JLG EC450AJ Operation & Safety Manual
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JLG EC450AJ Operation & Safety Manual

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Operation & Safety
Keep this manual with the machine at all times.
EC450AJ, EC520AJ
Copyright ©
ANSI
AS/NZS
Manual
Original Instructions -
Model
SN C300000700 to Present
31219187
June 29, 2023 - Rev D

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Summary of Contents for JLG EC450AJ

  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. Model EC450AJ, EC520AJ SN C300000700 to Present 31219187 June 29, 2023 - Rev D Copyright © ANSI AS/NZS...
  • Page 2 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 re- productive 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 3: Foreword

    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 4 It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 31219187 EC450AJ, EC520AJ...
  • Page 5 NOTICE 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.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG Description Date Revision July 5, 2022 Original Issue September 1, 2022 Revision February 1, 2023 Revision June 29, 2023 Revision Other Publications Available Publication Publication Number 31217104 Service & Maintenance Manual 31219189 Illustrated Parts Manual EC450AJ, EC520AJ 31219187...
  • Page 8 This Page is intentionally left blank...

  • Page 9: Table Of Contents

    SkyGuard® Function Test ............. 36 SECTION 3 MACHINE CONTROLS AND INDICATORS........37 General................37 Controls and Indicators ............38 Ground Control Station............39 Multifunction Display............43 Platform Control Station ............. 47 Platform Control Indicator Panel .......... 51 EC450AJ, EC520AJ 31219187...
  • Page 10 Manual Swing Override............86 Emergency Towing Procedures ..........87 Machine Safety System Override (MSSO) (If Equipped) .... 89 SECTION 6 ACCESSORIES.................. 91 Available Accessories and Relationship Table ......91 Pipe Racks................. 93 Platform Work Lights ............95 SkyGlazier®................ 96 31219187 EC450AJ, EC520AJ...
  • Page 11 Operating Specifications ............. 99 Operator Maintenance and Lubrication Diagram ....104 Operator Maintenance ............104 Tires and Wheels.............. 110 Supplemental Information Only Applicable to CE/UKCA Machines ................ 112 EC Declaration of Conformity..........113 UKCA Declaration of Conformity ........114 EC450AJ, EC520AJ 31219187...
  • Page 12 This Page is intentionally left blank...

  • Page 13: Safety Precautions

    Read, understand, and study the Operation and Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognizing and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 14 • Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

  • Page 15: Operation

    Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 16 Ensure that the platform assembly is fully lowered. Face the platform when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. 31219187 EC450AJ, EC520AJ...
  • Page 17 10 (3) 0 to 50 KV 15 (5) Over 50K V to 200 KV 20 (6) Over 200 KV to 350 KV 25 (8) Over 350 KV to 500 KV 35 (11) Over 500 KV to 750 KV EC450AJ, EC520AJ 31219187...
  • Page 18 The user must be familiar with the operating surface before driving. Do not exceed the allowable side slope and grade while driving. • Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. 31219187 EC450AJ, EC520AJ...
  • Page 19 • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis of the machine a minimum of 2 ft (0.6m) from holes, bumps, drop- offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
  • Page 20 Use the boom functions, not the drive function, to position the platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft (1.8 m) away from machine during all operations. 31219187 EC450AJ, EC520AJ...

  • Page 21: Towing, Lifting, And Hauling

    1.5.1 Maintenance Hazards • Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs. EC450AJ, EC520AJ 31219187...
  • Page 22 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.
  • Page 23 Immediately rinse any contacted area with clean water and seek medical attention. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. EC450AJ, EC520AJ 31219187...
  • Page 24 This Page is intentionally left blank...

  • Page 25: User Responsibilities, Machine Preparation, And Inspection

    2.1.3 Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. EC450AJ, EC520AJ 31219187...

