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JLG X770AJ Operation And Safety Manual
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JLG X770AJ Operation And Safety Manual

JLG X770AJ Operation And Safety Manual

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ANSI
ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model(s)
X770AJ
June 29, 2018 - Rev D
3121703

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Summary of Contents for JLG X770AJ

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model(s) X770AJ ANSI ANSI 3121703 ® June 29, 2018 - Rev D...
  • 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 POLICY THAT RELATES DIRECTLY OR INDICATES A POTENTIALITY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY. RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. – JLG Lift – 3121703...
  • Page 6 • Questions Regarding Prod- • Questions Regarding uct Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT Contact : THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
  • Page 7 SECTION - REVISION LOG REVISION LOG Original Issue A - June 9, 2016 Revised B - March 16, 2017 Revised C - April 3, 2018 Revised D - June 29, 2018 - Revised, Prop 65 – JLG Lift – 3121703...
  • Page 8 Diesel Engine Shutdown Procedure ..4-3 2.1 PERSONNEL TRAINING ..... 2-1 3121703 – JLG Lift –...
  • Page 9 Emergency Lowering ..... 4-24 without Electrical Power ....5-8 – JLG Lift – 3121703...
  • Page 10 Engine Oil Filter (if equipped)....6-14 System) ....... 6-30 3121703 – JLG Lift –...
  • Page 11 4-6. Platform/Remote Control Box ... . . 4-21 4-7. Platform - Load/Reach Chart - X770AJ ..4-22 4-8. SkyGuard™ Sensor and Override Switch Location ......4-23 4-9.
  • Page 12 SkyGuard™ Function Table ....4-23 X770AJ - Decal Installation - Standard ..4-36 Operating Specifications....6-2 Dimensional Data .
  • 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 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”). 3121703 – JLG Lift –...
  • Page 15 • 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 • Check the machine for modifications to original components. Ensure that any modifications have • Never slam a control switch or lever through neutral been approved by JLG. to an opposite direction. Always return switch to neutral and stop before moving the switch to the •...
  • Page 17 • 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 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. 3121703 – JLG Lift –...
  • Page 19 • 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 – 3121703...
  • Page 20 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 – 3121703...
  • Page 22 • 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. 3121703 – JLG Lift –...
  • Page 23 • 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 – 3121703...
  • Page 24 • Never attempt to move heavy parts without the aid TURER. of a mechanical device. Do not allow heavy objects to rest in an unstable position. Ensure adequate sup- port is provided when raising components of the machine. 3121703 – JLG Lift – 1-11...
  • Page 25 • 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 – 3121703...
  • 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 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. 3121703 – JLG Lift –...
  • Page 28 JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNI- tions and maintenance required by JLG Industries, Inc. CIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE Consult local regulations for further requirements for TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
  • Page 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. 3121703 – JLG Lift –...
  • Page 30 Inspection is complete, perform a functional check of all systems in an area free of overhead and ground level obstructions. Refer to Section 4 for more specific operating instructions. – JLG Lift – 3121703...
  • Page 31 SONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION. MAKE SURE THE ENGINE KEY SWITCH IS ON, THE BATTERY DISCONNECT SWITCH IS TURNED ON, AND THE POWER/EMERGENCY STOP BUTTONS AT THE GROUND AND PLATFORM CONTROL BOX IS TURNED CLOCKWISE (ON). 3121703 – JLG Lift –...
  • Page 32 See Inspection Note. 2. Platform/Remote & Ground Control Stations - Switches and levers return to neutral, decals/plac- ards secure and legible, control markings legible. 3. Outriggers - See Inspection Note; pads pivot freely. – JLG Lift – 3121703...
  • Page 33 SECTION 2 - PREPARATION AND INSPECTION Figure 2-1. Daily Walk-Around Inspection 3121703 – JLG Lift –...
  • Page 34 Check that all guards protecting the function ™ the SkyGuard sensor is disengaged. control switches and controllers are in place; c. Operate all functions. – JLG Lift – 3121703...
  • Page 35 SECTION 2 - PREPARATION AND INSPECTION 1. SkyGuard™ Sensor 2. SkyGuard™ Override Switch (button number 8) Figure 2-2. SkyGuard™ Sensor and Override Switch Location 3121703 – JLG Lift –...
