JLG 520AJ HC3 Operation & Safety Manual
  1. Manuals
  2. Brands
  3. JLG Manuals
  4. Boom Lifts
  5. 520AJ HC3
  6. Operation & safety manual
JLG 520AJ HC3 Operation & Safety Manual

JLG 520AJ HC3 Operation & Safety Manual

Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
520AJ HC3
PVC 2501
3122343200
January 13, 2025 - Rev A
Copyright ©
ANSI
AS/NZS GB
English (en-US)

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the 520AJ HC3 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for JLG 520AJ HC3

Summary of Contents for JLG 520AJ HC3

  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. 520AJ HC3 PVC 2501 3122343200 January 13, 2025 - Rev A Copyright © ANSI AS/NZS GB English (en-US)
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other repro- ductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.

  • Page 3: Foreword

    Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.
  • Page 4 It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 3122343200 520AJ HC3...
  • Page 5 NOTICE JLG Industries, Inc. sends safety related bulletins to the owner of record of this machine. Contact JLG Industries, Inc. to ensure that the current owner records are updated and accurate.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG DATE REVISION DESCRIPTION January 13, 2025 Original Issue Other Publications Available Publication Publication Number Service & Maintenance Manual 31223433 Illustrated Parts Manual 31223434 520AJ HC3 3122343200...
  • Page 8 This Page is intentionally left blank...

  • Page 9: Table Of Contents

    Oscillating Axle Lockout Test ..........33 SECTION 3 MACHINE CONTROLS AND INDICATORS......35 General ................35 Controls and Indicators .............35 Ground Control Station .............36 Ground Control Indicator Panel..........41 Platform Control Station ............43 Platform Control Indicator Panel ........48 Beacons ................50 520AJ HC3 3122343200...
  • Page 10 Section Contents SECTION 4 MACHINE OPERATION............... 53 General ................53 Operating Characteristics and Limitations......53 Stability................54 520AJ HC3 Reach Chart...........56 Engine Operation .............56 Fuel Reserve / Shut-Off System.........60 Diesel Particulate Filter (If Equipped) .........60 Traveling (Driving) ............61 Traveling (Grade/Side Slope) ..........62 4.10 Steering................63...
  • Page 11 Operator Maintenance ............ 110 7.10 Tires and Wheels............117 7.11 Radio Frequency (RF) Information ........119 7.12 Supplemental Information Only Applicable to CE/UKCA Machines ............... 121 7.13 EC Declaration of Conformity .......... 123 7.14 UKCA Declaration of Conformity........124 520AJ HC3 3122343200...
  • Page 12 This Page is intentionally left blank...

  • Page 13: Safety Precautions

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

  • Page 15: Operation

    Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 16 • Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform assembly is fully lowered. Face the platform when entering or leaving the platform. Always maintain “three point 3122343200 520AJ HC3...
  • Page 17 Over 350 KV to 500 KV 35 (11) Over 500 KV to 750 KV 45 (14) Over 750 KV to 1000 KV Note: This requirement shall apply except where employer, local or governmental regulations are more stringent. 520AJ HC3 3122343200...
  • Page 18 Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity of the surfaces. • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. 3122343200 520AJ HC3...
  • Page 19 Wind motion visible in smoke 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion 13-18 5.5-7.9 Moderate Dust and loose paper raised. Small breeze branches begin to move. 520AJ HC3 3122343200...

  • Page 20: Crushing And Collision Hazards

    • Be aware of stopping distances in all drive speeds. When driving in high speed, reduce drive speed before stopping. Travel grades in low speed only. 3122343200 520AJ HC3...

  • Page 21: Towing, Lifting, And Hauling

    • DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure. 520AJ HC3 3122343200...
  • Page 22 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.

  • Page 23: Long-Term Storage

    • For long-term storage of battery-electric machines, store machines in a cool, dry place away from direct sunlight and heat sources. Avoid storing batteries in a fully discharged or fully charged state. 520AJ HC3 3122343200...
  • Page 24 This Page is intentionally left blank...