  • Page 26: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
  • Page 27 Owner, Dealer, or Qualified JLG Service & Mainte- nance Manual and tion (See Note) lease, or rental User Mechanic delivery applicable JLG in- spection form Frequent Inspection In service for 3 Owner, Dealer, or Qualified JLG Service & Mainte- (See Note) User...

  • Page 28: Machine Components

    Manual Service & Mainte- nance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.

  • Page 29: Pre-Start Inspection

    7. Hydraulic Oil — Check the hydraulic oil level. Ensure hydraulic oil is added as required. 8. Accessories/Attachments — Refer to the Accessories section in this manual or accessory installed upon the machine for specific inspection, operation, and maintenance instructions. EC450AJ, EC520AJ 31219187...

  • Page 30: Walk-Around Inspection

    Do not operate the machine until it is declared safe for operation. WALK-AROUND INSPECTION OAC03330 Begin the Walk-Around Inspection at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist. 31219187 EC450AJ, EC520AJ...
  • Page 31 14. Tie Rod Ends and Steering Spindles - See Inspection Note. 15. Swing Motor and Worm Gear - No evidence of damage. 16. Battery - Batteries should not be damaged; cables tight; no visible damage or corrosion. EC450AJ, EC520AJ 31219187...

  • Page 32: Function Check

    2. Pull out the Power/Emergency Stop Switch on the ground console to power up the machine. 3. Turn the Battery Disconnect Switch to the Off position. 4. Watch the Display Gauge on the Ground Control Con- sole to verify the power is disconnected. 31219187 EC450AJ, EC520AJ...
  • Page 33 Function Check. If the power did not shut down or turn on properly, Report the problem to the prop- er maintenance personnel. Do not operate the machine until it is declared safe for operation. EC450AJ, EC520AJ 31219187...

  • Page 34: Oscillating Axle Lockout Test

    Note: Ensure boom is fully retracted, lowered, and centered between drive wheels pri- or to beginning lockout cylinder test. 1. Place a 6 in (15.2 cm) high block with ascension ramp in front of left front wheel. 31219187 EC450AJ, EC520AJ...
  • Page 35 Drive to release cylinders. 11. Repeat steps 4 - 7 to check the opposite side of the oscillating axle. 12. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. EC450AJ, EC520AJ 31219187...

  • Page 36: Skyguard® Function Test

    Note: On machines equipped with SkyLine, reattach the rod to the right bracket. If SkyGuard remains activated after function reversal or cutout, press and hold the SkyGuard Override Switch to allow normal use of machine functions until the sensor is disengaged. 31219187 EC450AJ, EC520AJ...

  • Page 37: Machine Controls And Indicators

    Machine Controls and Indicators GENERAL NOTICE The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. This section provides the necessary information needed to understand control functions. EC450AJ, EC520AJ 31219187...

  • Page 38: Controls And Indicators

    This indicator will be yellow. Indicates important information regarding the oper- ating condition, i.e. procedures essential for safe op- eration. This indicator will be green with the exception of the capacity indicator which will be yellow. 31219187 EC450AJ, EC520AJ...

  • Page 39: Ground Control Station

    2. Machine Safety System Override (MSSO) 9. Tower Boom Lift 3. Power / Emergency Stop 10. Swing 4. Platform Level 11. Auxiliary Descent Enable 5. Platform Rotate 12. Multifunction Display 6. Jib Lift 7. Main Boom Telescope EC450AJ, EC520AJ 31219187...
  • Page 40 Provides raising and lowering of the jib. Machine Safety System Override (MSSO) (If Equipped) Provides emergency override of function controls that are locked out in the event of Load Sense System activation. Main Boom Lift Provides raising and lowering of the main boom. 31219187 EC450AJ, EC520AJ...
  • Page 41 / descending a grade. WARNING Only use the platform leveling override function for slight leveling of the platform. Incorrect use could cause the load/occupant to shift or fall. Failure to do so could result in death or serious injury. EC450AJ, EC520AJ 31219187...
  • Page 42 Always position emergency stop switch to the Off position (pushed in) when machine is not in use. Swing Provides 355 degrees non-continuous turntable rotation. Tower Boom Lift This switch provides raising and lowering of the tower boom. 31219187 EC450AJ, EC520AJ...