  • Page 36 @ 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 Figure 3-1. Basic Machine Component Locations 3121703 – JLG Lift –...
  • Page 38 17. Lithium ION - Battery Charger LED Indicator - on top of battery pack (if equipped) 9. Ladder 18. Diesel Engine Compartment or Lithium ION - Bat- tery Pack, Inverter, and Battery Charger Compart- ment (if equipped) – JLG Lift – 3121703...
  • Page 39 A two-position red switch supplies power to PLAT- FORM/GROUND/REMOTE SELECT switch when twisted clockwise to be in the out (on) position. When pushed in (off ), power is shut off to the PLATFORM and GROUND controls. 3121703 – JLG Lift –...
  • Page 40 Provides for positioning the platform up and down 8. Tower Boom Lift Control to adjust the level of the platform. Provides raising and lowering of the tower boom. 9. Main Boom Lift Control Provides raising and lowering of the main boom. – JLG Lift – 3121703...
  • Page 41 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-2. Ground Control Station 3121703 – JLG Lift –...
  • Page 42 DISTANCE OF AT LEAST 6 FT (1.8M) FROM THE TRACKS. Ground control position for the platform/remote control is possible by connecting the platform/remote control station to the (optional) ground/remote control cable (item 1) see photo below. – JLG Lift – 3121703...
  • Page 43 2. In the platform, slide the remote control station assembly into the storage box and place the rib on the right side of the control station assembly 3121703 – JLG Lift –...
  • Page 44 3. Lower remote control station assembly into the remote box is operated from the ground position. storage box, ensure the attached flexible cable slides into the slot also on the right side of the box. – JLG Lift – 3121703...
  • Page 45 (icon extension of all 4 outriggers at one time. on button) or used as numerical keys (per number below the button) when the SERVICE button 6 (item 6) sub-menus is activated on the LCD display. 3121703 – JLG Lift –...
  • Page 46 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Figure 3-3. Platform/Remote Control Station 3-10 – JLG Lift – 3121703...
  • Page 47 If each con- gas/diesel engine. trol is moved individually, different amounts or in opposite directions steering the machine occurs. 13. Electric Engine Start This button allows the operator to start or stop the electric engine. 3121703 – JLG Lift – 3-11...
  • Page 48 23. Right Side Track Drive And Steer This control when moved forward or rearward simultaneously with the left side track control (17), allows the operator to move the machine in a straight forward or reverse direction or, if each 3-12 – JLG Lift – 3121703...
  • Page 49 Displays if selected engine (gas/diesel or outriggers are not contacting the ground. electric) is on or off. The X on the icon indi- cates the engine is off. Position 4 Displays selected engine speed. 3121703 – JLG Lift – 3-13...
  • Page 50 • Lithium ION - Signals an error in the Battery Charger Plugged In. BMS - Battery Management System • Skyguard™ - System Enabled. • Battery cold/heater activated system is enabled. SWING SEN.1 SEN.3 FAIL FAIL CARD 3-14 – JLG Lift – 3121703...
  • Page 51 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions Battery cold/ eater activated ystem enabled 3121703 – JLG Lift – 3-15...
  • Page 52 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-1. LCD Display Icon Descriptions (Continued) 3-16 – JLG Lift – 3121703...
  • Page 53 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2. LCD Display Error Descriptions 3121703 – JLG Lift – 3-17...
  • Page 54 SECTION 3 - MACHINE CONTROLS, INDICATORS AND OPERATION Table 3-2. LCD Display Error Descriptions (Continued) 3-18 – JLG Lift – 3121703...
  • Page 55 @ 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 56 • Platform is only operated within its work area specifica- tion for rated load and boom reach. (See Figure 4-4., Fig- ure 4-5., and Figure 4-7.) 3121703 – JLG Lift –...
  • Page 57 (1) Key switch must be set to ON, battery disconnect switch must be ON, and NOTE: Allow gas/diesel engine to warm-up for a few minutes both the ground and platform emergency stop switches must be reset to ON. at low speed before applying any load. – JLG Lift – 3121703...
  • Page 58 5. Turn engine key to off. 1. Before connecting the machine to the electrical circuit, ensure the key on the gas/diesel engine is in the OFF position. 3121703 – JLG Lift –...
