Operation and Safety Manual - Action Rentalactionrental.com/wp-content/ldmt/pdf/JLG/JLG 600S 660SJ Operation... · Operation and Safety Manual ... JLG REPRESENTATIVE FOR INFORMATION

ANSI ®

Operation and Safety ManualKeep this manual with the machine at all times.

Boom Lift Models600SC660SJCS/N 74785 to Present

3121156September 13, 2006

FOREWORD

a

l times.

lessors, and lessees with the precautions anderation for its intended purpose.

erves the right to make specification changesformation.

3121156 – JLG Lift –

FOREWORD

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

The purpose of this manual is to provide owners, users, operators,operating procedures essential for the safe and proper machine op

Due to continuous product improvements, JLG Industries, Inc. reswithout prior notification. Contact JLG Industries, Inc. for updated in

FOREWORD

b 3121156

SIGNAL WORDS

INDIAVOWIL

INDAVODEC

OTENTIALLY HAZARDOUS SITUATION. IF NOTRESULT IN MINOR OR MODERATE INJURY. IT MAYAINST UNSAFE PRACTICES. THIS DECAL WILL HAVEGROUND.

the potential personalymbol to avoid possible

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

L HAVE A RED BACKGROUND.

ICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOTIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THISAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A PAVOIDED, MAY ALSO ALERT AGA YELLOW BACK

This is the Safety Alert Symbol. It is used to alert you toinjury hazards. Obey all safety messages that follow this sinjury or death

FOREWORD

c

act:

duct Safety and Reliability Department Industries, Inc.G Driveonnellsburg, PA 17233

our Local JLG Officee addresses on inside of manual cover)

A:

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

ide USA:

ne: 717-485-5161ail: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

tions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

3121156 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

IMPORTANTJLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

IMPORTANTJLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNELOR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONALPROPERTY OR THE JLG PRODUCT.

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FOREWORD

d 3121156

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– JLG Lift –

REVISION LOG

riginal Issue - October 28, 2003

evised - May 4, 2005

evised - July 18, 2006

evised - September 13, 2006

TABLE OF CONTENTS

3121 i

SEC - PARAGRAPH, SUBJECT PAGE

SEC

SEC P

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

- 3 - MACHINE CONTROLS AND INDICATORS

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

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1Ground Control Indictor Panel . . . . . . . . . . . . . . 3-5Platform Control Station . . . . . . . . . . . . . . . . . . . 3-7Platform Control Indicator Panel . . . . . . . . . . . . 3-12

- 4 - MACHINE OPERATION

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-3Traveling Forward or Reverse . . . . . . . . . . . . . . . 4-6Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9PARKING AND STOWING . . . . . . . . . . . . . . . . . . . 4-9PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-9Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . 4-9

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10Swinging the Boom. . . . . . . . . . . . . . . . . . . . . . 4-10

156 – 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 . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-81.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

TION - 2 - USER RESPONSIBILITIES, MACHINE REPARATION, AND INSPECTION

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

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4Daily Functional Check. . . . . . . . . . . . . . . . . . . . 2-5

SECTION

3.13.2

SECTION

4.14.2

4.3

4.44.54.6

4.7

TABLE OF CONTENTS

ii 3121156

SECTIO RAGRAPH, SUBJECT PAGE

4.84.9

4.104.11

4.12

SECTION

5.15.25.3

SECTION MAIN

6.16.2

ydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3ajor Component Weights. . . . . . . . . . . . . . . . . 6-5rial Number Locations . . . . . . . . . . . . . . . . . . 6-6RATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-12

INSPECTION AND REPAIR LOG

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

Raising and Lowering the Main Boom . . . . . . 4-10Telescoping the Main Boom . . . . . . . . . . . . . . 4-11

SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-11TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . 4-11

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . 4-12HYDRAULIC TOOL CIRCUIT INSTRUCTIONS (OPTIONAL) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

Tool Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15PLACARDS AND DECALS. . . . . . . . . . . . . . . . . . . 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

- 6 - GENERAL SPECIFICATIONS & OPERATOR TENANCE

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . 6-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

HMSe

6.3 OPE

SECTION - 7 -

TABLE OF CONTENTS

3121 iii

SEC - PARAGRAPH, SUBJECT PAGE

Decal Installation - Sheet 6 of 6 . . . . . . . . . . . . . . 4-23Serial Number Locations . . . . . . . . . . . . . . . . . . . . 6-6Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-7Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-8Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-9Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . 6-10Operator Maintenance and Lubrication Diagram. 6-11

156 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

LIST OF FIGURES

2-1. Drive Function Operating Range Diagrams - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-8

2-2. Drive Function Operating Range Diagrams - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-9

