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JLG-600S-600SJ-660SJ-UM-2009

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1. Item ANSI A French Spanish RI m Korean Australian 0273868 6 0273876 4 0273873 6 0273803 7 0273889 7 0273886 7 1001112941 2 1001114386 1 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 1705084 1705084 15 1705514 1705514 1705514 16 17 3251243 3251243 3251243 3251243 3251243 3251243 3251243 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Table 4 2 600SJ Decal Legend Item ANSI mo French Spanish phis Australian 0273868 6 0273876 4 0273873 6 0273803 7 0273889 7 0273886 7 1001112941 2 1001114386 1 18 19 20 21 22 1703953 1703942 1703941 1703944 1705903 1703945 23 24 1702868 1704000 1704001 1705967 1705969 25 1703797 1705921 1703924 1703923 1703926 1705895 1703927 1705921 26 1705336 1705822 1705347 1705917 1705344 1705896 1705345 1705822 27 1703804 1701518 1703948 1703947 1703950 1705898 1703951
2. 4 32 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Table 4 3 660SJ Decal Legend Item ANSI 5 4 Chinese pies Japanese eei Australian 0273869 6 0273874 6 027387744 0274925 7 0273871 7 0273884 7 0273890 7 0273887 7 1001114387 1 18 19 20 21 22 1703953 1703942 1703945 1703943 1703941 1703944 1705903 23 24 1702868 1704000 1705969 1705968 1704001 1705967 25 1703797 1703924 1705921 1703927 1703925 1703923 1703926 1705895 1705921 26 1705336 1705347 1705822 1705345 1705348 1705917 1705344 1705896 1705822 27 1703804 1703948 1701518 1703951 1703949 1703947 1703950 1705898 1701518 28 1703805 1703936 1705961 1703939 1703937 1703935 1703938 1705897 1705961 29 1703984 1705828 1703981 1703982 1703983 1703980 1705902 1705828 30 3251813 3251813 3251813 3251813 3251813 3251813 31 32 33 1703472 1703472 1703472 1703470 1703472 1703472 1703472 1703472 1703472 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 35 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 3121205 JLG Lift 4 33 SECTION 4 MACHINE OPERATION Table 4 3 660SJ Decal Legend Item ANSI UT idus Korean Chinese 66054 Japanese diens 88 Australian 0273869 6 0273874 6 0273877 4 0274925 7 0273871 7 0273884 7 0273890 7 0273887 7
3. 4 7 Platform Level Adjustment 4 7 JLG Lift i TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT 4 7 4 9 4 10 4 11 4 12 4 13 4 14 4 15 Platform BOOM detener det tenerte ded crier been 4 7 Swinging the 4 8 Raising and Lowering the 4 8 Telescoping the 4 8 SHUT DOWN AND PARK 4 8 OSCILLATING AXLE LOCKOUT TEST IEEQUIPPED ai tate m REG 4 9 STEER TOW SELECTOR IF EQUIPPED 4 9 TOWING IF 4 9 AUXILIARY POWER NON ADE EQUIPPED MA CHINES zzi tbe ei REESE 4 13 Activating from the Platform Control Station 4 13 Activating from the Ground Control Station 4 13 AUXILIARY POWER ADE EQUIPPED MACHINES 4 14 Activating from the Platform Control Station 4 14 Activating from the Ground Control Station 4 14 DUAL FUEL SYSTEM GAS ENGINE ONLY 4 15 Changing From Gasoline to LP 4 15 Changing From LP Gas to Gasoline 4 15 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS 4 15 FOOI Circuit eie E DEDE 4 15 SECTION PARAGRAPH SUBJECT PAGE 4 16 TIE DOWN AND 4 17 SECTION 5 EMERGENCY PROCEDURES 521 GENERALS nec pens cee renes 5 1 5 2 INCIDENT
4. 4 24 6005 Decal 4 28 JLG Lift 3121205 SECTION 1 SAFETY PRECAUTIONS 1 1 SECTION 1 SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and safe machine operation and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A maintenance program using the information provided in this manual and the Service and Maintenance Manual must also be estab lished by a qualified person and followed to ensure the machine is safe to operate The owner user operator lessor lessee of the machine should not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc ULG A WARNING FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROPERTY DAM AGE PERSONAL INJURY OR DEATH 3121205 JLG Lift 1 2 PRE OPERATION Operator Training and Knowledge Read and understand this manual before operating the machine Do not operate this machine until complete training is per formed by authorized persons Only authorized and qua
5. 4 20 2 2 Machine Nomenclature 6008 2 9 4 10 Decal Installation Sheet 2 of 4 4 21 2 3 Daily Walk Around Inspection Diagram 2 10 4 11 Decal Installation Sheet 3 of 4 4 22 2 4 Walk Around Inspection Points 4 12 Decal Installation Sheet 4 of 4 4 23 Sheet 1 13 2 11 6 1 Serial Number Locations 6 11 3121205 Lift iii TABLE OF CONTENTS 6 2 6 3 6 4 6 5 6 6 6 7 6 8 6 9 6 10 6 11 1 1 1 2 4 1 4 2 SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE Engine Operating Temperature Specifications Deutz 4 3 660SJDecalLegend 4 32 Sheet Ere EIE 6 12 6 1 Operating Specifications 6 2 Engine Operating Temperature Specifications Deutz 6 2 6 3 6 13 6 3 Ford LRG 425 Specifications 6 3 Engine Operating Temperature Specifications Ford 6 4 Deutz F4M1011F F4M2011 Specifications 6 4 e ed a ilius 6 14 6 5 Deutz 02011104 Specifications 6 4 Engine Operating Temperature Specifications Ford 6 6 Caterpillar 3044C 3 4 6 5 Sheet 2 012 s oreet Ghee 6 15 6 7 ES ion A evt erue ited 6 5 Engine Operating Temperature Specific
6. AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 F 439 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES 100 F 98 C OF 100 F 38 C OR ABOVE 90 F 32 C 8 80 F 27 C B 70 21 amp S gt 8 E HYDRAULIC 50 F 10 C gt oe SPECIFICATIONS 40 F 4 C 2 30 F 1 C 9 e 20 mo 9 ii 10 F 12 C 1856 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 F 28 C HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE 202 2926 DO NOT START UP HYDRAULIC SYSTEM 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES 30 F 34 WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS V HYDRAULIC OIL BELOW THIS TEMPERATURE HER NO OPERATION BELOW THIS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL AMBIENT TEMPERATURE 4150548 D Figure 6 9 Engine Operating Temperature Specifications GM Sheet 2 of 2 3121205 JLG Lift 6 19 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 9 12 THRU 25 ENGINE LOCATED ON OPPOSITE SIDE OF MACHINE FROM VIEW SHOWN Figure 6 10 Operator Maintenance amp Lubrication Diagram 6 20 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 3 OPERATOR MAINTENANCE NOTE The following numbers correspond to those in Figure 6 10 Operato
7. Syl Parent Metal Crack Weld Crack 3 Decals and Placards Check all for cleanliness and legibility Make sure none of the decals and placards are missing Make sure all illegible decals and placards are cleaned or replaced 4 Operators and Safety Manuals Make sure of the Operator and Safety Manual EMI Safety Manual Domestic only and ANSI Manual of Responsibilities 2 4 JLG Lift Domestic only is enclosed in the weather resistant storage container Walk Around Inspection Refer to Figure 2 3 thru Figure 2 6 Battery Charge as required Fuel Combustion Engine Powered Machines Add the proper fuel as necessary Hydraulic Oil Check the hydraulic oil level Ensure hydraulic oil is added as required Function Check Once the Walk Around 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 instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDIATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Function Check Perform the Function Check as follows 1 From the ground control panel with no load in the plat form a b Check that all guards protectin
8. 6 32 3 2 Ground Control Indicator Panel 3 5 Wheel 6 32 3 8 Malfunction Indicator Light and Test Button 3 7 6 5 OSCILLATING AXLE LOCKOUT TEST 3 4 Platform Control Console 3 8 IF EQUIPPED REIR 6 34 3 5 Platform Control Console w Drive Orientation 3 9 6 6 DRAINING OIL BUILD UP FROM THE PROPANE REG 3 6 Platform Control Indicator Panel 3 15 PRIOR TO S N 0300132529 6 36 3 7 Platform Control Indicator Panel w Drive 6 7 PROPANE FUEL FILTER REPLACEMENT 6 37 3 16 Removal 30 0b ie REED eG 6 37 4 1 Position of Least Backward Stability 4 8 Installation 6 39 4 2 Position of Least Forward Stability 4 4 6 8 PROPANE FUEL SYSTEM PRESSURE RELIEF 6 39 4 3 GradeandSideslope 4 6 6 9 SUPPLEMENTAL INFORMATION 6 40 4 4 Drive Disconnect 4 10 4 5 Towbar Connecting Points Prior to S N 75606 4 11 SECTION 7 INSPECTION AND REPAIR LOG 4 6 Towbar Connecting Points S N 75606 to Present to ot crane pado ee d bec 4 12 LIST OF FIGURES 4 7 Machine Tie Down 4 18 4 8 Lifting 4 19 2 1 Machine Nomenclature 600SJ 660SJ 2 8 4 9 Decal Installation Sheet 1 of 4
9. Operation and Safety Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models 600S 600SJ 660SJ 3121205 December 1 2009 ADE Identification All 6005 600SJ 6605 machines from S N 61927 incorporate ADE JLG Control System The follow ing machine serial numbers prior to S N 61927 also utilize ADE 58993 58998 59222 59223 59275 59281 59315 59319 59352 59358 59631 59769 60253 60254 60286 60642 60645 61120 61257 61402 61440 61491 61833 61840 61875 and 61878 A Machine that incorporates ADE JLG Con trol System can be outwardly identified by the analyzer connection at the base of the platform control box as shown by the arrow FOREWORD 3121205 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 reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information JLG Lift a FOREWORD 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 messages that follo
10. SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Tires NOTE When temperatures remain below 20 F 7 degrees JLG Industries recommends the use of Mobil DTE 13M Table 6 10 Tire Specifications Aside from JLG recommendations it is not advisable to mix Size 15x19 5 15x19 5 18x625 oils of different brands or types as they may not contain the Load Range G G H same required additives or be of comparable viscosities If Ply Rating 14 14 16 use of hydraulic oil other than Mobilfluid 424 is desired con tact JLG Industries for proper recommendations Tire Pressure 95 PSI 6 5 Bar Foam Filled 75 PSI 5 2 Bar Table 6 12 Mobilfluid 424 Specs Hydraulic Oil SAE Grade 10W30 MM Gravity API 29 0 Table 6 11 Hydraulic Cil Density Lb Gal 60 F 7 35 HYDRAULIC SYSTEM OPERATING Pour Point Max 46 F 43 C SAE VISCOSITY GRADE TEMPERATURE RANGE Flash Point Min 442 F 228 C 0 to 180 F 18 C to 83 10W Viscosity 0 Fto 210 F 18 C to 99 10W 20 10W 30 Brookfield cP at 18 C 2700 50 Fto 210 F 10 C to 210 C 20W 20 at 40 C 55 cSt NOTE Hydraulic oils must have anti wear qualities at least to API at 100 C 9 3 cSt Service Classification GL 3 and sufficient chemical stabil Viscosity Index 152 ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity index of 15
11. 5 1 5 3 EMERGENCY 5 1 Operator Unable to Control Machine 5 1 Platform or Boom Caught Overhead 5 2 5 4 EMERGENCY TOWING PROCEDURES 5 2 5 5 MANUAL DESCENT MACHINES PRIOR TO S N T0075 Sedes 5 2 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 61 6 1 6 2 OPERATING SPECIFICATIONS 6 2 6 3 Engine Data 22 22222 224 6 3 Dimensional Data 6 6 Torque 6 6 THOS aii a Te EN Eo 6 7 Hydraulic 6 7 Critical Stability Weights 6 9 Serial Number Locations 6 11 3121205 JLG Lift TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE 6 3 OPERATOR 6 21 2 5 Daily Walk Around Inspection Points 64 TIRES amp WHEELS 6 31 Shet Z Of 9i oce Le res eet 2 12 Tire Inflation 6 31 2 6 Daily Walk Around Inspection Points Tire 6 31 ONO of 9 visse ctus ir peas 2 13 Tire 6 31 3 1 Ground Control 3 2 Wheel
12. Lube Point s Repack Machines after S N 38047 will have composite bushings Capacity A R and no grease fittings Lube MPG 1 2 1200 h f ti 4 Steer Spindles 4WD Interval Every 2 years or 1200 hours of operation Lube Point s 4 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Machines after S N 38047 will have composite bushings and no grease fittings 6 22 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 Swing Drive Hub _ 7 Wheel Drive Hub Lube Point s Level Fill Plug Lube Point s Level Fill Plug Capacity 17 oz 1 2 Full Capacity 17 oz 1 2 Full Lube EPGL Lube EPGL Interval Check level every 3 months or 150 hrs of opera Interval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation tion change every 2 years or 1200 hours of operation 3121205 JLG Lift 6 23 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 8 Hydraulic Return Filter 9 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator 300 hrs thereafter or as indicated by Condition Indicator 6 24 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 10 Hydraulic Tan
13. JLG Lift 6 11 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120 F 49 C NO OPERATION ABOVE THIS 1 A AMBIENT TEMPERATURE 110 F 43 C 100 F 38 C 90 F 32 C 1 80 F 27 C a 2 fa fs m amp fs 70 F 21 0 ENGINE 5 i i E 60 F 16 C SPECIFICATIONS m fol e uu dm 5 lal 5 5 5 iiia 40 F 4 C 30 1 ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE Ly 20 67 0 TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10 12 FULLY CHARGED BATTERY ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER OP WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY GRADE 28 C AND THE AID OF ACOMPLETE JLG SPECIFIED COLD WEATHER MEN E 0 29 PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR KEROSENE GLOW PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ADDED 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE Figure 6 2 Engine Operating Temperature Specifications Deutz Sheet 1 of 2 6 12 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 180 F 82 C HYD OIL TANK TEMP AMBIENT AIR TEMPERATURE 120 F 49 C 110 F 43 C