  • Page 59 (item 2), and unhook the tioned behind the clear plastic cover near the elec- electric AC cord from receptacle (item 1). tric engine (— symbol is ON - O symbol is OFF). – JLG Lift – 3121703...
  • Page 60 (6) on the Platform/ Remote Control LCD display. UNLESS THESE CONDITIONS ARE MET, DRIVE, STEER, TRACK WIDTH ADJUSTMENT, AND OUTRIGGER MOVEMENT IS PRE- Boom/Jib and Base Alignment - Reflectors/Photocells VENTED. Base/Boom Alignment - Visual Indicator 3121703 – JLG Lift –...
  • Page 61 Press and hold button 3 for widening or button 9 for narrow- NOTE: The base and boom/jib must be aligned and retracted ing the track. before this function will operate, see Section 4.4, BASE AND BOOM/JIB ALIGNMENT. – JLG Lift – 3121703...
  • Page 62 • Always fully widen the track prior to driving, if possible, for easier steering and increased stability. • Always travel in the slow speed setting unless the travel path is firm, level and uniform. 3121703 – JLG Lift –...
  • Page 63 SECTION 4 - MACHINE OPERATION Figure 4-2. Grade and Side Slope Definition – JLG Lift – 3121703...
  • Page 64 If any of these conditions have not been met, the use of the JIB is not possible and one of the following error displays appears. 3121703 – JLG Lift –...
  • Page 65 • After slope has been passed, for which the jib had to be raised, fully lower jib and continue travelling. • With JIB raised, ALWAYS travel at minimum speed and keep JIB as near as possible to the ground. 4-10 – JLG Lift – 3121703...
  • Page 66 Outrigger in Transport Position Check correct positioning of the handle and two micro- switches at each outrigger before every use, as shown in fol- lowing illustration. 3121703 – JLG Lift – 4-11...
  • Page 67 (See Figure 4-4. and Figure 4-5.) NOTE: Swing and jib functions will not be allowed in certain areas. Figure 4-3. Outrigger Positions 1. Transport Position 3. Full Work Area Position 2. Restricted Work Area Position 4-12 – JLG Lift – 3121703...
  • Page 68 DISPLAYED ON THE LCD SCREEN WHEN ANY OF THE OUTRIGGERS ARE IN THE Unless all four (4) outriggers are set to "full work area posi- RESTRICTED AREA POSITION. tion" jib extend is restricted to the +/– 30° rotation area shown in (Figure 4-4. and Figure 4-5.). 3121703 – JLG Lift – 4-13...
  • Page 69 SECTION 4 - MACHINE OPERATION Figure 4-4. Boom Area of Operation for Various Outrigger Positions (Sheet 1 of 2) 4-14 – JLG Lift – 3121703...
  • Page 70 SECTION 4 - MACHINE OPERATION Figure 4-5. Boom Area Of Operation for Various Outrigger Positions (Sheet 2 of 2) 3121703 – JLG Lift – 4-15...
  • Page 71 INCL: if OK the machine is set up on an accepted slope. LOAD: if OK the load in the platform is acceptable. PLATFORM: if OK the platform/remote control box is in the proper location in the platform. PEDAL: If OK the footswitch is correctly depressed. 4-16 – JLG Lift – 3121703...
  • Page 72 Lights will be flashing if any of the outriggers are posi- tioned in the restricted operation area. No lights will be on if the outriggers are not set properly. 3121703 – JLG Lift – 4-17...
  • Page 73 FLASH OR REMAIN ON WHEN THAT OUTRIGGER IS LIFTED FROM THE 1) of the remote control. GROUND, STOP THE MACHINE IMMEDIATELY AND CALL A QUALIFIED JLG SERVICE TECHNICIAN AS THIS INDICATES A PROBLEM WITH THE CORRE- The 4 outriggers will all retract at the same SPONDING OUTRIGGER MICRO SWITCH.
  • Page 74 50°F (10°C) before operating the plat- form. • To manually Level Down, turn the select switch counter clockwise and hold until desired position is reached. 3121703 – JLG Lift – 4-19...
  • Page 75 • To swing boom to the left, depress foot switch and move controller forward. move controller backwards. Platform Rotation (Item 20, Figure 4-6.) • To rotate the platform to the right, depress the foot- switch and move the controller forward. 4-20 – JLG Lift – 3121703...
