29: Pre-Start Inspection

    Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific operating instructions. – JLG Lift – 3121773...
  • Page 30 SONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. MAKE SURE THE ENGINE KEY SWITCH IS ON, THE BATTERY DISCONNECT SWITCH IS TURNED ON, AND THE POWER/EMERGENCY STOP BUTTONS AT THE GROUND AND PLATFORM CONTROL BOX IS TURNED CLOCKWISE (ON). 3121773 – JLG Lift –...

  • Page 31: Daily Walk-Around Inspection

    See Inspection Note. 2. Platform/Remote & Ground Control Stations - Switches and levers return to neutral, decals/plac- ards secure and legible, control markings legible. 3. Outriggers - See Inspection Note; pads pivot freely. – JLG Lift – 3121773...

  • Page 32: Daily Walk-Around Inspection

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection 3121773 – JLG Lift –...

  • Page 33: Function Check

    Check that all guards protecting the function ™ the SkyGuard sensor is disengaged. control switches and controllers are in place; c. Operate all functions. – JLG Lift – 3121773...

  • Page 34: Skyguard™ Sensor And Override Switch Location

    SECTION 2 - PREPARATION AND INSPECTION 1. SkyGuard™ Sensor 2. SkyGuard™ Override Switch (button number 8) Figure 2-2. SkyGuard™ Sensor and Override Switch Location 3121773 – JLG Lift –...
  • Page 35 @ 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,...

  • Page 36: Section 3 - Machine Controls, Indicators And Operation

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION SECTION 3. MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-1. Basic Machine Component Locations 3121773 – JLG Lift –...
  • Page 37 7. Tower Boom Assembly tery Pack, Inverter, and Battery Charger Compart- ment (if equipped) 8. Jib 19. Fork Lift Pockets 9. Platform Fold-Down Entry Ladder 20. Platform Lanyard Attach Points 10. Platform 11. Manuals Compartment – JLG Lift – 3121773...

  • Page 38: Ground Control Station

    A two-position red switch supplies power to PLAT- FORM/GROUND/REMOTE SELECT switch when twisted clockwise to be in the out (on) position. When pushed in (off ), power is shut off to the PLATFORM and GROUND controls. 3121773 – JLG Lift –...
  • Page 39 Provides raising and lowering of the tower boom. Provides for positioning the platform up and down to adjust the level of the platform. 9. Main Boom Lift Control Provides raising and lowering of the main boom. – JLG Lift – 3121773...
  • Page 40 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-2. Ground Control Station 3121773 – JLG Lift –...

  • Page 41: Platform/Remote Control Station

    TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR CONTROL SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. – JLG Lift – 3121773...

  • Page 42: Control Position From In The Platform

    2. In the platform, slide the remote control station assembly into the storage box and place the rib on the right side of the control station assembly under the metal tab attached to the storage box assembly. 3121773 – JLG Lift –...
  • Page 43 (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- ation. – JLG Lift – 3121773...

  • Page 44: Platform/Remote Control Station Functions

    (icon extension of all 4 outriggers at one time. on button) or used as numerical keys (per number below the button) when the SERVICE button 6 (item 6) sub-menus is activated on the LCD display. 3121773 – JLG Lift –...
  • Page 45 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-3. Platform/Remote Control Station 3-10 – JLG Lift – 3121773...
  • Page 46 If each con- gas/diesel engine. trol is moved individually, different amounts or in opposite directions steering the machine occurs. 13. Electric Engine Start This button allows the operator to start or stop the electric engine. 3121773 – JLG Lift – 3-11...

  • Page 47: Platform/Remote Control Station Lcd Display

    23. Right Side Track Drive And Steer This control when moved forward or rearward simultaneously with the left side track control (17), allows the operator to move the machine in a straight forward or reverse direction or, if each 3-12 – JLG Lift – 3121773...
  • Page 48 Drive and steer are operational if all 4 electric) is on or off. The X on the icon indi- outriggers are not contacting the ground. cates the engine is off. Position 4 Displays selected engine speed. 3121773 – JLG Lift – 3-13...
  • Page 49 • Skyguard System enabled. • Battery cold/heater activated system is enabled. SWING SEN.3 FAIL CARD • 50 Hr. - 1st Service Interval - See Section 6 - Table 6-10 and Table 6-11, Compo- nent Maintenance Intervals. 3-14 – JLG Lift – 3121773...

  • Page 50: Lcd Display Icon Descriptions

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions 3121773 – JLG Lift – 3-15...
  • Page 51 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions (Continued) 3-16 – JLG Lift – 3121773...