  • Page 43: Multifunction Display

    12. Left Navigation Button 2. State of Charge Percentage 3. Scrolling DTC Messages 8. Battery Temperature 13. Scroll Page Left Button 14. Battery Heater 4. Capacity Zone Indicator 9. Scroll Page Right Button 5. System Distress 10. Right Navigation Button EC450AJ, EC520AJ 31219187...
  • Page 44 If available, will allow operator to scroll the screen left or scroll right to the next screen. Scrolling DTC Messages If DTCs are present, they will scroll across the top right of the display from left to right. 31219187 EC450AJ, EC520AJ...
  • Page 45 Displays the current state of charge of the battery pack in a percentage. System Distress The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memo- ry.
  • Page 46 5. Use the Scroll Page Left and Right Navigation buttons (3) to cycle through the different pages of your selection. 6. The page icon (5) will inform what page is currently being viewed. 7. To return to the Home Screen, press the Left Scroll Page button (2). 31219187 EC450AJ, EC520AJ...

  • Page 47: Platform Control Station

    1. Maximum Speed / Reduced Speed 9. Lights 2. Platform Leveling Override 10. Jib Lift 3. Horn 11. SkyGuard Override 4. Power / Emergency Stop 12. Tower Boom Lift 5. Auxiliary Descent 13. SkyGuard Indicator 6. Drive Orientation Override 14. Platform Rotate EC450AJ, EC520AJ 31219187...
  • Page 48 Note: The Drive joystick is spring loaded and will automatically return to neutral (Off) position when released. Drive / Steer Push forward to drive forward, pull back to drive in reverse. Steering is ac- complished via a thumb-activated rocker switch on the end of the Drive joystick. 31219187 EC450AJ, EC520AJ...
  • Page 49 Platform Rotate Provides rotation of the platform. Power / Emergency Stop A two-position red mushroom shaped switch furnishes power to Platform Controls when pulled out (On). When pushed in (Off), power is shut off to the platform functions. EC450AJ, EC520AJ 31219187...
  • Page 50 Indicates the SkyGuard sensor has been activated. All controls are cut out un- til the override button is pushed. SkyGuard Override The SkyGuard override switch enables functions cut out by the SkyGuard sys- tem to be operated again, allowing the operator to resume use of machine functions. 31219187 EC450AJ, EC520AJ...

  • Page 51: Platform Control Indicator Panel

    Provides for raising and lowering of the tower boom. PLATFORM CONTROL INDICATOR PANEL 100% BM000336A 1. Battery Charge Level 5. Creep Speed 6. Footswitch Enable 2. System Distress 3. Drive Orientation 7. Platform Overload 4. Tilt alarm / Warning 8. Capacity Zone Indicator EC450AJ, EC520AJ 31219187...
  • Page 52 (shorter boom lengths and higher boom angles). Creep Speed When the Function Speed Control is turned to the creep position, the indica- tor acts as a reminder that all functions are set to the slowest speed. 31219187 EC450AJ, EC520AJ...
  • Page 53 Indicates the platform has been overloaded. System Distress The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memo- ry. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.
  • Page 54 This Page is intentionally left blank...

  • Page 55: Machine Operation

    2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 4. Machine is as originally equipped from JLG. 4.2.2 Platform Load Sensing System (LSS) The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.

  • Page 56: Stability

    1. Main boom is horizontal. 3. Tower boom in the stowed position. 2. Telescope is fully extended. 4. Machine will tip over in the direction if overloaded or operated beyond the limits of the maximum operating slope. 31219187 EC450AJ, EC520AJ...