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

    2.1.3 Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. 520AJ HC3 3122343200...

  • Page 26: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.
  • Page 27 Mechanic tenance Manual Service & Main- tenance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.

  • Page 28: Machine Components

    1. Cleanliness — Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel. 2. Structure — Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies. 3122343200 520AJ HC3...
  • Page 29 13. Lanyard Attach Points — During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point. 520AJ HC3 3122343200...

  • Page 30: Walk-Around Inspection

    1. Platform Assembly and Gate - Footswitch works properly, not modified, disabled or blocked. Gate latches and hinges in working condition. 3122343200 520AJ HC3...

  • Page 31: Function Check

    18. Swing Motor and Worm Gear - No evidence of damage. 19. Hydraulic Pump - See Inspection Note. 20. Battery Compartment - Batteries have proper electrolyte level; cables tight; no visible damage or corrosion. FUNCTION CHECK Perform the Function Check as follows: 520AJ HC3 3122343200...

  • Page 32: Skyguard® Function Check

    SKYGUARD® FUNCTION CHECK From the Platform Control Station in an area free from obstructions: 1. Operate the telescope-out function. 2. Activate the SkyGuard SkyLine® sensor by pressing rod to break connection between the rod and the right bracket. 3122343200 520AJ HC3...

  • Page 33: Oscillating Axle Lockout Test

    7. Carefully return boom to stowed position (centered between rear wheels if swung or fully lowered if raised). When boom reaches stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders. 520AJ HC3 3122343200...
  • Page 34 10. Repeat steps 4 thru 7 to check the opposite side of the oscillating axle. 11. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. 3122343200 520AJ HC3...

  • Page 35: Machine Controls And Indicators

    This indicator will be yellow. Indicates important information regarding the oper- ating condition, i.e. procedures essential for safe op- eration. This indicator will be green with the exception of the capacity indicator which will be yellow. 520AJ HC3 3122343200...

  • Page 36: Ground Control Station

    1. Indicator Panel 7. Jib Lift (If Equipped) 2. Hourmeter 8. Telescope 3. Power/Emergency Stop 9. Main Boom Lift 4. Platform/Ground Select Switch 10. Tower Boom Lift 5. Platform Level 11. Swing 6. Platform Rotate 12. Engine Start/Auxiliary Power 3122343200 520AJ HC3...
  • Page 37 When operating the boom ensure there are no personnel around or under platform. WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. 520AJ HC3 3122343200...
  • Page 38 By connecting into the oil pressure circuit of the engine, only engine hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset. Indicator Panel The Indicator Panel contains indicator lights which signal problem conditions or functions operating during machine operation. ½ 3122343200 520AJ HC3...
  • Page 39 WARNING Only use the platform leveling override function for slight leveling of the platform. Incorrect use could cause the load/occupant to shift or fall. Failure to do so could result in death or serious injury. 520AJ HC3 3122343200...
  • Page 40 Always position emergency stop switch to the Off position (pushed in) when machine is not in use. Swing Provides 355 degrees non-continuous turntable rotation. Tower Boom Lift This switch provides raising and lowering of the tower boom. 3122343200 520AJ HC3...

  • Page 41: Ground Control Indicator Panel

    Refer to the capacity decals on the machine for restricted and unrestricted platform capacities. Drive and Steer Disable Indicates the Drive and Steer Disable function has been activated. Emissions Temperature Indicator illuminates when exhaust temperature reaches 1022° F (550° C). 520AJ HC3 3122343200...
  • Page 42 Indicates the platform has been overloaded. System Distress Indicates the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

  • Page 43: Platform Control Station

    To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. Note: Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) position when released. 520AJ HC3 3122343200...
  • Page 44 To operate the Drive joystick, pull up on the locking ring below the handle. Note: The Drive joystick is spring loaded and will automatically return to neutral (off) position when released. Engine Start / Auxiliary Power When pushed forward, the switch energizes the starter motor to start the engine. 3122343200 520AJ HC3...
  • Page 45 If machine is equipped with SkySense, the switch will mute the SkySense speakers. Main Boom Telescope Provides extension and retraction of the main boom. 520AJ HC3 3122343200...
  • Page 46 Platform Rotate Provides rotation of the platform. Power / Emergency Stop A two-position, red, mushroom-shaped switch furnishes power to Platform Controls when pulled out (On). When pushed in (Off), power is shut off to the platform functions. 3122343200 520AJ HC3...
  • Page 47 Tower Boom Lift This switch provides for raising and lowering of the Tower Boom. 520AJ HC3 3122343200...