  • Page 52: Lcd Display Error Descriptions

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2. LCD Display Error Descriptions 3121773 – JLG Lift – 3-17...
  • Page 53 @ 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,...

  • Page 54: Section 4 - Machine Operation

    • Platform is only operated within its work area specifica- tion for rated load and boom reach. (See Figure 4-4.) 3121773 – JLG Lift –...

  • Page 55: Engine Operation

    (1) Key switch must be set to ON, battery disconnect switch must be ON, and NOTE: Allow gas/diesel engine to warm-up for a few minutes both the ground and platform emergency stop switches must be reset to ON. at low speed before applying any load. – JLG Lift – 3121773...

  • Page 56: Diesel Engine Shutdown Procedure

    5. Turn engine key to off. 1. Before connecting the machine to the electrical circuit, ensure the key on the gas/diesel engine is in the OFF position. 3121773 – JLG Lift –...
  • Page 57 (item 2), and unhook the 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). – JLG Lift – 3121773...

  • Page 58: Base And Boom/Jib Alignment

    Platform Rotation Alignment Indicator There are also platform alignment indicators on the platform rotator assembly. When re-aligning the plat- form straight machine, align these indi- cators on the platform rota- tor assembly. Base/Boom Alignment - Visual Indicator 3121773 – JLG Lift –...

  • Page 59: Tracks - Driving, Steering And Track Width

    Press and hold button 3 for widening or button 9 for narrow- NOTE: The base and boom/jib must be aligned and retracted ing the track. before this function will operate, see Section 4.4, BASE AND BOOM/JIB ALIGNMENT. – JLG Lift – 3121773...

  • Page 60: Travelling (Drive And Steer)

    • Always fully widen the track prior to driving, if possible, for easier steering and increased stability. • Always travel in the slow speed setting unless the travel path is firm, level and uniform. 3121773 – JLG Lift –...

  • Page 61: Grade And Side Slope Definition

    SECTION 4 - MACHINE OPERATION Figure 4-2. Grade and Side Slope Definition – JLG Lift – 3121773...

  • Page 62: Jib Position For Travelling

    NOTE: The aerial part safety device by-pass key must not have been activated after the machine has been • Activate joystick for moving the JIB arm. If a different closed and aligned. joystick is activated an error message will appear on the display. 3121773 – JLG Lift –...
  • Page 63 ERROR - Remove the Platform Before Proceeding 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 IN THE FOLLOWING PARAGRAPH. 4-10 – JLG Lift – 3121773...

  • Page 64: Outrigger Operation

    (Reference Figure 4-3. on page 4-16 for item number location) Either - Press and hold the outrigger auto- set and level button 7 (item 7) until OK appears on the platform LCD display; AUTO 3121773 – JLG Lift – 4-11...
  • Page 65 FLASH OR REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE THE 1° GREEN (CENTER) AREA) AND TRACKS ARE OFF THE GROUND BEFORE GROUND, STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG OPERATING THE BOOM FUNCTIONS. IF BUBBLE IN THE LEVEL INDICATOR IS...

  • Page 66: Retracting The Outriggers

    NOTE: At low temperatures start the motor and let it run for a few minutes, so that the hydraulic oil circulates and reaches at least 50°F (10°C) before operating the plat- form. 3121773 – JLG Lift – 4-13...

  • Page 67: Overload Alarm

    (Item 18, Figure 4-3.) • To raise the main boom, depress the foot switch and move the controller forward. • To lower the main boom, depress the foot switch and move the controller backwards. 4-14 – JLG Lift – 3121773...

  • Page 68: Telescope The Main Boom

    • To swing boom to the left, depress foot switch and • To lower the jib, depress the foot switch and move the move controller backwards. controller backwards. 3121773 – JLG Lift – 4-15...

  • Page 69: Platform/Remote Control Box

    SECTION 4 - MACHINE OPERATION Figure 4-3. Platform/Remote Control Box 4-16 – JLG Lift – 3121773...

  • Page 70: Platform - Load/Reach Chart - X430Aj

    SECTION 4 - MACHINE OPERATION Figure 4-4. Platform - Load/Reach Chart - X430AJ (Full 360° Rotation and Jib Extend ONLY with Outriggers Set to Full Work Area Position) 3121773 – JLG Lift – 4-17...

