Operation and Safety Manual - Acme Liftacmelift.com/.../Tracked-JLG-600-Operation-Safety-Manual.pdf · Daily Walk-Around Inspection Diagram ... • The Operation and Safety Manual

ANSI ®

Operation and Safety ManualOriginal Instructions - Keep this manual with the machine at all times.

Boom Lift Models600SC660SJCS/N 0300174703 to Present

3121606March 8, 2016

FOREWORD

a

s.

rs, and lessees with the precautions and operatingtended purpose.

the right to make specification changes without

3121606 – JLG Lift –

FOREWORD

This manual is a very important tool! Keep it with the machine at all time

The purpose of this manual is to provide owners, users, operators, lessoprocedures essential for the safe and proper machine operation for its in

Due to continuous product improvements, JLG Industries, Inc. reservesprior notification. Contact JLG Industries, Inc. for updated information.

FOREWORD

b 3121606

SIGNAL WORDS

INDIRESUGROU

INDIRESUGROU

TIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULTRATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.

AVE A YELLOW BACKGROUND.

ATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-ETY OF PERSONNEL OR PROTECTION OF PROPERTY.

potential personal injury avoid possible injury or

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILLLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-ND.

CATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULDLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-ND.

INDICATES A POTENIN MINOR OR MODETHIS DECAL WILL H

INDICATES INFORMRECTLY TO THE SAF

This is the Safety Alert Symbol. It is used to alert you to the hazards. Obey all safety messages that follow this symbol todeath

FOREWORD

c

ct:uct Safety and Reliability Department

Industries, Inc.4 Fountainhead Plaza

erstown, MD 21742

ur Local JLG Office addresses on inside of manual cover)

A:

Free: 877-JLG-SAFE (877-554-7233)

de USA:e: 240-420-2661

301-745-3713il: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

ions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Prod-uct Modifications

3121606 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLGINDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FORTHIS PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OFRECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THECURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHEREJLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURYOR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-SONAL PROPERTY OR THE JLG PRODUCT.

ContaProdJLG 1322HagUSA

or Yo(See

In US

Toll

OutsiPhonFax: E-ma

For:• Accid

• Produtions

• Curre

• QuestProdu

FOREWORD

d 3121606

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Re

Re

– JLG Lift –

REVISION LOG

riginal Issue - November 27, 2013

vised - January 5, 2015

vised - March 8, 2016

312 i

SEC PARAGRAPH, SUBJECT PAGE

TABLE OF CONTENTS

SEC

SECA

SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

- MACHINE CONTROLS AND INDICATORS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Ground Control Indictor Panel . . . . . . . . . . . . . . . . . . . . . 3-9Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . 3-11Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-17

- MACHINE OPERATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Traveling Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . 4-8Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . 4-11Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

1606 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION -TION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-111.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

TION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, ND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Daily Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION - 3

3.13.2

SECTION - 4

4.14.2

4.3

4.4

4.54.6

ii 3121606

TABLE OF CONTENTS

SECTIO AGRAPH, SUBJECT PAGE4.7

4.84.9

4.14.1

4.1

SECTION

5.15.25.3

5.4

NERAL SPECIFICATIONS & OPERATOR E

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1RATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6-1pacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2gine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3draulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

ajor Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-7rial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

RATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12PLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-16

SPECTION AND REPAIR LOG

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PARBOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-13

SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

0 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-141 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

2 AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15Activating from the Platform Control Station . . . . . . 4-15Activating from the Ground Control Station . . . . . . . 4-17

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-2Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2

MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

SECTION - 6 - GEMAINTENANC

6.1 INTR6.2 OPE

CaEnHyMSe

6.3 OPE6.4 SUP

SECTION - 7 - IN

312 iii

LIST OF FIGURES

FIG MBER - TITLE PAGEDecal Installation - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-20Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-21Decal Installation - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-22Decal Installation - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-23Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8Engine Operating Temperature Specifications -

Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9Engine Operating Temperature Specifications -

Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10Operator Maintenance and Lubrication Diagram. . . . . 6-11


URE NUMBER - TITLE PAGE FIGURE NU2-1. Drive Function Operating Range Diagrams -

Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92-2. Drive Function Operating Range Diagrams -

Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-102-3. Drive Function Operating Range Diagrams -

Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112-4. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . 2-122-5. Daily Walkaround Inspection Points - Sheet 1 of 2 . . . . 2-132-6. Daily Walkaround Inspection Points - Sheet 2 of 2 . . . . 2-143-1. Ground Control Station - 600SC . . . . . . . . . . . . . . . . . . . . . . 3-33-2. Ground Control Station - 600SC with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . . 3-43-3. Ground Control Station - 660SJC . . . . . . . . . . . . . . . . . . . . . 3-53-4. Ground Control Station - 660SJC with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . . 3-63-5. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . 3-103-6. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-123-7. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-184-1. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-24-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-34-3. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64-4. Machine Motion Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74-5. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-104-6. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-164-7. Decal Installation - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-184-8. Decal Installation - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-19

4-9.4-10.4-11.4-12.6-1.6-2.

6-3.

6-4.

iv 3121606

LIST O

FIGURE ER - TITLE PAGE

lly.

– JLG Lift –

F FIGURES

NUMBER - TITLE PAGE FIGURE NUMB

This Page Left Blank Intentiona

312 v

LIST OF TABLES

TAB MBER - TITLE PAGE


LE NUMBER - TITLE PAGE TABLE NU1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-61-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-92-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-34-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144-2 600SC Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-244-3 660SJC Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-286-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26-3 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-36-4 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36-5 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-6 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-7 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-8 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-9 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-10 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-11 Major Component Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-76-12 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-127-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

vi 3121606

LIST O

TABLE N R - TITLE PAGE

lly.

– JLG Lift –

F TABLES

UMBER - TITLE PAGE TABLE NUMBE

This Page Left Blank Intentiona

SECTION 1 - SAFETY PRECAUTIONS

1-1

UTIONS

MPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR

-OPERATION

raining and Knowledge Operation and Safety Manual must be read and under-d in its entirety before operating the machine. For clarifi-

on, questions, or additional information regarding anytions of this manual, contact JLG Industries, Inc.

3121606 – JLG Lift –

SECTION 1. SAFETY PRECA

1.1 GENERALThis section outlines the necessary precautions for proper andsafe machine usage and maintenance. It is mandatory that a dailyroutine is established based on the content of this manual to pro-mote proper machine usage. A maintenance program, using theinformation provided in this manual and the Service and Mainte-nance Manual, must also be established by a qualified person andmust be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must notaccept operating responsibility until this manual has been read,training is accomplished, and operation of the machine has beencompleted under the supervision of an experienced and quali-fied operator.

This section contains the responsibilities of the owner, user, oper-ator, lessor, and lessee concerning safety, training, inspection,maintenance, application, and operation. If there are any ques-tions with regard to safety, training, inspection, maintenance,application, and operation, please contact JLG Industries, Inc.(“JLG”).

FAILURE TO COCOULD RESULTDEATH.

1.2 PRE

Operator T• The

stoocatipor


1-2 3121606

pectionns to avoid all hazards in the work area must be

the user before and during operation of the machine.

perate or raise the platform from a position on trucks,ailway cars, floating vessels, scaffolds or other equip-less the application is approved in writing by JLG.

peration, check work area for overhead hazards suchic lines, bridge cranes, and other potential overheadions.

erating surfaces for holes, bumps, drop-offs, obstruc-bris, concealed holes, and other potential hazards.

e work area for hazardous locations. Do not operateine in hazardous environments unless approved forose by JLG.

hat the ground conditions are adequate to supportimum tire load indicated on the tire load decalsn the chassis adjacent to each wheel. Do not travelported surfaces.

– JLG Lift –

• An operator must not accept operating responsibilities untiladequate training has been given by competent and autho-rized persons.

• Allow only those authorized and qualified personnel to oper-ate the machine who have demonstrated that they under-stand the safe and proper operation and maintenance of theunit.

• Read, understand, and obey all DANGERS, WARNINGS, CAU-TIONS, and operating instructions on the machine and in thismanual.

• Ensure that the machine is to be used in a manner which iswithin the scope of its intended application as determined byJLG.

• All operating personnel must be familiar with the emergencycontrols and emergency operation of the machine as specifiedin this manual.

• Read, understand, and obey all applicable employer, local, andgovernmental regulations as they pertain to your utilizationand application of the machine.

Workplace Ins• Precautio

taken by

• Do not otrailers, rment un

• Before oas electrobstruct

• Check options, de

• Check ththe machthat purp

• Ensure tthe maxlocated oon unsup


1-3

RATION

hine operation requires your full attention. Bring thehine to a full stop before using any device, i.e. cell phones,-way radios, etc. that will distract your attention fromly operating the machine.

not use the machine for any purpose other than position-personnel, their tools, and equipment.

re operation, the user must be familiar with the machineabilities and operating characteristics of all functions.

er operate a malfunctioning machine. If a malfunctionrs, shut down the machine. Remove the unit from service

notify the proper authorities.

ot remove, modify, or disable any safety devices.

er slam a control switch or lever through neutral to anosite direction. Always return switch to neutral and stopre moving the switch to the next function. Operate con- with slow and even pressure.

not allow personnel to tamper with or operate thehine from the ground with personnel in the platform,pt in an emergency.

3121606 – JLG Lift –

Machine Inspection • Do not operate this machine until the inspections and func-

tional checks as specified in Section 2 of this manual havebeen performed.

• Do not operate this machine until it has been serviced andmaintained according to the maintenance and inspectionrequirements as specified in the machine’s Service and Main-tenance Manual.

• Ensure all safety devices are operating properly. Modificationof these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADEONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instructionplacards or decals are missing or illegible.

• Check the machine for modifications to original components.Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil,grease, and other slippery substances from footwear and plat-form floor.

1.3 OPE

General • Mac

mactwosafe

• Do ing

• Befocap

• Nevoccuand

• Do n

• Nevoppbefotrols

• Do macexce


1-4 3121606

ine will remain stationary, hydraulic oil temperature, air temperature, and boom and platform position.

azards peration, occupants in the platform must wear a fullness with a lanyard attached to an authorized lanyarde point. Attach only one (1) lanyard per lanyarde point.

d exit only through gate area. Use extreme cautiontering or leaving platform. Ensure that the platform is fully lowered. Face the machine when entering orhe platform. Always maintain “three point contact” machine, using two hands and one foot or two feethand at all times during entry and exit.

– JLG Lift –

• Do not carry materials directly on platform railing unlessapproved by JLG.

• When two or more persons are in the platform, the operatorshall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and neverleft hanging by their cord from the platform work area.

• When driving, always position boom over rear axle in line withthe direction of travel. Remember, if boom is over the frontaxle, steer and drive functions will be reversed.

• Do not assist a stuck or disabled machine by pushing or pull-ing except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leavingmachine.

• Remove all rings, watches, and jewelry when operatingmachine. Do not wear loose fitting clothing or long hair unre-strained which may become caught or entangled in equip-ment.

• Persons under the influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

• Hydraulic cylinders are subject to thermal expansion and con-traction. This may result in changes to the boom and/or plat-form position while the machine is stationary. Factorsaffecting thermal movement can include the length of time

the machambient

Trip and Fall H• During o

body haranchoraganchorag

• Enter anwhen enassemblyleaving twith theand one


1-5

ion Hazards machine is not insulated and does not provide protection contact or proximity to electrical current.

3121606 – JLG Lift –

• Before operating the machine, make sure all gates are closedand fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at alltimes. Never position ladders, boxes, steps, planks, or similaritems on unit to provide additional reach for any purpose.

• Keep oil, mud, and slippery substances cleaned from footwearand the platform floor.

Electrocut• This

from


1-6 3121606

a clearance of at least 10 ft. (3m) between any part ofhine and its occupants, their tools, and their equip-m any electrical line or apparatus carrying up toolts. One foot additional clearance is required forditional 30,000 volts or less.

