1. Manuals
  2. Brands
  3. Oshkosh Manuals
  4. Boom Lifts
  5. JLG X600AJ
  6. Operation and safety manual

Oshkosh JLG X600AJ Operation And Safety Manual

Hide thumbs Also See for JLG X600AJ:
Table of Contents

Advertisement

Quick Links

Download this manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X600AJ
ANSI
3121637
June 29, 2018 - Rev F

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the JLG X600AJ and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Oshkosh JLG X600AJ

Summary of Contents for Oshkosh JLG X600AJ

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) X600AJ ANSI 3121637 June 29, 2018 - Rev F...
  • Page 2 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • 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 SECTION - FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc.

  • Page 5: Safety Alert Symbols And Safety Signal Words

    SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety mes- sages that follow this symbol to avoid possible injury or death. INDICATES A POTENTIALITY HAZARDOUS SITUATION.

  • Page 6: Contact

    SECTION - SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS For : 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- •...

  • Page 7: Revision Log

    SECTION - REVISION LOG REVISION LOG Original Issue A - 05-07-2014 Revised B - January 22, 2016 Revised C - July 25, 2016 Revised D - January 19, 2017 Revised E - March 16, 2017 Revised F - June 29, 2018 - Revised Covers, Prop 65 –...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE FOREWORD ........A Operator Training.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE LIMITATIONS ........4-1 Telescope The Main Boom .

  • Page 10: Section - Paragraph, Subject Page

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Manual Descent with Engine Running and Lubrication ........6-7 Electrical Power.
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Procedure For Handling Hot Cells ... . 6-42 LIST OF FIGURES Procedure For Handling Vented Cells..6-43 2-1.
  • Page 12 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE 4-14. Decal installation - Lithium-Ion - Left Side . . .4-38 LIST OF TABLES 4-15. Decal Installation - Lithium-Ion - Right Side. .4-39 Minimum Approach Distances (M.A.D.) ..1-6 5-1.
  • Page 13 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 14: Section 1 - Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN proper and safe machine usage and maintenance. It is THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY mandatory that a daily routine is established based on DAMAGE, PERSONAL INJURY OR DEATH.

  • Page 15: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibili- Workplace Inspection ties until adequate training has been given by com- • Precautions to avoid all hazards in the work area petent and authorized persons. must be taken by the user before and during opera- •...

  • Page 16: Machine Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection OPERATION • Do not operate this machine until the inspections General and functional checks as specified in Section 2 of this manual have been performed. • Machine operation requires your full attention. Bring the machine to a full stop before using any device, •...

  • Page 17: Trip And Fall Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not allow personnel to tamper with or operate • Persons under the influence of drugs or alcohol or the machine from the ground with personnel in the who are subject to seizures, dizziness or loss of phys- platform, except in an emergency.

  • Page 18: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates Electrocution Hazards are closed and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current.

  • Page 19: Minimum Approach Distances (M.a.d.)

    SECTION 1 - SAFETY PRECAUTIONS • Maintain distance from electrical lines, apparatus, or tional clearance is required for every additional any energized (exposed or insulated) parts accord- 30,000 volts or less. ing to the Minimum Approach Distance (MAD) as • The minimum approach distance may be reduced if shown in Table 1-1.

  • Page 20: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • Never exceed the maximum work load as specified on the platform. Keep all loads within the confines of • The user must be familiar with the surface before the platform, unless authorized by JLG. driving.
  • Page 21 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S). Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 22: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Under all travel conditions, the operator must limit travel speed according to conditions of ground sur- • Approved head gear must be worn by all operating face, congestion, visibility, slope, location of person- and ground personnel.

  • Page 23: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lift- This sub-section contains general safety precautions ing, or hauling. which must be observed during maintenance of this machine. Additional precautions to be observed dur- •...
  • Page 24 SECTION 1 - SAFETY PRECAUTIONS • Always relieve hydraulic pressure from all hydraulic • When performing welding or metal cutting opera- circuits before loosening or removing hydraulic tions, precautions must be taken to protect the components. chassis from direct exposure to weld and metal cut- ting spatter.

  • Page 25: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electri- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND cal components or when performing welding on the CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA machine.
  • Page 26 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 27: Section 2 - Preparation And Inspection

    SECTION 2 - PREPARATION AND INSPECTION SECTION 2. PREPARATION AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, The aerial platform is a personnel handling device; so it obstacles, depressions, holes, and drop-offs exist. is necessary that it be operated and maintained only by 7.

  • Page 28: Maintenance

    SECTION 2 - PREPARATION AND INSPECTION 2.2 PREPARATION, INSPECTION, AND MAINTENANCE The following table covers the periodic machine JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS inspections and maintenance required by JLG Indus- A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING tries, Inc.
  • Page 29 SECTION 2 - PREPARATION AND INSPECTION Table 2-1.Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Before using each day; or User or Operator User or Operator Operation and Safety Manual whenever there’s an Operator change. Pre-Delivery Inspection (See Before each sale, lease, or rental delivery.

  • Page 30: Pre-Start Inspection

    SECTION 2 - PREPARATION AND INSPECTION Pre-Start Inspection enclosed in the weather resistant storage con- tainer. The Pre-Start Inspection should include each of the fol- 5. Walk-Around Inspection – Refer to Figure 2-1. lowing: 6. Battery – Charge as required. 1.
  • Page 31 SECTION 2 - PREPARATION AND INSPECTION IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAIN- TENANCE PERSONNEL. 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).