  • Page 71: Skyguard Operation (If Equipped)

    Lift Tele Tele Swing Lift Lift Forward Level Rotate Lift Reverse Down R = Indicates Reversal is Activated C = Indicates Cutout is Activated N/A Indicates the function does not exist for this model 4-18 – JLG Lift – 3121773...

  • Page 72: Emergency Lowering

    5. Position the emergency stop switch to the off posi- tion. Determine the reason for the primary power failure and have the problem corrected by a qualified JLG service tech- nician. 3121773 – JLG Lift –...

  • Page 73: Battery Charging - Diesel/Ac-Electric

    • Do not open or disassemble charger. • Do not operate charger if the AC supply cord is dam- aged or if the charger has been damaged in any way. 4-20 – JLG Lift – 3121773...

  • Page 74: Battery Charging - Lithium-Ion Machine

    • If the charge is less than 20% an audible also shows the machine charge indicator. warning signal and an icon will be acti- vated whenever the electric motor is started, to alert the user to charge the machine. 3121773 – JLG Lift – 4-21...
  • Page 75 Operation/Maintenance Man- ual. If any questions, contact your local JLG Service Center or the local electrical company. • An AC class circuit breaker can be used as a protection...

  • Page 76: Charge Curve

    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 Center. charger is connected to the machine. 3121773 –...

  • Page 77: Cooling Fans

    1. Drive machine to a reasonably well protected area. 2. Ensure boom and jib are in the stowed (aligned) position. 3. Remove all load and allow engine to operate 3-5 minutes at LOW setting to permit reduction of internal engine temperatures. 4-24 – JLG Lift – 3121773...

  • Page 78: 4.11 Lifting And Tie Down

    To lift machine, a separate sling must be attached to each outrigger using the appropriate lifting points as indicated in Figure 4-6.. Weight of machine is not spread equally over the four out- riggers (See Figure 4-7.). Minimum required capacity of the 3121773 – JLG Lift – 4-25...

  • Page 79: Machine Lifting Points

    (2000 kg) and their length no less than 10 ft (3m) and all identical. Figure 4-6. Machine Lifting Points Figure 4-7. Lifting Machine - Attach Points 1. Outrigger Lifting Lug (4 corners) 1. Lifting Slings 4-26 – JLG Lift – 3121773...

  • Page 80: Tie Down

    3. Secure chassis using straps or chains of adequate strength. 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. 3121773 – JLG Lift – 4-27...

  • Page 81: Machine Tie-Down Points

    SECTION 4 - MACHINE OPERATION 1703814A Figure 4-8. Machine Tie-Down Points (both sides of machine) 1. Tie-Down Loop 2. Tie-Down Decal 4-28 – JLG Lift – 3121773...

  • Page 82: Decal Installation - Left Side - Machine

    SECTION 4 - MACHINE OPERATION MACHINE DECALS Figure 4-9. Decal installation - Left Side - Machine 3121773 – JLG Lift – 4-29...

  • Page 83: Decal Installation - Left Side - Chassis

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal installation - Left Side - Chassis 4-30 – JLG Lift – 3121773...

  • Page 84: Decal Installation - Platform

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal installation - Platform 3121773 – JLG Lift – 4-31...

  • Page 85: Decal Installation - Right Side - Machine

    SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Installation - Right Side - Machine 4-32 – JLG Lift – 3121773...

  • Page 86: Decal Installation - Right Side - Chassis

    SECTION 4 - MACHINE OPERATION Figure 4-13. Decal installation - Right Side - Chassis 3121773 – JLG Lift – 4-33...

  • Page 87: Compartments

    SECTION 4 - MACHINE OPERATION Figure 4-14. Decal Installation - Right Side- Valve Compartments 4-34 – JLG Lift – 3121773...

  • Page 88: Power Only

    SECTION 4 - MACHINE OPERATION Figure 4-15. Decal Installation - Machines with Lithium-Ion Power Only 3121773 – JLG Lift – 4-35...

  • Page 89: X430Aj - Decal Installation - Lithium-Ion

    SECTION 4 - MACHINE OPERATION Table 4-2. X430AJ - Decal Installation - Lithium-Ion Power Only (See Figure 4-15.) ITEM # PART NUMBER DESCRIPTION 17107300 DECAL INSTALLATION 07107200 Decal, Danger - Batteries 1001125483 Decal, No Pressure Washing At This Location 06520600...
  • Page 90 @ 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,...

  • Page 91: Section 5 - Emergency Procedures

    E-mail: ProductSafety@JLG.com Failure to notify the manufacturer of an incident involv- ing a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine. FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT MACHINE AND TEST ALL FUNCTIONS FIRST FROM GROUND CONTROLS, THEN FROM PLATFORM CON- TROLS.