  • Page 76 SECTION 4 - MACHINE OPERATION Figure 4-6. Platform/Remote Control Box 3121703 – JLG Lift – 4-21...
  • Page 77 SECTION 4 - MACHINE OPERATION Figure 4-7. Platform - Load/Reach Chart - X770AJ (Full 360° Rotation and Jib Extend ONLY with Outriggers Set to Full Work Area Position) 4-22 – JLG Lift – 3121703...
  • Page 78 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 3121703 – JLG Lift – 4-23...
  • Page 79 6. Position the emergency stop switch to the off posi- upward direction. Place platform aside for later tion. installation. Determine the reason for the primary power failure and have the problem corrected by a qualified JLG service tech- nician. 4-24 – JLG Lift – 3121703...
  • Page 80 The machine has a built-in battery charger. To activate this feature connect the machine to an appropriately grounded AC receptacle and activate the charging switch behind the clear plastic door. (See photo) Verify the battery disconnect switch is on. 3121703 – JLG Lift – 4-25...
  • Page 81 YELLOW LED: shows that the battery has reached 80% charge. GREEN LED: shows that the battery has reached 100% of charge. If machine is powered on while charging, the LCD display on the platform control station also shows the machine charge indicator. 4-26 – JLG Lift – 3121703...
  • Page 82 • The batteries can be charged when they are not fully depleted. • If the charge is less than 20% an audible warning signal will be activated whenever the electric motor is started, to alert the user to charge the machine. 3121703 – JLG Lift – 4-27...
  • Page 83 Operation/Maintenance Man- ual. If any questions, contact your local JLG Service Center or the local electrical company. • An AC class circuit breaker can be used as a protection...
  • Page 84 The battery cold/heater activated icon will be the battery socket and contact your local JLG Service shown on the display when the heaters are Center. enabled. The machine can only be moved in...
  • Page 85 7. If machine is to be shut down for long periods of time, turn battery disconnect switch, RED handle 4-30 – JLG Lift – 3121703...
  • Page 86 1. Outrigger Lifting Lug (4 corners) Figure 4-9.. Weight of machine is not spread equally over the four out- riggers (See Figure 4-10.). Minimum required capacity of the 3121703 – JLG Lift – 4-31...
  • Page 87 Figure 4-10. Lifting Machine - Attach Points 1. Lifting Slings DO NOT MAKE CONNECTIONS AT POINTS DIFFERENT THAN THOSE IDENTI- FIED BY THE TIE DOWN LOCATION DECAL SHOWN. THIS COULD CAUSE PER- MANENT DAMAGE RESULTING IN COLLAPSE OF THE PRODUCT. 4-32 – JLG Lift – 3121703...
  • Page 88 SECTION 4 - MACHINE OPERATION 1703814A Figure 4-11. Machine Tie-Down Points (both sides of machine) 1. Tie-Down Loop 2. Tie-Down Decal 3121703 – JLG Lift – 4-33...
  • Page 89 SECTION 4 - MACHINE OPERATION 4.12 MACHINE DECALS Figure 4-12. Decal installation - Standard - Left Side 4-34 – JLG Lift – 3121703...
  • Page 90 SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Installation - Standard - Right Side 3121703 – JLG Lift – 4-35...
  • Page 91 SECTION 4 - MACHINE OPERATION Table 4-2. X770AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION 17633600 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. X770AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION 06165000 Decal, Hydraulic Oil Tank - Fluid Level Check 06136900 Decal, Lubrication Point 07678300 Decal, Outrigger, Max. Ground Pressure 07240300 Decal, Keep 3 ft./1m Away When Operating With Tele /Radio Commands...
  • Page 93 SECTION 4 - MACHINE OPERATION Table 4-2. X770AJ - Decal Installation - Standard (See Figure 4-12. and Figure 4-13.) ITEM # PART NUMBER DESCRIPTION 07058700 Decal, Warning - Tip-Over Hazard - Platform 072423GB Decal, Maximum Platform Capacity 07042100 Decal, Boom Functions Safety System Bypass (Key Switch)
  • Page 94 @ 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 95 E-mail: ProductSafety@JLG.com Failure to notify the manufacturer of an incident involv- ing a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine. FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT MACHINE AND TEST ALL FUNCTIONS FIRST FROM GROUND CONTROLS, THEN FROM PLATFORM CON- TROLS.