  • Page 32: Daily Walk-Around Inspection

    SECTION 2 - PREPARATION AND INSPECTION Daily Walk-Around Inspection 2. Platform/Remote Control Station - Switches and levers return to neutral, decals/placards secure and General legible, control markings legible. Begin the "Walk-Around Inspection" at Item 1, as noted 3. Platform Rotator & Machine Bubble Level - See on the diagram.

  • Page 33: Daily Walk-Around Inspection

    SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection 3121637 – JLG Lift –...

  • Page 34: Function Check

    SECTION 2 - PREPARATION AND INSPECTION Function Check e. Ensure all machine functions are disabled when Emergency Stop Button is pushed in. f. Ensure main lift down, tower lift down, and jib lift down, work properly when using the emer- ENSURE NO FUNCTIONS (EXCEPT TRACK FUNCTIONS) OPERATE WHEN gency lowering controls.

  • Page 35: Skyguard™ Sensor And Override Switch

    SECTION 2 - PREPARATION AND INSPECTION 1. SkyGuard™ Sensor 2. SkyGuard™ Override Switch (button number 8) Figure 2-2. SkyGuard™ Sensor and Override Switch Location 3121637 – JLG Lift –...
  • Page 36 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 37: 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) 3121637 – JLG Lift –...
  • Page 38 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Basic Machine Nomenclature 1. Main Boom 12. Track and Outrigger Valves/Manual Controls - (Under Cover) 2. Tower Boom Assembly 13. Jib 3. Gas or Diesel Engine 14. Platform Ladder 4. Outriggers (4 places) 15.

  • Page 39: Ground Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION GROUND CONTROL STATION Before operating the Ground Control Station, determine which control valve is installed on your machine. If your ground control station looks like this with the (RED) If your ground control station looks like this with the Function Enable Lever on the left side of the valve set, See (BLACK) Function Enable Knob on the right side of the valve “Ground Control Station - With Enable Lever”...

  • Page 40: Ground Control Station - With Enable Lever

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Ground Control Station - With Enable Lever 3. Platform/Ground/Remote Select Switch This three position selector switch provides power See Figure 3-4., Ground Control Station - with Enable Lever to the platform when in the center (neutral) posi- tion.
  • Page 41 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 5. Function Enable Light 10. Main Boom Telescope Control Illuminates when outriggers are properly set and Provides extension and retraction of the main boom functions are allowed. Not illuminated indi- boom section. cates outriggers are not properly set and boom 11.

  • Page 42: 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 – 3121637...

  • Page 43: Ground Control Station - With Enable Knob

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Ground Control Station - With Enable Knob form (remote) control box may be connected to the ground/maintenance cable port located in the See Figure 3-5., Ground Control Station - with Enable Knob electrical components compartment and operated from the ground.
  • Page 44 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 5. Platform Level Control 8. Telescope Control Provides for positioning the platform up and down Provides extension and retraction of the main to adjust the level of the platform. boom section. 9. Main Boom Lift Control Provides raising and lowering of the main boom ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT section.

  • Page 45: Ground Control Station - With Enable Knob

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-5. Ground Control Station - with Enable Knob 3121637 – JLG Lift –...

  • Page 46: Platform/Remote Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION PLATFORM/REMOTE CONTROL STATION NOTE: Before removing or connecting the platform flex cable connector plug from the control box, depress the emergency stop buttons and the key on the engine Maintenance Control Position On The Ground must be in the OFF position.

  • Page 47: Platform/Remote Control Position From The Ground

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION control station to the ground/remote cable connector. This key switch overrides the footswitch in the platform. WHEN CONTROLLING THE MACHINE FROM THE GROUND POSITION, KEEP A DISTANCE OF AT LEAST 3 FT. (1 M) FROM THE TRACKS. ALWAYS BE CERTAIN THE COMPONENT THAT IS BEING MOVED IS COM- TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL PLETELY VISIBLE AND CONSTANTLY CHECK ITS TRAJECTORY.
  • Page 48 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 2. In the platform, slide the control station assembly into the storage box, on the right side of the con- trol station ensure the attached flexible cable slides into the slot in the box. Now place the rib on the right side of the control station assembly under the metal tab attached to the storage box assembly...
  • Page 49 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform/Remote Control Station Functions 1. Outrigger - Automatic Retract This control allows the operator to control the Footswitch (see photo below) retraction of all 4 outriggers at one time. To operate any function, the footswitch must be 2.
  • Page 50 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 8. Override/Selector 12. Electric Engine Start If the machine is driven into a tilt condition, this This button allows the operator to start or stop the button may be pressed to override the drive cut- electric engine.

  • Page 51: Platform/Remote Control Station

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-6. Platform/Remote Control Station 3121637 – JLG Lift – 3-15...
  • Page 52 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION 15. Left Side Track Drive And Steer 20. Jib This control when moved forward or rearward This control allows the operator to raise and lower simultaneously with the right side track control the jib.

  • Page 53: Machine

    SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Platform/Remote Control Station LCD Display Position 1 Not Used. At machine start-up and during machine operation the main LCD display screen (item 14 - Figure 3-6.) is activated. There are eight (8) display positions which indicate machine status during various stages of operation.
  • Page 54 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Position 7 Can indicate any of the following situations: Position 5 Displays that the outriggers are properly set and boom functions are allowed. No display • An emergency stop is pushed in (off). indicates that the outriggers are not prop- •...
  • Page 55 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 3121637 – JLG Lift – 3-19...
  • Page 56 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions 3-20 – JLG Lift – 3121637...
  • Page 57 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions (Continued) 3121637 – JLG Lift – 3-21...
  • Page 58 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2. LCD Display Error Descriptions 3-22 – JLG Lift – 3121637...
  • Page 59 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 60: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION BOOM OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a hydraulic personnel lift equipped with a work platform on the end of an elevating and rotating Capacities boom. The boom can be raised from the transport position with or The primary operator control station is in the platform.