-1. Minimum Approach Distances (M.A.D.)

e Rangeto Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

50 KV 10 (3)

V to 200 KV 15 (5)

V to 350 KV 20 (6)

V to 500 KV 25 (8)

V to 750 KV 35 (11)

V to 1000 KV 45 (14)

requirement shall apply except whereloyer, local or governmental regulations are

re stringent.

– JLG Lift –

• Maintain distance from electrical lines, apparatus, or any ener-gized (exposed or insulated) parts according to the MinimumApproach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintainthe macment fro50,000 vevery ad

Table 1

Voltag(Phase

0 to

Over 50K

Over 200 K

Over 350 K

Over 500 K

Over 750 K

NOTE: Thisempmo


1-7

azards user must be familiar with the surface before driving. Doexceed the allowable sideslope and grade while driving.

not elevate platform or drive with platform elevated whiler near a sloping, uneven, or soft surface. Ensure machine is

itioned on a firm, level and smooth surface before elevat-platform or driving with the platform in the elevated posi-.

re driving on floors, bridges, trucks, and other surfaces,ck allowable capacity of the surfaces.

3121606 – JLG Lift –

• The minimum approach distance may be reduced if insulatingbarriers are installed to prevent contact, and the barriers arerated for the voltage of the line being guarded. These barriersshall not be part of (or attached to) the machine. The mini-mum approach distance shall be reduced to a distance withinthe designed working dimensions of the insulating barrier.This determination shall be made by a qualified person inaccordance with the employer, local, or governmental require-ments 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 OTH-ERWISE.

Tipping H• The

not

• Do on oposing tion

• Befoche


1-8 3121606

perate the machine when wind conditions, includingay exceed 28 mph (12.5 m/s). Factors affecting winde; platform elevation, surrounding structures, localevents, and approaching storms. Refer to Table 1-2, scale (For Reference Only) or use other means towind conditions.

eed can be significantly greater at height than atevel.

ed can change rapidly. Always consider approachingevents, the time required to lower the platform, and to monitor current and potential wind conditions.

increase surface area of the platform or the load. areas exposed to wind will decrease stability.

crease the platform size with unauthorized modifica-ttachments.

– JLG Lift –

• Never exceed the maximum work load as specified on theplatform. Keep all loads within the confines of the platform,unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m)from holes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards at the ground level.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-offmachine to any adjacent structure. Never attach wire, cable, orany similar items to platform.

• If boom assembly or platform is in a position that one or morewheels are off the ground, all persons must be removed beforeattempting to stabilize the machine. Use cranes, forklift trucks,or other appropriate equipment to stabilize machine.

• Do not ogusts, mspeed arweather Beaufortmonitor

• Wind spground l

• Wind speweather methods

• Do not Increased

• Do not intions or a


1-9

nce Only)

Land Conditions

vertically

le in smoke

ed skin. Leaves rustle

twigs in constant motion

er raised. Small branches begin to move.

.

otion. Flags waving near horizontal. Umbrella use

ion. Effort needed to walk against the wind.

trees. Cars veer on road.

age.

3121606 – JLG Lift –

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).

Table 1-2. Beaufort Scale (For Refere

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises

1 1-3 0.3-1.5 Light air Wind motion visib

2 4-7 1.6-3.3 Light breeze Wind felt on expos

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller

4 13-18 5.5-7.9 Moderate breeze Dust and loose pap

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway

6 25-31 10.8-13.8 Strong breeze Large branches in mbecomes difficult.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in mot

8 39-46 17.2-20.7 Fresh Gale Twigs broken from

9 47-54 20.8-24.4 Strong Gale Light structure dam


1-1 3121606

Cru n-operating personnel at least 6 ft. (1.8m) away from during all driving and swing operations.

ll travel conditions, the operator must limit travelcording to conditions of ground surface, congestion, slope, location of personnel, and other factors whichse collision or injury to personnel.

of stopping distances in all drive speeds. When driv-h speed, switch to low speed before stopping. Travel low speed only.

se high speed drive in restricted or close quarters orving in reverse.

extreme caution at all times to prevent obstacles fromr interfering with operating controls and persons in

orm.

that operators of other overhead and floor levels are aware of the aerial work platform’s presence. Dis-power to overhead cranes.

rsonnel not to work, stand, or walk under a raised platform. Position barricades on floor if necessary.

0 – JLG Lift –

shing and Collision Hazards• Approved head gear must be worn by all operating and

ground personnel.

• Check work area for clearances overhead, on sides, and bot-tom of platform when lifting or lowering platform, and driving.

• During operation, keep all body parts inside platform railing.

• Use the boom functions, not the drive function, to position theplatform close to obstacles.

• Always post a lookout when driving in areas where vision isobstructed.

• Keep nomachine

• Under aspeed acvisibility,may cau

• Be awareing in higgrades in

• Do not uwhen dri

• Exercise striking othe platf

• Be sure machineconnect

• Warn peboom or


1-11

INTENANCEb-section contains general safety precautions which musterved during maintenance of this machine. Additional pre-ns to be observed during machine maintenance ared at the appropriate points in this manual and in the Ser-d Maintenance Manual. It is of utmost importance thatnance personnel pay strict attention to these precautionsd possible injury to personnel or damage to the machineerty. A maintenance program must be established by a

ied person and must be followed to ensure that thee is safe.

nce Hazardst off power to all controls and ensure that all moving partssecured from inadvertent motion prior to performing anystments or repairs.

er work under an elevated platform until it has been fullyered to the full down position, if possible, or otherwiseported and restrained from movement with appropriatety props, blocking, or overhead supports.

NOT attempt to repair or tighten any hydraulic hoses or fit-s while the machine is powered on or when the hydraulicem is under pressure.

ays relieve hydraulic pressure from all hydraulic circuitsre loosening or removing hydraulic components.

3121606 – JLG Lift –

1.4 TOWING, LIFTING, AND HAULING• Never allow personnel in platform while towing, lifting, or

hauling.

• This machine should not be towed, except in the event ofemergency, malfunction, power failure, or loading/unloading.Refer to the Emergency Procedures section of this manual foremergency towing procedures.

• Ensure boom is in the stowed position and the turntablelocked prior to towing, lifting or hauling. The platform must becompletely empty of tools.

• When lifting machine, lift only at designated areas of themachine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lift-ing information.

1.5 MAThis sube obscautioinsertevice anmainteto avoior propqualifmachin

Maintena• Shu

are adju

• Nevlowsupsafe

• DO tingsyst

• Alwbefo


1-1 3121606

se machine as a ground for welding.

rforming welding or metal cutting operations, pre- must be taken to protect the chassis from direct to weld and metal cutting spatter.

fuel the machine with the engine running.

approved non-flammable cleaning solvents.

eplace items critical to stability, such as batteries ors, with items of different weight or specification. Doify unit in any way to affect stability.

the Service and Maintenance Manual for the weightsl stability items.

LTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADERITTEN PERMISSION FROM THE MANUFACTURER.

2 – JLG Lift –

• DO NOT use your hand to check for leaks. Use a piece of card-board or paper to search for leaks. Wear gloves to help protecthands from spraying fluid.

• Ensure replacement parts or components are identical orequivalent to original parts or components.

• Never attempt to move heavy parts without the aid of amechanical device. Do not allow heavy objects to rest in anunstable position. Ensure adequate support is provided whenraising components of the machine.

• Do not u

• When pecautionsexposure

• Do not re

• Use only

• Do not rsolid tirenot mod

• Refer to of critica

MODIFICATION OR AONLY WITH PRIOR W


1-13

ID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH AND SEEK MEDICAL ATTENTION.

rge batteries only in a well ventilated area.

id overfilling the battery fluid level. Add distilled water toeries only after the batteries are fully charged.

3121606 – JLG Lift –

Battery Hazards• Always disconnect batteries when servicing electrical compo-

nents or when performing welding on the machine.

• Do not allow smoking, open flame, or sparks near battery dur-ing charging or servicing.

• Do not contact tools or other metal objects across the batteryterminals.

• Always wear hand, eye, and face protection when servicingbatteries. Ensure that battery acid does not come in contactwith skin or clothing.

BATTERY FLUCLOTHING ATCLEAN WATER

• Cha

• Avobatt


1-1 3121606
4 – JLG Lift –
NOTES:

S, MACHINE PREPARATION, AND INSPECTION

2-1

REPARATION, AND INSPECTION

e safest means to operate the machine where overheadstructions, other moving equipment, and obstacles,pressions, holes, or drop-offs exist.

eans to avoid the hazards of unprotected electrical con-ctors.

ecific job requirements or machine application.

upervisiong must be done under the supervision of a qualified per- an open area free of obstructions until the trainee hasped the ability to safely control and operate the machine.

esponsibilityerator must be instructed that he/she has the responsibil- authority to shut down the machine in case of a malfunc- other unsafe condition of either the machine or the job

SECTION 2 - USER RESPONSIBILITIE

3121606 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE P

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it is neces-sary that it be operated and maintained only by trained person-nel.

Persons under the influence of drugs or alcohol or who are sub-ject to seizures, dizziness or loss of physical control must notoperate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at theground, 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 themachine to recognize a malfunction or potential malfunc-tion.

6. Thobde

7. Mdu

8. Sp

Training STraininson indevelo

Operator RThe opity andtion orsite.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121606

2.2. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A

UCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL PRODUCT MODEL.

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCEThe following table covers the periodic machine inspections andmaintenance required by JLG Industries, Inc. Consult local regula-tions for further requirements for aerial work platforms. The fre-quency of inspections and maintenance must be increased asnecessary when the machine is used in a harsh or hostile environ-ment, if the machine is used with increased frequency, or if themachine is used in a severe manner.

JLG INDUSTRIES, INCPERSON WHO HAS SFOR THE SPECIFIC JLG


2-3

nce Table

yility

Service Qualification

Reference

User or Operator Operator and Safety Manual

User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

User Factory Trained Service Technician(Recommended)

Service and Maintenance Manual and applicable JLG inspection form

User Qualified JLG Mechanic Service and Maintenance Manual

ual to perform inspections.


3121606 – JLG Lift –

Table 2-1.Inspection and Maintena

Type FrequencyPrimar

Responsib

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operator

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer, or

Frequent Inspection(See Note)

In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer, or

Annual Machine Inspection(See Note)

Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or

Preventative Maintenance At intervals as specified in the Service and Maintenance Manual.

Owner, Dealer, or

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Man


2-4 3121606

Pre Around” Inspection – Refer to Figure 2-4., Figure 2-Figure 2-6.

y – Charge as required.

ombustion Engine Powered Machines) – Add the fuel as necessary.

Oil Supply - Ensure the engine oil level is at the Fulln the dipstick and the filler cap is secure.

ulic Oil – Check the hydraulic oil level. Ensure hydrau- added as required.

ories/Attachments - Reference the Operator andManual of each attachment or accessory installedhe machine for specific inspection, operation, andnance instructions.

on Check – Once the “Walk-Around” Inspection iste, perform a functional check of all systems in ane of overhead and ground level obstructions. Refer to 4 for more specific operating instructions.

ES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOTNE UNTIL IT IS DECLARED SAFE FOR OPERATION.

– JLG Lift –

-Start InspectionThe Pre-Start Inspection shall include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-tery fluid) or foreign objects. Report any leakage to theproper maintenance personnel.

2. Structure - Inspect the machine structure for dents, dam-age, weld or parent metal cracks or other discrepancies.

3. Decals and Placards – Check all for cleanliness and legibil-ity. Make sure none of the decals and placards are missing.Make sure all illegible decals and placards are cleaned orreplaced.

4. Operation and Safety Manuals – Make sure a copy of theOperator and Safety Manual, AEM Safety Manual (Domesticonly), and ANSI Manual of Responsibilities (Domestic only) isenclosed in the weather resistant storage container.

