JLG X500AJ Operation And Safety Manual
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JLG X500AJ Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X500AJ
ANSI
3121636
®
June 29, 2018 - Rev F

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Summary of Contents for JLG X500AJ

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) X500AJ ANSI 3121636 ® June 29, 2018 - Rev F...
  • 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 INDICATES INFORMATION OR A COMPANY POLIC Y THAT RELATES COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTEC- AN ORANGE BACKGROUND. TION OF PROPERTY. – JLG Lift – 3121636...

  • Page 6: Contact

    THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. • Accident Reporting • Standards and Regula- CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRE- tions Compliance Infor- • Product Safety Publi- SENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS...

  • Page 7: Revision Log

    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 – JLG Lift – 3121636...

  • Page 8: Table Of Contents

    LIMITATIONS ........4-1 2.1 PERSONNEL TRAINING ......2-1 3121636 – JLG Lift –...
  • Page 9 Platform or Boom Caught Overhead... 5-2 Telescope The Main Boom ....4-17 – JLG Lift – 3121636...
  • Page 10 6.3 SERVICE/MAINTENANCE ......6-6 DANGEROUS CONDITIONS....6-42 3121636 – JLG Lift –...
  • Page 11 4-4. Platform/Remote Control Box ....4-16 4-5. Platform - Load/Reach Chart - X500AJ..4-18 4-6. SkyGuard™ Sensor and Override Switch Location ........4-19 4-7.
  • Page 12 Lithium Ion Specifications ....6-4 X500AJ - Lithium-Ion Machine ....6-11 Major Component Weights .
  • Page 13 @ 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 14: 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”). 3121636 – JLG Lift –...

  • Page 15: 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 16: Machine Inspection

    • Never slam a control switch or lever through neutral components. Ensure that any modifications have to an opposite direction. Always return switch to been approved by JLG. neutral and stop before moving the switch to the • Avoid accumulation of debris on platform floor.

  • Page 17: 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 18: 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. 3121636 – JLG Lift –...

  • Page 19: 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 – 3121636...

  • Page 20: 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 21 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 – 3121636...

  • Page 22: 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. 3121636 – JLG Lift –...

  • Page 23: 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 – 3121636...
  • Page 24 Do not allow heavy objects to rest in an unstable position. Ensure adequate sup- port is provided when raising components of the machine. • Do not use machine as a ground for welding. 3121636 – JLG Lift – 1-11...

  • Page 25: 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 – 3121636...
  • Page 26 @ 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 27: 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. 3121636 – JLG Lift –...

  • Page 28: Preparation, Inspection, And

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECH- inspections and maintenance required by JLG Indus- NICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SER- tries, Inc. Consult local regulations for further require- VICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
  • Page 29 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. 3121636 – JLG Lift –...

  • Page 30: Pre-Start Inspection

    4. Operation and Safety Manuals – Make sure a copy of the Operation and Safety Manual, AEM Safety Manual (ANSI markets only), and ANSI Man- ual of Responsibilities (ANSI markets only) is – JLG Lift – 3121636...
  • Page 31 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). 3121636 – JLG Lift –...
  • Page 32 SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection – JLG Lift – 3121636...

  • Page 33: Daily Walk-Around Inspection

    Hydraulic oil level correct and See Inspection Note. platform properly installed and with both caps 11. Electric Motor and Ground Components screwed on. See Inspection Note. Hydraulic Valve Sets - See Inspection Note. 3121636 – JLG Lift –...

  • Page 34: Function Check

    Check that all guards protecting the function con- trol switches and controllers are in place; c. Operate all functions. d. Ensure all boom functions stop when the foot switch is released. – JLG Lift – 3121636...
  • 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 Nomenclature (Right Side View) 3121636 – JLG Lift –...
  • Page 37 19. Lithium ION - Battery Pack, Inverter, and Battery Charger Compartment 9. Hand Pump - (Right Side of Machine) 20. SkyGuard™ Sensor (If Equipped) 10. Hydraulic Oil tank - (Right Side of Machine) 11. Electric Motor – JLG Lift – 3121636...

  • Page 38: Ground Control Station

    See “Ground Control Station - With Enable Knob” on page 7. Figure 3-3. See “Ground Control Station - With Enable Figure 3-2. See “Ground Control Station - With Enable Knob” on page 7. Lever” on page 4. 3121636 – JLG Lift –...