  • Page 57: Motor Operation

    This red mushroom-shaped switch provides battery power to the Platform/Ground Select switch when pulled out (On) for all machine functions. The switch should be pushed in (Off ) when recharging the batteries or parking the machine overnight. EC450AJ, EC520AJ 31219187...
  • Page 58 Footswitch must be depressed prior to activating any function, otherwise function will not operate. The motor becomes activated and operates the desired function when the Emergency Stop switch is pulled out (On), the Platform/ Ground select switch is in the appropriate position and the footswitch is depressed. 31219187 EC450AJ, EC520AJ...

  • Page 59: Traveling (Driving)

    Use extreme caution when driving in reverse and at all times when the platform is elevated. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows for the intended direction of travel. EC450AJ, EC520AJ 31219187...

  • Page 60: Traveling (Grade/Side Slope)

    (drive) axle, and in line with the direction of travel. Drive the machine forward when climbing a grade, and in reverse when descending a grade. Do not exceed the machine's maximum rated gradeability. 31219187 EC450AJ, EC520AJ...
  • Page 61 Figure 5. Traveling on a Grade NOTICE If the boom is over the front (steer) axle, direction of steer and drive movement will be opposite from the movement of the controls. BM001073A Figure 6. Grade and Side Slope EC450AJ, EC520AJ 31219187...

  • Page 62: Steering

    To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level. 4.8.2 Platform Rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction. 31219187 EC450AJ, EC520AJ...

  • Page 63: Boom

    4.9.1 Swinging the Boom To swing boom, use Swing control to select Right or Left direction. NOTICE When swinging the boom make sure there is ample room for the boom to clear surrounding walls, partitions and equipment. EC450AJ, EC520AJ 31219187...

  • Page 64: Function Speed Control

    Creep Mode. Creep Mode puts the functions listed above, as well as the Drive/Steer and Main Lift/Swing functions into the slowest speed setting. 4.11 USB CHARGING PORT The machine is equipped with a USB charging port for the operator. 31219187 EC450AJ, EC520AJ...

  • Page 65: Machine Safety System Override (Msso) (If Equipped)

    SkyGuard Override Switch to allow normal functions until the sensor is disengaged. Consult the following illustrations to determine which type of SkyGuard the machine has and how it is activated. Regardless of type, SkyGuard function according to the SkyGuard Function Table does not change. EC450AJ, EC520AJ 31219187...
  • Page 66 Approximately 50 lb (222 Nm) of force is applied to yellow bar. 4.13.2 SkyGuard - SkyLine OAC03970 Rod is pressed, breaking the connection between the rod and right bracket. 4.13.3 SkyGuard - SkyEye OAC00140 Operator passes through path of sensor beam. 31219187 EC450AJ, EC520AJ...
  • Page 67 Machine Operation EC450AJ, EC520AJ 31219187...

  • Page 68: Battery Charging

    Do not operate charger if the AC supply cord is damaged or if the charger has been damaged in any way. • Do not puncture of physically damage the battery casing, circuit boards, battery cells, or any other part of the battery mechanism. BM001075B 31219187 EC450AJ, EC520AJ...
  • Page 69 AC receptacle. Verify the battery disconnect switch is on. The charger will start automatically. There is a second external LED indicator which mirrors the LEDs on the main charger unit. BM001237A Figure 7. External LED Charger Indicator 1. LED Charger Indicator 2. AC Charge Socket EC450AJ, EC520AJ 31219187...
  • Page 70 BM001235A Figure 8. Batteries Location Batteries are located in the battery assembly located in the frame. The images below show the layout of the 10 kWh and 20 kWh capacity battery options. BM001236A 31219187 EC450AJ, EC520AJ...