14. The minimum approach distance may be reduced if insulat Tipping Hazards ing barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These The user must be familiar with the surface before driving barriers shall not be part of or attached to the machine The Do not exceed the allowable sideslope and grade while minimum approach distance shall be reduced to a distance driving within the designed working dimensions of the insulating e barrier This determination shall be made by a qualified per son in accordance with the employer local or governmental requirements for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE 1 6 JLG Lift 3121205 SECTION 1 SAFETY PRECAUTIONS Do not elevate platform or drive with platform elevated f boom assembly or platform is in a position that one or while on a sloping uneven or soft surface more wheels are off the ground all persons must be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distribute loads evenly on platform floor Crushing and Colli
15. FACTURER The operator is to take safety measures to avoid all haz ards in the work area prior to machine operation Do not operate the machine in hazardous environments unless approved for that purpose by JLG Do not operate any machine on which safety or instruction Besure that the ground conditions are able to support the placards or decals are missing Or illegible maximum load shown on the decals located on the machine Avoid any buildup of debris on the platform floor Keep mud oil grease and other slippery substances from foot wear and platform floor 1 2 JLG Lift 3121205 SECTION 1 SAFETY PRECAUTIONS 1 3 OPERATION General 3121205 Do not use the machine for any purpose other than posi tioning personnel their tools and equipment Never operate a machine that is not working properly If a malfunctions occurs shut down the machine Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Oper ate controls with slow and even pressure 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 Contact JLG for approved material handling accessories When two or more persons are in the platform the opera tor shall be responsible for
16. Table 6 1 Operating Specifications Ground Bearing Pressure 600S 67 psi 4 7 kg cm 600SJ 70 psi 4 9 kg cm 660SJ 75 psi 5 3 kg cm Maximum Drive Speed 2WD 4 5 MPH 7 25 Km hr 4WD 4 MPH 6 44 Km hr Gross Machine Weight Approximate 6005 2WD 22 000 Ibs 9 979 2 kg Maximum Work Load Capacity Unrestricted 500 Ib 230 kg Restricted 1000 Ib 450 kg Maximum Travel Grade Gradeability 2WD 30 4WD 45 Maximum Travel Grade Side Slope 5 Turning Radius outside 2WS 2WD 17 ft 9 in 5 41 2WS 4WD 20 ft 4 6875 in 6 21 m 4WS 2WD 11 ft 4in 3 45 m 4WS 4WD 11 ft 2 6875 in 3 42 Turning Radius inside 2WS 2WD 12 ft 3 66 2WS AWD 14ft 3 875 in 5 25 m 4WS 2WD 5 ft Sin 1 65 4WS 4WD 5ft 3 625 in 1 22 m Maximum Tire Load 6005 amp 6005 11 800 105 5364 kg 6605 14 200 Ibs 6455 kg 6 2 6005 2WD 23 500 Ibs 10 660 kg 6605 2WD 25 500 Ibs 11 567 kg 6005 AWD 22 510 Ibs 10 211 kg 6005 AWD 23 980 Ibs 10 877 kg 6605 AWD 29 910 Ibs 11 753 kg 3121205 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Capacities Table 6 2 Capacities Fuel Tank 39 Gallons 147 6 L Engine Data Table 6 3 Ford LRG 425 Specifications Hydraulic Oil Tank 31 Gallons 117 3 L w 10 air space Hydraulic System Including Tank 37 2 Gallons
17. 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 10 C 50 F 10 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C 0 F 18 C 10 F 23 C 20 F 29 C 80 F 34 C 40 F 40 C EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE MOBIL 424 10W 30 HYDRAULIC SPECIFICATIONS EXXON UNIVIS HVI 26 MOBIL DTE 13 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER V HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THIS AMBIENT TEMPERATURE AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 32 23 14 5 4 5 10 15 SUMMER GRADE WINTER GRADE FUEL FUEL REN 0 10 20 30 40 50 OF ADDED KEROSENE Fiqure 6 3 Engine Operating Temperature Specifications Deutz Sheet 2 of 2 3121205 JLG Lift 60 4150548 D 6 13
18. 140 8L Torque Hub Drive 17 ounces 0 50 L Engine Crankcase Ford LRG 425 Gas w Filter 4 5 quarts 4 25L Ford LRG 423 Gas w Filter 5 00 quarts 4 731 Deutz FAM1011FDiesel w Filter 11 quarts 10 5L Deutz D2011L04 11 quarts 10 5 L Caterpillar 3044C Diesel w Filter 10 6 quarts 101 GM 4 5 qts 4 25 L w Filter Fuel Gasoline Oil Capacity 4 5 Quarts 4 25 L w Filter Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 40 Amp Belt Drive Battery 85 Amphour 550 Cold Cranking Amps 12 VDC Fuel Consumption Torque hubs should be one half full of lubricant 3121205 JLG Lift Low RPM 3 45 GPH 13 06 Iph High RPM 4 60 GPH 17 41 Iph Horsepower 54 2400 RPM full load Cooling System 16 Quarts 15 141 SparkPlug AWSF 52 C Spark Plug Gap 0 044 in 1 117 mm 6 3 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 4 Deutz 1011 4 2011 Specifications Table 6 5 Deutz 02011104 Specifications Fuel Diesel Oil Capacity Cooling System 5 Quarts 4 5L Crankcase 11 Quarts 10 5 L w Filter Total Capacity 16 Quarts 15L Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 60 Amp belt drive Battery 950 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC Fuel Consumption Fuel Diesel Oil Capacity Cooling System 5 Quarts 4 5L Crankcase 11 Quarts 10
19. SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE AN NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG 120 F 49 C 110 F 43 C 100 F 38 C 80 SAE 5W 20 90 F 32 2 70 F 21 60 F 1 50 F 10 SAE 5W 30 4 SAE 5W 40 4 40 F 4 30 F 1 ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY p 12C lt lt 10W 30 1 5 SAE 10W 40 c 4 A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS 18C 10 F 23 C 30 F 34 C y y 40 F 40 C C C 20 F 7 C 58 C 20 F 29 C C C NO OPERATION BELOW THIS AMBIENT TEMPERATURE Figure 6 4 Engine Operating
20. 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 33 34 35 36 37 38 39 3121205 Battery Proper electrolyte levels cables tight no vis ible damage or corrosion Engine Oil Supply Full mark on dipstick filler cap secure Muffler and Exhaust System See Note Hydraulic Pump See Note Engine Tray Pivot See Note Hydraulic Oil Medium Pressure Filter Housing Hous ing secure Hydraulic Swivel See Note 40 41 42 43 44 45 Horizontal Cutoff Limit Switch High Engine High Drive Cut off Switch Arm free to move and free from dirt and grease LP Gas Tank If Equipped See Note Flow Valves See Note Frame See Note Main Boom Sections Wear pads secure All cylinders rod end shafts and barrel end shafts properly secured evidence of proper lubrication Platform Pivot Pin See Note Figure 2 6 Daily Walk Around Inspection Points Sheet 3 of 3 JLG Lift 2 13 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION ex NOTES 2 14 JLG Lift 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY P
21. 9 O ring 13 Ring Filter Housing Figure 6 11 Filter Lock Assembly JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Installation 6 8 PROPANE FUEL SYSTEM PRESSURE RELIEF BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 BEFORE INSTALLING NEW SEAL PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRESSURE WHERE 1 Install the mounting plate to lock off O ring seal APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COM 2 lfequipped install the retaining bolt seal PONENTS 3 Install the housing seal To relieve propane fuel system pressure 4 Drop the magnet into the bottom of the filter housing 1 Close the manual shut off valve on the propane fuel 5 Install the filter into the housing fanis 6 If equipped install the retaining bolt into the filter hous stalls ing 3 Turn the ignition switch OFF 7 Install the filter up to the bottom of the electric lock off CAUTION Bs RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS Open manual shut off valve Start the vehicle and leak ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS check the propane fuel system at each serviced fitting CONNECTING ANY FUEL LINE Refer to Propane Fuel System Leak Test 3121205 JLG Lift 6 39 SECTION 6 GENERAL SPE
22. GENERAL This section explains the steps to be taken in case of an emergency situation while operating INCIDENT NOTIFICATION JLG Industries Inc must be notified immediately of any inci dent involving a JLG product Even if no injury or property damage is evident the factory should be contacted by tele phone and provided with all necessary details In USA JLG Phone 877 JLG SAFE 554 7233 8am till 4 45pm EST 9 2 Outside USA 240 420 2661 E mail ProductSafety JLG com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occur rence may void any warranty consideration on that particular machine 3121205 JLG Lift NOTICE FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY 5 3 EMERGENCY OPERATION Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE 1 Other personnel should operate the machine from ground controls only as required 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 3 Cranes forklift trucks or other equipment can be used to remove p
23. IF EQUIPPED DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COM PLETE TOW PACKAGE FROM MANUFACTURER A push pull type selector valve located adjacent to the steer cylinder and linkage regulates oil flow in the steer circuit for steering and towing When steering the unit the valve knob is pushed IN When towing the unit the valve knob is pulled OUT to the float position 3121205 JLG Lift 4 11 TOWING IF EQUIPPED RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOL LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 8 13 K M H MAXIMUM TOWING GRADE 25 Prior to towing the machine complete the following A CAUTION DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower and position boom over rear drive wheels in line with direction of travel lock turntable 4 9 SECTION 4 MACHINE OPERATION 4 10 2 Connect tow bar to front of frame with attach pins and tow bar to towing vehicle Disconnect drive hubs by inverting disconnect cap Refer to Figure 4 4 Drive Disconnect Hub Actuate steer tow selector valve for towing pull valve knob OUT to float position This opens the steer circuit to reservoir allowing the steer cylinder rod free travel The machine is now in the towing mode After towing the machine comp
24. Jib A 4 Power Emergency Stop 3 _ 10 5 Engine Start Auxiliary Power or OR 4 Engine Start Auxiliary Power Function Enable X 6 Boom Lift 7 Hourmeter EP 8 Platform Ground Select Switch 5 9 Swing 10 Boom Telescope 6 7 El com 4 1 9 8 Figure 3 1 Ground Control Station 3 2 JLG Lift 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 Jib If Equipped 5 Engine Start Auxiliary Power Switch or This switch provides raising and lowering of the jib Engine Start Auxiliary Power Switch Function Enable NOTE When Stop switch is in the ON posi To start the engine the switch must be held UP tion and engine is not running an alarm will sound indi until the engine starts 9 cating Ignition is To use auxiliary power the switch must be held DOWN for duration of auxiliary pump use Aux A CAUTION power can only be used if the engine is not run h WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP ning SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY If equipped the enable switch must be held DOWN to enable all boom controls when the NOTE machines with diesel engines when Glow Plug Indi engine is running cator is lighted Yellow wait until light goes out before cranking engine A CAUTION WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN O
25. Maintenance Manual ANSI Spec 1 secti ofthe manualkprovides additional necessary Prior to s n 0300080000 3120718 information to the operator for proper operation and mainte nance of this machine Service and Maintenance Manual Euro Spec The maintenance portion of this section is intended as infor Prior to s n 0300080000 3120840 mation to assist the machine operator to perform daily main Service and Maintenance Manual Global Spec tenance tasks only and does not replace the more thorough s n 0300080000 to 1 3121202 Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Illustrated Parts Manual ANSI Spec Prior to s n 0300068000 3120720 Illustrated Parts Manual Euro Spec Prior to s n 0300068000 3120842 Illustrated Parts Manual ANSI Spec s n 0300068000 to 0300085000 3121178 Illustrated Parts Manual Euro Spec s n 0300068000 to 0300085000 3121856 Illustrated Parts Manual Global Spec s n 0300085000 to 3121207 3121205 JLG Lift 6 1 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 2 OPERATING SPECIFICATIONS Table 6 1 Operating Specifications