2-3. Daily Walk-Around Inspection Diagram. . . . . . . . .2-102-4. Daily Walkaround Inspection Points -Sheet 1 . . . .2-112-5. Daily Walkaround Inspection Points -Sheet 1 . . . .2-122-6. Daily Walkaround Inspection Points - Sheet 2 . . .2-133-1. Ground Control Station - 600SC . . . . . . . . . . . . . . .3-33-2. Ground Control Station - 660SJC . . . . . . . . . . . . . .3-43-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . .3-63-4. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-93-5. Platform Control Indicator Panel . . . . . . . . . . . . . .3-134-1. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . .4-44-2. Machine Motion Hazard . . . . . . . . . . . . . . . . . . . . . .4-54-3. Position of Least Backward Stability . . . . . . . . . . . .4-74-4. Position of Least Forward Stability . . . . . . . . . . . . .4-84-5. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . .4-134-6. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-144-7. Decal Installation - Sheet 1 of 6 . . . . . . . . . . . . . . .4-184-8. Decal Installation - Sheet 2 of 6 . . . . . . . . . . . . . . .4-194-9. Decal Installation - Sheet 3 of 6 . . . . . . . . . . . . . . .4-204-10. Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . .4-214-11. Decal Installation - Sheet 5 of 6 . . . . . . . . . . . . . . .4-22

4-12.6-1.6-2.

6-3.

6-4.

6-5.

6-6.

TABLE OF CONTENTS

iv 3121156

SECTIO RAGRAPH, SUBJECT PAGE

1-12-14-14-26-16-26-36-46-56-66-76-86-96-107-1

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

LIST OF TABLES

Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5Inspection and Maintenance Table . . . . . . . . . . . . . 2-3600SC Decal Legend. . . . . . . . . . . . . . . . . . . . . . . 4-24660SJC Decal Legend. . . . . . . . . . . . . . . . . . . . . . 4-26Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-1Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2Deutz F4M1011F/F4M2011 Specifications . . . . . . . 6-2Caterpillar 3044C . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . 6-4Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-4Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . 6-5Major Component Weights . . . . . . . . . . . . . . . . . . . 6-5Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-12Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

SECTION 1 - SAFETY PRECAUTIONS

1-1

CAUTIONS

E-OPERATION

Training and Knowledged and understand this manual before operating thehine.

not operate this machine until complete training is per-ed by authorized persons.

y authorized and qualified personnel can operate thehine.

3121156 – JLG Lift –

SECTION 1. SAFETY PRE

1.1 GENERALThis section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the content of this manual. A maintenanceprogram, using the information provided in this manual andthe Service and Maintenance Manual, must also be estab-lished by a qualified person and followed to ensure themachine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not operate the machine until this manual has beenread, training is accomplished, and operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.

If there are any questions with regard to safety, training,inspection, maintenance, application, and operation, pleasecontact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTYDAMAGE, PERSONAL INJURY OR DEATH.

1.2 PR

Operator• Rea

mac

• Do form

• Onlmac


1-2 3121156

Wo

chine can be operated in temperatures of 0o F to-20o C to 40o C). Consult JLG for operation out- range.

pection achine operation, perform inspections and func-

hecks. Refer to Section 2 of this manual for instructions.

perate this machine until it has been serviced anded according to requirements specified in theand Maintenance Manual.

the footswitch and all other safety devices areg properly. Modification of these devices is aolation.

R ALTERATION OF AN AERIAL WORK PLATFORMONLY WITH WRITTEN PERMISSION FROM THE MANU-

perate any machine on which safety or instruction or decals are missing or illegible.

ny buildup of debris on the platform floor. Keep, grease, and other slippery substances from foot-d platform floor.

– JLG Lift –

• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

• Use the machine in a manner which is within the scope ofits intended application set by JLG.

• All operating personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain tooperation of the machine.

rkplace Inspection• The operator is to take safety measures to avoid all haz-

ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail-ers, railway cars, floating vessels, scaffolds or other equip-ment unless approved in writing by JLG.

• Do not operate the machine in hazardous environmentsunless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support themaximum load shown on the decals located on themachine.

• This ma104o F (side this

Machine Ins• Before m

tional cdetailed

• Do not omaintainService

• Be sureoperatinsafety vi

MODIFICATION OSHALL BE MADE FACTURER

• Do not oplacards

• Avoid amud, oilwear an


1-3

plies or tools which extend outside the platform arehibited unless approved by JLG.

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

not assist a stuck or disabled machine by pushing,ing, or by using boom functions. Only pull the unit the tie-down lugs on the chassis.

not place boom or platform against any structure tody the platform or to support the structure.

w boom and shut off all power before leaving machine.

Fall Hazards operation, occupants in the platform must wear a fullarness with a lanyard attached to an authorized lan-

nchorage point. Attach only one (1) lanyard per lan-nchorage point.