  • Page 61: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION NOTE: Before operating the Ground/Emergency Control box, determine which box is installed on your machine. Although the controls work the same they are config- ured slightly different. (See Figure 4-1. and Figure 4-2.) NOTE: Initial starting must always be performed from the ground controls.

  • Page 62: Gas Engine Shutdown Procedure

    SECTION 4 - MACHINE OPERATION NOTE: At low temperatures start the motor and let it run for a few minutes, until the hydraulic oil circulates and reaches at least 50°F (10°C) before operating the plat- form. Gas Engine Shutdown Procedure 1.

  • Page 63: Ac Voltage Machine

    SECTION 4 - MACHINE OPERATION Electric Engine Starting Procedure - AC Voltage Machine ENSURE THE ELECTRICAL CIRCUIT BEING USED IS THE SAME VOLTAGE AND FREQUENCY INDICATED ON THE ELECTRIC ENGINE PLATE. USE AN AC EXTENSION CORD WITH SUFFICIENT AMPERAGE CAPACITY TO PROP- ERLY POWER THE MACHINE.

  • Page 64: Lithium-Ion Machine

    SECTION 4 - MACHINE OPERATION Electric Engine Starting Procedure - LITHIUM-ION Machine 1. Set the ON/OFF switch on the lithium-ion battery pack to the ON position, (0 symbol is OFF, 1 is ON). 2. The electric engine will auto start when a function is activated at the platform or ground control sta- Figure 4-3.

  • Page 65: Base And Boom/Jib Alignment

    SECTION 4 - MACHINE OPERATION BASE AND BOOM/JIB ALIGNMENT The machine has two reflectors/photocells that check if the boom assembly is completely lowered and retracted, the jib is lowered, and the turntable is aligned with the base. (see photos) When these conditions are met this symbol will display in position (6) on the Platform/ Remote Control LCD display.

  • Page 66: Tracks - Driving, Steering And Track Width Adjust

    SECTION 4 - MACHINE OPERATION TRACKS - DRIVING, STEERING AND TRACK WIDTH Travelling (Drive and Steer) ADJUST USE EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TERRAIN OBSTACLE. CHECK FOR CURBS, LARGE STONES, OR OTHER TERRAIN KEEP EVERYONE A DISTANCE OF AT LEAST 3 FT. (1M) FROM THE MACHINE OBSTACLES INCLUDING OVERHEAD OBSTACLES AS THE MACHINE WILL WHEN OPERATING THE TRACKS.
  • Page 67 SECTION 4 - MACHINE OPERATION WHEN DRIVING ON SIDE-SLOPES, EXTEND THE LOW SIDE OUTRIGGERS machine as it could cause machine tipping with consequent UNTIL THEY ARE CLOSE TO THE GROUND TO HELP PREVENT A TIP-OVER danger for operator or people nearby the machine. IF A CHANGE IN SURFACE OCCURS.

  • Page 68: Grade And Side Slope Definition

    SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Side Slope Definition 3121637 – JLG Lift –...

  • Page 69: Jib Position For Travelling

    SECTION 4 - MACHINE OPERATION Jib Position for Travelling NOTE: The aerial part safety device by-pass key must not have been activated after the machine has been It is necessary to raise the JIB arm when driving up or down closed and aligned.

  • Page 70: Outrigger Operation

    SECTION 4 - MACHINE OPERATION After these conditions have been met, make sure that there OUTRIGGER OPERATION are no obstacles in the Jib working area and operate as fol- lows: • Activate the joystick for moving the JIB arm. If a different BE CERTAIN THAT THE OUTRIGGER PADS ARE SET ON A FIRM AND HORI- joystick is activated an error message will appear on the ZONTAL SURFACE.
  • Page 71 SECTION 4 - MACHINE OPERATION If the functions are selected when one of the above listed conditions is missing, an error message will appear on the platform/remote control display indicating which of the conditions are OK and which are not. If the condition is that an outrigger is not set properly, the message will also indi- cate which outrigger is not set properly.

  • Page 72: Setting Outriggers From The Platform/Remote Console

    SECTION 4 - MACHINE OPERATION Setting Outriggers From the Platform/Remote Console (Reference Figure 4-5. for item numbers) CHECK THE BUBBLE LEVEL TO CONFIRM UNIT IS LEVEL (BUBBLE IS COM- PLETELY IN THE 1° GREEN (CENTER) AREA) AND THAT THE TRACKS ARE Either - Press and hold the outrigger auto- set and level button 7 (item 7) until OK OFF THE GROUND BEFORE OPERATING THE BOOM FUNCTIONS.

  • Page 73: Retracting The Outriggers

    SECTION 4 - MACHINE OPERATION Retracting The Outriggers (Reference Figure 4-5. for item numbers) IF ONE OF THE ORANGE LIGHTS LOCATED ON EACH OUTRIGGER SHOULD Either - Press and hold button no. 1 (item REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE GROUND, 1) of the remote control.