  • Page 71: Battery Charging - Lithium-Ion Machine

    • Green Battery Cell: Battery capacity between 25% and 100% • Amber Battery Cell: Battery capacity between 10% and 25% • Red Battery Cell: Battery capacity below 10% EC450AJ, EC520AJ 31219187...
  • Page 72 12V System Low Voltage Warning: Indicates the 12V system has low voltage.. When the batteries are charging, the white hexagons will move in sequence from bottom to the top. The hexagons light up in an irregular pattern when the SOC os 100%. 31219187 EC450AJ, EC520AJ...
  • Page 73 Current provided by the charger • Time in hours until the end of charge • Ampere Hours (Ah) supplied Pressing the Mode button keeps the last value displayed. Pressing the Mode button again the information sequence restarts. EC450AJ, EC520AJ 31219187...
  • Page 74 Waiting to Charge (Idle - charge current and voltage are 0) Battery Heater XXX% Charging Active Charging Active Charge Voltage Charging Active Charge Current Charging Active AHr Charge Charging Active Charge Time Elapsed 100% Charging Complete Fault 31219187 EC450AJ, EC520AJ...

  • Page 75: Charging The Battery Pack

    • If the charge is less than 10%, in addition to the audible warning signal, reduced speed is activated and an icon comes on in position 6 on the ground control indicator panel. EC450AJ, EC520AJ 31219187...
  • Page 76 Be certain type of power supply available corresponds to voltage specified and indicated on the battery charger rating plate or in this Operation and Safety Manual. If any questions, contact your local JLG Service Center or the local electrical company.
  • Page 77 Do not open battery charger, opening it may affect the index of protection (IP) even after it has been closed again. • If battery charger is not working correctly or is damaged, disconnect it immediately from power outlet and the battery socket and contact a qualified JLG equipment mechanic. 4.16.1 Charging Phases The battery charger features four charging phases, designed specifically for charging the lithium-ion battery pack on this machine.

  • Page 78: Charging In Cold Temperatures

    2. Ensure boom is fully retracted and lowered over rear axle. 3. Shut down Emergency Stop at Platform Controls. 4. Shut down Emergency Stop at Ground Controls. Position Platform/Ground Select switch to center position Off. 5. Turn the Master Battery switch to the Off position. 31219187 EC450AJ, EC520AJ...

  • Page 79: Lifting And Tie Down

    2. Remove all loose items from the machine. 3. Ensure the platform is lowered so the wear pad on the bottom rests on the surface of the transportation vehicle. 4. Secure the chassis using straps or chains of adequate strength. EC450AJ, EC520AJ 31219187...

  • Page 80: Lifting And Tie Down Chart

    Machine Operation OAC014470 4.20 LIFTING AND TIE DOWN CHART BM001232A 31219187 EC450AJ, EC520AJ...

  • Page 81: Safety Decals

    Machine Operation 4.21 SAFETY DECALS 4.21.1 Safety Decals Locations Figure 9. Decals — Left Side 215B OAC03350 Figure 10. Decals — Right Side 215A OAC03360 Figure 11. Decals — Front and Rear EC450AJ, EC520AJ 31219187...
  • Page 82 Machine Operation 215B 215B OAC03370 Figure 12. Decals — Platform OAC03380 Figure 13. Decals — Frame 31219187 EC450AJ, EC520AJ...
  • Page 83 1001172217 1001189882 1001112551 1001255511 1001190913 1001190913 1001255512 1702868 1704000 1001131269 1001131269 3251243 3251243 1704885 1705351 1704885 1704885 1705351 1705429 1001223055 1001223971 1001223453 1001223453 1703953 1703942 1001260941 1001260939 1001260939 1001260941 1001260941 1001260941 1001260941 1001260941 1001262795 1001262795 1001262795 1001262795 EC450AJ, EC520AJ 31219187...
  • Page 84 1705669 1705669 1705669 EC520AJ 174 — 1001258490 1001258490 1001258490 1001258490 EC450AJ 174 — 1001258491 1001258491 1001258491 1001258491 EC520AJ 215A 1001243697 1001243697 1001243697 1001243697 215B 1001243698 1001243698 1001243698 1001243698 215C 1001166085 1001166085 1001166085 1001166085 1001141300 1001141300 1001141300 1001141300 31219187 EC450AJ, EC520AJ...