26. OF LEVEL SURFACE 4 3 ENGINE OPERATION NOTE Initial starting should always be performed from the Ground Control station 4 2 JLG Lift Starting Procedure A CAUTION IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED TIME SHOULD ENGINE FAIL TO START AGAIN ALLOW STARTER TO COOL OFF FOR 2 3 MINUTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MANUAL NOTE Diesel engines only After turning on ignition operator must wait until glow plug indicator light goes out before cranking engine 1 Turn key of SELECT switch to GROUND Position POWER EMERGENCY STOP switch to ON then push the ENGINE START switch until engine starts A CAUTION ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 2 After engine has had sufficient time to warm up shut engine off 3 Turn SELECT switch to PLATFORM 3121205 SECTION 4 MACHINE OPERATION 4 From Platform pull POWER EMERGENCY STOP switch out then push the ENGINE START switch until engine starts NOTE Footswitch must be in released up position before S E A starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE 2 Shutdown Procedure A CAUTION IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN DETERMINE THE CAUSE AND CORRECT IT BEF
27. OPERATION 3121205 O o 3539590 LIFT HERE CENTER F GRAVITY 43 1092 2 mm 44 1117 6 42 1066 8 mm ROTATION Figure 4 8 Lifting Chart JLG Lift 4 19 SECTION 4 MACHINE OPERATION BATTERY INSIDE 1 OF ENGINE Figure 4 9 Decal Installation Sheet 1 of 4 4 20 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Figure 4 10 Decal Installation Sheet 2 of 4 3121205 JLG Lift 4 21 SECTION 4 MACHINE OPERATION Figure 4 11 Decal Installation Sheet 3 of 4 4 22 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Figure 4 12 Decal Installation Sheet 4 of 4 3121205 JLG Lift 4 23 SECTION 4 MACHINE OPERATION Table 4 1 600S Decal Legend ME MIT MC EE T Ed 0273875 3 0273882 6 0273885 6 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 170
28. Temperature Specifications Ford Sheet 1 of 2 6 14 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 3121205 180 82 C HYD OIL TANK TEMP EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC A OIL COOLER CONSULT JLG SERVICE 120 F 49 110 43 C 100 F 38 90 F 32 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C C 0 18 C 10 F 23 C C 20 F 29 C C 30 F 84 C C MOBIL 424 10W 30 MOBIL DTE 13 PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE HYDRAULIC SPECIFICATIONS NOTE EXXON UNIVIS 26 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER V HYDRAULIC OIL BELOW THIS TEMPERATURE 40 F 40 C C NO OPERATION BELOW THIS AMBIENT TEMPERATURE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 4150548 D Figure 6 5 Engine Operat
29. all machine operations Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area Supplies or tools which extend outside the platform are prohibited unless approved by JLG When driving always position boom over rear axle in line with the direction of travel Remember if boom is over the front axle steer and drive functions will be reversed Do not assist a stuck or disabled machine by pushing pulling or by using boom functions Only pull the unit from the tie down lugs on the chassis Do not place boom or platform against any structure to steady the platform or to support the structure Stow boom and shut off all power before leaving machine Trip and Fall Hazards During operation occupants in the platform must wear a full body harness with a lanyard attached to an authorized lan yard anchorage point Attach only one 1 lanyard per lan yard anchorage point JLG Lift 2 SECTION 1 SAFETY PRECAUTIONS Before operating the machine make sure all gates are Use extreme caution when entering or leaving platform closed and fastened in their proper position Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform closer to the ground for entry exit Face the machine maintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Ele
30. at idle 6 psi 0 4 Bar 1000 rpm Hot 18 psi 1 2 Bar 2000 rpm Compression Ratio 9 2 1 Firing Order 1 3 4 2 Max RPM 2800 6 5 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Dimensional Data Table 6 8 Dimensional Data Torque Requirements Table 6 9 Torque Requirements Boom Elevation 6005 460ft 53 4 in 18 43 m 91t 93 16in 2 98 m Machine Height Stowed 8ft 4 75in 2 56 Torque Value Dry Interval Machine Length Stowed 6005 Over Drive Axle 27 ft 11 125in 8 51 m Bearing To Chassis See Note 50 600 6005 Over Drive Axle 32ft 11 75in 10 05 m 6606 Over Drive Axle 35ft 2 875in 11 40 Bearing To Turntable See Note 50 600 Machine Width Wire Rope 1511 105 20 Nm 150 2WS 2WD 7 ft 11 375 in 2 42 m 2WS AWD 71t 11 4375in 242 m Wheel Lugs DR 4WS 2WD 7ft 11 4375in 242m Engine Mounting Bolts 165ft Ibs 231 Nm R AWS AWD 71t 11 375in 242 m 9 ng M Engine Manifold Mountin 30 ft Ibs 42 Nm R Wheelbase Bit 1 50in 2 48m y Boom Elevation 6005 60 ft 213 16 in 18 36 m Check swing bearing bolts for security after first 50 hours of operation and 6 ft 1 11 16in 1 87 every 600 hours thereafter See Swing Bearing in Section 3 Boom Elevation 660SJ 66 ft 7 5 8 in 20 31 m 11ft 51 4in 3 49 m 6 6 JLG Lift 3121205
31. change Pre Delivery Inspection Before each sale lease or rental delivery Owner Dealer orUser Qualified JLG Service and Maintenance See Note Mechanic Manual and applicable JLG inspection form Frequent Inspection In service for 3 months 150 hours whichever Owner Dealer orUser Qualified JLG Service and Maintenance comes first Mechanic Manual and applicable JLG or inspection form Out of service for a period of more than 3 months or Purchased used Annual Machine Inspection Annually nolaterthan 13 months from the date of Owner Dealer orUser Factory Qualified Service and Maintenance prior inspection Service Technician Manual and applicable JLG inspection form Preventative Maintenance Atintervals as specified in the Service and Main Owner Dealer orUser Qualified JLG Service and Maintenance tenance Manual Mechanic Manual NOTE Inspection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 3121205 JLG Lift 2 3 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Pre Start Inspection The Pre Start Inspection should include each of the follow ing 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 discrep ancies
32. indicating loose cables JLG Lift 6 Swing turntable to LEFT and RIGHT a minimum of 45 degrees Check for smooth motion NOTE Step 7 is only applicable for machines with an external tilt Sensor 7 With the aid of an assistant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform control console manually activate the indicator light by com pressing any one of the three tilt indicator mounting springs If the light does not illuminate shut down machine and contact a qualified service technician before continuing operation NOTE Step 8 is applicable for machines with an internal tilt sen sol 8 Check the chassis out of level indicator located on the platform control console by driving with the machine in level position up a suitable ramp of at least 5 slope Check the out of level indicator with the machine on the ramp If the light does not illuminate return the machine to a level surface shut down the machine and contact a qualified technician before resuming operation 2 7 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 8 1 Platform 11 Turntable 2 Platform ControlBox 12 Steer Wheels 3 Rotator 13 Frame 4 Articulating Jib 14 Drive Wheels 5 FlyBoom 15 Swing Bearing 6 MidBoom 16 Lift Cylinder 7 BaseBoom 17 Slave Level Cylinder 8 Boom Assembly 18 Articulating Jib 9 Tel
33. of obstructions until the trainee has developed the ability to safely control and operate the machine Operator Responsibility The operator must be instructed that he she has the respon sibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site 2 1 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND 2 2 MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult local regulations for further requirements for aerial work platforms The frequency of inspections and mainte nance 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 NOTICE JLG INDUSTRIES INC RECOGNIZES A FACTORY QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL JLG Lift 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Table 2 1 Inspection and Maintenance Table Type Frequency Primary SEVICE Reference Responsibility Qualification Pre Start Inspection Before using each day or User or Operator User or Operator Operator and Safety Manual whenever there s an Operator
34. to conditions of ground sur face congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stop ping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in reverse Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and per sons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised boom or platform Position barricades on floor if neces sary 1 4 JLG Lift TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to the Emergency Procedures section of this manual for emergency towing procedures Ensure boom is in the stowed position and the turntable locked prior to towing lifting or hauling The platform must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift the unit with equipment of adequate capac ity Refer to the Machine Operatio
35. 1001114387 1 Spanish 37 1701645 1707055 1705978 1707058 1707060 1707056 1707059 1707057 1705978 38 1707013 1707047 1705978 1707042 1707044 1707049 1707054 1707052 1705978 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 4 34 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Table 4 3 660SJ Decal Legend Item ANSI 5 4 Chinese pies Japanese Australian 0273869 6 0273874 6 0273877 4 0274925 7 0273871 7 0273884 7 0273890 7 0273887 7 1001114387 1 54 55 56 57 58 59 60 61 4420051 4420051 62 1700584 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 1706941 1706941 65 1705351 1705429 1705427 1705430 1705910 1705426 1705905 66 1001112551 3121205 JLG Lift 4 35 SECTION 4 MACHINE OPERATION ex NOTES 4 36 JLG Lift 3121205 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1
36. 1701518 28 1703805 1705961 1703936 1703935 1703938 1705897 1703939 1705961 29 1705828 1703984 1703983 1703980 1705902 1703981 1705828 30 3251813 3251813 3251813 3251813 3251813 31 1705494 32 33 1703471 1703471 1703471 1703471 1703471 1703471 1703471 1703471 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 35 1702816 1702816 1702816 1702816 1702816 1702816 1702816 1702816 3121205 JLG Lift 4 29 SECTION 4 MACHINE OPERATION 4 30 Table 4 2 600SJ Decal Legend Item 2 ANSI 0273868 6 CE Australian 0273876 4 French 0273873 6 Spanish 0273883 7 Japanese 6006 0273889 7 Portuguese 600SJ 0273886 7 Korean 1001112941 2 Australian 1001114386 1 36 37 1701645 1705978 1707055 1707056 1707058 1707057 1707058 1705978 38 1707013 1705978 1707047 1707049 1707054 1707052 1707042 1705978 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 JLG Lift 3121205 SECTION 4 MACHINE OPERATION 3121205 Table 4 2 600SJ Decal Legend Item ANSI 4525
37. 2 3121205 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 13 Mobil DTE 13M Specs Table 6 14 Exxon Univis HVI 26 Specs ISO Viscosity Grade 32 Specific Gravity 0 877 Pour Point Max 40 F 40 C Flash Point Min 330 F 166 C Viscosity at 40 C 33cSt at 100 C 6 6 cSt at 100 F 169 SUS at 210 F 48 SUS cp at 20 F 6 200 Viscosity Index 140 Specific Gravity 32 1 Pour Point 76 F 60 C Flash Point 217 F 103 C Viscosity at40 C 25 8 cSt at100 C 9 3 cSt Viscosity Index 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity 6 8 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 15 Quintolubric 888 46 Density 0 91 15 C 59 F Pour Point lt 20 C lt 4 F Flash Point 275 C 527 F Fire Point 325 C 617 F Autoignition Temperature 450 C 842 F Viscosity at 0 C 32 F 360 cSt at 20 C 68 F 102 cSt at 40 C 104 F 46 cSt at 100 C 212 F 10 cSt Viscosity Index 220 3121205 Critical Stability Weights A WARNING DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF FERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES COUNTERWEIGHT ENGINE amp PLATFORM DO NOT MOD IFY U
38. 300 hours of operation 3121205 JLG Lift 23 AirFilter Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator 6 29 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 24 Electronic Pressure Regulator LP only 25 Fuel Filter Propane GM Engine Interval 3 Months or 150 hours of operation Interval 3 Months or 150 hours of operation Comments Drain oil build up Refer to Section 6 6 Comments Replace filter Refer to Section 6 7 Propane DRAINING OIL BUILD UP FROM THE PROPANE REGU Fuel Filter Replacement LATOR Prior to S N 0300132529 6 30 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 4 TIRES amp WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics Tire Damage For pneumatic tires JLG Industries Inc recommends that when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures must be taken to remove the JLG product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires JLG Industries Inc recom mends that when any of the following are discovered measures must be taken to remove the JLG pr
