Jlg 510AJ Series II Operator Manual Bedienungsanleitung

Operation and Safety Manual ANSI®Original Instructions - Keep this manual with the machine at all times.Boom Lift Models510AJ Series IIS/N E300001115

TABLE OF CONTENTSiv – JLG Lift – 3121292SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGELIST OF TABLES1-1 Minimum Approach Distance

SECTION 7 - INSPECTION AND REPAIR LOG7-2 – JLG Lift – 3121292Table 7-1. Inspection and Repair LogDate Comments

TRANSFER OF OWNERSHIPTo Product Owner:If you now own but ARE NOT the original purchaser of the product covered by this manual, we would like to know w

Corporate OfficeJLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA (717) 485-5161 (717) 485-6417JLG Worldwide LocationsJLG Industries (

SECTION 1 - SAFETY PRECAUTIONS3121292 – JLG Lift – 1-1SECTION 1. SAFETY PRECAUTIONS1.1 GENERALThis section outlines the necessary precautions for pro

SECTION 1 - SAFETY PRECAUTIONS1-2 – JLG Lift – 3121292• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the m

SECTION 1 - SAFETY PRECAUTIONS3121292 – JLG Lift – 1-31.3 OPERATION General • Do not use the machine for any purpose other than posi-tioning personnel

SECTION 1 - SAFETY PRECAUTIONS1-4 – JLG Lift – 3121292• Before operating the machine, make sure all gates areclosed and fastened in their proper posit

SECTION 1 - SAFETY PRECAUTIONS3121292 – JLG Lift – 1-5• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) par

SECTION 1 - SAFETY PRECAUTIONS1-6 – JLG Lift – 3121292• The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent

SECTION 1 - SAFETY PRECAUTIONS3121292 – JLG Lift – 1-7• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft sur

SECTION 1 - SAFETY PRECAUTIONS1-8 – JLG Lift – 3121292• Use the boom functions, not the drive function, to positionthe platform close to obstacles. •

SECTION 1 - SAFETY PRECAUTIONS3121292 – JLG Lift – 1-91.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.• When performing we

NOTE: This manual also applies to the following machine withthe following Serial Number: E0300001068.

SECTION 1 - SAFETY PRECAUTIONS1-10 – JLG Lift – 3121292DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28MPH (12.5 M/S).Table 1-2. Beaufort Sca

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-1SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION,

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-2 – JLG Lift – 31212922.2 PREPARATION, INSPECTION, AND MAINTENANCEThe followin

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-3Table 2-1.Inspection and Maintenance TableType Frequency

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-4 – JLG Lift – 3121292Pre-Start InspectionThe Pre-Start Inspection should incl

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-511. Function Check – Once the “Walk-Around” Inspection i

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-6 – JLG Lift – 3121292431611821711101298137614515Figure 2-1. Basic Nomenclatur

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-7Figure 2-2. Basic Nomenclature - Sheet 2 of 21. Front Dr

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-8 – JLG Lift – 3121292Figure 2-3. Daily Walk-Around Inspection - Sheet 1 of 3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-9GENERALBegin the "Walk-Around Inspection" at I

FOREWORD3121292 – JLG Lift – aFOREWORDThis manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to p

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-10 – JLG Lift – 31212929. Tie Rod Ends and Steering Spindles - See Inspection

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121292 – JLG Lift – 2-112.3 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)LOCKOUT

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-12 – JLG Lift – 312129211. Have an assistant check to see that right front or

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-1SECTION 3. MACHINE CONTROLS AND INDICATORS3.1 GENERALTHE MANUFACTURER HAS NO DIREC

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-2 – JLG Lift – 3121292TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SW

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-31HOURS10QUARTZ891011121234567Figure 3-1. Ground Control Station1. Platform Rotate2.