  • Page 48: Platform Control Indicator Panel

    When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. Diesel Particulate Filter Icon will illuminate when standstill exhaust system cleaning is required. 3122343200 520AJ HC3...
  • Page 49 Indicates the level of the fuel in the fuel tank. ½ Glow Plug Indicates the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine. Platform Overload Indicates the platform has been overloaded. 520AJ HC3 3122343200...

  • Page 50: Beacons

    System Distress The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.
  • Page 51 Blue or Red SkyGuard® Beacon The SkyGuard beacon is available in blue or red lamp options. The beacon will flash in conjunction with an audible alarm when the SkyGuard sensor is activated. Refer to the SkyGuard Operation section for more information. 520AJ HC3 3122343200...
  • Page 52 This Page is intentionally left blank...

  • Page 53: Machine Operation

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

  • Page 54: Stability

    , and its position of least BACKWARD stability is shown in Section — Position of Least Backward Stability WARNING To avoid forward or backward tipping, do not overload machine or operate the machine beyond the limit of the maximum operating slope. 3122343200 520AJ HC3...
  • Page 55 Figure 5. Position of Least Forward Stability 1. Machine will tip over in this direction if overloaded or operated beyond the limits of the maximum operating slope. 2. Tower boom in stowed position. 3. Main boom and jib horizontal. 4. Telescope fully extended. 520AJ HC3 3122343200...

  • Page 56: 520Aj Hc3 Reach Chart

    Machine Operation 520AJ HC3 REACH CHART Figure 6. 520AJ HC3 Platform Reach Chart ENGINE OPERATION Note: When operating a machine at high altitudes, a decrease in machine perform- ance may occur due to a decrease in air density. 3122343200 520AJ HC3...
  • Page 57 CAUTION For every 8 hours of low intensity machine operation or extended engine idle time, drive the machine continuously for 15 minutes. Note: Contact JLG Customer Service for operation under abnormal conditions. 4.5.1 Starting Procedure Note: Initial starting should always be performed from the Ground Control station.

  • Page 58: Shutdown Procedure

    Doing so may cause wet stacking, which may result in premature wear of engine or engine failure. 4.5.2 Shutdown Procedure CAUTION If an engine malfunction causes an unscheduled shutdown, determine the cause and correct it before restarting the engine. 3122343200 520AJ HC3...
  • Page 59 Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature. Push Power/Emergency Stop switch in. Turn Platform/Ground Select switch to Off. Note: Refer to Engine Manufacturer’s manual for detailed information. 520AJ HC3 3122343200...

  • Page 60: Fuel Reserve / Shut-Off System

    2 minutes of run time. The operator can repeat this process until there is no more fuel available. NOTICE Contact a qualified JLG mechanic if the machine needs restarted after no more fuel is available. •...

  • Page 61: Traveling (Driving)

    Use extreme caution when driving in reverse and at all times when the platform is elevated. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows for the intended direction of travel. 520AJ HC3 3122343200...

  • Page 62: Traveling Forward And Reverse

    (drive) axle, and in line with the direction of travel. Drive the machine forward when climbing a grade, and in reverse when descending a grade. Do not exceed the machine's maximum rated gradeability. 3122343200 520AJ HC3...

  • Page 63: Steering

    If the boom is over the front (steer) axle, direction of steer and drive movement will be opposite from the movement of the controls. Figure 8. Grade and Side Slope 4.10 STEERING Press footswitch. Position thumb switch on Drive/Steer controller to Right for steering right, or to Left for steering left. 520AJ HC3 3122343200...