39. 4412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 1705084 1705084 1705084 15 1705514 1705514 16 17 3251243 3251243 3251243 3251243 3251243 3251243 3251243 3251243 4 24 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Table 4 1 600S Decal Legend Item ANSI French NUM Korean Japanese 2 Chinese Australian 0273867 6 0273872 6 0273875 3 0273870 6 0273882 6 0273888 6 0273885 6 0275099 6 1001114385 1 18 19 20 22 1703953 1703942 1703945 1703941 1703944 1705903 1703943 23 24 1702868 1704000 1705969 1704001 1705967 1705968 25 1703797 1703924 1705921 1703927 1703923 1703926 1705895 1703925 1705921 26 1705336 1705347 1705822 1705345 1705917 1705344 1705896 1705348 1705822 27 1703804 1703948 1701518 1703951 1703947 1703950 1705898 1703949 1701518 28 1703805 1703936 1705961 1703939 1703935 1703938 1705897 1703937 1705961 29 1703984 1705828 1703981 1703983 1703980 1705902 1703982 1705828 30 3251813 3251813 3251813 3251813 3251813 3251813 31 32 33 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 35 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 3121205 JLG Lift 4 25 SECTIO
40. 5 L w Filter Total Capacity 16 Quarts 151 Idle RPM 1000 Low RPM 1800 High RPM 2500 Alternator 60 Amp belt drive Battery 950 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC Low RPM 1 90 7 19 Iph High RPM 2 50 9 46 Iph Horsepower 65 Fuel Consumption 6 4 Low RPM 1 90 7 19 Iph High RPM 2 50 GPH 9 46 Iph Horsepower 49 3121205 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 6 Caterpillar 3044C 3 4 Table 6 7 GM 3 0L Fuel Gasoline or Gasoline LP Gas of Cylinders 4 BHP Gasoline 83 hp 3000 rpm LP 75 hp 3000 rpm Bore 4 0in 101 6 mm Stroke 3 6in 91 44 mm Displacement 181 cu in 3 0 L 2966 Oil Capacity w filter 4 5 qts 4 25 L Minimum Oil Pressure Type Four Stroke Cycle Cylinders 4in line Bore 3 70 inch 94 mm Stroke 4 72 inch 120 mm Aspiration turbocharged Compression ratio 19 1 Displacement 203 in 3 331 Firing Order 1 3 4 2 Rotation viewed from flywheel Counterclockwise Oil Capacity w filter 10 6 quarts 101 Cooling System Engine Only 5 8 quarts 5 5L Idle RPM 1000 Low RPM 1800 High RPM 3044C 2600 High RPM 3 4 2500 Alternator 60 Amp belt drive Battery 930 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC 3121205 JLG Lift
41. 64 degrees If limit switch settings need to be changed you will need to recheck that the 500 Ib 230 kg light comes on at 45 degrees to 50 degrees when lifting down 4 Check capacity limit switch as follows Main Boom Length Switch a b JLG Lift Lift main boom to approximately horizontal Telescope boom out until 500 Ib 230 kg light comes on may need to used auxiliary power to position boom correctly 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121205 c Mark the wear pad location on the main fly boom d Telescope the main boom to full extension e Measure from the mark on the fly boom to the wear pad The dimension should be 125 to 127 317 5 to 322 5 cm Main Boom Angle Switch a Lift main boom to approximately horizontal b Telescope boom out until 500 Ib 230 kg light comes on may need to used auxiliary power to position boom correctly c Lift main boom up until 1000 Ib 450 kg light comes on The boom angle at this point should be 55 degrees to 60 degrees d Lift main boom down until 500 Ib 230 kg light comes on The boom angle at this point should be 45 degrees to 50 degrees If limit switch settings need to be changed you will need to recheck that the 500 Ib 230 kg light comes on at 45 degrees to 50 degrees when lifting down 5b Raise main boom extend and retract telescope Check for delayed movement of fly section
42. 7 FreshGale Twigs broken from trees Cars veer on road 9 47 54 20 8 24 4 Strong Gale Light structure damage 1 10 Lift 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is necessary that it be operated and maintained only by trained personnel Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Operator Training Operator training must cover 1 Use and limitations of the controls in the platform and at the ground emergency controls and safety systems 2 Control labels instructions and warnings on the machine 3 Rules of the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 3121205 Lift 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles depressions holes dropoffs 7 Means to avoid the hazards of unprotected electrical conductors 8 Specific job requirements or machine application Training Supervision Training must be done under the supervision of a qualified person in an open area free
43. CIFICATIONS amp OPERATOR MAINTENANCE 6 40 SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006 42 EC and is only applicable to CE machines For electric powered machines the equivalent continuous A Weighted sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is subjected does not exceed 2 5 m s The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s JLG Lift 3121205 SECTION 7 INSPECTION AND REPAIR LOG Machine Serial Number SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3121205 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 JLG Lift 3121205 PROPOSITION 65 WARNING Battery posts terminals and WA R N N G related accessories contain lead
44. CTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 21 PERSONNEL TRAINING 2 1 Operator 0 2 1 Training 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function 2 5 3121205 SECTION PARAGRAPH SUBJECT PAGE 2 3 LIMIT SWITCH FUNCTIONAL CHECK 2 5 General we tlc caen s 2 11 SECTION 3 MACHINE CONTROLS AND INDICATORS GENERAL 2 eR EX Bux 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control 3 1 Ground Control Indicator Panel 3 5 Platform 3 7 Platform Control Indicator Panel 3 14 SECTION 4 MACHINE OPERATION 41 4 1 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS 4 1 Capacities IRE x dryer 4 1 STAD E 4 2 43 ENGINE 4 2 Starting Procedure 4 2 Shutdown Procedure 4 3 4 4 TRAVELING 4 5 Traveling Forward and Reverse 4 5 4 5 STEERING EE Ett 4 7 46
45. D BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE IF BOOM IS OVER FRONT WHEELS STEER AND DRIVE CONTROLS WILL BE REVERSED 3121205 JLG Lift Traveling Forward and Reverse 1 At Platform Controls pull out Emergency Stop switch and activate footswitch 2 Position Drive controller to FORWARD or REVERSE as desired This machine is equipped with a Drive Orientation Indicator The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer in the opposite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both plat form control panel and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direction of machine travel The indicator light will flash during the 3 second interval until the drive function is selected 4 5 SECTION 4 MACHINE OPERATION DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLACARD DO NOT DRIVE ON SIDESLOPES EXCEEDING 5 8 7596 Figure 4 3 Grade and Sideslope 4 6 JLG Lift 3121205 SECTION 4 MACHINE OPERATION 4 5 STEERING Position thumb switch on Drive Steer con
46. FICATIONS amp OPERATOR MAINTENANCE 2 Tighten nuts in the following sequence 9 LUG PATTERN CI MENN TONUGPATTERN 3 The tightening of the nuts should be done in stages Fol lowing the recommended sequence tighten nuts per wheel torque chart 3121205 JLG Lift 6 33 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 34 Table 6 20 Wheel Torque Chart 9 Lug TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 40 ft Ibs 95 ft Ibs 170 ft Ibs 55 Nm 130 Nm 230 Nm Table 6 21 Wheel Torque Chart 10 Lug TORQUE SEQUENCE ist Stage 2nd Stage 3rd Stage 70 ft Ibs 170ft Ibs 300 ft Ibs 95 Nm 225 Nm 405 Nm Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal Check torque every 3 months or 150 hours of operation JLG Lift 6 5 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and centered between drive wheels prior to beginning lockout cylinder test 1 Place a 6 inches 15 2 cm high block with ascension ramp in front of left front wheel 2 From platform control station start engine 3 Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left
47. FOR THE BOOM TO CLEAR SURROUNDING WALLS PARTITIONS AND EQUIP MENT NOTE When boom functions are being operated there is an interlock that prevents the use of DRIVE and STEER func tions Raising and Lowering the Boom To raise and lower the Boom position LIFT control switch or controller to UP or DOWN and hold until desired height is reached Telescoping the Boom To extend or retract the Boom position MAIN TELESCOPE control switch to IN or OUT and hold until platform reaches desired position 4 8 JLG Lift 4 8 SHUT DOWN AND PARK 1 Drive machine to a protected area 2 Assure boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured 3 Remove all load and allow engine to operate 3 5 min utes at LOW setting to permit reduction of engine inter nal temperatures 4 At Ground Controls turn KEY SELECT switch to center OFF Position POWER EMERGENCY STOP switch down to OFF Remove key 5b Cover Platform Control console to protect instruction placards warning decals and operating controls from hostile environment 3121205 SECTION 4 MACHINE OPERATION 4 9 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED Refer to Section 6 5 Oscillating Axle Lockout Test If Equipped for procedure 4 10 STEER TOW SELECTOR
48. ITIES MACHINE PREPARATION AND INSPECTION NOTE For adjustments see Service Manual Limit Switch Adjust ments 2 Check elevation limit switch as follows a Lift boom up to 2 degrees to 7 degrees above hori zontal The switch should activate at this point b Lift boom down to 2 5 degrees to 7 5 degrees below horizontal The switch should reset at this point 3 Check capacity limit switch as follows Boom Length Switch a Raise boom to horizontal place angle indicator on base boom between boom pivot pin and lift cylinder attach pin Telescope boom out until 500 Ib 230 kg light comes on may need to used auxiliary power to position boom correctly Mark wear pad location on the fly and mid booms d Telescope boom out to full extension 2 6 Measure from the mark on the fly boom to the wear pad and measure from mark on the mid boom to the wear pad f Add These two numbers together they should be approximately equal they should measure 137 to 139 348 to 353 cm Boom Angle Switch a b c NOTE Telescope boom to full extension Lift boom up until 1000 Ib 450 kg light comes on Lift boom down using auxiliary power until 500 Ib 230 kg light comes on Boom angle must be 45 degrees to 50 degrees place angle indicator on base boom between boom pivot pin and lift cylinder attach pin Lift boom up until 1000 Ib 450 kg light comes on Boom angle should be 55 degrees to
49. Inspection Check list A WARNING TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DUR ING WALK AROUND INSPECTION NOTICE DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE NOTE each item make sure there are no loose or missing parts that they are securely fastened and that no visible damage exists in addition to any other criteria men tioned gt N 10 11 Platform Assembly Platform mounting pins secure Footswitch in good working order not modified dis abled or blocked Platform Control Console Switches and levers return to neutral and are properly secured decals placards secure and legible control marking legible Rotator See Note Rotator Motion Control Valve See Note Jib Boom If Equipped See Note Dual Capacity Limit Switch Arm free to move and free from dirt and grease Power Track See Note Steer Cylinder Assembly 4 Wheel Steer See Note Spindle 4 Wheel Steer Evidence of proper lubrica tion Drive Motor and Brake See Note Drive Hub See Note Figure 2 4 Daily Walk Around Inspection Points Sheet 1 of 3 3121205 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 12 13 14 15 16 17 18 19 20 21 22 2 12 Wheel Tire Assembly No loose or missing lug nuts Inspe
50. N 4 MACHINE OPERATION Table 4 1 600S Decal Legend Item ANSI French UM Korean jd Japanese iod Chinese Australian 0273867 6 0273872 6 0273875 3 0273870 6 0273882 6 0273888 6 0273885 6 0275099 6 1001114385 1 37 1704096 1704099 1705978 1704103 1704098 1704102 1706380 1704101 1705978 38 1707014 1704107 1705978 1707043 1707048 1707053 1707051 1707045 1705978 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 4 26 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Table 4 1 600S Decal Legend Item ANSI French MM Korean yen Japanese cus Chinese Australian 0273867 6 0273872 6 0273875 3 0273870 6 0273882 6 0273888 6 0273885 6 0275099 6 1001114385 1 54 55 56 57 58 59 60 61 4420051 4420051 62 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 1706941 1706941 65 1705351 1705429 1705910 1705426 1705905 1705430 66 1001112551 3121205 JLG Lift 4 27 SECTION 4 MACHINE OPERATION 4 28 Table 4 2 600SJ Decal Legend
51. NIT IN ANY WAY TO AFFECT STABILITY Table 6 16 Critical Stability Weights 600S LB KG Tire and Wheel Ballasted Only Size 15 19 5 253 115 Engine Ford 460 209 Deutz 534 242 Continental 558 253 Counterweight Weight 2900 1315 Platform 6ft 1 83 205 93 8ft 2 44 230 105 Lift 6 9 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 17 Critical Stability Weights 6005 Table 6 18 Critical Stability Weights 660SJ LB KG LB KG Tire and Wheel Ballasted Only Size 15 19 5 253 115 Tire and Wheel Ballasted Only Size 15 19 5 253 115 Engine Ford 460 209 Engine Ford 460 209 Deutz 534 242 Deutz 534 242 Continental 558 253 Continental 558 253 Counterweight Weight 3500 1588 Counterweight Weight 4650 2109 Platform 6ft 1 83 205 93 Platform 6ft 1 83M 205 93 8ft 2 44 M 230 105 8ft 2 44 M 230 105 6 10 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Serial Number Locations A serial number plate is affixed to the left rear side of the frame If the serial number plate is damaged or missing the machine serial number is stamped on the left side of the frame 48 SERIAL NUMBER SERIAL NUMBER PLATE STAMPED ON FRAME Figure 6 1 Serial Number Locations 3121205