  • Page 74: Boom/Platform Operation

    SECTION 4 - MACHINE OPERATION BOOM/PLATFORM OPERATION TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT THE BOOM WILL NOT OPERATE UNTIL THE OUTRIGGERS ARE PROPERLY RETURN TO THE 'OFF' OR NEUTRAL POSITION WHEN RELEASED. SET AND MACHINE IS LEVELED.

  • Page 75: Platform/Remote Control Box

    SECTION 4 - MACHINE OPERATION Figure 4-5. Platform/Remote Control Box 4-16 – JLG Lift – 3121637...

  • Page 76: Raise And Lower The Tower Boom

    SECTION 4 - MACHINE OPERATION • To manually Level Down, turn the select switch counter • To retract the main boom, depress the foot switch and clockwise and hold until desired position is reached. move the controller forward. (Item 19, Figure 4-5.) Platform Rotation •...

  • Page 77: Platform - Load/Reach Chart - X600Aj

    SECTION 4 - MACHINE OPERATION Figure 4-6. Platform - Load/Reach Chart - X600AJ 4-18 – JLG Lift – 3121637...

  • Page 78: Skyguard Operation (If Equipped)

    SECTION 4 - MACHINE OPERATION SkyGuard Operation (If Equipped) The SkyGuard™ feature is used to provide enhanced control panel protection. When the SkyGuard™ sensor is activated, functions that were in use at the time of actuation will reverse or cutout and the ground alarm will beep.

  • Page 79: Platform Removal/Installation

    SECTION 4 - MACHINE OPERATION PLATFORM REMOVAL/INSTALLATION Platform Installation 1. Lift the platform and align the platform mounts The platform may only be removed to allow passage with the jib mounting posts and lower until through areas measuring a minimum of 39 in. (99cm). seated.

  • Page 80: Battery Charging - Gas/Ac-Electric

    SECTION 4 - MACHINE OPERATION BATTERY CHARGING - GAS/AC-ELECTRIC Battery Charging - Daily NOTE: Be sure that the machine is parked in a well ventilated area free of flames and sparks. BEFORE CONNECTING THE BUILT-IN CHARGER TO THE RECEPTACLE, • Only plug the charger into a properly grounded outlet. ENSURE THE KEY ON THE ENGINE IS POSITIONED TO OFF.

  • Page 81: 4.10 Battery Charging - Lithium-Ion Machine

    SECTION 4 - MACHINE OPERATION 4.10 BATTERY CHARGING - LITHIUM-ION MACHINE Charging the Battery Pack To check the battery condition on the lithium ION equipped machine, power up the machine and use the special indicator shown DO NOT LEAVE THE MACHINE IN CONTINUOUS CHARGING FOR TIME at position 8 on the platform control station PERIODS EXCEEDING 24 HOURS.
  • Page 82 SECTION 4 - MACHINE OPERATION • 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 4 on the platform station LCD dis- play. To start charging the battery connect the main AC power supply to the AC socket (item 1 - photo) located on the right rear of the machine next to the electric engine.

  • Page 83: Charge Curve

    SECTION 4 - MACHINE OPERATION case, contact an electrician to have the socket replaced. Do not use adapters to resolve ungrounded circuit plug problems. THE BATTERY CHARGER SUPPLIED WITH THE LIFT WAS DESIGNED TO ENSURE SAFE AND RELIABLE PERFORMANCE. IT IS ALREADY FITTED ON •...

  • Page 84: 4.11 Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 7. If machine is to be shut down for long periods of time, turn the battery disconnect switch, RED han- dle located on the electrical/battery tray housing, to the POWER OFF position. (photos below and WHEN PARKING THE MACHINE ON A SLOPE OR UNEVEN GROUND WITH next page) THE OUTRIGGERS RETRACTED, PARK WITH THE TRACKS IN THE FULLY...

  • Page 85: 4.12 Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.12 LIFTING AND TIE DOWN POWER ON Lifting - Outrigger Lifting Rings Clockwise 1. Determine gross weight of machine, refer to the serial number tag, or weigh the individual unit to find out the gross vehicle weight. 2.

  • Page 86: Lifting Machine - Lifting Lugs Location

    SECTION 4 - MACHINE OPERATION LIFTING POINTS AS INDICATED IN FIGURE 4-8. OTHERWISE THE MACHINE MAY NOT BALANCE PROPERLY AND MOVE UNEXPECTEDLY. THE USE OF ROPES, CHAINS OR SLINGS WITH LENGTH LESS THAN 10 ft. (3m) COULD CAUSE PERMANENT DAMAGE TO THE MACHINE OUTRIG- GERS.

  • Page 87: Lifting Machine - Lifting Bar Rigging

    SECTION 4 - MACHINE OPERATION Figure 4-9. Lifting Machine - Lifting Bar Rigging 4-28 – JLG Lift – 3121637...

  • Page 88: Lifting - Fork Lift Pockets

    SECTION 4 - MACHINE OPERATION Lifting - Fork Lift Pockets The machine is equipped with two tubular fork lift pockets designed to lift the machine using a forklift of suitable capacity. 1. Determine gross weight of machine, refer to the serial number tag, or weigh the individual unit to find out the gross vehicle weight.

  • Page 89: Loading And Unloading The Machine On Transport Vehicles Using Ramps

    SECTION 4 - MACHINE OPERATION Loading and Unloading the Machine on Transport • Make sure that the ramps do not exceed the maximum inclination of 15°; Vehicles Using Ramps • Make sure that the ramps and the trailer have the capac- ity to support the machine and are free from debris or slippery material;...