  • Page 92: Emergency Operation

    When switched off - handle turn all the way counter- Counter- clockwise - all electrical power to the machine is shut down. Clockwise 1702155A BATTERY DISCONNECT SWITCH - GAS/DIESEL/AC-ELECTRIC – JLG Lift – 3121773...

  • Page 93: Operator Unable To Control Machine

    3. Cranes, forklift trucks or other equipment can be system. In the event either/or both are not operating used to remove platform occupants and stabilize properly, the following procedures will allow the low- machine motion. ering of the boom and platform. 3121773 – JLG Lift –...

  • Page 94: Manual Descent With Engine Running And Electrical

    The manual descent system is provided as an emergency means to lower personnel in the platform. 1. Check emergency stop button (item 10) is in the ON position by turning it clockwise.          – JLG Lift – 3121773...

  • Page 95: Platform/Remote Control Station

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-1. Platform/Remote Control Station 3121773 – JLG Lift –...

  • Page 96: Using Emergency/Ground Controls From

    7. When finished, release mode selector switch (item machine down. 3) back to the neutral position. 8. Position (press) emergency stop switch (item 1) to the OFF position. – JLG Lift – 3121773...

  • Page 97: Ground Control Station

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-2. Ground Control Station 3121773 – JLG Lift –...

  • Page 98: Hand Pump - Chassis Control Valve Tray

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-3. Hand Pump - Chassis Control Valve Tray – JLG Lift – 3121773...
  • Page 99 2. Lift the function enable lever UP and hold (item 6 - Figure 5-2.), While pumping the hand pump (item 4) and activating the swing control lever (item 7 - Figure 5-2.) in the desired direction of travel, until the turntable is aligned with the chassis. 3121773 – JLG Lift –...
  • Page 100 5-2.) in the appropriate direction to lower the main boom. 7. Rotate the platform (if necessary). Lift the function enable lever UP and hold (item 6 - Figure 5-2.), while pumping the handpump, acti- 5-10 – JLG Lift – 3121773...

  • Page 101: Outrigger/Track Movement Emergency Procedure

    Right Track Drive functions. left side (item 6) outrigger and right and left track function solenoids. 2. Locate and remove the pump handle (item 3) secured to the bottom of the Ground Control com- partment. 3121773 – JLG Lift – 5-11...
  • Page 102 • 3rd valve from the left in the group of four, oper- ates the Left Track Drive functions. • 4th valve from the left in the group of four, oper- ates track extension and retraction. 5-12 – JLG Lift – 3121773...

  • Page 103: Safety Devices Bypass Key Use

    Remove key and insert it into the bypass key switch (item 1 - photo). After using the safety device bypass, a qualified JLG mechanic must be contacted to determine the reason for needing THIS FEATURE MUST ONLY BE USED AS DESCRIBED BELOW. THE MACHINE to use this feature.

  • Page 104: Using Emergency Descent In Case Of An Outrigger Losing Contact With The Ground

    2. Activate safety device bypass by turning key in a counterclockwise direction and hold it in position (see decal). 3. The safety devices BYPASS icon will appear on the platform/remote con- trol box display. 5-14 – JLG Lift – 3121773...

  • Page 105: Machine Realignment Emergency Procedure

    NOTE: In case of machine with restricted work area, the safety device bypass key. bypass of the safety devices does not allow the boom assembly to go out of the working area related to that outrigger configuration. 3121773 – JLG Lift – 5-15...
  • Page 106 @ 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,...

  • Page 107: Section 6 - General Specifications And Operator Maintenance

    LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPO- The maintenance portion of this section is intended as infor- NENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 mation to assist the machine operator to perform daily PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 IN (30.5 CM) AWAY FROM maintenance tasks only, and does not replace the more THESE COMPONENTS.

  • Page 108: Operating Specifications

    90 lb (400 N) Electrical system voltage Stowed Length (without Platform) 11 ft. 2 in. (3.40 m) Gross machine weight (platform empty) Approach/Depart angle 20° / 36° Gas: 4,277 lbs (1,940 kg) Lithium-Ion: 4,932 lbs (1,992 kg) – JLG Lift – 3121773...

  • Page 109: Capacities

    Output 11.66 hp (8.7 kW) High engine speed 3600 RPM Torque 19.5 ft. lb. (26.5 Nm) @ 2500RPM Weight 80.0 lb. (36.4 Kg) Ignition System CDI Type Magneto Alternator Output 10 A @ 3600 RPM 3121773 – JLG Lift –...