52. NK TEMPERATURES 180 F 82 OR ABOVE 180 F 82 C HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES OF 100 38 C OR ABOVE 90 F 32 C 8 27 70 F 21 C 8 5 60 F 16 8 z o gt v HYDRAULI pd SPECIFICATIONS 40 F 4 C a SE 8 30 F 1 C a 5 20 7 9 10 F 12 C DN DO NOT START UP HYDRAULIC SYSTEM 1826 WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE 20 F 29 C DO NOT START UP HYDRAULIC SYSTEM 30 34 C WITHOUT HEATING AIDS AND COLD WEATHER V HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTENTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 4150548 D Figure 6 7 Engine Operating Temperature Specifications Caterpillar Sheet 2 of 2 3121205 JLG Lift 6 17 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE
53. ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG 120 F 49 C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 30 F ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY SAE 10w 30 lt A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 6 18 SAE 5W 30 gt NO OPERATION BELOW THIS AMBIENT TEMPERATURE 20F 7C 10 pide F 18 C 10 F 23 C 20 F 29 C 30 F 34 C C 40 0 SS 40 F 40 C Figure 6 8 Engine Operating Temperature Specifications GM Sheet 1 of 2 JLG Lift AMBIENT AIR TEMPERATURE 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 180 F 82 C 82 C OR ABOVE HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS
54. ORE RESTARTING THE ENGINE MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE PLATFORM ROTATED 90 DEGREES MAIN BOOM FULLY RETRACTED AND ELEVATED 1 Remove all load and allow engine to operate at low speed for 3 5 minutes this allows further reduction of internal engine temperature 2 Push POWER EMERGENCY STOP switch in 3 Turn MASTER switch to Off Refer to Engine Manufacturer s manual for detailed informa tion LEVEL SURFACE Figure 4 1 Position of Least Backward Stability 3121205 JLG Lift 4 3 SECTION 4 MACHINE OPERATION BOOM FULLY EXTENDED 9 HORIZONTAL 0 DEGREES m KEY MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE LEVEL SURFACE Figure 4 2 Position of Least Forward Stability 4 4 JLG Lift 3121205 SECTION 4 MACHINE OPERATION 4 4 TRAVELING DRIVING DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID 1055 OF TRAVEL CONTROL OR OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE BE SURE THE TURNTABLE LOCK 15 ENGAGED BEFORE EXTENDED TRAVELING DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATE
55. OWN AND LIFTING When transporting machine boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck Four tie down eyes are pro vided in the frame slab one at each corner of the machine See Figure 4 3 Machine Tie Down If it becomes necessary to lift the machine using an over head or mobile crane it is very important that the lifting devices are attached only to the designated lifting eyes and that the turntable lock pin is engaged See Figure 4 4 Lifting Chart NOTE NOTE If not equipped front lifting eyes on the S Models machines are available P N 3539590 Lifting eyes are provided at the front and rear in the frame slab Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated NOTICE SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK TRAILER JLG Lift SECTION 4 MACHINE OPERATION NOTE When transporting machine over rough terrain or long distance the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad This prevents the boom from bouncing up and down preventing possible damage while transporting Figure 4 7 Machine Tie Down 4 18 JLG Lift 3121205 SECTION 4 MACHINE
56. PERATION 4 13 AUXILIARY POWER ADE EQUIPPED MACHINES CAUTION WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE 12 VOLT AUXILIARY PUMP MOTOR A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electri 2 cally driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump 3 will operate boom lift telescope and swing To activate auxil 4 iary power Activating from the Platform Control Station 5 1 Position PLATFORM GROUND SELECT KEY SWITCH to 6 PLATFORM 2 Position POWER EMERGENCY STOP switch to ON 3 Depress and hold footswitch 4 Position AUXILIARY POWER switch to ON and hold 4 14 Lift 7 Operate appropriate control switch lever or controller for desired function and hold Release AUXILIARY POWER switch selected control switch lever or controller and footswitch Position POWER EMERGENCY STOP switch to OFF Activating from the Ground Control Station 1 Position PLATFORM GROUND SELECT KEY SWITCH to GROUND Position POWER EMERGENCY STOP switch to ON Position AUXILIARY POWER switch to ON and hold Operate appropriate control switch or controller for desired function and hold Release AUXILIARY POWER switch and appropr
57. RACTICES This section provides the necessary information needed to understand control functions CONTROLS AND INDICATORS This machines is equipped with control panels that use symbols to indicate control functions On ANSI machines refer to decal located on the control box guard in front of the control box or by the ground controls for these sym bols and the corresponding functions 3 2 NOTE 3121205 JLG Lift Ground Control Station See Figure 3 1 Ground Control Station NOTE lf equipped the Function Enable switch must be held down in order to operate Telescope Swing Lift Jib Lift Platform Level Override and Platform Rotate functions 1 Platform Rotate A three position switch permits rotation of the platform A 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 2 Platform Leveling Override A three position switch allows the operator to compen sate for any difference in the automatic self leveling sys tem 3 1 SECTION 3 MACHINE CONTROLS AND INDICATORS 1 6 21 0 9 1 Platform Rotate E 2 Platform Leveling Override 1 9 2 i 3
58. S OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED 9 10 JLG Lift Swing Control Provides 360 degrees continuous turntable rotation Telescope Control Provides extension and retraction of the boom when positioned to IN or OUT 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 1 Battery Charging Indicator See Figure 3 2 Ground Control Indicator Panel Indicates a problem in the battery or charging circuit and service is required 2 Low Engine Oil Pressure Indicator Indicates that engine oil pressure is below normal and service is required 3 High Engine Coolant Temperature Ford and Continental Indicator Indicates that engine coolant temperature is abnormally high and service is required 4 High Engine Oil Temperature Indicator Deutz Indicates the temperature of the engine oil which also serves as engine coolant is abnormally high and ser 1 Battery Charging Glow Plug vice is required 2 Low Engine Oil Pressure 8 Platform Overload 3 High Engine Coolant Temp 9 Hyd Filter Bypass 4 High Engine Oil Temp 10 Transmission Filter By Pass 5 Engine Malfunction Indicator 11 Engine Air Filter By Pass 6 Low Fuel Figure 3 2 Ground Control Indicator Panel 3121205 JLG Lift 3 5 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 6 5 Engine Malfunction Indicator Li
59. Spanish pisi m Korean Australian 0273868 6 0273876 4 0273873 6 0273803 7 0273889 7 0273886 7 1001112941 2 1001114386 1 54 55 56 57 58 59 60 61 4420051 4420051 62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 1706941 65 1705351 1705429 1705910 1705426 1705095 1705427 66 1001112551 Lift 4 31 SECTION 4 MACHINE OPERATION Table 4 3 660SJ Decal Legend Item ANSI ER nho Korean Chinese pec Japanese T Australian 0273869 6 0273874 6 02738774 0274925 7 0273871 7 0273884 7 0273890 7 0273887 7 1001114387 1 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 1705084 1705084 1705084 1705084 15 1705514 1705514 1705514 1705514 16 17 3251243 3251243 3251243 3251243 3251243 3251243 3251243
60. VERLOAD THE 12 VOLT AUXILIARY PUMP MOTOR 4 Power Emergency Stop Switch A two position red mushroom shaped switch supplies power to PLATFORM GROUND SELECT switch when pulled out on When pushed in off power is shut off to the PLATFORM GROUND SELECT switch 3121205 JLG Lift 3 3 SECTION 3 MACHINE CONTROLS AND INDICATORS 6 Lift Control Provides raising and lowering of the main boom Hourmeter Registers the amount of time the machine has been in use with engine running By connecting into the oil pressure circuit of the engine only engine run hours are recorded The hourmeter registers up to 9 999 9 hours and cannot be reset 8 Platform Ground Select NOTE 3 4 A three position key operated switch supplies power to the platform control console when positioned to PLAT FORM With the switch in GROUND position power is shut off to the platform control console and only the controls on the ground control panel are operable With the Platform Ground Select Switch in the center posi tion power is shut off to controls at both operating sta tions NOTE Lift Swing Platform Level Telescope Platform Rotator and Auxiliary control switches are spring loaded and will automatically return to neutral off when released A WARNING WHEN OPERATING THE 00 ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVER
61. WER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE 12 VOLT AUXILIARY PUMP MOTOR A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electri cally driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump will operate boom lift telescope and swing To activate auxil iary power Activating from the Platform Control Station 1 3121205 Position PLATFORM GROUND SELECT KEY SWITCH to PLATFORM Position POWER EMERGENCY STOP switch to ON Depress and hold footswitch Operate appropriate control switch lever or controller for desired function and hold 5 7 Position AUXILIARY POWER switch to ON and hold Release AUXILIARY POWER switch selected control switch lever or controller and footswitch Position POWER EMERGENCY STOP switch to OFF Activating from the Ground Control Station 1 JLG Lift Position PLATFORM GROUND SELECT KEY SWITCH to GROUND Position POWER EMERGENCY STOP switch to ON Operate appropriate control switch or controller for desired function and hold Position AUXILIARY POWER switch to ON and hold Release AUXILIARY POWER switch and appropriate control switch or controller Position POWER EMERGENCY STOP switch to OFF 4 13 SECTION 4 MACHINE O
62. all tires are inflated to the pressure recommended 6 31 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE by JLG Due to size variations between tire brands both tires Wheel Installation on the same axle should be the same It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque The rims installed on each product model have been designed A WARNING for stabilty requirements which kaf of Son e a WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER i ris 2 A 49 e n TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI Pee e DF AJO Or SMA Sr CIAM eN BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE factory recommendations may result in an unsafe condition TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE regarding stability WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels The proper procedure for attaching wheels is as follows 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 6 32 JLG Lift 3121205 SECTION 6 GENERAL SPECI
63. and lead compounds The engine exhaust from this product chemicals known to the State a of California to cause cancer contains chemicals known to the State and reproductive harm of California to cause cancer birth defects or other reproductive harm 1702961 Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1 JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 EL 717 485 6417 JLG Worldwide Locations JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia 461265811111 61265 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson JLG Industries UK Ltd Bentley House 80 Suite 71 Bentley Avenue 13092 310 Campinas SP Middleton Brazil Greater Manchester 55 19 3295 0407 55 19 3295 1025 24 2GP England 44 0 161 654 1000 25 44 0 161 654 1001 3121205 JLG France SAS 2 1 de Baulieu 47400 Fauillet France 33 0 5 53 88 31 70 33 0 5 53 88 31 79 e JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landm
64. ark North Via Po 22 39 Lung Sum Avenue 20010 Pregnana Milanese MI Sheung Shui N T Italy Hong Kong 2 39 029 359 5210 T 852 2639 5783 439 029 359 5845 852 2639 5797 JLG Industries Italia s r l Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 65 6591 9030 JLG Polska JLG Industries Scotland Plataformas Elevadoras JLG Sverige AB UI Krolewska Wright Business Centre JLG Iberica S L Enkopingsvagen 150 00 060 Warsawa 1 Lonmay Road Trapadella 2 Box 704 Poland Queenslie Glasgow G33 4EL Castellbisbal Sur SE 176 27 Jarfalla 2 48 0 914 320 245 Scotland 08755 Castellbisbal Barcelona Sweden 25 48 0 914 358 200 Spain 34 93 772 4700 34 93 771 1762 44 0 141 781 6700 444 0 141 773 1907 46 0 850 659 500 446 0 850 659 534 www jlg com