  • Page 96 When switched off - handle turn all the way counter- Counter- clockwise - all electrical power to the machine is shut down. Clockwise 1702155A BATTERY DISCONNECT SWITCH - GAS/DIESEL/AC-ELECTRIC – JLG Lift – 3121703...
  • Page 97 3. Cranes, forklift trucks or other equipment can be system. In the event either/or both are not operating used to remove platform occupants and stabilize properly, the following procedures will allow the low- machine motion. ering of the boom and platform. 3121703 – JLG Lift –...
  • Page 98 6. Position (press) the emergency stop switch to the means to lower personnel in the platform. OFF position. 1. Check emergency stop button (item 10) is in the ON position by turning it clockwise. 2. Depress platform foot switch on floor of platform. – JLG Lift – 3121703...
  • Page 99 SECTION 5 - EMERGENCY PROCEDURES Figure 5-1. Platform/Remote Control Station 3121703 – JLG Lift –...
  • Page 100 8. Position (press) emergency stop switch (item 1) to the OFF position. 3. Start engine, if not already running (item 4). 4. At Emergency/Ground Control box, turn mode selector switch (item 3) all the way clockwise and hold. – JLG Lift – 3121703...
  • Page 101 SECTION 5 - EMERGENCY PROCEDURES Figure 5-2. Ground Control Station 3121703 – JLG Lift –...
  • Page 102 4. Turn proportional valve adjustment knob clock- wise approximately four turns, the more turns the valve is open the faster the movement of the – JLG Lift – 3121703...
  • Page 103 SECTION 5 - EMERGENCY PROCEDURES Figure 5-3. Hand Pump - Chassis Control Valve Tray 3121703 – JLG Lift –...
  • Page 104 Figure 5-2.), While pumping the hand pump (item 4) and activating the swing control lever (item 7 - Figure 5-2.) in the desired direction of travel, until the turntable is aligned with the chassis. 5-10 – JLG Lift – 3121703...
  • Page 105 5-2.) in the appropriate direction to lower the main boom. 7. Rotate the platform (if necessary). Lift the function enable lever UP and hold (item 6 - Figure 5-2.), while pumping the handpump, acti- 3121703 – JLG Lift – 5-11...
  • Page 106 5. While holding the flow valve in, activate the lever valve set (item 6 - Figure 5-3.). in the desired direction on the appropriate valve solenoid (valve description below) while pumping the pump handle to achieve the desired function movement. 5-12 – JLG Lift – 3121703...
  • Page 107 (Item 6 - Figure 5-3.) • 1st valve, far left - toward front of machine in the group of four, operates Left Rear Outrigger. 3121703 – JLG Lift – 5-13...
  • Page 108 PLAY. REMOVE OVERLOAD FROM THE PLATFORM BEFORE OPERATION. Remove key and insert it into the bypass key switch (item 1 - photo). After using the safety device bypass, a qualified JLG mechanic must be contacted to determine the reason for needing 5-14 –...
  • Page 109 2. Activate safety device bypass by turning key in a counterclockwise direction and hold it in position (see decal). 3. The safety devices BYPASS icon will appear on the platform/remote con- trol box display. 3121703 – JLG Lift – 5-15...
  • Page 110 NOTE: In case of machine with restricted work area, the safety device bypass key. bypass of the safety devices does not allow the boom assembly to go out of the working area related to that outrigger configuration. 5-16 – JLG Lift – 3121703...
  • Page 111 @ 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 112 LIZED TO WASH AREAS CONTAINING ELECTRICAL/ELECTRONIC COMPO- The maintenance portion of this section is intended as infor- NENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 mation to assist the machine operator to perform daily PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 IN (30.5 CM) AWAY FROM maintenance tasks only, and does not replace the more THESE COMPONENTS.
  • Page 113 90 lb (400 N) Approach angle with Jib lowered: 9° Electrical system voltage with Jib raised: 26° Gross machine weight (platform empty) Departure angle 22° Diesel: 9,623 lbs (4,365 kg) Lithium: 9,665 lbs (4,384 kg) – JLG Lift – 3121703...