  • Page 39: Ground Control Station - With Enable Lever

    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. – JLG Lift – 3121636...
  • Page 40 Provides for positioning the platform assembly up Provides raising and lowering of the tower boom and down to adjust the level of the platform. section. 9. Main Boom Lift Control Provides raising and lowering of the main boom section. 3121636 – JLG Lift –...

  • Page 41: Ground Control Station - With Enable Lever

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 12 13 Figure 3-4. Ground Control Station - with Enable Lever – JLG Lift – 3121636...

  • Page 42: Ground Control Station - With Enable Knob

    With the switch turned clockwise and held, only the ground controls are operational. Provides for positioning the platform up and down With the switch turned counter clockwise, the plat- to adjust the level of the platform. 3121636 – JLG Lift –...
  • Page 43 This knob used during emergency ground opera- 7. Telescope Control tion (see Section-5), must be pressed in all the way Provides extension and retraction of the main before any of the hydraulic valve ground controls boom section. will function. – JLG Lift – 3121636...

  • Page 44: Ground Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-5. Ground Control Station 3121636 – JLG Lift –...

  • Page 45: Platform/Remote Control Station

    6. Attach the other end of the service cable to the service port connector (item 1). To enable this position it is necessary to have the select switch at the ground controls (Item 2 - Figure 3-5.) turned counterclockwise after connecting the platform/remote 3-10 – JLG Lift – 3121636...

  • Page 46: Platform/Remote Control Position From The Ground

    (aligned) position. From this control position walking along side or behind the machine, the operator IS NOT enabled to control the aerial part of the machine, but only the tracks, stabilizers and track extension function. 3121636 – JLG Lift – 3-11...
  • Page 47 3-12 – JLG Lift – 3121636...
  • Page 48 (icon on button) or used as numerical keys (per number below the button) when the SERVICE button 6 (item 6) sub-menus is activated on the LCD display. 3121636 – JLG Lift – 3-13...
  • Page 49 11. Gas Engine Starter by the depress footswitch error icon on the This button allows the operator to start or stop the platform/remote LCD display. gas engine. 3-14 – JLG Lift – 3121636...

  • Page 50: Platform/Remote Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-6. Platform/Remote Control Station 3121636 – JLG Lift – 3-15...
  • Page 51 19. Platform Rotate This switch allows the operator to rotate the plat- form to the right or left. 20. Jib This control allows the operator to raise and lower the jib. 3-16 – JLG Lift – 3121636...
  • Page 52 Position 3 Displays the selected engine (gas or elec- tric) and whether it is on or off. The X on the icon indicates the engine is off. Position 4 Displays the selected engine speed. 3121636 – JLG Lift – 3-17...
  • Page 53 • 50 Hr. - 1st Service Interval - See Section operational. Drive and steer are operational 6 - Figure 6-4. and Figure 6-5., Compo- if all 4 outriggers are not contacting the nent Maintenance Intervals. ground. SERV... 3-18 – JLG Lift – 3121636...
  • Page 54 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Position 8 • Indicates that emergency lowering has been selected. • Lithium ION - Battery Charge Status • Lithium ION - Battery Charger Plugged 3121636 – JLG Lift – 3-19...
  • Page 55 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions 3-20 – JLG Lift – 3121636...
  • Page 56 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions (Continued) 3121636 – JLG Lift – 3-21...
  • Page 57 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2. LCD Display Error Descriptions 3-22 – JLG Lift – 3121636...
  • Page 58 @ 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 59: Section 4 - Machine Operation

    • Platform is only operated within its work area specifica- tion for rated load and boom reach. (See Figure 4-5.) 3121636 – JLG Lift –...

  • Page 60: Engine Operation

    (Item 23, Figure 4-4.). (Turned CounterClockWise) NOTE: (1) Switch at engine must be set to ON, main battery disconnect switch must be ON, and both the ground and platform emergency stop switches must be set to – JLG Lift – 3121636...

  • Page 61: Gas Engine Shutdown Procedure

    (— symbol is ON - O symbol is OFF). 4. Start the electric engine using the engine start button at the ground/emergency control box. (item 5 - Figure 4-1.) and operate machine. 3121636 – JLG Lift –...