5. “Walk-5. and

6. Batter

7. Fuel (Cproper

8. Enginemark o

9. Hydralic oil is

10. AccessSafety upon tmainte

11. Functicomplearea freSection

IF THE MACHINE DOATELY! REPORT THE OPERATE THE MACHI

Parent Metal Crack Weld Crack


2-5

hile driving in high drive, elevate the boom to approxi-ately 10 degrees. Drive should cut back to low speed. Theitch should reset when the boom is fully lowered.

eck capacity limit switch as follows:

. Boom Length Switch.

Raise boom to horizontal. Telescope boom out until 500lb. light comes on. Make sure the switch resets and the1000 lb. light comes back on when telescoping in.

. Boom Angle Switch.

Telescope boom to full extension.

Lift boom up until 1000 lb. light comes on.

Lift boom down using auxiliary power until 500 lb. lightcomes on. Boom angle must be approximately 45 to 50degrees

Lift boom up until 1000 lb. light comes on. The switchshould reset when the boom angle is about 55 degreesto 64 degrees.

imit switch settings need to be changed, you will need toheck that the 500 lb. light comes on at 45 degrees to 50rees when lifting down.


3121606 – JLG Lift –

Daily Functional CheckA functional check of all systems should be performed, once thewalk-around inspection is complete, in an area free of overheadand ground level obstructions. First, using the ground controls,check all functions controlled by the ground controls. Next, usingthe platform controls, check all functions controlled by the plat-form controls.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORTOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THEOFF OR NEUTRAL POSITION WHEN RELEASED.

TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROLSWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-GENCY STOP TO STOP THE MACHINE.

NOTE: Perform checks from ground controls first, then from platformcontrols.

1. Operate machine from ground control.

NOTE: For adjustments see Service Manual, Limit Switch Adjustments.

2. Check elevation limit switch as follows:

Wmsw

3. Ch

a

b

NOTE: If lrecdeg


2-6 3121606

NOT

ut down the machine, and contact a qualified techni-fore resuming operation.

that platform automatic self-leveling system func-roperly during raising and lowering of the boom.

platform level adjustment system for proper opera-

platform rotator for smooth operation and assurem will rotate 90 degrees in both directions from cen- of boom.

orward and reverse; check for proper operation.

ft and right; check for proper operation.

nd lower Articulating Jib Boom. Check for smoothion.

SI, ANSI Export, CSA, Japan 5°

, Australia 3°

– JLG Lift –

4. Drive Disable Switch (Refer to Figure 2-2., Drive FunctionOperating Range Diagrams - Sheet 2 of 3).

a. Telescope the boom out over 40 ft. (12.2 m).

b. Manually tilt the tilt sensor.

c. Drive Disable Indicator Light should come on.

d. Retract the boom and elevate to at least 55°.

e. Manually tilt the tilt sensor.

f. The Drive Disable Indicator Light should come onagain.

5. Raise main boom, extend and retract telescope. Check fordelayed movement of fly section, indicating loose cables.

E: Turntable lock is on turntable facing platform. To disengagelock, pull snap pin from lock pin, lift lock pin up to unlock turnta-ble. Return snap pin to lock pin to hold lock pin in the disen-gaged position. Reverse procedure to engage turntable lock.

6. Swing turntable to Left and Right a minimum of 45 degrees.Check for smooth motion.

7. Check the chassis out of level indicator located on the plat-form control console by driving, with the machine in levelposition, up a suitable ramp of at least 5° slope. Check theout of level indicator, with the machine on the ramp. If thelight does not illuminate, return the machine to a level sur-

face, shcian be

8. Check tions p

9. Check tion.

10. Check platforterline

11. Drive f

12. Steer le

13. Raise aoperat

AN

CE


2-7

xiliary Power.

perate each function control switch (e.g. Tele, Lift anding) to assure that they function in both directions usingxiliary power instead of engine power.

ound Controls.

ace Ground/Platform Select switch to Ground. Startgine. Platform controls should not operate.


3121606 – JLG Lift –

14. Footswitch.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDALIS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

a. Activate hydraulic system. By depressing footswitch.Operate Main Telescope and hold control. Remove footfrom footswitch, motion should stop. If it does not, shutdown machine and contact a certified JLG service tech-nician.

b. With footswitch depressed, operate Lift and hold con-trol. Remove foot from footswitch, motion should stop.If it does not, shut down machine and contact a certi-fied JLG service technician.

c. With engine power shut down, depress the footswitch.Attempt to start engine. Engine should not attempt tostart when footswitch is depressed. If starter engages orengine turns over, shut down machine and contact acertified JLG service technician.

15. Au

OSwau

16. Gr

Plen


2-8 3121606

Sky achine is equipped with both SkyGuard and Soft Touch,s will not reverse, only stop.

ed, ensure the blue beacon illuminates when SkyGuardted.

the SkyGuard sensor, release controls, recycle the foote sure normal operation is available.

remains activated after function reversal or cutout, hold the SkyGuard Override Switch to allow normal

hine functions until the SkyGuard sensor is disen-

– JLG Lift –

Guard Function Test From the Platform Console:

Test the SkyGuard feature by operating the telescope out func-tions and then activating the SkyGuard sensor. The telescope outfunction will stop and the telescope in function will operate for ashort duration and the horn will sound until the SkyGuard sensorand footswitch are disengaged.

NOTE: If the mfunction

NOTE: If equippis activa

Disengage switch, mak

If SkyGuarddepress anduse of macgaged.


2-9

agrams - Sheet 1 of 3

NOTE: In the Transport Mode, High Drive will bedisabled above 10° elevation or past 3feet (1 m) of boom extension.


3121606 – JLG Lift –

Figure 2-1. Drive Function Operating Range Di


2-1 3121606

s - Sheet 2 of 3

E: In the Transport Mode, High Drive will bedisabled above 10° elevation or past 3 feet(1 m) of boom extension.

0 – JLG Lift –

70ft.21.34 m

60ft.18.29 m

60ft.18.29 m

50ft.15.24 m

50ft.15.24 m

40ft.12.19 m

40ft.12.19 m

30ft.9.14 m

30ft.9.14 m

20ft.6.10 m

20ft.6.10 m

10ft.3.05 m

10ft.3.05 m

0

10ft.3.05 m

CHASSISTILTED> 1.8∞

NO DRIVE IF CHASSIS

TILTED> 1.8∞

DRIVE CUTOUTPER

PERSONALITYSETTING

55 DEGREES

Figure 2-2. Drive Function Operating Range Diagram

NOT


2-11

grams - Sheet 3 of 3

NOTE: In the Transport Mode, High Drive will bedisabled above 10° elevation or past 3 feet(1 m) of boom extension.


3121606 – JLG Lift –

70ft.21.34 m

60ft.18.29 m

60ft.18.29 m

50ft.15.24 m

50ft.15.24 m

40ft.12.19 m

40ft.12.19 m

30ft.9.14 m

30ft.9.14 m

20ft.6.10 m

20ft.6.10 m

10ft.3.05 m

10ft.3.05 m

0

10ft.3.05 m

55 DEGREES

CHASSISTILTED

CREEP CUTOUTSPER PERSONALITY

SETTING

CREEP IF TILTED > 1.8∞ CUTOUTS PERPERSONALITY SETTING

Figure 2-3. Drive Function Operating Range Dia


2-1 3121606

gram

2 – JLG Lift –

Figure 2-4. Daily Walk-Around Inspection Dia


2-13

ib (If Equipped) - See Inspection Note.

ual Capacity Limit Switch, Transport Position Limitwitch - Switches operate properly.

ower Track - See Inspection Note.

urntable Bearing and Pinion - No evidence of looseolts or looseness between bearing and structure. Seespection Note.

racks - Properly secured plates, no loose or missing trackolts, no dislocation of the track pins. Proper tension. Seespection Note.

inal Drive, Both Sides - See Inspection Note.

urntable Lock - Operable; See Inspection Note.

ints - Sheet 1 of 2


3121606 – JLG Lift –

GeneralBegin the "Walk-Around Inspection" at Item 1, as noted onthe diagram. Continue checking each item in sequence forthe conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

INSPECTION NOTE: On all components, make sure there are noloose or missing parts, that they are securely fastened, and no visi-ble damage, leaks or excessive wear exists in addition to any othercriteria mentioned.

1. Platform Assembly and Gate - Footswitch works prop-erly, not modified, disabled or blocked. Latch, stop, andhinges in working condition.

2. Platform & Ground Control Consoles - Switches andlevers return to neutral, decals/placards secure and legible,control markings legible.

3. Rotator - See Inspection Note.

4. J

5. DS

6. P

7. TbIn

8. TbIn

9. F

10. T

Figure 2-5. Daily Walkaround Inspection Po


2-1 3121606

ank - See Inspection Note.

See Inspection Note.

Capacity Limit Switch - Switch operates properly.

ry - Proper electrolyte levels if adjustable; cablesno visible damage or corrosion.

ulic Pump - See Inspection Note.

- See Inspection Note.

Boom Sections - See Inspection Note.

uard (If Equipped) - See Inspection Note.

Sheet 2 of 2

4 – JLG Lift –

11. Auxiliary Power Pump - See Inspection Note.

12. Bottom Rollers - See Inspection Note.

13. Track Carrier Roller, Both Sides - See Inspection Note.

14. Swing Drive Motor and Brake - See Inspection Note.

15. Control Valve - See Inspection Note.

16. Hydraulic Tank - See Inspection Note.

17. Hood Assemblies - See Inspection Note.

18. Tension Mechanism - See Inspection Note.

19. Fuel T

20. Idler -

21. Dual

22. Battetight,

23. Hydra

24. Frame

25. Main

26. SkyG

Figure 2-6. Daily Walkaround Inspection Points -

N 3 - MACHINE CONTROLS AND INDICATORS

3-1

ND INDICATORS

indicator panels use different shaped symbols to alert therator to different types of operational situations that could

se. The meaning of those symbols are explained below.Indicates a potentially hazardous situation, which ifnot corrected, could result in serious injury or death.This indicator will be red.

Indicates an abnormal operating condition, which ifnot corrected, may result in machine interruption ordamage. This indicator will be yellow.

Indicates important information regarding the oper-ating condition, i.e. procedures essential for safe oper-ation. This indicator will be green with the exception ofthe capacity indicator which will be green or yellowdepending upon platform position.

SECTIO

3121606 – JLG Lift –

SECTION 3. MACHINE CONTROLS A

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION ANDOPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITHGOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: All machines are equipped with control panels that use symbolsto indicate control functions. On ANSI machines refer to decallocated on the control box guard in front of the control box or bythe ground controls for these symbols and the correspondingfunctions.

NOTE: Theopeari

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121606

Gro

NOT

ORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OFORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR SO COULD RESULT IN DEATH OR SERIOUS INJURY.

m Leveling Override

position switch allows the oper- adjust the automatic self level-tem. This switch is used to adjustm level in situations such asing/descending a grade.

quipped)

itch provides raising and lower-he jib.

– JLG Lift –

und Control Station(See Figure 3-1., Figure 3-2., Figure 3-3., and Figure 3-4.)

E: The Function Enable switch must be held down inorder to operate Telescope, Swing, Lift, Jib Lift,Platform Level Override, and Platform Rotatefunctions.

1. Platform Rotate

Provides rotation of the platform.