  • Page 90: Tie Down

    SECTION 4 - MACHINE OPERATION Tie Down 1. Configure the machine to the transport position; a. place the booms in the stowed position and (See Figure 4-11.) properly aligned b. all outriggers are fully retracted c. tracks are fully widened WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOW- d.
  • Page 91 SECTION 4 - MACHINE OPERATION 1701499 1703814A 1701499 1703814A Figure 4-11. Machine Tie-Down Points (both sides of machine) 1. Tie-Down Loop 2. Tie-Down Decal 4-32 – JLG Lift – 3121637...

  • Page 92: 4.13 Machine Decals

    SECTION 4 - MACHINE OPERATION 4.13 MACHINE DECALS Figure 4-12. Decal installation - Standard - Left Side 3121637 – JLG Lift – 4-33...

  • Page 93: Decal Installation - Standard - Right Side

    SECTION 4 - MACHINE OPERATION 32 32 GASOLINE Figure 4-13. Decal Installation - Standard - Right Side 4-34 – JLG Lift – 3121637...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-2. X600AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION DECAL INSTALLATION 06555500 Decal, Outrigger Number 1 06555600 Decal, Outrigger Number 2 06555700 Decal, Outrigger Number 3 06555800 Decal, Outrigger Number 4 1001125483...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-2. X600AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION 1701542 Decal, Gasoline Fuel Only 1701505 Decal, Diesel Fuel Only 06056300 Decal, Burn Hazard 06232100 Decal, Danger - Flammable - Gasoline 07240300 Decal, Keep 3 ft./1m Away When Operating With Tele /Radio Commands 07320400...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-2. X600AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION 07042100 Decal, Boom Bypass System 07042200 Decal, Track Bypass System 1702901 Decal, Instructions For Emergency Manual Pump 3252347 Decal, Pedal 1706128...

  • Page 97: Decal Installation - Lithium-Ion - Left Side

    SECTION 4 - MACHINE OPERATION Figure 4-14. Decal installation - Lithium-Ion - Left Side 4-38 – JLG Lift – 3121637...

  • Page 98: Decal Installation - Lithium-Ion - Right Side

    SECTION 4 - MACHINE OPERATION Figure 4-15. Decal Installation - Lithium-Ion - Right Side 3121637 – JLG Lift – 4-39...

  • Page 99: X600Aj - Decal Installation - Lithium

    SECTION 4 - MACHINE OPERATION Table 4-3. X600AJ - Decal Installation - Lithium Machine (See Figure 4-14. and Figure 4-15.) 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 06520600 Decal, Sound - 88 dB 07107100...
  • Page 100 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 101: Section 5 - Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 10 FT. (3M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND This section explains the steps to be taken in case of an THAT ALL CONTROLS ARE OPERATING CORRECTLY.

  • Page 102: Operator Unable To Control Machine

    SECTION 5 - EMERGENCY PROCEDURES Operator Unable to Control Machine Manual Descent with Engine Running and Electrical Power IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE: 1. Other personnel should operate the machine from ENSURE BOOM IS NOT POSITIONED OVER THE OUTRIGGERS OR OVER- ground controls only as required.
  • Page 103 SECTION 5 - EMERGENCY PROCEDURES Figure 5-1. Platform/Remote Control Station 3121637 – JLG Lift –...
  • Page 104 SECTION 5 - EMERGENCY PROCEDURES Using Emergency/Ground Controls from Ground 4. Check that the green (machine stabilized) indicator light on the Emergency/Ground Control box is on. NOTE: See Section 3.1 on page 3-3 to determine which 5. Operate the appropriate manual control lever next Ground Control Station is equipped on your machine.

  • Page 105: Ground Control Station

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-2. Ground Control Station - with Enable Lever 3121637 – JLG Lift –...

  • Page 106: Ground Control Station

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-3. Ground Control Station - Boom Control Valve - with Enable Knob – JLG Lift – 3121637...
  • Page 107 SECTION 5 - EMERGENCY PROCEDURES Manual Descent with Engine Running but without NOTE: The distributor enable valve adjusts the speed of the boom movements (pressure flow) when using the Electrical Power boom control valves at the valve distributor. Without (Combustion Engines Only) electrical power you must manually open this valve by (See Figure 5-2.
  • Page 108 SECTION 5 - EMERGENCY PROCEDURES Manual Descent without Engine and Electrical Power Using Hand Pump Mounted to Hydraulic Tank on Right side of Machine Platform Retrieval Sequence 1. Ensure the machine is level and all outriggers are properly deployed on a firm surface. If outrigger movement is required first, See “Outrigger/Track Movement Emergency Procedure:”...
  • Page 109 SECTION 5 - EMERGENCY PROCEDURES nel at the pump and eliminate the risk of lowering the jib onto an outrigger. NEVER WORK UNDER AN ELEVATED PLATFORM UNTIL PLATFORM HAS a. Depress the enable valve lever/button (Figure 5- BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR 2.
  • Page 110 SECTION 5 - EMERGENCY PROCEDURES 5. Lowering the Tower Boom (if necessary). Outrigger/Track Movement Emergency Procedure: While pumping the handpump, activate the tower Outrigger/Track Movement Using the Hydraulic Hand boom lift function lever (Figure 5-2. or Figure 5-3.) Pump on Right Side of Machine the appropriate direction to lower the tower boom.
  • Page 111 SECTION 5 - EMERGENCY PROCEDURES machine, secure in place with the provided screw. 7. With the aid of an assistant, activate the lever up or (item 3 - Figure 5-4.) down for the desired direction on the appropriate valve solenoid while pumping the handle to 4.
  • Page 112 SECTION 5 - EMERGENCY PROCEDURES • 4th valve (item 5 - Figure 5-6.) • 1st valve (item 7 - Figure 5-6.) (far from left in the group of four, right-right side of machine in operates track extension and the group of three) operates retraction.