  • Page 62: Lithium-Ion Machine

    3), if it was required. NOTE: At low temperatures start the motor and let it run for a few minutes, so that the hydraulic oil circulates and reaches at least 50°F (10°C) before operating the plat- form. – JLG Lift – 3121636...

  • Page 63: Ground/Emergency Control Box

    SECTION 4 - MACHINE OPERATION Figure 4-2. Ground/Emergency Control Box - Lithium 1. Platform/Remote (Center) 3. Platform/Remote Ground Platform Position Maintenance Position - (Turned CounterClockWise) 2. Ground Control Position - (Turn ClockWise and Hold) 4. Function Enable Indicator 3121636 – JLG Lift –...

  • Page 64: Base And Boom/Jib Alignment

    (6) on the Platform/ Remote Control LCD display. UNLESS THESE CONDITIONS ARE MET, DRIVE, STEER, TRACK WIDTH ADJUSTMENT, AND OUT- RIGGER MOVEMENT IS PREVENTED. Boom/Jib and Base Alignment - Reflectors/Photocells Base/Boom Alignment - Visual Indicator – JLG Lift – 3121636...

  • Page 65: Tracks - Driving, Steering And Track Width Adjust

    Travelling (Grades and Side Slopes) DO NOT DRIVE MACHINE ON GRADES EXCEEDING 15 DEGREES (26.7%). USE RAMPS WHEN TRAVELLING ON STEPS OR OTHER SURFACES THAT ARE NOT SMOOTH OR HAVE GOOD TRACTION. 3121636 – JLG Lift –...
  • Page 66 LCD - Showing Maximum Incline Exceeded - While Driving with each press of the override button) and reposition the machine to a safer condition, reducing the inclination. It is absolutely forbidden to increase the inclination of the – JLG Lift – 3121636...

  • Page 67: Grade And Side Slope Definition

    SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Side Slope Definition 3121636 – JLG Lift –...

  • Page 68: Jib Position For Travelling

    • All outriggers must be lifted from the ground • There must be no operator in the basket • The platform/remote control box must be removed from the platform and used from the ground. 4-10 – JLG Lift – 3121636...

  • Page 69: Outrigger Operation

    • With the JIB raised, ALWAYS travel at minimum speed and keep the JIB as near as possible to the ground. 3121636 – JLG Lift – 4-11...
  • Page 70 PEDAL: If OK the footswitch is correctly depressed. AUTOST: when using the auto stabilizer set button 7, if OK, stabilizers are set properly. If NO, button 7 was released before tilt sensor detected machine was level and stabilizers set properly. 4-12 – JLG Lift – 3121636...

  • Page 71: Setting Outriggers From The Platform/Remote Console

    Each outrigger has a yellow light installed. All lights will be on steady if the outriggers are positioned to the full opera- tion area. No lights will be on if the outriggers are not set properly. 3121636 – JLG Lift – 4-13...

  • Page 72: Retracting The Outriggers

    REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE GROUND, 1) of the remote control. STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG SERVICE The 4 outriggers will all retract at the same TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRESPOND- AUTO time and lower the machine.

  • Page 73: Boom/Platform Operation

    • To manually Level Up, turn the select switch clockwise the platform/remote display and the alarm sounds. To and hold until desired position is reached. restore the boom functions it is necessary to remove the extra load. 3121636 – JLG Lift – 4-15...

  • Page 74: Platform/Remote Control Box

    SECTION 4 - MACHINE OPERATION Figure 4-4. Platform/Remote Control Box 4-16 – JLG Lift – 3121636...

  • Page 75: Raise And Lower The Tower Boom

    • To extend the main boom, depress the foot switch and move the controller backward. • To swing the boom to the left, depress the foot switch and move the controller backwards. 3121636 – JLG Lift – 4-17...

  • Page 76: Platform - Load/Reach Chart - X500Aj

    SECTION 4 - MACHINE OPERATION Figure 4-5. Platform - Load/Reach Chart - X500AJ 4-18 – JLG Lift – 3121636...

  • Page 77: 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 3121636 – JLG Lift – 4-19...

  • Page 78: Platform Removal/Installation

    2. Loosen and remove the aluminum caps that secure the platform to the jib platform mounting posts. 3. Lift the platform off the mounting posts in an upward direction. Place platform aside for later installation. 4-20 – JLG Lift – 3121636...