ONLY USE THE PLATFTHE PLATFORM. INCFALL. FAILURE TO DO

2. Platfor

A threeator toing sysplatforascend

3. Jib (If E

This swing of t


3-3

- 600SC

SECTIO

3121606 – JLG Lift –

Figure 3-1. Ground Control Station

1. Platform Rotate2. Platform Leveling Override3. Not Used4. Power/Emergency Stop5. Engine Start/Auxiliary Power/Function Enable6. Lift7. Hourmeter8. Platform/Ground Select Switch9. Swing10. Telescope11. Indicator Panel


3-4 3121606

m Override (MSSO) (CE Only)

– JLG Lift –

Figure 3-2. Ground Control Station - 600SC with Machine Safety Syste

1. Platform Rotate2. Platform Leveling Override3. Not Used4. Power/Emergency Stop5. Engine Start/Auxiliary Power/Function Enable6. Lift7. Hourmeter8. Platform/Ground Select Switch9. Swing10. Telescope11. Indicator Panel12. Machine Safety System Override (MSSO)


3-5

- 660SJC

SECTIO

3121606 – JLG Lift –

1. Platform Rotate2. Platform Leveling Override3. Jib4. Power/Emergency Stop5. Engine Start/Auxiliary Power/Function Enable6. Lift7. Hourmeter8. Platform/Ground Select Switch9. Swing10. Telescope11. Indicator Panel

Figure 3-3. Ground Control Station


3-6 3121606

stem Override (MSSO) (CE Only)

– JLG Lift –

1. Platform Rotate2. Platform Leveling Override3. Jib4. Power/Emergency Stop5. Engine Start/Auxiliary Power/Function Enable6. Lift7. Hourmeter8. Platform/Ground Select Switch9. Swing10. Telescope11. Indicator Panel12. Machine Safety System Override (MSSO)

Figure 3-4. Ground Control Station - 660SJC with Machine Safety Sy


3-7

gine Start/ Auxiliary Power Switch /Function Enable

start the engine, the switch must be heldp" until the engine starts.

use auxiliary power, the switch must beld “Down” for duration of auxiliary pumpe.

hen the engine is running, the switch must held "Down" to enable all boom controls.

ING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC-. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP

ft Control

ovides raising and lowering of theom.

urmeter

gisters the amount of time theachine has been in use with enginenning.

SECTIO

3121606 – JLG Lift –

NOTE: When Power/Emergency Stop switch is in the “ON” position andengine is not running, an alarm will sound, indicating Ignition is“ON”.

WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUSTBE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.

NOTE: On machines with diesel engines, when Glow Plug Indicator islighted (Yellow), wait until light goes out before cranking engine.

4. Power/Emergency Stop Switch

A two-position red mushroom shaped switchsupplies power to Platform/Ground Selectswitch when pulled out (on). When pushed in(off ), power is shut off to the Platform/Ground Select switch.

NOTE: When the Platform/Ground Select Switch is in the center posi-tion, power is shut off to the controls at both operating stations.Remove the key to prevent the controls from being actuated. Thekey is removable in the platform position on CE specificationmachines. The key must be available to ground personnel in theevent of an emergency.

5. En

To"U

Toheus

Wbe

WHEN OPERATTION AT A TIMEMOTOR.)

6. Li

Prbo

7. Ho

Remru


3-8 3121606

NOT

HE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR

NJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE RELEASED.

Control

s 360 degrees continuous turn-tation.

pe Control

s extension and retraction ofom.

– JLG Lift –

E: When the Platform/Ground Select Switch is in thecenter position, power is shut off to the controls atboth operating stations. Remove the key to pre-vent the controls from being actuated. The key isremovable in the platform position on CE specifi-cation machines. The key must be available toground personnel in the event of an emergency.

8. Platform/Ground Select Switch

The three position, key operated switch sup-plies power to the platform control consolewhen positioned to Platform. With the switchkey turned to the Ground position onlyground controls are operable.

WHEN OPERATING TUNDER PLATFORM.

TO AVOID SERIOUS ITOGGLE SWITCHES COFF POSITION WHEN

9. Swing

Providetable ro

10. Telesco

Providethe bo


3-9

stem Distress Indicator

e light indicates that the JLG Control Systems detected an abnormal condition and aagnostic Trouble Code has been set in thestem memory. Refer to the Service Manual for instructionsncerning the trouble codes and trouble code retrieval.

e system distress indicator light will illuminate for 2-3 sec-ds when the key is positioned to the on position to act as

self test.

w Fuel Level Indicator

dicates that the fuel level is 1/8 full or less.uminates when there are approximately fourllons of fuel remaining.

SECTIO

3121606 – JLG Lift –

11. Machine Safety System Override (MSSO) (CEOnly)

Provides emergency override of functioncontrols that are locked out in the event ofLoad Sense System activation.

Ground Control Indictor Panel(See Figure 3-5., Ground Control Indicator Panel)

1. No Alternator Output Indicator

Indicates a problem in the charging circuit,and service is required.

2. Engine Oil Pressure Indicator

Indicates that engine oil pressure is below nor-mal and service is required.

3. Engine Oil Temperature Indicator (Deutz)

Indicates that the temperature of the engineoil, which also serves as engine coolant, isabnormally high and service is required.

4. Sy

ThhaDisyco

Thona

5. Lo

InIllga


3-1 3121606

nel

0 – JLG Lift –

1. Battery Charging2. Engine Oil Pressure3. Engine Oil Temp.4. Malfunction Indicator

5. Low Fuel6. Glow Plug7. Platform Overload

Figure 3-5. Ground Control Indicator Pa


3-11

ontrol Stationure 3-6., Platform Control Console)

OUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE

L POSITION WHEN RELEASED.

ive Speed/Torque Select

e machine has a three position itch.

e forward position gives maxi-um drive speed. The back posi-n gives maximum torque for

ugh terrain, climbing grades, and sharp turns. The center sition allows the machine to be driven as quietly as possi-

e.

SECTIO

3121606 – JLG Lift –

6. Glow Plug/ Wait to Start Indicator

Indicates the glow plugs are on. The glowplugs are automatically turned on with theignition circuit and remain on for approxi-mately seven seconds. Start the engine only after the lightgoes out.

7. Platform Overload Indicator. (If Equipped)

Indicates the platform has been overloaded.

Platform C(See Fig

TO AVOID SERITOGGLE SWITCOFF OR NEUTRA

1. Dr

Thsw

Thmtioropobl


3-1 3121606

erride

13. Soft Touch/SkyGuard Indicator14. Platform Rotate15. Function Speed Control16. Main Lift / Swing

2 – JLG Lift –

1. Drive Speed / Torque Select2. Platform Level Override3. Horn4. Power/Emergency Stop

5. Start / Aux Power6. Drive Orientation Override7. Drive/Steer Enable8. Drive Steer

9. Telescope10. Lights11. Jib12. Soft Touch/SkyGuard Ov

Figure 3-6. Platform Control Console


3-13

wer/Emergency Stop Switch

two-position red mushroom shaped switchrnishes power to Platform Controls whenlled out (on). When pushed in (off ), power isut off to the platform functions.

art/Auxiliary Power

hen pushed forward, the switch energizese starter motor to start the engine.

e Auxiliary Power control switch energizese electrically operated hydraulic pump.witch must be held on for duration of auxil-ry pump use.)

e auxiliary pump functions to provide sufficient oil flow toerate the basic machine functions should the main pump

engine fail. The auxiliary pump will operate main boomt, main telescope and swing.

SECTIO

3121606 – JLG Lift –

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OFTHE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT ORFALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

2. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situa-tions such as ascending/descending a grade.

3. Horn

A push-type Horn switch supplies electrical power to an audible warning device when pressed.

4. Po

A fupush

5. St

Wth

Thth(Sia

Thoporlif


3-1 3121606

teer

tional dual axis joystick is providedtrol drive and steer. Push forward totraight forward. The joystick is pro-al, with the drive speed increasingjoystick is moved further from its neutral position. the joystick forward and to the side steers thee in the direction of the side displacement of the joy-ith the joystick positioned all the way to the side and forward, the machine will turn in place with onetopped and the other one turning the machine the center of the stopped track.

the joystick to the side (no dislocation in the forwarddirection) will turn the machine by counter-rotation the center of the machine by powering the tracks inte directions.

the joystick back and to the sides controls speed andn of drive in reverse.

ive and steer functions work in the opposite directione boom is positioned over front of the chassis (over idler

4 – JLG Lift –

6. Drive Orientation Override

When the boom is swung over the rear ineither direction, the Drive Orientation indica-tor will illuminate when the drive function isselected. Push and release the switch, and within 3 secondsmove the Drive/Steer control to activate drive or steer.Before driving, locate the black/white orientation arrows onboth the chassis and the platform controls and match thecontrol direction arrow to the intended chassis direction.

7. Drive/Steer Enable

Located on the top of the Drive Steer Joystick,the button must be pushed in for the Drive/Steer control to function. If at any time theEnable Switch is pushed in and no function isoperated for a period of 3 seconds, the switch will "time-out"and the switch must be cycled again to renew normal func-tions.

8. Drive/S

Proporto condrive sportionas the Movingmachinstick. Wslightlytrack saround

Movingor aft aroundopposi

Pullingdirectio

NOTE: Both drwhen thwheels).


3-15

(If Equipped)

sh forward to lift up, pull back to lift down.riable lift speed is using the Function Speedntrol.

atform Rotate

ovides rotation of the platform when posi-ned to the right or left.

ft Touch/SkyGuard Override Switch (If equipped)

e machine can be equipped with one of three options. Itay have Soft Touch, SkyGuard, or both Soft Touch and Sky-ard.

equipped with Soft Touch, the switchables the functions that were cut out the Soft Touch system to operateain at creep speed, allowing theerator to move the platform away from the obstacle thatused the shutdown situation.

equipped with SkyGuard, the switchables functions cut out by the Sky-ard system to be operated again,

lowing the operator to resume use ofachine functions.

SECTIO

3121606 – JLG Lift –

NOTE: When boom is positioned above horizontal and any of the fol-lowing switches, DRIVE SPEED/TORQUE SELECT or FUNCTIONSPEED, are positioned to HIGH, high function speeds are auto-matically cut out and the machine continues to operate at alower speed.

NOTE: The drive/steer control joystick can only command counter-rotate by being moved in the joystick's left - to - right axis, afterfirst achieving the joystick neutral position.

DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEEDSWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL.

9. Telescope

Provides extension and retraction of the mainboom.

10. Lights (If Equipped)

This switch operates accessory light packagesif the machine is so equipped.

11. Jib

PuVaCo

12. Pl

Prtio

13. So

ThmGu

If enbyagopca

If engualm


3-1 3121606

ate the Main Boom Lift/Swing joystick,n the locking ring below the handle.

in Boom Lift/Swing joystick is springnd will automatically return to neutral

ition when released.

ift/Swing Controller

s main lift and swing. Pushd to lift up, pull backwardm down. Move right toright, move left to swingving the joystick activates

es to provide the functionsd.

6 – JLG Lift –

If equipped with both Soft Touch andSkyGuard, the switch operates likedescribed above and allows the opera-tor to override the system that hasexperienced a cutout situation.

14. Soft Touch/SkyGuard Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object or theSkyGuard sensor has been activated. All controls are cut outuntil the override button is pushed. For Soft Touch, controlsare then active in the Creep Mode or for SkyGuard, controlswill work normally.

15. Function Speed Control

Controls the speed of Boom and SwingFunctions. Rotate counterclockwise forslower speed and clockwise for fasterspeed. To adjust to creep, turn knob fullycounterclockwise until it clicks.

NOTE: To operpull up o

NOTE: The Maloaded a(off) pos

16. Main L

Provideforwarto booswing left. Moswitchselecte


3-17

pacity Indicator

dicates the maximum platform capacity fore current position of the platform.stricted capacities are permitted at

stricted platform positions (shorter boomngths and higher boom angles).

er to the capacity decals on the machine fortricted and unrestricted platform capacities.

ive Disabled Indicator

hen illuminated, the drive function has beensabled. (Refer to Drive Function Operatingnge Diagrams in Section 2).