  • Page 114 Table 6-5. Kubota D902 Specifications Model X770AJ Type Liquid cooled Number of cylinders Displacement 55 cu. in. (898 cm Output 21.6 hp (16.1 kW) High engine speed 3200 RPM Battery 12V - 70Ah - 760A Alternator 40A - 3200RPM 3121703 – JLG Lift –...
  • Page 115 83 volt - three phase - 2000 watt * The charge cycles have to be considered based on the fact that there is not mem- ory effect in the lithium batteries, i.e. 2000 charges at 100% or 4000 charges at 50%, etc.. – JLG Lift – 3121703...
  • Page 116 BE DRIED USING COMPRESSED AIR TO AVOID THE RISK OF SHORT CIRCUITS. will need to be re-greased (see lubrication chart). Do not wet the electric motors and the other elec- trical components directly. Do not aim the spray directly onto decals and rat- ing plates. 3121703 – JLG Lift –...
  • Page 117 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-1. Lubrication and Maintenance Point Locations – JLG Lift – 3121703...
  • Page 118 104deg F (+40deg C) NOTE: Use a brush to spread grease onto telescopic boom wear pad areas. NOTE: When adding or replacing hydraulic oil only use JLG approved hydraulic oil. Do not mix oils unless directed by JLG. Recommended Gearbox Oils...
  • Page 119 * 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 – 3121703...
  • Page 120 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Figure 6-3. Hydraulic Oil Operating Temperatures 3121703 – JLG Lift –...
  • Page 121 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Component Maintenance Intervals - X770AJ - with Diesel Engine Table 6-10. Hours Component Operation Pre-Start As Needed 100 250 500 1000 2000 • Dry Air Filter(Diesel Engine) Check/Clean Replace • Engine Oil (Diesel Engine) Check Level •...
  • Page 122 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Component Maintenance Intervals - X770AJ - with Diesel Engine Table 6-10. Hours Component Operation Pre-Start As Needed 100 250 500 1000 2000 Extension Arm Internal Sliding Ring (if equipped) Check Wear •...
  • Page 123 SECTION 6 - GENERAL SPECIFICATIONS AND OPERATOR MAINTENANCE Component Maintenance Intervals - X770AJ - with Lithium-Ion Battery Pack Table 6-11. Hours Component Operation Pre-Start As Needed 100 250 500 1000 2000 Hydraulic Oil Check Level • Replace • •* •...
  • Page 124 (See Table 6-10 ) then rinse and let dry, Dip in clean engine oil and squeeze out the excess oil. If too much oil is left in the foam the engine will smoke when started. 3121703 – JLG Lift – 6-13...
  • Page 125 Lube Point(s) - Filter Cartridge/replaceable Interval - Clean every 100 hours. Replace 500 hours. Interval - Check daily. Replace fluid every 500 hours NOTE: Coolant utilized is to be compliant with SAE J 1034 6-14 – JLG Lift – 3121703...
  • Page 126 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). 3121703 – JLG Lift – 6-15...
  • Page 127 5. If the grease does not begin to drain, slowly rotate LOOSEN GREASE VALVE 2. the track. 6. Once correct track tension has been achieved, turn grease valve 1 clockwise to tighten valve. 7. Clean area of all trace grease. 6-16 – JLG Lift – 3121703...
  • Page 128 TRACK NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSENING OF THE TRACK, BROKEN STUDS, AND POS- SIBLE DANGEROUS SEPARATION OF THE TRACK FROM THE TEETH. 3121703 – JLG Lift – 6-17...
  • Page 129 Apply an out- teeth in the track tensioning wheel ward force 6 to lift the track from the track tension- 5. Adjust track tension (see Loosening/Tightening ing wheel. track section). 6-18 – JLG Lift – 3121703...
  • Page 130 2. Inspect ropes for corrosion. 3. Inspect ropes for kinks or abuse. 7. Ropes passing inspection should be lubricated with wire rope lubricant before reassembly. 3121703 – JLG Lift – 6-19...
  • Page 131 10Nm (7.4ft-lbs) 5. Fully extend both boom extensions. Retract the boom extension sections between 12-15 inches. 8. Verify during the cycle testing that no rubbing occurs from the wire rope cables 6-20 – JLG Lift – 3121703...