  • Page 79: Battery Charging - Gas/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. 3121636 – JLG Lift – 4-21...

  • Page 80: 4.10 Battery Charging - Lithium-Ion Machine

    If the machine is powered on while charging, will be activated whenever the electric motor is started, the LCD display on the platform control sta- to alert the user to charge the machine. tion also shows the machine charge indica- tor. 4-22 – JLG Lift – 3121636...
  • Page 81 After a few seconds the charge indicator (item 2 - photo) located on the right-hand side of the machine on the lith- ium-ion battery pack turns red, meaning the battery has started charging. 3121636 – JLG Lift – 4-23...

  • Page 82: Charge Curve

    JLG Ser- is recommended to use a class A or even better class B vice Center.

  • Page 83: 4.11 Shut Down And Park

    6. Close the platform control console lid. If necessary to protect instruction placards, warning decals and operating controls from hostile environment, place a cover over this area. BATTERY DISCONNECT - GAS/AC-ELECTRIC 3121636 – JLG Lift – 4-25...

  • Page 84: 4.12 Lifting And Tie Down

    ATTACHED TO EACH OF THE (4) LIFTING RINGS USING THE APPROPRIATE (Mounted Inside Left-Side Electrical Component Compartment) LIFTING POINTS AS INDICATED IN FIGURE 4-7. OTHERWISE THE MACHINE MAY NOT BALANCE PROPERLY AND MOVE UNEXPECTEDLY. 4-26 – JLG Lift – 3121636...

  • Page 85: Lifting - Fork Lift Pockets

    Insert the forks into the lifting pockets on the machine and carefully lift machine. 5. Move machine to new location. Figure 4-7. Lifting Machine - Lifting Rings Location 1. Lifting Rings (4 - 1 Each Outrigger) 3121636 – JLG Lift – 4-27...

  • Page 86: Loading And Unloading The Machine On Transport Vehicles Using Ramps

    SECTION 4 - MACHINE OPERATION The JLG platform offers high maneuverability and stability even in travelling (stowed) configuration. Despite this, the operator is to take safety measures even when carrying out the simplest operations. ALWAYS LOAD/UNLOAD THE MACHINE WITH UNDERCARRIAGE (TRACKS) EXTENDED TO WIDEST WIDTH.

  • Page 87: Tie Down

    THIS COULD CAUSE PERMANENT DAMAGE RESULTING IN THE COLLAPSE OF THE PRODUCT. WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOW- ERED INTO THE BOOM REST. • Travel up ramps with the platform behind the machine. 3121636 – JLG Lift – 4-29...
  • Page 88 SECTION 4 - MACHINE OPERATION 1703814A 1701499 1703814A 1701499 Figure 4-9. Machine Tie-Down Points (both sides of machine) 1. Tie-Down Loop 2. Tie-Down Decal 4-30 – JLG Lift – 3121636...

  • Page 89: 4.13 Machine Decals

    SECTION 4 - MACHINE OPERATION 4.13 MACHINE DECALS Figure 4-10. Decal installation - Standard - Left Side 3121636 – JLG Lift – 4-31...

  • Page 90: Decal Installation - Standard - Right Side

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Standard - Right Side 4-32 – JLG Lift – 3121636...

  • Page 91: X500Aj - Decal Installation - Standard

    SECTION 4 - MACHINE OPERATION Table 4-2. X500AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.) ITEM # PART NUMBER DESCRIPTION DECAL INSTALLATION 06555500 Decal, Outrigger Number 1 06555600 Decal, Outrigger Number 2 06555700 Decal, Outrigger Number 3...
  • Page 92 SECTION 4 - MACHINE OPERATION Table 4-2. X500AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.) ITEM # PART NUMBER DESCRIPTION 06060000 Decal, Engine Oil Level 1701542 Decal, Gasoline Fuel Only 1701505 Decal, Fuel Only 06056300 Decal, Burn Hazard...
  • Page 93 SECTION 4 - MACHINE OPERATION Table 4-2. X500AJ - Decal Installation - Standard (See Figure 4-10. and Figure 4-11.) ITEM # PART NUMBER DESCRIPTION 1702901 Decal, Instructions For Emergency Manual Pump 3252347 Decal, Pedal 1706128 Decal, Danger of Electrocution 1703813...