  • Page 64: Platform

    Machine Operation 4.11 PLATFORM JLG offers multiple platform sizes to accommodate a variety of applications. Refer to the Illustrated Parts Manual for available platforms. Not all platform options may be of adequate size to allow for the maximum number of rated occupants shown on the machine's capacity decal.

  • Page 65: Boom

    When swinging the boom make sure there is ample room for the boom to clear surrounding walls, partitions and equipment. Note: On CE/UKCA Market machines, when boom functions are being operated there is an interlock that prevents the use of Drive and Steer functions. 520AJ HC3 3122343200...

  • Page 66: Telescoping The Main Boom

    Turning the knob all the way counterclockwise until it clicks puts the machine into Creep Mode. Creep Mode puts the functions listed above, as well as the Drive/Steer and Main Lift/Swing functions into the slowest speed setting. 4.14 USB CHARGING PORT The machine is equipped with a USB charging port for the operator. 3122343200 520AJ HC3...

  • Page 67: Clearsky Smart Fleet

    (if available) restrictions. Refer to the Access Control and Beacons sections of this manual for more information. Visit the ClearSky section of the JLG website for more resources and information about accessing web portal or mobile app data. 4.16 ACCESS CONTROL - CLEARSKY SMART FLEET™...

  • Page 68: Skyguard Activation/Deactivation

    At time of publication, Access Control is not available for CE/UKCA markets. 4.17 SKYGUARD ACTIVATION/DEACTIVATION SkyGuard provides enhanced protection at the Platform Control Station. When the SkyGuard sensor is activated, functions in use at the time of actuation will reverse or cutout. See SkyGuard Function Table. 3122343200 520AJ HC3...
  • Page 69 R * / C ** Drive Reverse Steer Swing Tower Lift Up Tower Lift Down Tower Telescope Out Tower Telescope In Boom Lift Up Boom Lift Down Boom Telescope Out Boom Telescope In Jib Lift (If equipped) Platform Level 520AJ HC3 3122343200...

  • Page 70: Shut Down And Park

    4.19 LIFTING AND TIE DOWN 4.19.1 Lifting 1. Refer to the Machine Serial Number Plate, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight. 2. Place the boom in the stowed position. 3. Remove all loose items from the machine.
  • Page 71 Note: Secure through the tie downs on the boom using straps or chains of ad- equate strength. OAC014470 NOTICE Secure turntable with turntable lock (if equipped) before traveling long distances or hauling machine on truck/trailer. 520AJ HC3 3122343200...

  • Page 72: Lifting And Tie Down Chart

    Machine Operation 4.20 LIFTING AND TIE DOWN CHART Figure 10. 450AJ HC3 / 520AJ HC3 Lifting Chart 4.21 SAFETY DECAL LOCATIONS Figure 11. 520AJ HC3 Decal Installation - 1 of 5 3122343200 520AJ HC3...
  • Page 73 Machine Operation 520AJ HC3 3122343200...
  • Page 74 Machine Operation 3122343200 520AJ HC3...
  • Page 75 Machine Operation 520AJ HC3 3122343200...
  • Page 76 Machine Operation 3122343200 520AJ HC3...
  • Page 77 Machine Operation Table 5. 520AJ HC3 Decal Legend CE/UKCA & GB Australia Chinese Item # 1001254307-B 1001254301-B 1001254305-B 1001162429 1001162429 1703925 1705822 1705822 1001116849 1705961 1705961 1703937 1703949 1001256733 1001256734 1001244301 (GB) 1702773 1702773 1702773 1705968 1001256726 1001256726 1701518 1701518...
  • Page 78 Machine Operation Table 5. 520AJ HC3 Decal Legend (continued) CE/UKCA & GB Australia Chinese Item # 1001254307-B 1001254301-B 1001254305-B 1701529 1701529 1701529 1701550 1701550 1001143852 1001143852 1001181145 1001224050 1001244298 (GB) 1001244212 1001244212 1001244212 1001256906 1001256906 1001256906 1704277 1704277 1704277 3122343200...