  • Page 85: Emergency Procedures

    This section explains the steps to be taken in case of an emergency situation during operation. INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

  • Page 86: Emergency Operation

    To operate the manual swing override, proceed as follows: 1. Using a 7/8 inch socket and ratchet wrench, locate nut on swing worm gear on left side of machine. 2. Install wrench on nut and ratchet in the direction desired. 31219187 EC450AJ, EC520AJ...

  • Page 87: Emergency Towing Procedures

    2. Using a 3/16 inch allen wrench, remove the cap retaining screw from the hub. 3. Locate the brake release bolts in front of the hydraulic pump and remove them. Install the cap retaining screws in the turntable in place of the brake release screws so they are not lost. BM001245B EC450AJ, EC520AJ 31219187...
  • Page 88 3. Using a 5/16 inch allen wrench, remove the brake release screw from each hub. 4. Replace each brake release screw with the corresponding cap retaining screw and return the brake release screws to the turntable. 5. Remove chocks from wheels as desired. 31219187 EC450AJ, EC520AJ...

  • Page 89: Machine Safety System Override (Msso) (If Equipped)

    Note: If the MSSO functionality is used, a fault indicator is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician. Note: No functional checks of the MSSO system are necessary. The JLG Control System will set a Diagnostic Trouble Code if the control switch is faulty.
  • Page 90 This Page is intentionally left blank...

  • Page 91: Accessories

    SECTION 6 Accessories AVAILABLE ACCESSORIES AND RELATIONSHIP TABLE Table 6. Available Accessories Table Market Accessory ANSI CE/UKCA Pipe Racks √ √ √ Platform Work Lights √ √ √ SkyGlazier® √ √ √ EC450AJ, EC520AJ 31219187...
  • Page 92 Accessories 31219187 EC450AJ, EC520AJ...

  • Page 93: Pipe Racks

    This accessory consists of two racks with adjustable straps to secure the load in place. 6.2.1 Capacity Specifications (Australia Only) Max. Platform Capacity Max. Capacity in Racks (With Max. Weight in Racks) 80 kg 184 kg EC450AJ, EC520AJ 31219187...
  • Page 94 2. Loosen and remove tie-down straps. Place material on racks with weight evenly distributed between both racks. 3. Route the tie-down straps at each end across loaded material and tighten. 31219187 EC450AJ, EC520AJ...

  • Page 95: Platform Work Lights

    Note: Reinstall tie-down straps across any remaining material before continuing ma- chine operations. PLATFORM WORK LIGHTS OAC04000 Figure 15. Platform Work Lights The Platform Work Lights accessory consists of two 12V lights mounted to the platform railing. EC450AJ, EC520AJ 31219187...

  • Page 96: Skyglazier

    150 lb (68 kg) 440 lb (200 kg) 1000 lb (450 kg/454 kg) 250 lb (113 kg) 500 lb (227 kg) * Refer to the capacity decals installed on the machine for capacity zone information. Required Platform Type: Side-Entry 31219187 EC450AJ, EC520AJ...
  • Page 97 6.4.3 Preparation and Inspection • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. • Ensure strap is not torn or frayed. 6.4.4 Operation 1. Load SkyGlazier tray with panel. EC450AJ, EC520AJ 31219187...
  • Page 98 Accessories 2. Position panel to its desired location on the tray. 3. Route the adjustable strap around the panel and tighten until secure. 31219187 EC450AJ, EC520AJ...