  • Page 94: Decal Installation - Lithium-Ion - Left Side

    SECTION 4 - MACHINE OPERATION Figure 4-12. Decal installation - Lithium-Ion - Left Side 4-36 – JLG Lift – 3121636...
  • Page 95 SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Installation - Lithium-Ion - Right Side 3121636 – JLG Lift – 4-37...

  • Page 96: X500Aj - Decal Installation - Lithium

    SECTION 4 - MACHINE OPERATION Table 4-3. X500AJ - Decal Installation - Lithium Machine (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION DECAL INSTALLATION 07107200 Decal, Danger - Batteries 1001125483 Decal, Do Not Pressure Wash 06506400 Decal, On/Off Power Switch - Lithium Ion Engine...
  • Page 97 @ 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 98: 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 THE MACHINE AND...

  • Page 99: Operator Unable To Control Machine

    In the event either/or both are not operating switch (item 4). properly, the following procedures will allow the low- ering of the boom and platform. 5. Position (press) the emergency stop switch to the OFF position. – JLG Lift – 3121636...
  • Page 100 SECTION 5 - EMERGENCY PROCEDURES Figure 5-1. Platform/Remote Control Station 3121636 – JLG Lift –...
  • Page 101 7. Position (press) the emergency stop switch (item 1) 2. Start the engine, if not already running. to the OFF position to shut machine down. 3. At the Emergency/Ground Control box, turn the key switch (item 2) all the way clockwise and hold. – JLG Lift – 3121636...

  • Page 102: Ground Control Station - With Enable Lever

    SECTION 5 - EMERGENCY PROCEDURES 12 13 Figure 5-2. Ground Control Station - with Enable Lever 3121636 – JLG Lift –...
  • Page 103 SECTION 5 - EMERGENCY PROCEDURES Figure 5-3. Ground Control Station - Boom Control Valves – JLG Lift – 3121636...

  • Page 104: Manual Descent With Engine Running But

    See “Outrigger/Track 5. When emergency operation is complete, release Movement Emergency Procedure:” on page 5-10. the proportional valve to the closed position. 6. At the engine, turn the key to the off position. 3121636 – JLG Lift –...

  • Page 105: Manual Descent Without Engine And Electrical

    Turned to the left - for right side outrigger, track and boom functions. (See - Figure 5-5.) Turn to right - for left side outrigger and track functions. Figure 5-5. Hand Pump Decal - On Top Of Hydraulic Tank – JLG Lift – 3121636...

  • Page 106: Machine

    NOTE: This will eliminate the possibility of an elevated or extended boom being positioned overhead of person- nel at the pump and eliminate the risk of lowering the jib onto an outrigger. 3121636 – JLG Lift –...

  • Page 107: Outrigger/Track Movement Emergency

    3. Install the pump handle on the manual hydraulic machine. pump on top of the hydraulic tank on right side of 5-10 – JLG Lift – 3121636...
  • Page 108 6. The lever on the hydraulic hand pump (item 2 - Fig- ure 5-4.) must be turned to right to manually pro- vide pressure to operate left side outrigger and track functions. 3121636 – JLG Lift – 5-11...
  • Page 109 (valve description below) while pumping 11. Remove the manual pump handle from the pump the pump handle to achieve the desired function and secure it in its original position. movement. 5-12 – JLG Lift – 3121636...

  • Page 110: Ground Component Valves

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-6. Ground Component Valves - Outriggers/Track Control - Location 3121636 – JLG Lift – 5-13...
  • Page 111 • Turn the key to the right for TRACK operations. After using the safety device bypass, a qualified JLG mechanic must be contacted to determine the reason required to use this feature.

  • Page 112: Using The Emergency Descent In The Case

    2. Activate the safety device bypass by turning the key in a counterclockwise direction and hold it in position (see decal). 3. The safety devices BYPASS icon will appear on the platform/remote con- trol box display. 3121636 – JLG Lift – 5-15...