65. ations 6 8 Dimensional 6 6 Caterpillar Sheet 1 2 6 16 6 9 Torque 6 6 Engine Operating Temperature Specifications 6 10 Tire Specifications 6 7 Caterpillar Sheet 2012 6 17 6 11 Hydraulic 6 7 Engine Operating Temperature Specifications GM 6 12 Mobilfluid 424 Specs 6 7 Sheet 1 2 6 18 6 13 Mobil DTE 13M Specs 6 8 Engine Operating Temperature Specifications GM 6 14 Exxon Univis HVI 26 Specs 6 8 Sheet 2 012 6 19 6 15 Quintolubric 888 46 6 9 Operator Maintenance amp Lubrication Diagram 6 20 6 16 Critical Stability Weights 600S 6 9 Filter Lock 6 38 6 17 Critical Stability Weights 600SJ 6 10 6 18 Critical Stability Weights 660SJ 6 10 LIST OF TABLES 6 19 Lubrication Specifications 6 21 Minimum Approach Distances M A D 1 5 6 21 Wheel Torque Chart 10 Lug 6 34 Beaufort Scale For Reference Only 1 10 6 20 Wheel Torque Chart 9Lug 6 34 Inspection and Maintenance Table 2 3 7 1 Inspection and Repair Log 6005 Decal
66. ch if not corrected may result in machine interruption or damage This indicator will be yel low Indicates important information regarding the operating condition i e procedures essential for safe operation This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position 1 Tilt Alarm Warning Light and Alarm This orange illuminator indicates that the chassis is on a slope An alarm will also sound when the chassis is on a slope and the boom is above horizontal If lit when boom is raised or extended retract and lower to below hori zontal then reposition machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated A WARNING IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL 2 Platform Overload If equipped Indicates the platform has been overloaded JLG Lift 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 3121205 eco Dot Tilt 5 Enable 9 ACGenerator Overload 6 Glow Plug 10 Soft Touch Capacity 7 Low Fuel 11 Creep CableService 8 Engine Malfunction Figure 3 6 Platform Cont
67. ct for worn tread cuts tears or other discrepan cies Inspect wheels for damage and corrosion Tie Rod and Steering Linkage 4 Wheel Steer Tie rod end studs locked Turntable Lock Operable Auxiliary Power Pump See Note Swing Drive Motor and Brake See Note Control Valve Tank Compartment See Note Turntable Bearing and Pinion Evidence of proper lubrication No evidence of loose bolts or looseness between bearing and structure Manual Descent See Note Hydraulic Oil Return Filter Housing See Note LP Gas Tank If Equipped See Note Hydraulic Oil Supply Recommended oil level sight gauge Check level with cold oil systems shut down machine in stowed position Cap in place and secure 23 24 25 26 27 28 29 30 31 32 Hydraulic Oil Breather Element in place not clogged no sign of overflow Ground Controls Switches operable decals secure and legible Fuel Supply Fuel filler cap secure Tank See Note Door and Latches Hood door and latches in working condition Tie Rod and Steering Linkage Tie rod end studs locked Oscillating Cam Valve If Equipped See Note Oscillating Axle Cylinder If Equipped See Note Oscillating Axle If Equipped See Note Dual Capacity Limit Switch Arm free to move and free from dirt and grease Engine Air Filter Element clean Figure 2 5 Daily Walk Around Inspection Points Sheet 2 of 3 JLG Lift
68. ctrically operated hydraulic pump when actuated Switch must be held ON for duration of auxiliary pump use The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail The auxiliary pump will operate tower boom lift tower telescope main boom lift main telescope and swing Fuel Select Dual Fuel Engine Only If Equipped Gasoline or liquid propane fuel may be selected by mov ing the switch to the appropriate position It is unneces sary to purge the fuel system before switching fuels so there is no waiting period when switching fuels while the engine is running Lights If Equipped This switch operates control console panel lights and head lights if the machine is so equipped The ignition Switch does not have to be on to operate the lights so care must be taken to avoid draining the battery if left unattended The master switch and or the ignition Switch at the ground control will turn off power to all lights NOTE LIFT SWING and DRIVE control levers are spring loaded and will automatically return to neutral OFF position when released A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED 9 10 JLG Lift Drive Steer The DRIVE joystick provides for driving either forward or backwar
69. ctrocution Hazards This machine is not insulated and does not provide pro tection from contact or proximity to electrical current 4 Keep both feet firmly positioned on the platform floor at all W times Never use ladders boxes steps planks or similar items on platform to provide additional reach Never use the boom assembly to enter or leave the plat form JLG Lift 3121205 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Approach Distances M A D Voltage Range MINIMUM APPROACH DISTANCE Phase to Phase in Feet Meters Oto 50 KV 10 3 Over 50KV to 200 KV 15 5 Over 200 KV to 350 KV 20 6 Over 350 KV to 500 KV 25 8 Over 500 KVto 750 KV 35 11 Over 750 KV to 1000 KV 45 14 NOTE This requirement shall apply except where employer local or governmental regulations are more stringent Maintain distance from electrical lines apparatus or any energized exposed or insulated parts according to the Maintain a clearance of at least 10 ft 3m between any part Minimum Approach Distance MAD as shown in Table 1 of the machine and its occupants their tools and their 1 equipment from any electrical line or apparatus carrying up Allow for machine movement and electrical line swaying to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less 3121205 JLG Lift 1 5 SECTION 1 SAFETY PRECAUTIONS
70. d The controller is ramped to allow variable drive speed Steering is controlled by a thumb operated switch on top of the joystick Telescope Control This control allows extension and retraction of the main boom 3 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 11 Jib If Equipped 14 Push forward to lift up pull back to lift down Variable lift speed is using the Function Speed Control 12 Platform Rotate This switch allows the operator to rotate the basket to the left or right A CAUTION DO NOT OPERATE MACHINE IF DRIVE SPEED TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORI ZONTAL 13 Function Speed Controls the speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed To adjust to creep turn knob fully CCW until it clicks 3 12 JLG Lift Main Lift Swing Controller An infinitely proportional dual axis joystick is provided for main lift and swing Push forward to lift up pull back ward to lift down Move right to swing right move left to swing left When boom is positioned above horizontal and any of the following switches DRIVE SPEED TORQUE SELECT or FUNCTION SPEED are positioned to HIGH high function speeds are automatically cut out and the machine continues to operate at a lower speed 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 15 16 3121205 Drive Orientation Override When the boom is swung over t
71. e Current Owner Updates cial Product Applications Questions Regarding Prod Questions Regarding uct Modifications Product Safety Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 or Your Local JLG Office See addresses on inside of manual cover 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 FOREWORD REVISION LOG Original Issue April 1 2005 Revised February 27 2006 Revised May 3 2006 Revised September 25 2007 Revised February 22 2008 Revised June 5 2008 Revised September 21 2009 Revised December 1 2009 JLG Lift 3121205 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION 1 SAFETY PRECAUTIONS 2GENERAL ope 1 1 12 1 1 Operator Training Knowledge 1 1 Workplace 1 2 Machine Inspection 1 2 1 9 OPERATION Dese mv he ee 1 8 Generales 2 tye EE ERR ERR EE 1 3 Trip and Fall 1 3 Electrocution Hazards 1 4 Tipping 1 6 Crushing and Collision Hazards 1 7 1 4 TOWING LIFTING AND HAULING 1 8 1 5 ADDITIONAL HAZARDS SAFETY 1 9 SE
72. escope Cylinder Lift Cylinder Inside 19 Footswitch 10 Ground Control Box Figure 2 1 Machine Nomenclature 600SJ 660SJ JLG Lift 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121205 Figure 2 2 Machine Nomenclature 600S JLG Lift Platform Platform Control Box Rotator FlyBoom MidBoom BaseBoom BoomAssembly Telescope Cylinder Inside Ground Control Box Turntable Steer Wheels Frame Drive Wheels Swing Bearing Lift Cylinder Slave Level Cylinder Footswitch 2 9 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 19 20 21 22 23 24 25 26 14 15 16 17 8 28 29 30 i5 Au 18 d 9 10 27 13 9 10 8 e S a n n 1 B i TI m E 5 5 43 31 12 11 39 12 11 8 9 10 44 45 8 9 10 29 37 38 41 42 26 32 33 34 35 36 Figure 2 3 Daily Walk Around Inspection Diagram 2 10 JLG Lift 3121205 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION General Begin the Walk Around Inspection at Item 1 as noted on the diagram Continue to the right counterclockwise viewed from top checking each item in sequence for the conditions listed in the Walk Around
73. est Button 3121205 JLG Lift 3 7 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 8 1 Drive Speed 5 Power Emergency Stop 9 Drive Steer 2 Steer Select 6 Aux Power 10 Telescope 3 Platform Leveling Override 7 Fuel Select 11 Jib 4 Horn 8 Lights Figure 3 4 Platform Control Console JLG Lift 12 Platform Rotate 13 Function Speed 14 Main Lift Swing 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 1 Drive Speed 6 Aux Power 11 Jib 16 Soft Touch Override 2 SteerSelect 7 FuelSelect 12 Platform Rotate 17 Soft Touch Indicator 3 Platform Leveling Override 8 Lights 13 Function Speed 4 Horn 9 Drive Steer 14 MainLift Swing 5 Power EmergencyStop 10 Telescope 15 Drive Orientation Override Figure 3 5 Platform Control Console w Drive Orientation 3121205 JLG Lift 3 9 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 10 2 Steer Select If Equipped When equipped with four wheel steering the action of the steering system is operator selectable The center Switch position gives conventional front wheel steering with the rear wheels unaffected This is for normal driv ing at maximum speeds The forward position is for crab steering When in this mode both front and rear ax
74. front wheel is on top of block 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Carefully activate Swing control lever and position boom over right side of machine With boom over right side of machine place Drive con trol lever to Reverse and drive machine off of block and ramp Have an assistant check to see that left front wheel remains locked in position off of ground Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary to activate Drive to release cylinders Place the 6 inches 15 2 cm high block with ascension ramp in front of right front wheel Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block JLG Lift 10 11 12 13 With boom over left side of machine place Drive control lever to Reverse and drive machine off of block and ramp Have an assistant check to see that right front wheel remains locked in position off of ground Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and allow wheel to rest on ground it may be necessary activate Drive to release cylinders If lockout c
75. g the switches or locks are in place Operate all functions and check all limiting and cut out switches Check auxiliary power or manual descent Ensure that all machine functions are disabled when the Emergency Stop Button is activated 2 From the platform control console a b 3121205 Ensure that the control console is firmly secured in the proper location Check that all guards protecting the switches or locks are in place Operate all functions and check all limiting and cut out switches Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in 3 With the platform in the transport stowed position a Drive the machine on a grade not to exceed the rated gradeability and stop to ensure the brakes hold b Check the tilt sensor alarm to ensure proper opera tion 2 3 LIMIT SWITCH FUNCTIONAL CHECK TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE NOTE Perform checks from ground controls first then from plat form controls NOTE The following procedures cover machines with dual capacities 500 amp 100 Ib 230 amp 450 kg Single capacity machines will only require the procedures associated with the 500 Ib 230 kg indicator light 1 Operate machine from ground control JLG Lift 2 5 SECTION 2 USER RESPONSIBIL
76. ght Ford Engines S N 48907 to S N 61927 refer to ADE System Identifica tion page at the front of the book Indicates that the Engine Control Module has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test Low Fuel Level Indicator Indicates that the fuel level is 1 8 full or less When the light first turns on there are approximately four usable gallons of fuel remaining Glow Plug Indicator Diesel Indicates glow plugs are on The glow plugs are auto matically turned on with the ignition circuit and remain on for approximately about seven seconds Start the engine only after the light goes out 10 11 JLG Lift Platform Overload If equipped Indicates the platform has been overloaded Hydraulic Oil Filter Indicator Prior to S N 84827 Indicates the return oil filter is too restrictive and in the bypass mode and needs to be replaced Engine Air Filter Indicator Prior to S N 84827 Indicates that the air filter is too restrictive and needs to be replaced Transmission Pump Oil Filter Indicator Prior to S N 84827 Indicates that charge pump filter is too restrictive and needs to be replaced This ind