  • Page 113: Ground Component Valves - Outriggers

    SECTION 5 - EMERGENCY PROCEDURES Figure 5-6. Ground Component Valves - Outriggers/Track Control - Location 3121637 – JLG Lift – 5-13...
  • Page 114 SECTION 5 - EMERGENCY PROCEDURES SAFETY DEVICES BYPASS KEY USE Remove the key and insert it into the bypass key switch (item 2 - photo). THIS FEATURE MUST ONLY BE USED AS DESCRIBED BELOW. THE MACHINE COULD TIP OVER IF THESE DIRECTIONS ARE NOT FOLLOWED. The machine requires a key for bypassing the platform safety systems.
  • Page 115 SECTION 5 - EMERGENCY PROCEDURES Using The Emergency Descent In The Case Of An Outrigger 4. Operate the machine from the platform/remote control ONLY carrying out operations that allow Losing Contact With The Ground the tower boom lowering, main boom retract and One or more of the outriggers may loose contact with the jib lowering.
  • Page 116 SECTION 5 - EMERGENCY PROCEDURES Machine Realignment Emergency Procedure Movement Of The Tracks With The Machine Not Aligned: OPERATION ONLY ALLOWED TO GO TO A CONDITION THIS OPERATION MUST ONLY BE PERFORMED WITH THE SUITABLE TO CARRY OUT THE PROCEDURE INDICATED IN BOOMS AND JIB FULLY LOWERED AND RETRACTED.
  • Page 117 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 118 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SECTION 6. GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE INTRODUCTION This section of the manual provides additional necessary IT IS GOOD PRACTICE TO AVOID PRESSURE-WASHING ELECTRICAL/ELEC- information to the operator for proper operation and main- TRONIC COMPONENTS.

  • Page 119: Operating Specifications

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE OPERATING SPECIFICATIONS Dimensional Data Table 6-2. Dimensional Data Table 6-1. Operating Specifications Model X600AJ Model X600AJ Overall Width (with platform removed-tracks 31.29 in. (80cm) Maximum work load (capacity) 500 lb. (230 kg) retracted) Max.

  • Page 120: Chassis Data

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Chassis Table 6-3. Chassis Data Table 6-3. Chassis Data Model X600AJ Gross machine weight (platform empty) Model X600AJ Gas Engine: 6,350 lb. (2880 kg) Maximum Travel Grade w/ boom in stowed position 15°...

  • Page 121: Engine Data

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Data Lithium-Ion Specifications Table 6-5. Honda iGX440 Specifications Table 6-6. Lithium Ion Specifications Model X600AJ Model X600AJ Type Gasoline/Air cooled Battery Pack Number of cylinders No. of cells in the battery pack: 22 cells Displacement 27 cu.
  • Page 122 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Machine Major Component Weights Performance Table 6-7. Major Component Weights Table 6-8. Function Speeds Model X600AJ X600AJ FUNCTION TIME (SECONDS) Engine (tank full) Gasoline: 86 lb. (39 kg) Telescope Extend: 21 - 28 Retract: 16 - 20 Lithium Ion Battery Pack (72V)

  • Page 123: Service & Maintenance

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE SERVICE/MAINTENANCE 0 , 5 0 , 5 0 , 5 0 , 5 0 , 5 0 , 5 M= ENGINE OIL T = TRANSMISSION OIL M=OLIO MOTORE I = HYDRAULIC OIL T=OLIO TRASMISSIONE I=OLIO IDRAULICO G = GREASE...

  • Page 124: Hydraulic Oil Specifications

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Recommended Gearbox Oils 600 XP 150 FOLLOW THE LUBRICATION INTERVALS INDICATED AND USE ONLY THE EP 150 RECOMMENDED LUBRICANTS IN ORDER TO PROTECT PINS AND CONNEC- TIONS FROM WEAR. Blasia 150 Spartan EP150 Lubrication (See Figure 6-1.) Engine Oil...

  • Page 125: Hydraulic Oil Specifications

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Hydraulic Oil Specifications Figure 6-2. 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.
  • Page 126 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-3. Hydraulic Oil Operating Temperatures 3121637 – JLG Lift –...

  • Page 127: Component Maintenance Intervals

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE HONDA GAS ENGINE INTERVAL (HOURS) BEFORE PART INTERVENTION NEEDED STARTING 500 1000 • CHECK, CLEAN DRY AIR FILTER • CHANGE • • CHECK LEVEL ENGINE OIL • • CHANGE • OIL SUMP CLEAN •...