  • Page 113: Machine Realignment Emergency Procedure

    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 safety device bypass key. 5-16 – JLG Lift – 3121636...
  • Page 114 @ 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 115: Section 6 - General Specifications And Operator Maintenance

    SURE-WASHING. IF PRESSURE WASHING IS USED TO WASH AREAS CON- mation to assist the machine operator to perform daily TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. maintenance tasks only, and does not replace the more RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI- thorough Preventive Maintenance and Inspection Schedule MUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO-...

  • Page 116: Operating Specifications

    (2.88 m x 2.88 m) Max. Horizontal Platform Reach 24.60 ft (7.5 m) Stowed Height 6 ft 5 in (1.99m) Stowed Length 14 ft 85 in (4.53m) Approach angle with Jib lowered: 20° Departure angle 21° – JLG Lift – 3121636...

  • Page 117: Chassis

    Gasoline: 0.3 gal (1.1 L) 2.23 mph (3.6 km/hr) Max hydraulic system pressure Track/Outrigger: 2,393 psi (165 bar) Boom: 2,683 psi (185 bar) Maximum wind speed 28 mph (12.5m/s) Maximum manual force 90 lb (400 N) 3121636 – JLG Lift –...

  • Page 118: Engine Data

    48 volt - three phase - 2000 watt * Charge cycles have to be considered based on the fact there is no memory effect in the lithium batteries, i.e. 2000 charges at 100% or 4000 charges at 50%, etc. – JLG Lift – 3121636...

  • Page 119: Machine Major Component Weights

    40 - 45 Telescope cylinder: 88 lb (40 kg) 7 -10 Platforms Down: 7 - 10 2 occupant: 110.2 lb (50 kg) Basket Level 40 - 58 Chassis 2,368 lb (1074 kg) Down: 35 - 52 3121636 – JLG Lift –...

  • Page 120: Service/Maintenance

    = TRANSMISSION OIL I = HYDRAULIC OIL G = GREASE 10 h OR BEFORE WORK SHIFT 50 h OR EVERY WEEK 100 h 250 h 500 h WHICH COMES FIRST Figure 6-1. Lubrication and Maintenance Point Locations – JLG Lift – 3121636...

  • Page 121: Lubrication

    104deg F (+40deg C) coupler and belt tensioner Greasing Locations (See Figure 6-1.) NOTE: When adding or replacing hydraulic oil only use JLG approved hydraulic oil. Do not mix oils unless directed NOTE: Use a brush to spread grease onto telescopic boom by JLG.

  • Page 122: 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 – 3121636...
  • Page 123 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-3. Hydraulic Oil Operating Temperatures 3121636 – JLG Lift –...

  • Page 124: Component Maintenance Intervals

    TURNTABLE BOLT • • CHECK Install dry without TIGHTENING using oil or grease to CHECK TORQUE • # PLATFORM MOUNT PIN NUTS 200 Nm specified torque. Figure 6-4. Component Maintenance Intervals - with Honda Engine 6-10 – JLG Lift – 3121636...

  • Page 125: Component Maintenance Intervals - X500Aj - Lithium-Ion Machine

    TURNTABLE BOLT Install dry without • • CHECK using oil or grease to TIGHTENING specified torque. Figure 6-5. Component Maintenance Intervals - X500AJ - Lithium-Ion Machine 3121636 – JLG Lift – 6-11...
  • Page 126 Change oil per maintenance interval chart - then rinse and let dry, Dip in clean engine oil and squeeze (Figure 6-4.) out the excess oil. If too much oil is left in the foam the engine will smoke when started. 6-12 – JLG Lift – 3121636...
  • Page 127 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). 3121636 – JLG Lift – 6-13...

  • Page 128: Rubber Track Maintenance/Replacement

    NOTE: If the track is out of tolerance immediately discontinue use of the machine THE GREASE CONTAINED WITHIN THE HYDRAULIC TRACK IS PRESSUR- IZED. NEVER LOOSEN GREASING VALVE 1 MORE THAN ONE (1) TURN. NEVER LOOSEN GREASE VALVE 2. 6-14 – JLG Lift – 3121636...
  • Page 129 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 7. Clean area of all trace grease. 3121636 – JLG Lift – 6-15...
  • Page 130 TRACK NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSENING OF THE TRACK, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF THE TRACK FROM THE TEETH. Replacing Rubber Tracks 6-16 – JLG Lift – 3121636...