  • Page 99: General Specifications And Operator Maintenance

    5° Travel Speed — Stowed 2.98 mph (4.8 km/h) Maximum Gross Machine Weight — EC450AJ – 13,800 lb (6260 kg) EC450AJ – 14,211 lb (6446 kg) Approximate EC520AJ – 16, 954 lb (7690 kg) EC520AJ – 17,364 lb (7876 kg) EC450AJ —...
  • Page 100 Foam-Filled — Non-Marking Pressure Weight 286 lb (130 kg) 286 lb (130 kg) 7.2.3 Dimensional Data — EC450AJ Turning Radius (Inside) 6 ft 9 in (2.06 m) Turning Radius (Outside) 15 ft 8 in (4.78 m) Machine Height (Stowed) 89.3 in (2269 mm) Machine Length (Stowed) 258.9 in (6576 mm)
  • Page 101 General Specifications and Operator Maintenance Machine Length (Stowed) 305.8 in (7768 mm) Up and Over Platform Height 24 ft (7.3 m) 32.8 ft (10 m) Horizontal Reach 92.6 in (2353 m) Machine Width 93 in (2362 m) Wheel Base EC450AJ, EC520AJ 31219187...
  • Page 102 Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 103 (for example: batteries, filled tires, platform) do not modify unit in any way to affect stability. Component Upper Counterweight 2817 ±84.4 1278±38.3 EC450AJ 5353±107 2428±48.6 EC520AJ 617±18.5 280±8.4 Lower Counterweight 99.8 Tire and Wheel — 20x9 Foam-Filled 242.5 Platform and Console — 30x60 EC450AJ, EC520AJ 31219187...

  • Page 104: Operator Maintenance And Lubrication Diagram

    Note: The following numbers correspond to those in the Operator Maintenance and Lubrication diagram. Table 8. Lubrication Specifications. SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. Hydraulic Oil. API service classification GL-4, e.g. Standard UTTO. EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L- 2105.
  • Page 105 Lube Point(s) - Fitting • Capacity - A/R • Lube - BG • Interval - Every 3 months or 150 hours of operation • Comments - Apply grease and rotate in 90 degree intervals until bearing is completely lubricated BM001081A EC450AJ, EC520AJ 31219187...
  • Page 106 • Lube - Mobil SHC 007 • Interval - A/R • Interval - A/R BM001082A BM001083A CAUTION Do not over grease bearings. Excessive grease in bearings will result in damage to outer seal in housing. 3. Hydraulic Tank 31219187 EC450AJ, EC520AJ...
  • Page 107 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. • Comments - On new machines, those recently overhauled, or after changing hydraulic oil, operate all systems a minimum of two complete cycles and recheck oil level in reservoir. BM001084B EC450AJ, EC520AJ 31219187...
  • Page 108 Interval - Change after first 50 hours and every 6 months or 300 hours thereafter. • Comments – Filter blockage indicator should be checked while operating a high flow function (telescope in or tower boom down). BM001085B 31219187 EC450AJ, EC520AJ...
  • Page 109 5. Hydraulic Tank Breather • Interval - Change after first 50 hours. and every 6 months or 300 hours thereafter. • Comments - Under certain conditions, it may be necessary to replace on a more frequent basis. BM001086B EC450AJ, EC520AJ 31219187...

  • Page 110: Tires And Wheels

    7.5.1 Tire Damage For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.
  • Page 111 JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics: •...

  • Page 112: Supplemental Information Only Applicable To Ce/Ukca Machines

    The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s 31219187 EC450AJ, EC520AJ...

  • Page 113: Ec Declaration Of Conformity

    EN13849-1:2015 • EN 60204-1:2018 • IEC 62061:2021 • EN 280:2013+ A1:2015 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) Note: This declaration conforms with the requirements of annex II-A of the council di- rective 2006/42/EC.

  • Page 114: Ukca Declaration Of Conformity

    EN 60204-1:2018 • IEC 62061:2021 • EN 280:2013+ A1:2015 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 20165 •...
  • Page 115 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 116 Inspection, Maintenance and Repair Log...
  • Page 118 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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Ec520aj

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