77. he rear tires or further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driv ing locate the black white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction Soft Touch Override Switch If equipped This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shutdown situation JLG Lift 17 Soft Touch Indicator If Equipped Indicates the Soft Touch bumper is against an object All controls are cut out until the override button is pushed at which time controls are active in the Creep Mode 3 13 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel See Figure 3 6 Platform Control Indicator Panel NOTE The platform control indicator panel uses different shaped symbols to alert the operator to different types of opera tional situations that could arise The meaning of those symbols are explained below 3 14 Indicates a potentially hazardous situation which if not corrected could result in serious injury or death This indicator will be red Indicates an abnormal operating condition whi
78. iate control switch or controller Position POWER EMERGENCY STOP switch to OFF 3121205 SECTION 4 MACHINE OPERATION 4 14 DUAL FUEL SYSTEM GAS ENGINE ONLY The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas A CAUTION IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 Start engine from Ground Control Station 2 Open hand valve on LP gas supply tank by turning counterclockwise 3 While engine is operating on GASOLINE under a no load condition place FUEL SELECT switch at Platform Control to LP position Changing From LP Gas to Gasoline 1 With engine operating on LP under a no load condition position FUEL SELECT switch at Platform Control Sta tion to GASOLINE position 3121205 JLG Lift 2 Close hand valve on LP gas supply tank by turning clockwise 4 15 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS Tool Circuit Operate with engine running and foot switch released 1 Be sure hydraulic switch is OFF It is located on the left side of platform below console box HYDRAULIC POWERTOOL SWITCH 4 15 SECTION 4 MACHINE OPERATION 2 Make sure the hydraulic tool about to be operated is 4 Setflow control knob to desired setting safe setting g NOTE Each
79. icator has an integral tem perature sensor 70 F 21 C so that false signals are not generated when the hydraulic oil is below normal operating temperature 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 12 EFI System Test Button Ford Engines S N 48907 to S N Platform Station 61927 refer to ADE System Identification page at the front of the book See Figure 3 5 Platform Control Console w Drive Orientation By pushing and holding the system test button on the 1 Drive Speed Torque Select side of the ground control box the Diagnostic Trouble Codes will be displayed on the Malfunction Indicator The machine has a three position switch The forward Light Refer to the Service Manual for instructions con position gives maximum drive speed by shifting the cerning the trouble codes and trouble code retrieval drive motors to minimum the displacement and giving high engine when drive controller is moved The back ENGINE MALFUNCTION position gives maximum torque for rough terrain and INDICATOR LIGHT TEST BUTTON climbing grades by shifting the wheel motors to maxi mum displacement and giving high engine speed when drive controller is moved The center position allows the machine to be driven as quietly as possible by leaving the engine at mid speed and the drive motors in maxi mum displacement AGE Figure 3 3 Malfunction Indicator Light and T
80. illar Lube Point s Fill Cap Spin on Element Capacity 10 6 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual Lube Point s Fill Cap Spin on Element Capacity 11 Quarts Crankcase 5 Quarts Cooler Lube EO Interval Every Year or 1200 hours of operation Comments Check level daily Change in accordance with engine manual 3121205 JLG Lift 6 27 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 18 Fuel Filter Ford EN 4 7224 U wA Y Lube Point s Fill Cap Spin on Element JLG P N 7027965 Capacity 4 5 qt 4 25 L w filter Lube EO 19 Fuel Filter Continental Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual Lube Point s Replaceable Element Interval Every Year or 1200 hours of operation Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 6 28 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 20 Fuel Filter Deutz Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 21 FuelFilter Caterpillar Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 22 Fuel Filter Gasoline GM Lube Point s Replaceable Element Interval Every 6 months or
81. ing Temperature Specifications Ford Sheet 2 of 2 JLG Lift 6 15 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120 F 49 C NO OPERATION ABOVE THIS 1 AMBIENT TEMPERATURE 110 F 43 C 1 171 100 F 38 C 90 F 32 C 1 80 F 27 C 70 F 21 C ENGINE 60 F 16 C SPECIFICATIONS 1 50 F 10 C s gs 5 40F 4 C i 3 ig d e B sl m 30 F 1 C i 5 s lal s 5 8 8 5 20 F 70 ENGINE WILL START AND OPERATE UNAIDED AT THIS Ed TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 190 FULLY CHARGED BATTERY F 18 C ENGINE WILL START AND OPERATE AT THIS TEMPERATURE 10 F 23 C WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY y AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER 20 F 29 C PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 30 F 34 C 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE Figure 6 6 Engine Operating Temperature Specifications Caterpillar Sheet 1 of 2 6 16 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TA
82. k 11 Suction Strainers in tank REMOVE FILL CAP PLATE FROM GAINACCESSTO STRAINERS du FULL NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION ADD Lube Point s Fill Cap Capacity 30 6 gal Tank 32 7 gal System Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation Lube Point s 2 Interval Every 2 years or 1200 hours of operation remove and clean at time of hydraulic oil change 3121205 JLG Lift 6 25 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 12 Oil Change w Filter Ford LRG423 6 26 13 Oil Chang Lube Point s Fill Cap Spin on Element Capacity 5 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual e w Filter Ford LRG425 pu Lube Point s Fill Cap Spin on Element Capacity 4 5 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual JLG Lift 14 Oil Change w Filter Continental Lube Point s Fill Cap Spin on Element Capacity 6 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 15 Oil Change w Filter Deutz 16 Oil Change w Filter Caterp
83. latform occupants and stabilize motion of the machine 5 1 SECTION 5 EMERGENCY PROCEDURES Platform or Boom Caught Overhead If the platform or boom becomes jammed or snagged in 70975 9 4 5 2 overhead structures or equipment rescue platform occu pants prior to freeing the machine EMERGENCY TOWING PROCEDURES 5 5 MANUAL DESCENT MACHINES PRIOR TO S N The manual descent valves are used in the event of total power failure to retract and lower the boom using gravity The manual descent valves are located on the right side of the turntable in tank compartment Look for the instruction Towing this machine is prohibited unless properly equipped decal located on the right side of turntable below control However provisions for moving the machine have been valve The procedures are as follows incorporated For specific procedures refer to Section 4 1 To lower and retract the boom Close knob 1 clock wise open knob 2 counterclockwise Observe the boom powertrack to see if the boom is lowering and retracting When the boom is completely retracted go to STEP 2 If no movement is observed go to step 2 2 Tolower boom Open knob 1 counterclockwise knob 2 must remain open JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 1 INTRODUCTION Other Publications Available Ai Service and
84. les steer in the same direction which allows the chas sis to move sideways as it goes forward This can be used for positioning the machine in aisle ways or against buildings The back switch position is for coordinated steering In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas To re synchronize the front and rear axles position the rear drive wheels to the forward drive position by select ing either crab or compound steer then select front steer center switch position to operate the normal steering function A 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 50 COULD RESULT IN DEATH OR SERIOUS INJURY 3 Platform Leveling Override This switch allows the operator to adjust the level of the platform 4 Travel Warning Horn Supplies electrical power to an audible warning device when pressed 5 Power Emergency Stop An ON OFF POWER EMERGENCY STOP switch and a separate ENGINE START AUXILIARY POWER toggle switch on the platform console supply electrical power to the starter solenoid when the ignition switch is placed in the ON position and the ENGINE START switch is push forward JLG Lift 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 6 3121205 Auxiliary Power Energizes the ele
85. lete the following 1 Actuate steer tow selector valve for steering push valve knob IN to the actuated position Reconnect drive hubs by inverting disconnect cap Disconnect tow bar from steering hitch and from towing vehicle The machine is now in the driving mode JLG Lift uU DISCONNECT BE Drive Hub Engaged UT DISCONNECT E a CAP E Drive Hub Disconnected Figure 4 4 Drive Disconnect Hub SECTION 4 MACHINE OPERATION A WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES STEER SELECT TOWING VEHICLE MUST BE ABLE TO 0 VALVE CONTROL MACHINE AT ALL TIMES ON P Aal HIGHWAY TOWING NOT PERMITTED FAILURE FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR lt gt ae DEATH d Sa Fiqure 4 5 Towbar Connecting Points Prior to S N 75606 3121205 JLG Lift SECTION 4 MACHINE OPERATION A WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH Figure 4 6 Towbar Connecting Points S N 75606 to Present 4 12 JLG Lift 3121205 SECTION 4 MACHINE OPERATION 4 12 AUXILIARY POWER NON ADE EQUIPPED MACHINES A CAUTION WHEN OPERATING ON AUXILIARY PO
86. lified personnel can operate the machine 1 1 SECTION 1 SAFETY PRECAUTIONS Read understand and obey all DANGERS WARNINGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by JLG All operating personnel must be familiar with the emer gency controls and emergency operation of the machine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine This machine can be operated in temperatures of 0 F to 104 F 20 C to 40 C Consult JLG for operation out side this range Machine Inspection Before machine operation perform inspections and func tional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual Workplace Inspection Be sure the footswitch and all other safety devices are operating properly Modification of these devices is a safety violation Do not operate or raise the platform while on trucks trail A WARNING ers railway cars floating vessels scaffolds or other equip MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM ment unless approved in writing by JLG SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU
87. move the retainer clip for the LPG fuel temperature 6 7 PROPANE FUEL FILTER REPLACEMENT sensor and remove the sensor from the regulator body F 3 uer Removal 1 Relieve the propane fuel system pressure Refer to Pro pane Fuel System Pressure Relief Disconnect the negative battery cable Slowly loosen the Filter housing and remove it Pull the filter housing from the Electric lock off assembly Remove the filter from the housing Locate Filter magnet and remove it Remove and discard the housing seal NOTE Have a small container ready to collect oil that will drain If equipped remove and discard the retaining bolt seal freely from the regulator at this point SON Remove and discard mounting plate to lock off O ring 7 Once all of the oil has been drained reinstall the LPG seal fuel temperature sensor and reconnect the electrical connector 8 Open the fuel tank manual valve 9 Startthe engine and verify all connections are secure 10 Dispose of any drained oil per local regulations in a safe and proper fashion 3121205 JLG Lift 6 37 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 38 e 4 co m Electric Lock Off Solenoid 6 Seal 10 Filter Mounting Plate 7 Electrical Connector 11 Fuellnlet Housing Seal 8 Fuel Outlet 12 Retaining Bolt Filter Magnet