  • Page 79: Emergency Procedures

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

  • Page 80: Manual Swing Override

    Towing this machine is prohibited, unless properly equipped. However, provisions for moving the machine, in case of a malfunction or power failure, have been incorporated. The following procedures are to be used ONLY for emergency movement to a suitable maintenance area. 3122343200 520AJ HC3...

  • Page 81: Clearsky Smart Fleet™ - Locked Out State

    If the CS550 (ClearSky® LED Motion / Amber Beacon) is removed from a machine or disconnected from the control system through damage, the machine may also be placed into a Locked Out state. NOTICE Contact the ClearSky Smart Fleet™ account owner if the machine is in a Locked Out state. 520AJ HC3 3122343200...
  • Page 82 This Page is intentionally left blank...

  • Page 83: Accessories

    SkyPower® - 7.5 ✔ ✔ ✔ ✔ ✔ Generator - 4 kW SkySense® ✔ ✔ ✔ ✔ ✔ SkySense® Plat- form Bumper ✔ ✔ ✔ Padding Soft Touch ✔ ✔ ✔ Storage Tray ✔ ✔ ✔ ✔ ✔ 520AJ HC3 3122343200...
  • Page 84 Accessories 3122343200 520AJ HC3...
  • Page 85 Accessories 520AJ HC3 3122343200...

  • Page 86: Bolt-On External Fall Arrest

    If the external fall arrest system is used to arrest a fall or is otherwise damaged, the entire system must be replaced and the platform fully inspected before returning to service. Refer to the service manual for removal and installation procedures. 3122343200 520AJ HC3...
  • Page 87 Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tightened. • Platform Rails: No visible damage is acceptable. 520AJ HC3 3122343200...

  • Page 88: Cable Ladder Carrier

    Accessories CABLE LADDER CARRIER BM000362A Figure 19. Cable Ladder Carrier The Cable Ladder Carrier accessory consists of two vertical brackets mounted to the outside of the platform used to carry a “ladder” style cable tray. 3122343200 520AJ HC3...

  • Page 89: Pipe Racks

    Max. Length of Material in Racks: 6.1 m Min. Length of Material in Racks: 2.4 m 6.4.2 Safety Precautions WARNING Reduce platform capacity by 100 lb (45.5 kg) when installed. WARNING Weight in racks plus weight in platform must not exceed rated capacity. 520AJ HC3 3122343200...
  • Page 90 3. Route the tie-down straps at each end across loaded material and tighten. 4. To remove material, loosen and remove tie-down straps, then carefully remove material from racks. Note: Reinstall tie-down straps across any remaining material before continuing machine operations. 3122343200 520AJ HC3...

  • Page 91: Platform Work Lights

    Accessories PLATFORM WORK LIGHTS OAC04000 Figure 21. Platform Work Lights The Platform Work Lights accessory consists of two 12V lights mounted to the platform railing. 520AJ HC3 3122343200...

  • Page 92: Platform Work Surface

    Accessories PLATFORM WORK SURFACE BM000276A Figure 22. Platform Work Surface The platform work surface option consists of a corner tray bolted onto the top and mid rails of the platform. 3122343200 520AJ HC3...

  • Page 93: Skyglazier

    * Refer to the capacity decals installed on the machine for capacity zone information. Required Platform Type: Side-Entry Maximum Dimensions of Panel: 32 sq ft (3 sq m) Maximum Wind Speed: 20 mph (32 kph) 6.7.2 Safety Precautions WARNING Ensure panel is secured with strap. 520AJ HC3 3122343200...
  • Page 94 Ensure strap is not torn or frayed. 6.7.4 Operation 1. Load SkyGlazier tray with panel. 2. Position panel to its desired location on the tray. 3. Route the adjustable strap around the panel and tighten until secure. 3122343200 520AJ HC3...