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-4 – JLG Lift – 31212924. Engine Start/ Auxiliary Power Switch /Function EnableTo start the engine, the sw

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-59. Tow e r B o om L i f tProvides raising and lowering of theLower and Mid Booms.1

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-6 – JLG Lift – 312129291. Battery Charging2. Low Engine Oil Pressure3. High Engine Coolant Temp.4. Engine

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-75. System Distress IndicatorThe light indicates that the JLG ControlSystem has dete

FOREWORDb – JLG Lift – 3121292SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDSINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-8 – JLG Lift – 3121292Platform Control StationTO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-91. Drive Speed/Torque Select2. Platform Leveling 3. Horn4. Power/Emergency Stop5. S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-10 – JLG Lift – 3121292TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-119. Telescope Control This switch allows extension and retractionof the main boom.1

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-12 – JLG Lift – 312129216. Function Speed ControlThis control affects the speed of tele-scope, tower lift

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-131. AC Generator2. Platform Overload3. Tilt Alarm Warning4. Glow Plug/Wait to Start

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-14 – JLG Lift – 31212923. Tilt Alarm Warning Light and AlarmThis illuminator indicates that the chassis i

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121292 – JLG Lift – 3-155. Enable Indicator/FootswitchTo operate any function, the footswitchmust be depre

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-16 – JLG Lift – 31212928. System Distress IndicatorThe light indicates that the JLG ControlSystem has det

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-1SECTION 4. MACHINE OPERATION4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equip

FOREWORD3121292 – JLG Lift – cTHIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG RE

SECTION 4 - MACHINE OPERATION4-2 – JLG Lift – 3121292StabilityMachine stability is based on two (2) conditions which arecalled FORWARD and BACKWARD st

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-32. After engine has had sufficient time to warm up, shutengine off.3. Turn SELECT switch to PLATF

SECTION 4 - MACHINE OPERATION4-4 – JLG Lift – 3121292TELESCOPEFULLY EXTENDEDTOWER BOOMSTOWED POSITIONMAIN BOOMHORIZONTALMACHINE TIP OVER INTHIS DIREC

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-5.4.4 TRAVELING (DRIVING)NOTE: Refer to the Operating Specifications table in Section 6 forGradeab

SECTION 4 - MACHINE OPERATION4-6 – JLG Lift – 3121292DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON ASMOOTH, FIRM AND LEVEL SURFACE.TO AVOID LOSS O

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-7LEVELGRADESIDESLOPEFigure 4-3. Grade and Side Slopes

SECTION 4 - MACHINE OPERATION4-8 – JLG Lift – 31212924.5 STEERINGPosition thumb switch on Drive/Steer controller to RIGHT forsteering right, or to LEF

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-9TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANYCONTROL LEVER OR TOGGLE SWITCH CONTROLLIN

SECTION 4 - MACHINE OPERATION4-10 – JLG Lift – 31212924.9 AUXILIARY PUMPWHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORETHAN ONE FUNCTION AT THE

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-114.11 SHUT DOWN AND PARKThe procedures to shut down and park the machine are asfollows: 1. Drive

FOREWORDd – JLG Lift – 3121292REVISION LOGOriginal Issue - April 1, 2013

SECTION 4 - MACHINE OPERATION4-12 – JLG Lift – 31212921001143110 A450ASERIES II510AJAB450AJSERIES II62.8 in(1595 mm)64.3 in(1634 mm)63.7 in(1618 mm)4

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-134.13 TOWINGRUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE A

SECTION 4 - MACHINE OPERATION4-14 – JLG Lift – 3121292142637383618672445147Figure 4-6. Decal Installation - Sheet 1 of 6

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-1543524515403Figure 4-7. Decal Installation - Sheet 2 of 6

SECTION 4 - MACHINE OPERATION4-16 – JLG Lift – 3121292252420 22213348263535252479Figure 4-8. Decal Installation - Sheet 3 of 6

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-17262627274443Figure 4-9. Decal Installation - Sheet 4 of 6

SECTION 4 - MACHINE OPERATION4-18 – JLG Lift – 312129211340459341041111242395415012Figure 4-10. Decal Installation - Sheet 5 of 6

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-1912134112328313249Figure 4-11. Decal Installation - Sheet 6 of 6

SECTION 4 - MACHINE OPERATION4-20 – JLG Lift – 3121292Table 4-1. Decal LegendItem # ANSI1001143099-AAustralian1001143100-AJapanese1001143101-AKorean10