  • Page 110: Lithium-Ion Battery Pack Specifications

    2000 charges at 100% or 4000 charges at Lower Boom Lift Cylinder: 61.7 lb. (28 kg) 50%, etc.. Platform Assembled: 132.3 lb (60 kg) Chassis Gas: 4,718 lb. (2,140 kg) – JLG Lift – 3121773...

  • Page 111: Service/Maintenance

    BE DRIED USING COMPRESSED AIR TO AVOID THE RISK OF SHORT CIRCUITS. will need to be re-greased (see lubrication chart). Do not wet the electric motors and the other elec- trical components directly. Do not aim the spray directly onto decals and rat- ing plates. 3121773 – JLG Lift –...

  • Page 112: Machine Maintenance Locations

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Machine Maintenance Locations M = ENGINE OIL T = TRANSMISSION OIL I = HYDRAULIC OIL AND FILTER G = GREASE Figure 6-1. Lubrication and Maintenance Point Locations – JLG Lift – 3121773...

  • Page 113: Lubrication Types

    104deg F (+40deg C) NOTE: Use a brush to spread grease onto telescopic boom wear pad areas. NOTE: When adding or replacing hydraulic oil only use JLG approved hydraulic oil. Do not mix oils unless directed by JLG. Recommended Gearbox Oils...

  • Page 114: Hydraulic Oil Specifications

    * Readily biodegradable classification indicates one of the following: CO2 Conversion > 60% per EPA 560/6-82-003 / CO2 Conversion > 80% per CEC-L-33-A-93. ** Virtually Non-toxic classification indicates an LC50 > 5000 per OECD 203. *** Fire Resistant classification indicates Factory Mutual Research Corp. (FMRC) Approval. – JLG Lift – 3121773...

  • Page 115: Hydraulic Oil Operating Temperatures

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-3. Hydraulic Oil Operating Temperatures 3121773 – JLG Lift –...

  • Page 116: Component Maintenance Intervals - X430Aj

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Component Maintenance Intervals - X430AJ - with Gas Engine Table 6-10. Hours Component Operation Pre-Start As Needed 100 250 500 1000 2000 • Dry Air Filter(Diesel Engine) Check/Clean • Replace Engine Oil (Gas Engine) Check Level •...

  • Page 117: Component Maintenance Intervals - X430Aj - With Lithium-Ion Battery Pack

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Component Maintenance Intervals - X430AJ - with Lithium-Ion Battery Pack Table 6-11. Hours Component Operation Pre-Start As Needed 100 250 500 1000 2000 Hydraulic Oil Check Level • Replace • Hydraulic Oil Filter Replace Cartridge •*...

  • Page 118: Gas Engine Maintenance Procedures

    NOTE: Hydraulic oil levels are to be checked with the machine in transport position while on a firm, level and uniform surface. Oil level must be half-way in the level indicator (Indicator-A). To add hydraulic oil use (cap-B). 6-12 – JLG Lift – 3121773...

  • Page 119: Hydraulic Oil Filter Cartridge

    NOTE: If the track is out of tolerance immediately discontinue replaced. use of the machine THE GREASE CONTAINED WITHIN THE HYDRAULIC TRACK IS PRESSURIZED. NEVER LOOSEN GREASING VALVE 1 MORE THAN ONE (1) TURN. NEVER LOOSEN GREASE VALVE 2. 3121773 – JLG Lift – 6-13...
  • Page 120 • If broken metal cores are noted discontinue use until 6. Once correct track tension has been achieved, turn damaged components are replaced grease valve 1 clockwise to tighten valve. 7. Clean area of all trace grease. 6-14 – JLG Lift – 3121773...
  • Page 121 6 to lift the track from the track tension- ing wheel. TRACK NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSENING OF THE TRACK, BROKEN STUDS, AND POS- SIBLE DANGEROUS SEPARATION OF THE TRACK FROM THE TEETH. 3121773 – JLG Lift – 6-15...

  • Page 122: Wear Pad Inspection

    4. Verify the track links have engaged the wheel teeth in the track tensioning wheel 3. Connect the cables of the charger to the battery poles. and turn on the battery charger 5. Adjust track tension (see Loosening/Tightening track section). 6-16 – JLG Lift – 3121773...

  • Page 123: Electric Motor Maintenance

    Check the condition of the bearings, in the event RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM of noise contact JLG for replacement, the life of the DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF...