SECTIO

3121606 – JLG Lift –

Platform Control Indicator Panel(See Figure 3-7., Platform Control Indicator Panel)

1. Tilt Alarm Warning Light and Alarm

Indicates that the chassis is on a slope. Analarm will also sound when the chassis is on aslope and the boom is above horizontal. If litwhen boom is raised or extended, retract and lower tobelow horizontal then reposition machine so that it is levelbefore continuing operation. If the boom is above horizontaland the machine is on a slope, the tilt alarm warning lightwill illuminate and an alarm will sound and CREEP is auto-matically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED,RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THATIT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

2. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

3. Ca

InthRerele

NOTE: Refres

4. Dr

WdiRa


3-1 3121606

eneratorsed

p Speed Orientationel

8 – JLG Lift –

1. Tilt Alarm Warning2. Platform Overload3. Platform Capacity4. Drive Disabled

5. Footswitch/Enable6. Glow Plug7. Low Fuel8. System Distress

9. AC G10. Not U11. Cree12. Drive

Figure 3-7. Platform Control Indicator Pan


3-19

ow Plug/Wait to Start Indicator

dicates the glow plugs are operating. Afterrning on ignition, wait until light goes outfore cranking engine.

w Fuel Indicator.

dicates the fuel tank is 1/8 full or less. Whene light first turns on, there are approximatelyur usable gallons of fuel remaining.

stem Distress Indicator

e light indicates that the JLG Control Systems detected an abnormal condition and aagnostic Trouble Code has been set in thestem memory. Refer to the Service Manual for instructionsncerning the trouble codes and trouble code retrieval.

Generator

dicates the generator is in operation..

SECTIO

3121606 – JLG Lift –

5. Footswitch/Enable Indicator

To operate any function, the footswitch mustbe depressed and the function selected withinseven seconds. The enable indicator showsthat the controls are enabled. If a function is not selectedwithin seven seconds, or if a seven second lapse betweenending one function and beginning the next function, theenable light will go out and the footswitch must be releasedand depressed again to enable the controls.

Releasing the footswitch removes power from all controlsand applies the drive brakes.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCHBY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLYOPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

6. Gl

Intube

7. Lo

Inthfo

8. Sy

ThhaDisyco

9. AC

In


3-2 3121606

Speed Indicator

the Function Speed Control is turned toeep position, the indicator acts as aer that all functions are set to the slow-ed. The light flashes if the control system puts thee into creep speed and will be on continuously if the

or selects creep speed..

0 – JLG Lift –

10. Drive Orientation Indicator

When the boom is swung beyond the rear in either direction, the Drive Orientation indica-tor will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (i.e. controls reversed situations).

11. Creep

When the crremindest spemachinoperat

SECTION 4 - MACHINE OPERATION

4-1

RATION

RATING CHARACTERISTICS AND LIMITATIONS

om can be raised above horizontal with or without any platform, if:

achine is positioned on a smooth, firm and level surface.

ad is within manufacturer’s rated capacity.

l machine systems are functioning properly.

achine is as originally equipped from JLG.

3121606 – JLG Lift –

SECTION 4. MACHINE OPE

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. From thiscontrol station, the operator can drive and steer the machine inboth forward and reverse directions. The operator can raise orlower the upper or lower boom or swing the boom to the left orright. Standard boom swing is 360 degree continuous left andright of the stowed position. The machine has a Ground ControlStation which will override the Platform Control Station. GroundControls operate Boom Lift and Swing, and are to be used in anemergency to lower the platform to the ground should the oper-ator in the platform be unable to do so.

4.2 OPE

CapacitiesThe boload in

1. M

2. Lo

3. Al

4. M


4-2 3121606

Sta

TO AATE O

4-1. Position of Least Backward Stability

ROTATEDREES

MACHINE WILL UPSETIN THIS DIRECTION IF

OVERLOADED OR OPERATED ON AN

OUT-OF-LEVEL SURFACE

M FULLYED ANDTED

– JLG Lift –

bilityMachine stability is based on two positions which are called FOR-WARD STABILITY and BACKWARD STABILITY. The machines posi-tion of Least Backward Stability is shown in Figure 4-1., and itsposition of Least Forward Stability is shown in Figure 4-2.

VOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOAD MACHINE OR OPER-N AN OUT-OF-LEVEL SURFACE.

Figure

PLATFORM90 DEG

MAIN BOORETRACT

ELEVA


4-3

Stability

LEVEL SURFACE

DEES)

3121606 – JLG Lift –

Figure 4-2. Position of Least Forward

MACHINE WILL UPSET IN THISDIRECTION IF OVERLOADED

OR OPERATED ON ANOUT-OF-LEVEL SURFACE

BOOM FULLY EXTENDE@ HORIZONTAL (O DEGR


4-4 3121606

4.3

NOT

Sta

IF ENSHOUMINUNANC

NOT

Power/Emergency Stop switch to On.

he Engine Start switch until engine

ARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING

ngine has had sufficient time to warmsh in the Power/Emergency Stop switchut engine off.

latform/Ground Select switch to Plat-

Platform, pull Power/Emergency Stop out.

– JLG Lift –

ENGINE OPERATION

E: Initial starting should always be performedfrom the Ground Control station.

rting Procedure

GINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED PERIOD.LD ENGINE FAIL TO START ONCE AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3TES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTE-E MANUAL.

E: After turning on ignition, operator must wait untilglow plug indicator light goes out before crankingengine.

1. Turn key of Platform/Ground Select switch toGround.

2. Pull the

3. Push tstarts.

ALLOW ENGINE TO WANY LOAD.

4. After eup, puand sh

5. Turn Pform.

6. From switch


4-5

VELING (DRIVING)

4-3., Grades and Sideslopes.

er to the Operating Specifications table for Gradeability andeslope ratings.

ratings for Gradeability and Sideslope are based upon thechine’s boom being in the stowed position, fully lowered, and

racted.

ng is limited by two factors:

adeability, which is the percent of grade of the incline the achine can climb.

deslope, which is the angle of the slope the machine can driven across.

3121606 – JLG Lift –

7. Push the Engine Start switch until engine starts.

NOTE: Footswitch must be in released (up) position before starter willoperate. If starter operates with footswitch in the depressed posi-tion, DO NOT OPERATE MACHINE.

Shutdown Procedure

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINETHE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.

1. Remove all load and allow engine to operate at low speedsetting for 3-5 minutes; this allows for further reduction ofinternal engine temperature.

2. Push Power/Emergency Stop switch in.

3. Turn Platform/Ground Select switch to Off.

Refer to Engine Manufacturer’s manual for detailedinformation.

4.4 TRA

See Figure

NOTE: RefSid

All maret

Traveli

1. Grm

2. Sibe


4-6 3121606
– JLG Lift –
Figure 4-3. Grades and Sideslopes


4-7

ard

3121606 – JLG Lift –

Figure 4-4. Machine Motion Haz


4-8 3121606

DO NSMO

TO AVDRIVFACT

ENSUTRAVUPSE

DRIV

USE ING WOF TMANTION

ON WHEN APPROACHING A CREST OF ANY TERRAIN OBSTACLE. LARGE STONES, OR OTHER TERRAIN OBSTACLES INCLUDINGES AS THE MACHINE WILL MAKE UNCONTROLLED PIVOTING CENTER OF GRAVITY (CENTER OF TRACK FRAME) SHIFTS OVERN TO MINIMIZE ACCELERATION DURING PIVOTING MOVEMENT.

AKE SURE THE BOOM IS POSITIONED OVER THE REAR OF THEL DRIVES AND SPROCKETS). IF THE BOOM IS OVER THE FRONT OFHE IDLER WHEELS) STEER AND DRIVE CONTROLS WILL MOVE INS TO MACHINE CONTROLS.

ard or Reverseform Controls, with the engine running,t Emergency Stop switch and activateitch.

n Drive control to Forward or e as desired.

– JLG Lift –

OT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTAL EXCEPT ON AOTH, FIRM AND LEVEL SURFACE.

OID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOTE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED ON MANU-URERS NAMEPLATE LOCATED ON THE FRAME.

RE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGINNING ANY EXTENDEDELING. AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE TOT.

E SPEED/TORQUE SELECT SWITCH SHOULD BE IN THE BACKWARD POSITION FOR:

• TRAVELING GRADES

• TRAVELING IN DIFFICULT CONDITIONS

• SHARP TURNS (ESPECIALLY WITH ONE TRACK STOPPED

• COUNTERROTATION

EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIV-ITH THE PLATFORM ELEVATED AND SPECIALLY WHEN DRIVING WITH ANY PART

HE MACHINE WITHIN 6 FEET (2M) OF AN OBSTRUCTION. DO NOT USE DRIVE TOEUVER PLATFORM CLOSE TO AN OBSTRUCTION. USE ONE OF THE BOOM FUNC-S.

USE EXTREME CAUTICHECK FOR CURBS,OVERHEAD OBSTACLMOTIONS WHEN THEAN EDGE. SLOW DOW

BEFORE DRIVING, MCHASSIS (OVER FINATHE CHASSIS (OVER TOPPOSITE DIRECTION

Traveling Forw1. At Plat

pull oufootsw

2. PositioRevers


4-9

obtain maximum travel speed, position the Drive control-r to Fast and activate the following switches:

. Position Drive Speed/TorqueSelect switch to Fast. (ForwardPosition)

ior to stopping the machine, position switches as follows:

. Position Drive Speed/TorqueSelect switch to Low. (BackwardPosition)

r traveling up grades, position switches as follows:

. Position Drive Speed/TorqueSelect switch to High. (Backwardposition)

smoother operation when driving with fully extended boom,ce Drive control to Slow before stopping.

3121606 – JLG Lift –

3. Depress footswitch, move joystick (Drive/Steer Control) to select desired direction of travel (forward or reverse), move Drive/Steer control to Right for smooth turn to right and Left for smooth turn to left.

4. To obtain sharp turns, move Drive Speed/Torque Select switch to the back position, slow down the travel speed and move the Drive control lever to Right for a turn to the right and to Left for a turn to the left. The sharpest possible turn is achieved when the joy-stick is in the position to command one track to stop and the other to move slowly.

TURN IN PLACE ONLY IN AN AREA FREE OF OBSTACLES AND ONLY WITH THE BOOMFULLY RETRACTED. USE SLOW, GENTLE CONTROL MOVEMENTS AND DO NOT OPERATEANY OTHER FUNCTIONS DURING COUNTER-ROTATION.

5. To obtain counter-rotation (turn in place), stop the machine, move the Drive/Steer control lever directly to Right to get clockwise rotation and to Left to get counterclockwise rota-tion.

6. Tole

a

7. Pr

a

8. Fo

a

NOTE: Forpla


4-1 3121606

Grade

a grade, maximum braking and traction are obtained stowed, in position over the rear drive, and in line

ion of travel. Drive the machine forward when climb-d in reverse when descending a grade. Do not exceed

aximum rated gradability.

THE FRONT, DIRECTION OF STEER AND DRIVE MOVEMENT WILLHE MOVEMENT OF THE CONTROLS.

Figure 4-5. Traveling on a Grade

0 – JLG Lift –

This machine is equipped with a Drive OrientationIndicator. The yellow light on the platform controlconsole indicates that the boom is swung beyondthe rear and the machine may Drive/Steer in theopposite direction from the movement of the con-trols. If the indicator is illuminated, operate the Drive function inthe following manner:

1. Match the black andwhite direction arrowson both platform con-trol panel and the chas-sis to determine thedirection the machinewill travel.

2. Push and release the Drive Orientation Over-ride switch. Within 3 seconds, slowly move theDrive control toward the arrow matching theintended direction of machine travel. The indi-cator light will flash during the 3 second inter-val until the drive function is selected.

Traveling on a

When travelingwith the boomwith the directing a grade, anthe machine's m

IF THE BOOM IS OVERBE OPPOSITE FROM T


4-11

TFORM

evel Adjustment

PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT ORTO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

el Up or Down - Position the Platform/Levell switch Up or Down and hold until the plat- level.

otation

te the platform to the left or right, use them Rotate control switch to select the direc-d hold until desired position is reached.

3121606 – JLG Lift –

4.5 PARKING AND STOWINGPark and stow machine as follows:

1. Park machine in travel position; boom lowered over rear, allaccess panels and doors closed and secured, ignition off,turntable locked.