  • Page 128: Component Maintenance Intervals - X600Aj - Lithium-Ion Machine

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE LITHIUM-ION INTERVAL (HOURS) MACHINE MAINTENANCE BEFORE PART AS NEEDED WORK STARTING 500 1000 • CHECK LEVEL HYDRAULIC OIL • CHANGE HYDRAULIC OIL REPLACE • • FILTER CARTRIDGE SERV... ARTICULATE • • GREASING JOINT POINTS •...
  • Page 129 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Air Filter Engine Oil Honda Honda DIPSTICK UPPER LIMIT Lube Point(s) - Replaceable Paper Element, or Foam Filter Lube Point(s) - Fill Cap/Dip Stick Tube Element Capacity - Gasoline 0.3 gal (1.1L) Interval - Check daily.
  • Page 130 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Engine Fuel Filter/Sediment Bowl (if equipped) Hydraulic Oil Honda Interval - Clean or replace every 500 hours Lube Point(s) - Fill Cap Capacity - 6.6 gallons (25 liters) Interval - Check level daily. Change every two years or 1200 hours of operation NOTE: Hydraulic oil levels are to be checked with the machine in transport position while on a firm, level...
  • Page 131 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Hydraulic Oil Filter Cartridge Rubber Track Maintenance/Replacement Check track tension Stop the machine on a firm, level, and uniform surface. Raise the machine off the surface using the outriggers. Measure distance A from the bottom of the roller to the inside of the rubber belt.
  • Page 132 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 1. Ensure all debris has been removed between the Tightening of the track wheel teeth and track links. • Connect a grease gun to grease valve (2) and add grease 2. Remove the screws from the adjustment access lid until belt tension is within the specified values.

  • Page 133: Worn Parts

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE • If metal cores are separating discontinue use of the 1. Elevate the machine on firm, level and uniform sur- machine until the damaged components are replaced. face utilizing the outriggers. 2. Remove the screws and remove cover 3 as shown in figure.
  • Page 134 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Wear Pad Inspection Check for distance between wear pads and boom sections. Distance is to be no more than 1/32nd inch. Turntable Attach Bolts Ensure the bolts of the coupling elements (turntable) are torqued to 183 ft-lb.
  • Page 135 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Battery Maintenance and Charging - Gas/AC-Electric 4. When charging is completed turn off the battery charger before disconnecting the cables from the NOTE: The battery is a maintenance free battery. Do NOT battery poles attempt to open a maintenance-free sealed battery.

  • Page 136: Electric Motor Maintenance

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE ELECTRIC MOTOR MAINTENANCE • FAN Keep air intakes clean and make sure the fan can rotate Periodically check the condition of the following electric freely. motor components. • BEARINGS Electric Motor Check the condition of the bearings, in the event of The electric motor is located inside of the rear hydraulic noise contact JLG for replacement, the life of the bear- valve distributor support cover.
  • Page 137 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE PLATFORM/REMOTE CONTROL SERVICE MENU 1 - INPUT 2 - LANGUAGE Service Button A SERVICE button is present on the remote control which 3 - ERRORS allows to view the status of the machine parameters and is 4 - RAMPS an aid in the safety checks of the machine.

  • Page 138: Menu Input

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Menu Input 1 - PREV - access the previous input 2 - NEXT - access the successive input The signals that arrive at the board from the various sensors mounted on the machine and from the platform/remote 9 - ESC - escape from the INPUT menu control commands are displayed.
  • Page 139 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Do not consider ST2 OPEN A Do not consider Do not consider ST2 OPEN B Do not consider Outrigger N° 3 on the ground – the switch is released and A line is closed ST3 GND A Outrigger N°...
  • Page 140 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Outrigger N 4 lifted the switch is pressed and B line is opened Do not consider ST4 OPEN A Do not consider Do not consider ST4 OPEN B Do not consider The aerial part safeties are disconnected through the key button (emergency condition) –...
  • Page 141 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE The ground part safeties are disconnected through the key button (emergency condition)– “B” line of the ground part safeties by-pass button is closed. BYPASCB B The ground part safeties are connected (normal working condition) – “B” line of the ground part safeties by-pass button is opened Emergency stop on the ground is released –“A”...
  • Page 142 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Turret is not almost completely rotated, contact is close, the 1 arm is not above the engine PROXIMITY Turret is almost completely rotated, contact is open, the 1 arm is above the engine The stop button on ground remote control is released.
  • Page 143 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE TEMP ALRM B The temperature external probe reached the maximum value – “B” line of the Option reserved for some temperature probe is closed markets The temperature external probe hasn’t reached the maximum value – “B” line of the temperature probe is open The switch of 1-2 arm position is released, contact is close, the 1 arm is open...
  • Page 144 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE The ground button for engine start is pressed START M.TE The ground button for engine start is released The engine reached the max functioning temperature (emergency condition – the MOTOR TEMP engine remains at min) To consider only for X20JP The engine maintains the correct functioning temperature (normal working - X600AJ...
  • Page 145 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE The pedal is pressed– the pedal electric line is closed PEDAL The pedal is released – the pedal electric line is open FREE B Do not consider this signal The stop button on remote control in basket is released – “A” line is closed EM.BASK.A The stop button on remote control in basket is pressed or the ground remote control is disconnected –...
  • Page 146 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Do not consider POSM2 B Do not consider Do not consider POSM3 A Do not consider Do not consider POSM3 B Do not consider Do not consider POSM4 A Do not consider Do not consider POSM4 B Do not consider...
  • Page 147 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Indicates the inclination of the machine on the X axis in tenth of degrees INCLIN. X (accelerometer A) Indicates the inclination of the machine on the X axis in tenth of degrees (accel B) Indicates the inclination of the machine on the Y axis in tenth of degrees (accelerom- eter A) INCLIN.
  • Page 148 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Indicates (in tenth of mA) the current ECM1-2 is sending to the aerial part CURRENT A proportional valve or to the left-side undercarriage proportional valve (values less that 5 not relevant) Indicates (in tenth of mA) the current ECM1-2 is sending to the right-side CURRENT B 45,3 undercarriage proportional valve (values less that 5 not relevant)
  • Page 149 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Errors Menu Working Hours Menu Indicates the agreement (OK) or not (FAULT) status of the Indicates the number of machine working hours. sensors that have a double control. Set-up Menu The sensors are listed on different screens use: The items in this menu cannot normally be accessed.