  • Page 131: Wear Pad Inspection

    3. Slowly rotate the drive wheel in reverse while, using one steel pipe, pushing the track plate inside the frame. 4. Verify track links have engaged wheel teeth on the track tensioning wheel. 5. Adjust track tension (see Loosening/Tightening track section). 3121636 – JLG Lift – 6-17...

  • Page 132: Gas/Ac-Electric

    SURE-WASHING. IF PRESSURE WASHING IS USED TO WASH AREAS CON- 2. Disconnect terminal clamps from battery poles. TAINING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. 3. Connect charger cables to the battery poles. Turn RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINI- on battery charger MUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPO-...

  • Page 133: Electric Motor Maintenance

    Electric Motor Check condition of the bearings. In the event of noise, The electric motor is located inside of the rear hydraulic contact JLG for replacement. Bearing life is reduced sig- valve distributor support cover. nificantly in heavy duty operating conditions.

  • Page 134: Platform/Remote Control Service Menu

    6 - W. HOURS control buttons (numbered 1 thru 9) below the buttons. 7 - SETUP 8 - JOYSTICK 9 - EXIT MENUS 4; 5; CANNOT BE ACCESSED 6-20 – JLG Lift – 3121636...

  • Page 135: Menu Input

    Outrigger N° 2 lifted – the switch is pressed and A line is opened Outrigger N° 2 on the ground – the switch is released and B line is closed ST2 GND B Outrigger N° 2 lifted – the switch is pressed and B line is opened 3121636 – JLG Lift – 6-21...
  • Page 136 Outrigger N° 4 lifted – the switch is pressed and A line is opened Outrigger N° 4 on the ground – the switch is released and B line is closed ST4 GND B Outrigger N° 4 lifted – the switch is pressed and B line is opened 6-22 – JLG Lift – 3121636...
  • Page 137 “A” line of the ground part safeties by-pass button is closed. BYPASCB A The ground part safeties are connected (normal working condition) – “A” line of the ground part safeties by-pass button is opened 3121636 – JLG Lift – 6-23...
  • Page 138 Photocell B does not receive the signal from the reflector (Aerial part opened) The emergency stop on ground remote control is released. EM.R.C.GND The emergency stop on ground remote control is pressed or the ground remote control is disconnected 6-24 – JLG Lift – 3121636...
  • Page 139 The temperature external probe reached the maximum value – “A” line of the Option reserved for some temperature probe is closed markets The temperature external probe hasn’t reached the maximum value – “A” line of the temperature probe is open 3121636 – JLG Lift – 6-25...
  • Page 140 (normal working condition) LL20JP - X600AJ At list one cable on the extension is out of order. The control switch of the cables on extension is pressed and the line is open (emergency condition) 6-26 – JLG Lift – 3121636...
  • Page 141 The JIB is open – the control switch is pressed and “A” line is open The JIB is closed – the control switch is released and “B” line is closed MICROJIB B The JIB is open – the control switch is pressed and “B” line is open 3121636 – JLG Lift – 6-27...
  • Page 142 The stop button on remote control in basket is pressed or the ground remote control is disconnected – “B” line is open Do not consider POSM1 A Do not consider Do not consider POSM1 B Do not consider Do not consider POSM2 A Do not consider 6-28 – JLG Lift – 3121636...
  • Page 143 POSM4 A Do not consider Do not consider POSM4 B Do not consider The remote control is in the support in basket R.C. BASKET The remote control is not in the support in basket 3121636 – JLG Lift – 6-29...
  • Page 144 Indicates the opening of the 3 arm cylinder in tenths of a millimetre POS. 3 2398 ROTATION A Do not consider MOTOR RPM Diesel 2200 Indicate the engine RPM Only I di A) th t ECM1 2 i 6-30 – JLG Lift – 3121636...
  • Page 145 Indicates the temperature of the control module in C° SUPPLY (V) 12,1 Indicates the batteries voltage, or the output voltage from the battery charger BATTERY % Only for Lithium version: indicates the % level of charge of the pack 3121636 – JLG Lift – 6-31...

  • Page 146: Errors Menu

    “Platform/Remote Control Station LCD Dis- play” on page 3-17.). 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. 6-32 – JLG Lift – 3121636...