2. Check that brakes hold machine in position.

3. Chock tracks front and rear.

4. Turn off Platform Select switch and remove key.

5. When parking on frozen ground overnight, drive the machine up on boards to prevent freezing to the ground.

4.6 PLA

Platform L

ONLY USE THE THE PLATFORMFALL. FAILURE

To Levcontroform is

Platform R

To rotaPlatfortion an


4-1 3121606

4.7

A REDSOLEOR GHORI

DO NALARSIS MZONT

TO AEXTENEARBEFO

TRAVON G

TO AOR TOFF O

TO A

RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER- THE MACHINE.

Boom

oom, use Swing control switch to selectt direction.

E BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TOG WALLS, PARTITIONS AND EQUIPMENT.

arket machines, when boom functions are being oper-re is an interlock that prevents the use of Drive and Steers.

wering the Main Boomlower the Main Boom, position the Mainswitch to Up or Down until the desiredched.

2 – JLG Lift –

BOOM

TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CON-, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE (5 DEGREESREATER). DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVEZONTAL WHEN LIT.

OT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILTM INDICATES CHASSIS IS ON A SEVERE SLOPE (5 DEGREES OR GREATER). CHAS-UST BE LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM ABOVE HORI-AL.

VOID UPSET, IF RED TILT ALARM WARNING LIGHT LIGHTS WHEN MAIN BOOM ISNDED OR RAISED ABOVE HORIZONTAL, RETRACT AND LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVELRE EXTENDING OR RAISING MAIN BOOM.

ELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTEDRADES AND SIDE SLOPES SPECIFIED ON CAUTION PLACARD AT PLATFORM.

VOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERSOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE

R NEUTRAL POSITION WHEN RELEASED.

VOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL

SWITCH OR LEVER ISGENCY STOP TO STOP

Swinging the

To swing bRight or Lef

WHEN SWINGING THCLEAR SURROUNDIN

NOTE: On CE Mated thefunction

Raising and LoTo raise or Boom Lift height is rea


4-13

CHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE LY)achine Safety System Override (MSSO) is override function controls for Emergency

rm Retrieval only. Refer to Section 5.4,e Safety System Override (MSSO)(CE Only)rating procedures.

3121606 – JLG Lift –

Telescoping the Main Boom

To extend or retract the main boom, use the MainTelescope Control Switch to select In or Out move-ment.

4.8 SHUT DOWN AND PARK1. Drive machine to a protected area.

2. Assure main boom is fully retracted and lowered over rear of the machine; all access panels and doors closed and secured.

3. Remove all load and allow engine to operate 3-5 minutes at Low setting to permit reduction of engine internal tempera-tures.

4. At Ground Controls, turn Key Select switch to (center) Off position. Position Power/Emergency Stop switch (down) to Off position. Remove key.

5. Cover Platform Control console to protect instruction plac-ards, warning decals and operating controls from hostile environment.

4.9 MAON

The Mused toPlatfoMachinfor ope


4-1 3121606

4.1

TowerLift

Down

PlatformLevel

PlatformRotate

JibLift

C C C C

e.

4 – JLG Lift –

0 SKYGUARD OPERATIONSkyguard is used to provide enhanced control panel protection.When the SkyGuard sensor is activated, functions that were inuse at the time of actuation will reverse or cutout. The tablebelow outlines these functions.

Table 4-1. Skyguard Function Table

MainLift

MainTele

In

MainTeleOut

Swing

DriveForward

DriveReverse Tower

LiftUpDOS

Enabled

DOSNot

Enabled

DOSEnabled

DOSNot

Enabled

R C R R C C* C C R

R = Indicates Reversal is Activated

C = Indicates Cutout is Activated

* Disregard when boom is in line and driving forward with or without steering and no other functions activ


4-15

tach lifting device and equipment only to the designated ting points.

operly adjust the rigging to prevent damage to the achine and so the machine remains level.

ILIARY POWERle type auxiliary power control switch is located

platform control station and another is located onund control station. Operation of either switch

n the electrically driven auxiliary hydraulic pump.ould be used in case of failure of the main power plant.xiliary pump will operate boom lift, telescope and swing.vate auxiliary power:

from the Platform Control Stationsition Platform/Ground Select Key Switch to

atform.

sition Power/Emergency Stop switch to On.

press and hold footswitch.

3121606 – JLG Lift –

4.11 TIE DOWN AND LIFTING

Tie Down

WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTOTHE BOOM REST.

1. Place the boom in the stowed position with the turntablelocked.

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or chains of adequate strength and attached to the designated tie down points.

Lifting

(See Figure 4-6., Lifting Chart)

1. Weigh the individual unit, refer to the Serial Number plate orcall JLG Industries to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position with the turntable locked.

3. Remove all loose items from the machine.

4. Atlif

5. Prm

4.12 AUXA toggon thethe groturns oThis shThe auTo acti

Activating1. Po

Pl

2. Po

3. De


4-1 3121606
6 – JLG Lift –
Figure 4-6. Lifting Chart


4-17

from the Ground Control Station

sition Platform/Ground Select Key Switch toound.

sition Power/Emergency Stop switch to On.

sition Auxiliary Power switch to On and hold.

perate appropriate control switch or controller for sired function and hold.

lease Auxiliary Power switch, and appropriate control itch or controller.

sition Power/Emergency Stop switch to Off.

3121606 – JLG Lift –

4. Position Auxiliary Power switch to On and hold.

5. Operate appropriate control switch, lever or control-ler for desired function and hold.

6. Release Auxiliary Power switch, selected control switch, lever or controller, and footswitch.

7. Position Power/Emergency Stop switch to Off.

Activating

1. PoGr

2. Po

3. Po

4. Ode

5. Resw

6. Po


4-1 3121606

27

R

B

B

6

8 – JLG Lift –

39

33

41

27

WARNINGCRU SHING HAZARD

1703953 A

Do not stand unde r a ra ised platfo rm or boom,or between a rotating platform and the boom.

Ke ep all b ody parts away from an y moving c omponen ts.

Fai lu re to f ol low th e se in s tru c tion s cou ldresu l t in d ea th o r s eriou s in ju ry .

DANGERELECTROCUTION HAZARD

1703805 B

This mach ine is no t ins ulated .Main ta in a clearanc e of at le ast 10 ft. between any part of ma chineor loa d an d an y e le ctrical l in e or a ppa rtu s charg ed u p to 50,000 vo lts.One foo ta ddtional c le ara nce is re qui red foreach add tiona l 30,00volts o r le ss.Al lowa nces m ust b e ma de fo r e rro r, m ach ine d eflec tion an delec trical li ne sway ing.

F ai lu re to fo l low th e se in stru ctions cou ldre sult in de ath or serious injur y.

6155

22 28

Figure 4-7. Decal Installation - Sheet 1 of


4-19

CE ONLY

1701518

28 27

28

60

ANSI

22DANGER

ELECTROCUTIO N HAZAR D

1703805 B

This ma chine is no t insulated .Ma intain a clearance of at lea st 10 ft. betwee n an y part of m achineor load and an y electrical l ine or appartus ch arge d up to 50 ,000 volts.On e footaddtional clearance is req uired fo rea ch a ddtional 30,00vol ts or less.Allowan ces must be ma de fo r erro r, ma chine def lection andele ctrica l li ne swayin g.

Fai lure to fol low thes e ins tructions c ouldresult in d eath o r seriou s injury .

WARNINGCRU SHING HAZARD

1703953 A

Do not stand unde r a raised platform or boom ,or between a rotating p la tform and the boom .

Keep al l body parts awa y from any movin g c omponen ts.

F ai lu re to fo llow th es e ins tru c tion s cou ldre su l t in de ath o r s e riou s inju ry.

5936

26

33

2 of 6

3121606 – JLG Lift –

VIEW A-A

27 CE/AUS

1705961

28CE

1701518

WARNINGCRUSHING HAZARD

1703804 B

Do no t stand under a r aised p latfor m or b oom,or between a rotatin g p latform and t he boom.

Keep a ll body pa rts away from any mo ving com po nents.

Fa ilure t o follow these inst ructi ons couldresult in death or serious i njury.


1703805 B

This m ac hin e is not insulated.Maint ain a c lea ran ce of at least 10 ft. between any par t of machineor l oad and any electr ic al line or a pp ar tus char ge d up to 50,00 0 volts.One foot add tio nal cle arance is r equ i red foreach ad dtional 30,0 0volts or less .Allow anc es must be ma de for e rro r, m achine d eflecti on andelectr ical line swaying.

Fa ilure t o follow these inst ructi ons couldresult in death or serious i njury.

28

27

24

40 55A

A

R

Figure 4-8. Decal Installation - Sheet


4-2 3121606

E E

NDERCARRIAGE

162

3238 55

6

0 – JLG Lift –

VIEW D-D

1703

814

1703

811

11

10

D D

GRADALL U

216

6

15

VIEW E-E 11 2

Figure 4-9. Decal Installation - Sheet 3 of


4-21

30

R

41

22

CALLED OUT ON MACHINELIFTING ATTACH INSL'L

3251 243

120V - 60HZ

17

170

381

1

28

14

ANSI

CE

170

381

1

WARNINGCRUSHING HAZARD

1703953 A

Do not stand under a raised platform or boom,or between a rotating platform and th e boom.

Keep all body par ts away from any moving components.

Failure to follow t hese instruct ions couldresult in death or se rious injury.

1701518

CE/AUSONLY

62

1700584

ANSI

27


1703805 B

This mach ine is not insulated.Maintain a clearance of at least 10 ft. be tween any pa rt of machineor load and any electrical l ine or a ppart us charged up to 50,00 0 volts.On e fo otaddtional cl ear ance is req ui red for each addtional 30, 00volts o r le ss.Allowances must be made for error, m achine d eflection andelectr ical line swayin g.

Failure to follow t hese instruct ions coul dresult in death or se rious injury.