  • Page 95: Skypower® 7.5 Kw And Generator 4 Kw

    1-phase: 240 V / 120 V, 60 Hz, 6 kW (Peak: 6 kW) Generator 4 kW Specifications: • 1-phase: 240 V / 120 V, 60 Hz, 4 kW • 1-phase: 230 V / 115 V, 50 Hz, 4 kW 520AJ HC3 3122343200...

  • Page 96: Skysense

    SkySense is intended to assist the operator. SkySense may not detect certain objects depending on shape, type of material, or orientation of the object to the sensors. It is the operator’s responsibility to be aware of their surroundings at all times. 3122343200 520AJ HC3...
  • Page 97 7. Recycle the footswitch and press the override button on the platform control console. 8. Continue to lower the platform. The machine should move in the elevated drive speed mode (SkySense Status LED will remain red). Note: The SkySense system will not stop machine operation while in Creep. 520AJ HC3 3122343200...
  • Page 98 LED Red: Machine is in SkySense stop zone and all machine functions will cease. • LED Flashing Red: SkySense sensor is obstructed or damaged. Obstructions must be removed and proper function verified. Damaged sensors must be replaced. 3122343200 520AJ HC3...
  • Page 99 Note: Override is only required to be engaged if the operator desires to move the platform closer to an object that is in or entering the stop zone. 520AJ HC3 3122343200...
  • Page 100 SkyGuard will function normally. 6.9.6 SkySense Coverage Areas BM000009A BM000010A Figure 25. SkySense Coverage Level Figure 26. SkySense Coverage Level 1 Areas (2– Bar) 2 Areas (3 — Bar) Note: Sensor Cones shown are approximations for reference only. 3122343200 520AJ HC3...

  • Page 101: Skysense® Platform Bumper Padding

    A padding kit is mounted to the platform rails and to a frame suspended below the platform. Limit switches deactivate platform functions when the padded framework contacts an adjacent structure. A button on the platform console allows override of the system. 520AJ HC3 3122343200...

  • Page 102: Soft Touch (Work Load Capacity)

    6. Limit Switch 6.12 SOFT TOUCH (WORK LOAD CAPACITY) Table 8. Maximum Work Load Capacity with Soft Touch Machine Model Weight Maximum Work Load (Capacity) - 520AJ HC3 ANSI/GB Unrestricted: 588 lb (266 kg) Restricted: 678 lb (307 kg) Restricted:...

  • Page 103: General Specifications And Operator Maintenance

    Unrestricted: CE/UKCA, AS/NZS, GB, EAC 660 lb (300 kg) Restricted: ANSI 750 lb (340 kg) Restricted: CE/UKCA, AS/NZS, GB, EAC 750 lb (340 kg) Restricted: ANSI 1000 lb (454 kg) Restricted: CE/UKCA, AS/NZS, GB, EAC 1000 lb (450 kg) 520AJ HC3 3122343200...

  • Page 104: Dimensional Data

    6’9" (2.06 m) Turning Radius (Outside) 15’8" (4.78 m) Wheel Base 93.0" (2.36 m) Ground Clearance 16.5" (419 mm) Platform Height 52’6" (16 m) Up and Over Platform Height 24’ (7.3 m) Horizontal Reach 32.8’ (10 m) 3122343200 520AJ HC3...

  • Page 105: Engine Data

    Stage V 0.47 gph (1.78 Lph) Output 49 hp (36.4 kW) Table 13. Deutz D 2.3 L3 (T4i) Fuel Diesel Number of Cylinders Displacement 2.3 L (142 cu. in) Oil Capacity (Engine Only) 1.5 gal (5.5 L) 520AJ HC3 3122343200...

  • Page 106: Hydraulic Oil Specifications

    GL-3 and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends standard UTTO. Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 107 General Specifications and Operator Maintenance Note: When temperatures remain consistently below 20° F (-7° C), JLG Industries recommends the use of a premium “cold weather” hydraulic fluid (Viscosity Gr. 32). Table 16. Hydraulic Oil Properties and Classifications Fluid Properties Base...