  • Page 147: Lithium-Ion Machine Only - Additional Maintainance Information

    THESE MUST BE DRIED USING COMPRESSED AIR TO AVOID THE RISK OF SHORT CIRCUITS. Do not wet electric motors and other electrical compo- nents directly. Do not aim spray directly onto decals and rating plates. 3121636 – JLG Lift – 6-33...

  • Page 148: Example Of Lithium-Ion Battery Pack

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Battery Pack System Components and Maintenance Figure 6-6. Example of Lithium-Ion Battery Pack Components 6-34 – JLG Lift – 3121636...
  • Page 149 Shoes with antistatic coating able to insulate the 11. Battery Management System worker during work on the electrical parts of the sys- 12. Battery Charge Indicator tem. 13. Blower Fan 14. Battery Case - 15 Cells (90Ah) 3121636 – JLG Lift – 6-35...

  • Page 150: Lithium-Ion Machine Fault Codes

    Solution – This is generally a temporary problem due to certain working Cause – Inverter supplies power to relay coil but contact doesnft close. conditions. If problem persists, replace inverter. Solution – Check relay and power supply to coil. 6-36 – JLG Lift – 3121636...
  • Page 151 Solution – Check relay power supply. This is generally a temporary prob- Cause – High temperature inside the inverter. lem due to certain working conditions. If problem persists, replace Solution – Improve cooling to inverter. If fault persists, contact JLG after- inverter. sales service.
  • Page 152 Cause – With power connected, battery test detected incorrect batteries fitted. Solution – Replace batteries with the original ones supplied directly by JLG. Current sensor KO Cause – Set up procedure for maximum current in progress. Solution – Contact JLG after-sales service. 6-38 – JLG Lift – 3121636...

  • Page 153: Bms Fault Codes - (Battery Management System)

    A99E11 – Incorrect self.protection device temperature A99E99 – General error A99E12 – Fault on all temperature sensors A99E13 – Temperature sensor fault A99E14 – Earth connection fault A99E01 – Incorrect system configuration A99E02 – Incorrect voltage 3121636 – JLG Lift – 6-39...

  • Page 154: 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. 6-40 – JLG Lift – 3121636...
  • Page 155 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. 3121636 – JLG Lift – 6-41...

  • Page 156: Lithium-Ion Battery Pack - Handling In Dangerous Conditions

    4. Fire enveloping the lithium batteries Minimum Equipment Required: • Infrared temperature probe • Safety glasses • Hard hat with impact resistant face visor • Non-conductive pliers • Hand, arm and body protection 6-42 – JLG Lift – 3121636...

  • Page 157: Procedure For Handling Vented Cells

    The procedures in cases of venting or explosion are examined in the following paragraphs. • Neoprene gloves • Acid.resistant lab coats • Baking soda, calcium oxide or acid absorbent in kit form • Vermiculite • Plastic bags 3121636 – JLG Lift – 6-43...
  • Page 158 9. Place the absorbent material in a bag and seal it. 10. Clean the area with plenty of water. 11. Dispose of the hazardous material in accordance with the local legislation in force. 6-44 – JLG Lift – 3121636...

  • Page 159: Procedure For Exploded Cells

    7. Place the contaminated material in a sealable plastic • Plastic bags bag and remove the excess air. 8. Seal the bag. 9. Place a cup of vermiculite in a second bag, place the first bag in the second and seal it. 3121636 – JLG Lift – 6-45...

  • Page 160: Lithium Battery Fire

    This condition may cause serious damage to the respiratory tract, skin and eyes. All precautions needed to limit expo- sure to these fumes must be adopted. It should be noted that this procedure is applicable only to fires on individual 6-46 – JLG Lift – 3121636...
  • Page 161 10. The residual material may contain unreacted lithium, 2. Evacuate personnel from all areas and sound the fire therefore limit exposure to rain by covering, for exam- alarm. ple, with mineral oil. 3121636 – JLG Lift – 6-47...
  • Page 162 16. Clean the area with plenty of water and keep cleaning by trained personnel. If breathing stops apply mouth-to- with water and soap. mouth resuscitation and immediately seek emergency 17. Dispose of hazardous material in accordance with the medical help. local legislation in force. 6-48 – JLG Lift – 3121636...

  • Page 163: Section 7 - Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _________________________________ DATE COMMENTS 3121636 – JLG Lift –...
  • Page 164 @ 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,...

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