  • Page 132 External Battery Charger Use ING. SHOULD PRESSURE WASHING BE UTILIZED TO WASH AREAS CONTAIN- ING ELECTRICAL/ELECTRONIC COMPONENTS, JLG INDUSTRIES, INC. RECOMMENDS A MAXIMUM PRESSURE OF 750 PSI (52 BAR) AT A MINIMUM DISTANCE OF 12 INCHES (30.5 CM) AWAY FROM THESE COMPONENTS. IF...
  • Page 133 2 - LANGUAGE • BEARINGS 3 - ERRORS Check the condition of the bearings, in the event of noise contact JLG for replacement, the life of the 4 - RAMPS bearings is reduced significantly in heavy duty 5 - CURRENT operating conditions.
  • Page 134 ON or OFF depending on whether, the engine is ON or OFF. Both ON indicate the stabilizer 2 is completely open, TOTAL AREA ST2 OPEN B EMERG. COMM ON position indicates the emergency buttons are activated. 3121703 – JLG Lift – 6-23...
  • Page 135 SUPPLY (V) Indicate the voltage (In volts). Both ON indicates the stabilizer 2 is in stabilization position. POSM 2 B POSM 3A Both ON indicates the stabilizer 3 is in stabilization position. POSM 3B 6-24 – JLG Lift – 3121703...
  • Page 136 “Platform/Remote Control Station Functions” on page 3-9.). If there are operating problems with the machine and the “spanner” icon is shown on the display, do not operate machine until repaired by a JLG factory trained technician. 3121703 – JLG Lift – 6-25...
  • Page 137 Shoes with antistatic coating able to insulate the LEAST THE PERSONAL PROTECTIVE EQUIPMENT (PPE) LISTED BELOW. worker during work on the electrical parts of the system. • Eye protection devices Protective glasses, for protection against sprays of hazardous materials. 6-26 – JLG Lift – 3121703...
  • Page 138 Cause – Feedback current from motor sensor not constantly at 0. conditions. If problem persists, replace inverter. Solution – Check connection to motor. Logic Failure #2 Cause – Internal fault in the inverter. Solution – Replace inverter. 3121703 – JLG Lift – 6-27...
  • Page 139 If problem persists, replace Cause – High temperature inside the inverter. inverter. Solution – Improve cooling to inverter. If fault persists, contact JLG after- sales service. Driver shorted Cause – Relay power supply fault.
  • Page 140 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. Check up needed Cause – Solution – Contact Hinowa after.sales service.
  • Page 141 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 6-30 – JLG Lift – 3121703...
  • Page 142 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. 3121703 – JLG Lift – 6-31...
  • Page 143 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. 6-32 – JLG Lift – 3121703...
  • Page 144 3. Exploded cells Minimum Equipment Required: 4. Fire enveloping the lithium batteries • Infrared temperature probe • Safety glasses • Hard hat with impact resistant face visor • Non-conductive pliers • Hand, arm and body protection 3121703 – JLG Lift – 6-33...
  • Page 145 • Acid.resistant lab coats Procedures in cases of venting or explosion are examined in the following paragraphs. • Baking soda, calcium oxide or acid absorbent in kit form • Vermiculite • Plastic bags 6-34 – JLG Lift – 3121703...
  • Page 146 9. Place the absorbent material in a bag and seal it. 10. Clean area with plenty of water. 11. Dispose of hazardous material in accordance with the local legislation in force. 3121703 – JLG Lift – 6-35...
  • Page 147 Avoid contact between the metallic residues and charged cells, as this condition may cause a short.circuit. 7. Place contaminated material in a sealable plastic bag and remove excess air. 8. Seal the bag. 6-36 – JLG Lift – 3121703...
  • Page 148 All precautions needed to limit exposure to these fumes must be adopted. It should be noted that this proce- dure is applicable only to fires on individual cells. Larger fires have to be managed only by professionally trained person- nel. 3121703 – JLG Lift – 6-37...
  • Page 149 3. The fire-fighting personnel go to the area where the fire is located and gather all the information 11. Wear safety equipment: coat, gloves, mask and fil- regarding the situation and the person who gave ters. the alarm. 6-38 – JLG Lift – 3121703...
  • Page 150 If breathing stops apply mouth-to-mouth resus- citation and immediately seek emergency medical help. 17. Dispose of hazardous material in accordance with the local legislation in force. 3121703 – JLG Lift – 6-39...
  • Page 151 @ 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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