  • Page 108: Hydraulic Oil Operating Temperature Specifications

    The addition of a hydraulic oil cooler is highly recommended for prolonged operation in this temperature range (Consult JLG Service). Operation in this temperature range should include the use of hydraulic system heating aids (Consult JLG Service). The addition of a hydraulic oil cooler is not recommended for operation in this temperature range. 3122343200...

  • Page 109: Deutz D2011 Engine Oil Operating Temperature Specifications

    General Specifications and Operator Maintenance DEUTZ D2011 ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS DEUTZ (T4F/STAGE V) ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS 520AJ HC3 3122343200...

  • Page 110: Operator Maintenance And Lubrication Diagram

    Lubrication Diagram. Table 17. Lubrication Specifications. SPECIFICATIONS Bearing Grease (JLG Part No. 3020029) Mobilith SHC 460. Hydraulic Oil. API service classification GL-4, e.g. Standard UTTO. EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil- Spec Mil-L-2105.
  • Page 111 1. Swing Bearing Lube Point(s) - Fitting Capacity - A/R Lube - BG Interval - Every 3 months or 150 hrs of operation Comments - Apply grease and rotate in 90 degree intervals until bearing is completely lubricated 520AJ HC3 3122343200...
  • Page 112 Lube - Lubriplate 930-AAA Interval - A/R Lube Point(s) - Grease Fitting Capacity - A/R Lube - Mobil SHC 007 Interval - A/R CAUTION Do not overgrease bearings. Overgreasing bearings will result in damage to outer seal in housing. 3122343200 520AJ HC3...
  • Page 113 4. Hydraulic Return Filter Lube Point(s) - Replaceable Element Interval - Change after first 50 hours and every 6 months or 300 hours thereafter 520AJ HC3 3122343200...
  • Page 114 Capacity - 24 oz. (0.8 L)(1/2 Full) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation 1. Oil Level Check And Fill 3122343200 520AJ HC3...
  • Page 115 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 10 Quarts (9.5 L) with Filter Lube - EO Interval - Check level daily; change every 500 hours or six months, whichever comes first. Adjust final oil level by mark on dipstick. 520AJ HC3 3122343200...
  • Page 116 Interval - Every year or 500 hours of operation 10. Charge Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter. Comments - Remove the engine tray retaining bolt and pull out engine tray to gain access. 3122343200 520AJ HC3...

  • Page 117: Tires And Wheels

    JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved...
  • Page 118 When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

  • Page 119: Radio Frequency (Rf) Information

    Sky Smart Fleet telematics must be received by countries that are certified to have ClearSky Smart Fleet. For a full listing of ClearSky Smart Fleet certified countries, please refer to the ClearSky webpage on the JLG website. 520AJ HC3 3122343200...
  • Page 120 Consequently, a person within 20 cm (8 inches) of a CS550 that is connected to machine battery power could expose that person to RF energy in excess of what has been established by the ISED RF exposure guidelines. 3122343200 520AJ HC3...

  • Page 121: Supplemental Information Only Applicable To Ce/Ukca Machines

    JLG Industries, Inc. declares that the radio equipment ClearSky Smart Fleet CS550 Connectivity Module complies with Directive 2014/53/EU. Full details can be found on the declaration of conformity. The CS550 is intended to be mounted on JLG machines and has integrated beacon functionality. Additionally, it provides telematics data via WiFi or Cell, and provides local diagnostic data exchange with a mobile device connected via WiFi and BLE.
  • Page 122 General Specifications and Operator Maintenance 3122343200 520AJ HC3...

  • Page 123: Ec Declaration Of Conformity

    EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) •...

  • Page 124: Ukca Declaration Of Conformity

    EN 60204-1:2018 • EN 280–1:2022 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 2016 •...
  • Page 125 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Any additional required certificates can be attached to the rear cover of this manual or stored in the manual box. Date Comments...
  • Page 126 Inspection, Maintenance and Repair Log...
  • Page 128 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

Table of Contents