  • Page 150: Lithium Ion

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE LITHIUM-ION MACHINE ONLY - ADDITIONAL • Cleaning the electrical system; MAINTAINANCE INFORMATION Cleaning the Machine NEVER CLEAN THE INVERTER OR THE ELECTRIC MOTOR WITH WATER, AS THIS MAY CAUSE DAMAGE TO THE ELECTRICAL SYSTEM. WHEN WASHING THE MACHINE, THE MAIN POWER SWITCH MUST BE DISENGAGED, THE KEY REMOVED AND THE EMERGENCY STOP BUTTON Only use dry detergents, in accordance with the manufacturers’...

  • Page 151: 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 – 3121637...
  • Page 152 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE WHEN RECHARGING THE BATTERY PACK AND DURING ANY OTHER MAIN- 1. Battery Case Cover TENANCE OPERATION ON THE BATTERY PACK, IT IS NECESSARY TO USE 2. External Main Contactor AT LEAST THE PERSONAL PROTECTIVE EQUIPMENT (PPE) LISTED BELOW. 3.
  • Page 153 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Lithium-Ion Machine Fault Codes Table 6-10. Inverter Fault Codes (See “Errors Menu” on page 6-32 info for display information) CODE DESCRIPTION Table 6-10. Inverter Fault Codes Logic failure #1 Cause – Sudden voltage surge or voltage drop. CODE DESCRIPTION Solution –...
  • Page 154 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-10. Inverter Fault Codes Table 6-10. Inverter Fault Codes CODE DESCRIPTION CODE DESCRIPTION STBY I high Thermis sensor KO Cause – Internal fault detected in the inverter. Cause – Signal from temperature sensor greater than 4.95 Volts or less Solution –...
  • Page 155 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-10. Inverter Fault Codes CODE DESCRIPTION Incorrect start Cause – Incorrect starting procedure. Solution – Check electrical connections. This is generally a temporary problem due to certain working conditions. If problem persists, replace inverter.
  • Page 156 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE BMS Fault Codes - (Battery Management System) A99E03 – Incorrect temperature A99E04 – Excess discharge current (See “Errors Menu” on page 6-32 info for display information) A99E05 – Excess charge current NOTE: The CODE column indicates the CAN CODE in the mes- sage sent by the battery charger.

  • Page 157: Battery Charger Fault Codes

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Battery Charger Fault Codes (See “Errors Menu” on page 6-32 info for display information) Table 6-11. Battery Charger Fault Codes CODE DESCRIPTION STATUS ACTION Internal logic fault. Battery charger stops working. Contact service dept. or change product. Communication pro.blem with external memory.
  • Page 158 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Table 6-11. Battery Charger Fault Codes CODE DESCRIPTION STATUS ACTION Stage 1 ended by timeout without reaching control Battery charger stops working. Make sure battery capacity is compatible or check voltage. that battery is compliant with battery charger. If bat- tery is correct and problem persi.sts, contact service dept.

  • Page 159: Procedure For Handling Hot Cells

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE LITHIUM-ION BATTERY PACK - HANDLING IN Procedure For Handling Hot Cells DANGEROUS CONDITIONS As soon as it has been established that the temperature of a cell has risen considerably, the first action is the evacuation The battery cells must be handled correctly in order to of personnel from the affected area.

  • Page 160: Procedure For Handling Vented Cells

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Start Procedure; Procedure For Handling Vented Cells 1. Evacuate the area as soon as abnormal cell tempera- In normal conditions a cell does not show leaks or venting, ture has been established. however a cell may vent or release substances if the critical temperature is reached or if the protective glass.metal seal 2.
  • Page 161 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Start Procedure; First Aid In The Event Of Contact With The Electrolyte In the event of electrolyte release from the cells, proceed as EYES follows: Immediately wash the eyes in abundant running water for 1.

  • Page 162: Procedure For Exploded Cells

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Procedure For Exploded Cells Start Procedure; In the event of cell explosion, proceed as follows: The explosion of lithium batteries is not likely, it is a rare event that only occurs when an abnormal condition causes 1.

  • Page 163: Lithium Battery Fire

    SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 10. Clean the area with plenty of water and keep cleaning Lithium Battery Fire with water and soap. All metals may burn in certain conditions, which depend on 11. Dispose of the hazardous material in accordance with certain factors such as: physical state, presence of oxidizing the local legislation in force.
  • Page 164 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE cells. Larger fires have to be managed only by profession- 3. The fire-fighting personnel go to the area where the ally trained personnel. fire is located and gather all the information regarding the situation and the person who gave the alarm.
  • Page 165 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE 11. Wear safety equipment: coat, gloves, mask and filters. First Aid In The Event Of Contact With The Electrolyte; 12. The area around the cell will be covered by a black car- EYES bonaceous deposit which contains metallic parts of the Immediately wash the eyes in abundant running water for...
  • Page 166 TO PURCHASE THIS PRODUCT PLEASE CONTACT US Equipment Financing and Extended Warranties Available Discount-Equipment.com is your online resource for commercial and industrial quality parts and equipment sales. 561-964-4949 visit us on line @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

Table of Contents