88. n section of this manual for lifting information 3121205 SECTION 1 SAFETY PRECAUTIONS 1 5 ADDITIONAL HAZARDS SAFETY Do not refuel the machine with the engine running Do not use machine as a ground for welding Battery fluid is highly corrosive Avoid contact with skin and clothing at all times When performing welding or metal cutting operations Charge batteries only in a well ventilated area precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter 3121205 JLG Lift 1 9 SECTION 1 SAFETY PRECAUTIONS NOTICE DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH 12 5 M S Table 1 2 Beaufort Scale For Reference Only reci Description Land Conditions 0 0 0 0 2 Calm Calm Smoke rises vertically 1 1 3 0 3 1 5 Lightair Wind motion visible in smoke 2 4 7 1 6 3 3 Light breeze Wind felt on exposed skin Leaves rustle 3 8 12 3 4 5 4 Gentle breeze Leaves and smaller twigs in constant motion 4 13 18 5 5 7 9 Moderate breeze Dust and loose paper raised Small branches begin to move 5 19 24 8 0 10 7 Freshbreeze Smallertrees sway 6 25 31 10 8 13 8 Strong breeze Large branches in motion Whistling heard in overhead wires Umbrella use becomes difficult 7 32 38 13 9 17 1 Near Gale Moderate Gale Whole trees in motion Effort needed to walk against the wind 8 39 46 17 2 20
89. ndicates that the Engine Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory Refer to the Service Manual for instructions concerning the trouble codes and trou 10 11 12 JLG Lift ble code retrieval The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test AC Generator Green Indicates the generator is in operation Soft Touch Indicator If Equipped Indicates the Soft Touch bumper is against an object All controls are cut out until the override button is pushed at which time controls are active in the Creep mode Creep Speed Indicator When the Function Speed Control is turned to the creep position the indicator acts as a reminder that all func tions are set to the slowest speed Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct 3121205 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION 4 2 OPERATING CHARACTERISTICS AND This machine is a self propelled hydraulic personnel lift LIMITATIONS equipped with a work platform on the end of an elevating rotati
90. ng boom Capacities The primary operator control station is in the platform From this control station the operator can drive and steer the machine in both forward and reverse directions The opera tor can raise or lower the main or tower boom or swing the 1 Machine is positioned on a smooth firm and level sur boom to the left or right Standard boom swing is 360 degree face continuous left and right of the stowed position The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Boom Lift and Swing and are to be used in an emergency to lower the plat form to the ground should the operator in the platform be unable to do so The boom can be raised above horizontal with or without any load in platform if Load is within manufacturer s rated capacity All machine systems are functioning properly Proper tire pressure gu cg 29 Machine is as originally equipped from JLG 3121205 JLG Lift 4 1 SECTION 4 MACHINE OPERATION Stability Machine stability is based on two positions which are called FORWARD BACKWARD stability The machines position of least FORWARD stability is shown in Figure 4 2 Position of Least Forward Stability and its position of least BACK WARD stability is shown in Figure 4 1 Position of Least Backward Stability A WARNING TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT
91. ning the next function the enable light will go out and the footswitch must be released and depressed again to enable the controls Releasing the footswitch removes power from all con trols and applies the drive brakes WARNING TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS A WARNING FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOT TOM JLG Lift 3 17 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 18 6 Glow Plug Indicator Diesel Only When illuminated the glow plugs are operating After turning on ignition wait until light goes out before crank ing engine Low Fuel Indicator Yellow Indicates the fuel tank is 1 8 full or less When the light first turns on there are approximately four usable gal lons of fuel remaining Engine Malfunction Indicator On all machines prior to S N 48907 and machines with a Deutz engine prior to S N 61927 the light turns on and an alarm sounds when machine s power system requires immediate service Any of the following condi tions will turn on light and alarm low engine oil pres sure high engine coolant temperature clogged engine air filter low alternator output clogged hydraulic oil return filter or clogged charge pump filter On machines with Ford engines from S N 48907 and machines with Deutz engines after S N 61927 the light i
92. notch in the flow control knob corresponds to 3 Plug tool into quick disconnect fittings mounted on plat approximately 1 GPM ex setting 2 2 GPM At setting form rail The male quick connect is the pressure feed seven 7 the pump has reached its maximum flow rate line therefore any setting past 7 will produce no additional flow HYDRAULIC POWERTOOL SWITCH HYDRAULIC POWERTOOL SWITCH ADJUSTMENT KNOB FLOW CONTROL VALVE QUICK DISCONNECTS QUICK DISCONNECTS E 4 16 JLG Lift 3121205 SECTION 4 MACHINE OPERATION Turn hydraulic power tool switch Oil will now flow to the tool It is possible to adjust the flow control knob during operation to achieve desired tool performance When finished turn the hydraulic tool switch OFF Disconnect tool from the quick disconnects A CAUTION TURN HYDRAULIC TOOL SWITCH TO THE OFF POSITION IN ORDER TO SWITCH TOOLS NOTE NOTE NOTE 3121205 The tool circuit will not work with the foot switch depressed If the foot switch is depressed during tool cir cuit operation the tool circuit will stop functioning until the foot switch is released The tool is designed to operate at 2600 psi 179 Bar If necessary this can be adjusted for a higher or lower pres sure With the foot switch released to operate the tool circuit all drive and boom functions are cut out 4 16 TIE D
93. oduct from service immedi ately and arrangements must be made for replacement of the tire or tire assembly a smooth even cut through the cord plies which exceeds 3 inches 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter 3121205 JLG Lift any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement 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 replace ment tire we recommend that replacement tires have the follow ing characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast filled tire assembly with a pneu matic tire When selecting and installing a replacement tire ensure that
94. r Maintenance amp Lubrication Diagram Table 6 19 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F 177 C Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classifica tion GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 Lube Point s 2 Grease Fittings Engine crankcase Oil Gas API SF SH SG class MIL L 2104 Capacity A R Diesel API CC CD class MIL L 2104B MIL L 2104C Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access NOTICE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON DITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD INGLY 3121205 JLG Lift 6 21 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 2 Steer Spindles 2WS 5 Wheel Bearings Lube Point s 8 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Machines after S N 38047 will have composite bushings and no grease fittings 3 Steer Spindles AWS Lube Point s 2 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation
95. rol Indicator Panel JLG Lift 3 15 SECTION 3 MACHINE CONTROLS AND INDICATORS UNRESTRICTED CAPACITY RESTRICTED CAPACITY 1 Tilt 5 Enable 9 ACGenerator 2 Overload 6 Glow Plug 10 Not Used 3 Capacity 7 Low Fuel 11 Creep 4 Cable Service 8 Engine Malfunction 12 Drive Orientation Figure 3 7 Platform Control Indicator Panel w Drive Orientation 3 16 JLG Lift 3121205 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 Capacity Indicator Indicates the maximum platform capacity for the current position of the platform Restricted capacities are permit ted at restricted platform positions shorter boom lengths and higher boom angles NOTE Refer to the capacity decals on the machine for restricted and unrestricted platform capacities 4 Cable Service Indicator If Equipped When illuminated the light indicates the boom cables are loose or broken and must be repaired or adjusted immediately A WARNING IF THE CABLE SERVICE INDICATOR IS ILLUMINATED RETURN THE PLATFORM TO THE STOWED POSITION SHUT DOWN THE MACHINE AND HAVE 3121205 THE BOOM CABLES INSPECTED 5 Enable Indicator Footswitch To operate any function the footswitch must be depressed and the function selected within seven sec onds The enable indicator shows that the controls are enabled If a function is not selected within seven sec onds or if a seven second lapse between ending one function and begin
96. sion Hazards Do not raise the platform or drive from an elevated posi Approved head gear must be worn by all operating and tion unless the machine is on firm level and smooth sur ground personnel faces Check work area for clearances overhead on sides and Keep the chassis of the machine at least 2 ft 0 6m from bottom of platform when lifting or lowering platform and holes bumps drop offs obstructions debris concealed driving holes and other potential hazards on the floor surface Do not push or pull any object with the boom Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Do not operate the machine when wind conditions exceed 28 mph 12 5 m s Refer to Table 1 2 Beaufort Scale For Reference Only Do not increase the surface area of the platform or the load Increase of the area exposed to the wind will decrease stability Do not increase the platform size with unauthorized deck oxtensi ts or attachments During operation keep all body parts inside platform rail ing 3121205 JLG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS Use the boom functions not the drive function to position the platform close to obstacles Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 6 ft 1 8m away from machine during all driving and swing operations Limit travel speed according
97. troller to RIGHT for steering right or to LEFT for steering left 4 66 PLATFORM Platform Level Adjustment To Level Up or Down Position the Platform Level control switch Up or Down and hold until the platform is level A 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 Platform Rotation To rotate the platform to the left or right use the Platform Rotate control switch to select the direction and hold until desired position is reached 3121205 JLG Lift 47 BOOM DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS TO AVOID TIP OVER LOWER PLATFORM TO GROUND LEVEL THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE MENT DOES NOT RETURN TO THE OR NEUTRAL POSITION WHEN RELEASED IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE 4 7 SECTION 4 MACHINE OPERATION Swinging the Boom To swing boom use SWING control switch to select RIGHT or LEFT direction NOTICE WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM
98. w this symbol to avoid possible injury or death DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION IF NOT INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH THIS DECAL AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS WILL HAVE A RED BACKGROUND DECAL WILL HAVE AN ORANGE BACKGROUND A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND b JLG Lift 3121205 FOREWORD A WARNING THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE TINS CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT 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 NOTICE JLG INDUSTRIES INC MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT 3121205 JLG Lift For Accident Reporting Standards and Regulations Product Safety Publica Compliance Information tions Questions Regarding Sp
99. ylinders do not function properly have quali fied personnel correct the malfunction prior to any fur ther operation 6 35 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 6 DRAINING OIL BUILD UP FROM THE 4 Push in the Emergency Switch once the engine stops PROPANE REGULATOR PRIOR TO S N 5 Disconnect the electrical connection to the LPG fuel 03001 32529 temperature sensor in the auxiliary fuel port of the EPR During the course of normal operation oils may build inside the primary and secondary chambers of the propane pres sure regulator These oils may be a result of poor fuel quality contamination of the fuel supply chain or regional variation in the make up of the fuel If the build up of the oil is signifi cant this can effect the operation of the fuel control system Refer to Section 6 3 Operator Maintenance for maintenance intervals More frequent draining may be required if the fuel supply has been contaminated NOTICE FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERA TURE BEFORE DRAINING THIS WILL ALLOW THE OILS TO FLOW FREELY FROM THE REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Startthe engine and bring to operating temperature 3 With the engine running close the manual tank valve and run the engine out of fuel 6 36 JLG Lift 3121205 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 Re

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