4 of 6

3121606 – JLG Lift –

37

1703

811

Figure 4-10. Decal Installation - Sheet


4-2 3121606

f 6

2 – JLG Lift –

58

Figure 4-11. Decal Installation - Sheet 5 o


4-23

t 6 of 6

3121606 – JLG Lift –

Figure 4-12. Decal Installation - Shee


4-2 3121606

SimplifiedChinese

1001116970-D

TraditionalChinese

1001116971-D

- - - -

1701499 1701499

1701502 1701502

1701503 1701503

1701509 1701509

1701529 1701529

- - - -

- - - -

- - - -

1703811 1703811

1703814 1703814

1704277 1704277

1704412 1704412

1705084 1705084

1705514 1705514

1704461 1704461

3251243 3251243

4 – JLG Lift –

Table 4-2. 600SC Decal Legend

Item # ANSI0273906-D

CanadianFrench

0273982-D

CE/Australian0273985-E

English/Portuguese

1001093424-D

1 - - - - - - - -

2 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529

7 - - - - - - - -

8 - - - - - - - -

9 - - - - - - - -

10 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243


4-25

- - - -

4 1705342 1001117034

6 1705507 1001117035

- - - -

3 1001116845 1703943

- - - -

7 1705968 1001116846

5 1001116847 1703925

6 1001116848 1001116849

8 1001116850 1703949

7 1703937 1001116851

2 1001116852 1703982

- - - -

- - - -

1 1702631 1702631

4 1704434 1704434

- - - -

806 1001121811 1001121809

d

/ese24-D

SimplifiedChinese

1001116970-D

TraditionalChinese

1001116971-D

3121606 – JLG Lift –

18 - - - - - - - -

19 - - - - - - 170590

20 - - - - - - 170590

21 - - - - - - - -

22 1703953 1703942 - - 170590

23 - - - - - - - -

24 1702868 1704000 - - 170596

25 1703797 1703924 1705921 170589

26 1705336 1705347 1705822 170589

27 1703804 1703948 1701518 170589

28 1703805 1703936 1705961 170589

29 - - 1703984 1705828 170590

30 - - - - - - - -

31 - - - - - - - -

32 1702631 1702631 1702631 170263

33 1704434 1703165 1704434 170443

34 - - - - - - - -

35 1001121800 1001121802 1705978 1001121

Table 4-2. 600SC Decal Legen


CanadianFrench

0273982-D


EnglishPortugu

10010934


4-2 3121606

1001121824 1001121822

1704885 1704885

1706948 1706948

1705177 1705177

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

- - - -

SimplifiedChinese

1001116970-D

TraditionalChinese

1001116971-D

6 – JLG Lift –

36 1001121813 1001121815 1705978 1001121819

37 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948

39 1705177 1705177 1705177 1705177

40 - - - - - - - -

41 - - - - - - - -

42 - - - - - - - -

43 - - - - - - - -

44 - - - - - - - -

45 - - - - - - - -

46 - - - - - - - -

47 - - - - - - - -

48 - - - - - - - -

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -

53 - - - - - - - -

Table 4-2. 600SC Decal Legend


CanadianFrench

0273982-D


English/Portuguese

1001093424-D


4-27

- - - -

- - - -

- - - -

439 1001116963 1001116964

494 1001108494 1001108494

3 1706943 1706943

- - - -

- - - -

- - - -

d

/ese24-D

SimplifiedChinese

1001116970-D

TraditionalChinese

1001116971-D

3121606 – JLG Lift –

54 - - - - - - - -

55 - - - - - - - -

56 - - - - - - - -

57 1704468 1001093684 1704468 1001093

58 1001108494 1001108494 - - 1001108

59 1706943 1706943 - - 170694

60 - - - - - - - -

61 - - - - - - - -

62 1001131269 1001131269 - - - -

Table 4-2. 600SC Decal Legen


CanadianFrench

0273982-D


EnglishPortugu

10010934


4-2 3121606

- - - - - - - -

- - - - - - 1705904

- - - - - - 1705906

- - - - - - - -

703953 1703942 - - 1705903

- - - - - - - -

702868 1704000 - - 1705967

703797 1703924 1705921 1705895

705336 1705347 1705822 1705896

703804 1703948 1701518 1705898

703805 1703936 1705961 1705897

532347 1703984 1705828 1705902

- - - - - - 3251813

- - - - - - - -

702631 1702631 1702631 1702631

703165 1703165 1703165 1703165

- - - - - - - -

01121801 1001121803 1705978 1001121801

Table 4-3. 660SJC Decal Legend

ANSI73908-D

CanadianFrench

0273984-D


English/Portuguese

1001103292-D

8 – JLG Lift –



CanadianFrench

0273984-D


English/Portuguese

1001103292-D

1 - - - - - - - -

2 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529

7 - - - - - - - -

8 - - - - - - - -

9 - - - - - - - -

10 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243

18

19

20

21

22 1

23

24 1

25 1

26 1

27 1

28 1

29 3

30

31

32 1

33 1

34

35 10

Item #02


4-29

- - - - - - - -

- - - - - - - -

- - - - - - - -

1704468 1001093684 1704468 1001093439

1001108494 1001108494 - - 1001108494

1706943 1706943 - - 1706943

- - - - - - - -

- - - - - - - -

1001131269 1001131269 - - - -


ANSI0273908-D

CanadianFrench

0273984-D


English/Portuguese

1001103292-D

3121606 – JLG Lift –

36 1001121814 1001121816 1705978 1001121655

37 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948

39 1705177 1705177 1705177 1705177

40 - - 1001093553 - - 1001093553

41 - - - - - - - -

42 - - - - - - - -

43 - - - - - - - -

44 - - - - - - - -

45 - - - - - - - -

46 - - - - - - - -

47 - - - - - - - -

48 - - - - - - - -

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -

53 - - - - - - - -



CanadianFrench

0273984-D


English/Portuguese

1001103292-D

54

55

56

57

58

59

60

61

62

Item #


4-3 3121606
0 – JLG Lift –
NOTES:

SECTION 5 - EMERGENCY PROCEDURES

5-1

OCEDURES

to notify the manufacturer of an incident involving a JLGries product within 48 hours of such an occurrence mayy warranty consideration on that particular machine.

NY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALLST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-

LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HASD, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-

3121606 – JLG Lift –

SECTION 5. EMERGENC Y PR

5.1 GENERALThis section explains the steps to be taken in case of an emer-gency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any incidentinvolving a JLG product. Even if no injury or property damage isevident, the factory should be contacted by telephone and pro-vided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

[email protected]

FailureIndustvoid an

FOLLOWING AFUNCTIONS FIRTROLS. DO NOTBEEN REPAIRERECTLY.

SECTION 5 - EMERGENCY PROCEDURES

5-2 3121606

5.3

Ope

Pla

E SAFETY SYSTEM OVERRIDE (MSSO)(CE

e Safety System Override (MSSO) isused to retrieve an operator that isapped, or unable to operate thed function controls are locked outtform due to a platform overload sit-

SSO functionality is used, the fault indicator will flashult code is set in the JLG Control System which must bea qualified JLG Service Technician.

tional checks of the MSSO system are necessary. The JLGsystem will set a Diagnostic Trouble Code if the control faulty.

he MSSO:

he ground control console, place the Platform/ Select switch in the Ground position.

t the Power/Emergency Stop control.

e engine.

nd hold the MSSO switch and the control switch for ired function.

– JLG Lift –

EMERGENCY OPERATION

rator Unable to Control MachineIF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TOOPERATE 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 plat-form controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

3. Cranes, forklift trucks or other equipment can be used to remove platform occupants and stabilize motion of the machine.

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged in over-head structures or equipment, rescue platform occupants prior tofreeing the machine.

5.4 MACHINONLY)

The Machinonly to be pinned, trmachine anfrom the plauation.

NOTE: If the Mand a fareset by

NOTE: No funcControl switch is

To operate t

1. From tGround

2. Pull ou

3. Start th

4. Press athe des

PECIFICATIONS & OPERATOR MAINTENANCE

6-1

PERATOR MAINTENANCE

RATING SPECIFICATIONS

Table 6-1. Operating Specifications

rk Load (Capacity) - ANSId:

- 600SC - 660SJC

500 lb. (227 kg)1000 lb. (454 kg)

500 lb. (227 kg)

rk Load (Capacity) - CE & Australiad:

- 600SC - 660SJC

500 lb. (230 kg)1000 lb. (450 kg)

500 lb. (230 kg)

vel Grade (Gradeability)* 55%

vel Grade (Side Slope)* 5°

Platform Height:60 ft. 3 in. (18.36 m)66 ft. 8 in. (20.32 m)

al Platform Reach:49 ft. 6 in. (15.09 m)

56 ft. 9 in. (17.3 m)

s 0

SECTION 6 - GENERAL S

3121606 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS & O

6.1 INTRODUCTIONThis section of the manual provides additional necessary infor-mation to the operator for proper operation and maintenance ofthis machine.

The maintenance portion of this section is intended as informa-tion to assist the machine operator to perform daily maintenancetasks only, and does not replace the more thorough PreventiveMaintenance and Inspection Schedule included in the Serviceand Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual (S/N - 0300174703 to Present..................................................3121607

Illustrated Parts Manual (S/N - 0300174703 to Present) ................................................3121608

6.2 OPE

Maximum Wo Unrestricte Restricted Restricted

Maximum Wo Unrestricte Restricted Restricted

Maximum Tra

Maximum Tra

Max.Vertical 600SC 660SJC

Max.Horizont 600SC 660SJC

Turning Radiu

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121606

M

M

M

M

M

El

G

*

Table 6-2. Capacities

39 US. Gallons (147.6 L)

26 U.S. Gallons (98.4 L)31.1 U.S. Gallons (117.7 L)

cluding Tank) 40 U.S. Gallons (151.4 L)

11 quarts (10.5 L)

– JLG Lift –

Capacitiesaximum Ground Bearing Pressure

600SC

660SJC 5.45 psi (0.383 kg/cm2)

6.5 psi (0.457 kg/cm2)

aximum Drive Speed: 1.6 mph (2.6 kph)

ax. Hydraulic System Pressure 4500 psi (310 Bar)

aximum Wind Speed 28 mph (12.5 m/s)

aximum Manual Force 101 lb. (450 N)

ectrical System Voltage 12 Volts

ross Machine Weight (Platform Empty)

600SC 660SJC

22,500 lb. (10,205 kg)27,100 lb. (12,292 kg)

With boom in stowed position.

Table 6-1. Operating Specifications

Fuel Tank

Hydraulic Oil Tank Total Volume at Full Mark

Hydraulic System (In

Engine Crankcase


6-3

Oil

raulic oils must have anti-wear qualities at least to API Ser-e Classification GL-3, and sufficient chemical stability forbile hydraulic system service. JLG Industries recommendsbilfluid 424 hydraulic oil, which has an SAE viscosity index of.

en temperatures remain below 20° F (-7 degrees C), JLGustries recommends the use of Mobil DTE 13M.

rom JLG recommendations, it is not advisable to mix oils ofnt brands or types, as they may not contain the sameed additives or be of comparable viscosities. If use oflic oil other than Mobilfluid 424 is desired, contact JLGies for proper recommendations.

Table 6-4. Hydraulic Oil

RAULIC SYSTEM OPERATING TEMPERATURE RANGE

SAE VISCOSITY GRADE

° to +180° F (-18° C to +83° C) 10W

F to +210° F (-18° C to +99° C) 10W-20, 10W-30

F to +210° F (+10° C to +210° C) 20W-20


3121606 – JLG Lift –

Engine Data

Hydraulic

NOTE: HydvicmoMo152

NOTE: WhInd

Aside fdiffererequirhydrauIndustr

Table 6-3. Deutz D2011L04 Specifications

Fuel Diesel

Oil Capacity Cooling System Crankcase Total Capacity

5 Quarts (4.5 L)11 Quarts (10.5 L) w/Filter

16 Quarts (15 L)

Idle RPM 1000

Low RPM 1800

High RPM 2500

Alternator 60 Amp, belt drive

Battery 950 Cold Cranking Amps, 205 MinutesReserve Capacity, 12 VDC

Fuel Consumption 0.65 GPH (2.46 lph)

Horsepower 49

HYD

+0

+0°

+50°


6-4 3121606

ble 6-6. Mobil DTE 10 Excel 32 Specs

cosity Grade #32

ific Gravity 0.877

Point, Max -65.2°F (-54°C)

Point, Min. 482°F (250°C)

Viscosity

t 40° C 32.7cSt

t 100° C 6.63 cSt

t 100° F 32.7 cSt

t 212° F 6.63 cSt

at -20° F 6,200

sity Index 164

– JLG Lift –

Table 6-5. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

Ta

ISO Vis

Spec

Pour

Flash

a

a

a

a

cp

Visco


6-5

Table 6-8. Mobil EAL 224H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max -25°F (-32°C)

Flash Point, Min. 428°F (220°C)

Operating Temp. 0 to 180°F (-17 to 162°C)

Weight 7.64 lb. per gal.(0.9 kg per liter)

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

Must be stored above 32°F (14°C)


3121606 – JLG Lift –

Table 6-7. Quintolubric 888-46

Density @ 15° 220

Pour Point 275°C (527°F)

Flash Point 325°C (617°F)

Fire Point 50-0 ml

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 2.0 mg KOH/g

NOTE:


6-6 3121606

ble 6-10. Exxon Univis HVI 26 Specs

fic Gravity 32.1

ur Point -76°F (-60°C)

sh Point 217°F (103°C)

Viscosity

t 40° C 25.8 cSt

100° C 9.3 cSt

sity Index 376

il/Exxon recommends that this oil be checked yearly basis for viscosity.