SECTION 4 - MACHINE OPERATION3121292 – JLG Lift – 4-2117- -- -- -- -- -- -- -- -- -18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

TABLE OF CONTENTS3121292 – JLG Lift – iSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGESECTION - 1 - SAFETY PRECAUTIONS1.1 GENERAL

SECTION 4 - MACHINE OPERATION4-22 – JLG Lift – 312129235- -- -- -- -- -- -- -- -- -36- -- -- -- -- -- -- -- -- -37- -- -- -- -- -- -- -- -- -38- -- --

SECTION 5 - EMERGENCY PROCEDURES3121292 – JLG Lift – 5-1SECTION 5. EMERGENCY PROCEDURES5.1 GENERALThis section explains the steps to be taken in case

SECTION 5 - EMERGENCY PROCEDURES5-2 – JLG Lift – 31212925.3 EMERGENCY OPERATIONOperator Unable to Control MachineIF THE PLATFORM OPERATOR IS PINNED, T

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-1SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6.1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-2 – JLG Lift – 3121292Reach SpecificationsMaximum Drive Speed: 4.5 mph (2.0 m/s)Maximum

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-3Dimensional Data ChassisTable 6-3. Dimensional DataOverall Width

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-4 – JLG Lift – 3121292CapacitiesTiresEngineNOTE: RPM Tolerances are ± 100. Table 6-5. C

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-5Major Component WeightsTable 6-8. Caterpillar C2.2Fuel DieselNo.

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-6 – JLG Lift – 3121292Hydraulic OilNOTE: Hydraulic oils must have anti-wear qualities a

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-7Table 6-12. Mobil DTE 13M SpecsISO Viscosity Grade #32Specific G

TABLE OF CONTENTSii – JLG Lift – 3121292SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE4.5 STEERING . . . . . . . . . . . . . . .

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-8 – JLG Lift – 3121292Table 6-14. Mobil EAL H 46 SpecsType Synthetic BiodegradableISO V

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-9Table 6-16. Quintolubric 888-46Density0.91 @ 15°C (59°F)Pour Poin

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-10 – JLG Lift – 3121292Serial Number LocationA serial number plate is affixed to the le

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-11-40°F(-40°C)-30F°(-34°C)-20°F(-29°C)-10°F(-23°C) 0°F(-18°C) 10°

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-12 – JLG Lift – 3121292(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHL

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-13-40°°F(-40 C)-30° °F(-34 C)-20°F(-29°C)-10°F(-23°C) 0°F(-18°C)

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-14 – JLG Lift – 3121292(HYD. OIL TANK TEMP.)IF EITHER OR BOTH CONDITIONSEXIST JLG HIGHL

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-15Figure 6-6. Operator Maintenance and Lubrication Diagram

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-16 – JLG Lift – 31212926.3 OPERATOR MAINTENANCENOTE: The following numbers correspond t

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-172. Swing Bearing/Worm Gear TeethLube Point(s) - Grease FittingCa

TABLE OF CONTENTS3121292 – JLG Lift – iiiSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE6.5 SUPPLEMENTAL INFORMATION . . . . . .

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-18 – JLG Lift – 31212923. Wheel Drive HubLube Point(s) - Level/Fill PlugCapacity - 17 o

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-196. Hydraulic TankLube Point(s) - Fill CapCapacity - 27 gallons (

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-20 – JLG Lift – 31212928. Oil Change w/Filter - CaterpillarLube Point(s) - Fill Cap/Spi

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-2111. Air Filter Lube Point(s) - Replaceable ElementInterval - Eve

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-22 – JLG Lift – 31212926.4 TIRES & WHEELSTire InflationThe air pressure for pneumat

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-23by JLG. Due to size variations between tire brands, both tires

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-24 – JLG Lift – 31212922. Tighten nuts in the following sequence: 3. The tightening of

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121292 – JLG Lift – 6-256.5 SUPPLEMENTAL INFORMATIONThe following information is provide

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-26 – JLG Lift – 3121292NOTES:

SECTION 7 - INSPECTION AND REPAIR LOG3121292 – JLG Lift – 7-1SECTION 7. INSPECTION AND REPAIR LOGMachine Serial Number ______________________________