  • Page 124: Platform/Remote Control Service

    Both ON indicate the stabilizer 1 is completely open, TOTAL 9 - EXIT AREA. ST1 OPEN B MENUS 4; 5; CANNOT BE ACCESSED ST2 OPEN A Both ON indicate the stabilizer 2 is completely open, TOTAL AREA ST2 OPEN B 6-18 – JLG Lift – 3121773...
  • Page 125 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. POSM 4B 3121773 – JLG Lift – 6-19...

  • Page 126: Errors Menu

    “Platform/Remote Control Station Functions” on page 3-9.). If there are operating problems with the machine and the “spanner” icon is shown on the display, do not operate machine until repaired by a JLG factory trained technician. 6-20 – JLG Lift – 3121773...

  • Page 127: Working Hours Menu

    Hand protection gloves, for protection and insula- tion during work on live parts. • Foot protection devices Shoes with antistatic coating able to insulate the worker during work on the electrical parts of the system. 3121773 – JLG Lift – 6-21...

  • Page 128: Lithium-Ion Machine Fault Codes

    Cause – Feedback current from motor sensor not constantly at 0. conditions. If problem persists, replace inverter. Solution – Check connection to motor. Logic Failure #2 Cause – Internal fault in the inverter. Solution – Replace inverter. 6-22 – JLG Lift – 3121773...
  • Page 129 If problem persists, replace Cause – High temperature inside the inverter. inverter. Solution – Improve cooling to inverter. If fault persists, contact JLG after- sales service. Driver shorted Cause – Relay power supply fault.

  • Page 130: Bms Fault Codes

    Current sensor KO A99E09 – High battery compartment temperature Cause – Set up procedure for maximum current in progress. Solution – Contact JLG after-sales service. A99E10 – High electronic board temperature Check up needed A99E11 – Incorrect self.protection device temperature Cause –...
  • Page 131 A99E18 – Power board error A99E19 – I2C module not ready A99E20 – I2C TX error A99E21 – I2C RX error A99E22 – I2C RX error 2 A99E23 – AD error A99E99 – General error 3121773 – JLG Lift – 6-25...

  • Page 132: Battery Charger Fault Codes

    Abnormal current draw in primary section. Battery charger stops supplying power. Operation If problem persists, contact service dept. or change resumes as soon as alarm conditions are no longer product. present. 6-26 – JLG Lift – 3121773...
  • Page 133 If problem persists, contact service dept. or change product. Mains voltage higher than maximum operating Battery charger won’t start charging until mains Make sure mains voltage is within correct operating range tolerance. voltage returns within normal operating range. parameters. 3121773 – JLG Lift – 6-27...

  • Page 134: Lithium-Ion Battery Pack - Handling In Dangerous Conditions

    3. Exploded cells Minimum Equipment Required: 4. Fire enveloping the lithium batteries • Infrared temperature probe • Safety glasses • Hard hat with impact resistant face visor • Non-conductive pliers • Hand, arm and body protection 6-28 – JLG Lift – 3121773...

  • Page 135: Procedure For Handling Vented Cells

    • Acid.resistant lab coats Procedures in cases of venting or explosion are examined in the following paragraphs. • Baking soda, calcium oxide or acid absorbent in kit form • Vermiculite • Plastic bags 3121773 – JLG Lift – 6-29...
  • Page 136 9. Place the absorbent material in a bag and seal it. 10. Clean area with plenty of water. 11. Dispose of hazardous material in accordance with the local legislation in force. 6-30 – JLG Lift – 3121773...

  • Page 137: Procedure For Exploded Cells

    Avoid contact between the metallic residues and charged cells, as this condition may cause a short.circuit. 7. Place contaminated material in a sealable plastic bag and remove excess air. 8. Seal the bag. 3121773 – JLG Lift – 6-31...

  • Page 138: Lithium Battery Fire

    All precautions needed to limit exposure to these fumes must be adopted. It should be noted that this proce- dure is applicable only to fires on individual cells. Larger fires have to be managed only by professionally trained person- nel. 6-32 – JLG Lift – 3121773...
  • Page 139 3. The fire-fighting personnel go to the area where 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. 3121773 – JLG Lift – 6-33...
  • Page 140 If breathing stops apply mouth-to-mouth resus- citation and immediately seek emergency medical help. 17. Dispose of hazardous material in accordance with the local legislation in force. 6-34 – JLG Lift – 3121773...

  • Page 141: Section 7 - Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _________________________________ Date Comments 3121773 – JLG Lift –...
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