– JLG Lift –

Table 6-9. Mobil EAL H 46 Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 46

Specific Gravity .910

Pour Point -44°F (-42°C)

Flash Point 500°F (260°C)

Operating Temp. 0 to 180°F (-17 to 162°C)

Weight 7.64 lb. per gal.(0.9 kg per liter)

Viscosity

at 40° C 45 cSt

at 100° C 8.0 cSt

Viscosity Index 153

Ta

Speci

Po

Fla

a

at

Visco

NOTE: Mobon a


6-7

ber Locationsl number plate is affixed to the left rear side of the frame. Ifial number plate is damaged or missing, the machine serialr is stamped on the left side of the frame.


3121606 – JLG Lift –

Major Component Weights Serial NumA seriathe sernumbe

Table 6-11. Major Component Weights

660SJ 600S

LB. KG. LB. KG.

Platform Control Console 250 113 250 113

Platform Level Cylinder 60 27 46 21

Main Boom (Includes Lift Cyl., Rotator, and Support)

3783 1716 3527 1600

Turntable Complete (including engine) 9065 4112 7315 3318


6-8 3121606

s

SERIAL NUMBER(STAMPED ON FRAME)

– JLG Lift –

Figure 6-1. Serial Number Location

SERIAL NUMBERPLATE


6-9

-40°F(-40°C)

-30F°(-34°C)

-20°F(-29°C)

-10°F(-23°C)

0°F(-18°C)

10°F(-12°C)

20°F(-7°C)

30°F(-1°C)

40°F(4°C)

50°F(10°C)

60°F(16°C)

70°F(21°C)

80°F(27°C)

90°F(32°C)

100°F(38°C)

110°F(43°C)

120°F(49°C)

AMBIENT AIRTEMPERATURE

ns - Deutz - Sheet 1 of 2


3121606 – JLG Lift –

ENGINESPECIFICATIONS

ENGINE WILL START AND OPERATE AT THIS TEMPERATUREWITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY

AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHERPACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR

ENGINE WILL START AND OPERATE UNAIDED AT THISTEMPERATURE WITH THE RECOMMENDED FLUIDS AND A

FULLY CHARGED BATTERY.

SUMMERGRADEFUEL

WINTERGRADEFUEL

WINTERGRADEFUELWITH

KEROSENEADDED

NO OPERATION BELOW THISAMBIENT TEMPERATURE

NO OPERATION ABOVE THISAMBIENT TEMPERATURE

Figure 6-2. Engine Operating Temperature Specificatio


6-1 3121606

ITIONSMENDSAULIC

SERVICE

INRES.

NOTE:

1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS

2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.

0+32

-5

-10

-15

-20

-25

-30

+23

+14

+5

-4

-13

-22

CF

0 10 20 30 40 50 60

% OF ADDED KEROSENE

AMBI

ENT T

EMPE

RATU

RE

SUMMER-GRADEFUEL

WINTER-GRADEFUEL

Deutz - Sheet 2 of 24150548-E

0 – JLG Lift –

(HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDEXIST JLG HIGHLY RECOMTHE ADDITION OF A HYDR

OIL COOLER (CONSULT JLG

180° F (82° C)

-40° F (-40° C)

-30° F (-34° C)

-20° F (-29° C)

-10° F (-23° C)

0° F (-18° C)

10° F (-12° C)

20° F (-7° C)

30° F (-1° C)

40° F (4° C)

50° F (10° C)

60° F (16° C)

70° F (21° C)

80° F (27° C)

90° F (32° C)

100° F (38° C)

110° F (43° C)

120° F (49° C)

AMBIENT AIRTEMPERATURE

PROLONGED OPERATIONAMBIENT AIR TEMPERATUOF 100°F(38°C) OR ABOVE

EXTENDED DRIVING WITHHYDRAULIC OIL TANKTEMPERATURES OF 180°F(82°C) OR ABOVE.

NO OPERATION BELOW THISAMBIENT TEMPERATURE

MO

BIL

424

10W

-30

HYDRAULICSPECIFICATIONS

NO OPERATION ABOVE THISAMBIENT TEMPERATURE

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 WEATHERHYDRAULIC OIL BELOW THIS TEMPERATURE

EX

XO

N U

NIV

IS H

VI 2

6

MO

BIL

DTE

13

Figure 6-3. Engine Operating Temperature Specifications -


6-11

ation Diagram


3121606 – JLG Lift –

Figure 6-4. Operator Maintenance and Lubric


6-1 3121606

6.3

NOT

LUBRCONDTO HINCR

Bearing

nt(s) - 2 Grease Fittings - A/RPG Every 3 months or 150 hrs of operationts - Remote Access

2 – JLG Lift –

OPERATOR MAINTENANCE

E: The following numbers correspond to those in Figure 6-4., Oper-ator Maintenance and Lubrication Diagram.

ICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMALITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED

OSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BEEASED ACCORDINGLY.

1. Swing

Lube PoiCapacityLube - MInterval -Commen

Table 6-12. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel-lent 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 classification GL-5 or MIL-Spec MIL-L-2105

HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.


6-13

draulic Return Filter

rval - Change after first 50 hrs. and every 6 months or 300thereafter or as indicated by Condition Indicator.


3121606 – JLG Lift –

2. Swing Drive Hub

Lube Point(s) - Level/Fill PlugCapacity - 17 oz. (1/2 Full)Lube - EPGLInterval - Check level every 3 months or 150 hrs of operation;change every 2 years or 1200 hours of operation

3. Final Drive Hub

Lube Point(s) - Level/Fill PlugCapacity - 2.1 gal.(7.9 L); 1/2 FullLube - EPGLInterval - Check level every 3 months or 150 hrs of operation;change every 2 years or 1200 hours of operation

4. Hy

Intehrs.


6-1 3121606

lic Tank

nt(s) - Fill Cap - 30.6 gal. Tank; 32.7 gal. System

- Check Level daily; Change every 2 years or 1200operation.

NORMAL OPERATINGRANGE WITH BOOMIN STOWED POSITION

4 – JLG Lift –

5. Hydraulic Charge Filter

Interval - Change after first 50 hrs. and every 6 months or 300hrs. thereafter or as indicated by Condition Indicator.

6. Hydrau

Lube PoiCapacityLube - HOInterval hours of


6-15

el Filter - Deutz

e Point(s) - Replaceable Elementrval - Every Year or 600 hours of operation


3121606 – JLG Lift –

7. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 11 Quarts Crankcase; 5 Quarts CoolerLube - EOInterval - Every Year or 1200 hours of operationComments - Check level daily/Change in accordance withengine manual.

8. Fu

LubInte


6-1 3121606

MENTAL INFORMATIONng information is provided in accordance with thets of the European Machinery Directive 2006/42/EC

applicable to CE machines.

powered machines, the equivalent continuous A-ound pressure level at the work platform is less than

tion engine powered machines, guaranteed Soundl (LWA) per European Directive 2000/14/EC (Noise the Environment by Equipment for Use Outdoors)est methods in accordance with Annex III, Part B,nd 0 of the directive, is 104 dB.

n total value to which the hand-arm system is sub- not exceed 2,5 m/s2. The highest root mean squareighted acceleration to which the whole body is sub- not exceed 0,5 m/s2.

6 – JLG Lift –

9. Air Filter

Lube Point(s) - Replaceable ElementInterval - Every 6 months or 300 hours of operation or as indi-cated by the condition indicator

6.4 SUPPLEThe followirequiremenand is only

For electricWeighted s70dB(A)

For combusPower LeveEmission inbased on tMethod 1 a

The vibratiojected doesvalue of wejected does

SECTION 7 - INSPECTION AND REPAIR LOG

7-1

REPAIR LOG

ir Log

nts

3121606 – JLG Lift –

SECTION 7. INSPECTION ANDMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121606
– JLG Lift –
Table 7-1. Inspection and Repair Log

Date Comments

TRA

NSF

ER O

F O

WN

ERSH

IP

To P

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ct O

wne

r:If

you

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purp

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safe

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mai

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Plea

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JLG

wit

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d in

form

atio

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ith

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p of

JLG

pro

duct

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JLG

Pro

duct

Saf

ety

&

Relia

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facs

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elia

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Foun

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USA

Tele

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1-71

7-48

5-65

91Fa

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1-30

1-74

5-37

13

NO

TE: L

ease

d or

rent

ed u

nits

sho

uld

not b

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clud

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n th

is fo

rm.

Mfg

. Mod

el:

____

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____

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____

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al N

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____

____

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____

____

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ious

Ow

ner:

__

____

____

____

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____

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____

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ress

: __

____

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____

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____

____

____

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Coun

try:

___

____

____

____

____

____

____

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leph

one:

(___

____

) __

____

____

____

____

____

__

Dat

e of

Tra

nsfe

r:

____

____

____

____

____

____

____

____

____

__

Curr

ent O

wne

r:

____

____

____

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____

____

____

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ress

: __

____

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____

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Who

in y

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Nam

e: _

____

____

____

____

____

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Titl

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JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA

(717) 485-5161 (Corporate) (800) 544-5438 (Service) (717) 485-6417

www.jlg.com

JLG Worldwide LocationsJLG Industries 358 Park RoadRegents ParkNSW 2143Sydney 2143Australia

+6 (12) 87186300 +6 (12) 65813058

Email: [email protected]

JLG Ground Support OudeBunders 1034Breitwaterstraat 12A3630 MaasmechelenBelgium

+32 (0) 89 84 82 26Email: [email protected]

JLG Latino Americana LTDARua Antonia Martins Luiz, 580Distrito Industrial Joao NarezziIndiaatuba-SP 13347-404Brasil

+55 (19) 3936 7664 (Parts) +55(19)3936 9049 (Service)

Email: [email protected]: [email protected]

Oshkosh-JLG (Tianjin) Equipment Technology LTDShanghai BranchNo 465 Xiao Nan RoadFeng Xian DistrictShanghai 201204China

+86 (21) 800 819 0050

JLG Industries DubaiJafza ViewPO Box 262728, LB 1920th Floor, Office 05Jebel Ali, Dubai

+971 (0) 4 884 1131 +971 (0) 4 884 7683


JLG France SASZ.I. Guillaume Mon Amy30204 Fauillet47400 TonniensFrance

+33 (0) 553 84 85 86 +33 (0) 553 84 85 74


JLG Deutschland GmbHMax Planck Str. 2127721 Ritterhude - IhlpohlGermany

+49 (0) 421 69350-0 +49 (0) 421 69350-45

Email:[email protected]

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

+(852) 2639 5783 +(852) 2639 5797

JLG Industries (Italia) S.R.L.Via Po. 2220010 Pregnana Milanese (MI)Italy

+39 (0) 2 9359 5210 +39 (0) 2 9359 5211


JLG EMEA B.V. Polaris Avenue 632132 JH HoofdorfThe Netherlands

+31 (0) 23 565 5665Email: [email protected]

JLG NZ Access Equipment & Services2B Fisher CresentMt Wellington 1060Auckland, New Zealand

+6 (12) 87186300 +6 (12) 65813058


JLG IndustriesVahutinskoe shosse 24b.KhimkiMoscow Region 141400Russia Federation

+7 (499) 922 06 99 +7 (499) 922 06 99

Oshkosh-JLG Singapore Technology Equipment Pte Ltd.35 Tuas Avenue 2Jurong Industrial Estate Singapore 639454

+65 6591 9030 +65 6591 9045


JLG Iberica S.L.Trapadella, 2Pol. Ind. Castellbisbal Sur08755 Castellbisbal BarcelonaSpain

+34 (0) 93 772 47 00 +34 (0) 93 771 1762


JLG Sverige ABEnkopingsvagen 150176 27 JarfallaSweden

+46 (0) 8 506 595 00 +46 (0) 8 506 595 27


JLG Industries (UK) Ltd.Bentley HouseBentley AvenueMiddleton, Greater ManchesterM24 2GPUnited Kingdom

+44 (0) 161 654 1000 +44 (0) 161 654 1003


Documents

Operation and Safety Manual - Acme Liftacmelift.com/.../Tracked-JLG-600-Operation-Safety-Manual.pdf · Daily Walk-Around Inspection Diagram ... • The Operation and Safety Manual