3121156 – JLG Lift –

1.3 OPERATION

General • Do not use the machine for any purpose other than posi-

tioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If amalfunctions occurs, shut down the machine.

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

• Hydraulic cylinders should never be left fully extended orfully retracted before shutdown or for long periods of time.

• Do not allow personnel to tamper with or operate themachine from the ground with personnel in the platform,except in an emergency.

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

• When two or more persons are in the platform, the opera-tor shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Suppro

• Whwithfron

• Do pullfrom

• Do stea

• Sto

Trip and Duringbody hyard ayard a


1-4 3121156

reme caution when entering or leaving platform. that the boom is fully lowered. It may be neces-elescope out to position the platform closer to thefor entry/exit. Face the machine, maintain “threentact” with the machine, using two hands and one

o feet and one hand during entry and exit.

n Hazardschine is not insulated and does not provide pro-rom contact or proximity to electrical current.

– JLG Lift –

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

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

• Never use the boom assembly to enter or leave the plat-form.

• Use extBe suresary to tground point cofoot or tw

Electrocutio• This ma

tection f


1-5

in a clearance of at least 10 ft. (3m) between any part machine and its occupants, their tools, and their

ent from any electrical line or apparatus carrying up00 volts. One foot additional clearance is required for

additional 30,000 volts or less.

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

oltage Rangease to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

r 50KV to 200 KV 15 (5)

200 KV to 350 KV 20 (6)

350 KV to 500 KV 25 (8)

500 KV to 750 KV 35 (11)

50 KV to 1000 KV 45 (14)

This requirement shall apply except whereemployer, local or governmental regulationsare more stringent.

3121156 – JLG Lift –

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintaof theequipmto 50,0every

Table

V(Ph

Ove

Over

Over

Over

Over 7

NOTE:


1-6 3121156

•

DO ZONENE

ardsr should be familiar with the surface before driv-not exceed the allowable sideslope and grade

iving.

– JLG Lift –

The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Theminimum safe approach distance shall be reduced to a dis-tance within the designed working dimensions of the insulat-ing barrier. This determination shall be made by a qualifiedperson in accordance with the employer, local, or govern-mental requirements for work practices near energizedequipment

NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARERGIZED UNLESS KNOWN OTHERWISE.

Tipping Haz• The use

ing. Do while dr


1-7

oom assembly or platform is in a position that one ore wheels are off the ground, all persons must beoved before attempting to stabilize the machine. Usees, forklift trucks, or other appropriate equipment toilize machine and remove personnel.

and Collision Hazardsroved head gear must be worn by all operating and

und personnel.

ck work area for clearances overhead, on sides, andom of platform when lifting or lowering platform, anding.

ing operation, keep all body parts inside platform rail-

3121156 – JLG Lift –

• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft surface.

• Before driving on floors, bridges, trucks, and other sur-faces, check allowable capacity of the surfaces.

• Never exceed the maximum platform capacity. Distributeloads evenly on platform floor.

• Do not raise the platform or drive from an elevated posi-tion unless the machine is on firm, level and smooth sur-faces.

• Keep the chassis of the machine at least 2 ft. (0.6m) fromholes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards on the floor/surface.

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

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed28 mph (12.5 m/s).

• Do not increase the surface area of the platform or theload. Increase of the area exposed to the wind willdecrease stability.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If bmorremcranstab

Crushing• App

gro

• Chebottdriv

• During.


1-8 3121156

G, LIFTING, AND HAULINGllow personnel in platform while towing, lifting, or

chine should not be towed, except in the event ofcy, malfunction, power failure, or loading/unload-

er to the Emergency Procedures section of thisfor emergency towing procedures.

boom is in the stowed position and the turntablerior to towing, lifting or hauling. The platform mustletely empty of tools.

ting machine, lift only at designated areas of the. Lift the unit with equipment of adequate capac-

the Machine Operation section of this manual forormation.

– JLG Lift –

• Use the boom functions, not the drive function, to positionthe platform close to obstacles.

• Always post a lookout when driving in areas where visionis obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) awayfrom machine during all driving and swing operations.

• Limit travel speed according to conditions of ground sur-face, congestion, visibility, slope, location of personnel,and other factors which may cause collision or injury topersonnel.

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quartersor when driving in reverse.

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Be sure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedboom or platform. Position barricades on floor if neces-sary.

1.4 TOWIN• Never a

hauling.

• This maemergening. Refmanual

• Ensure locked pbe comp

• When lifmachineity.

• Refer tolifting inf


1-9
3121156 – JLG Lift –
1.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.

• When performing welding or metal cutting operations,precautions must be taken to protect the chassis fromdirect exposure to weld and metal cutting spatter.

• Do not refuel the machine with the engine running.

• Battery fluid is highly corrosive. Avoid contact with skinand clothing at all times.

• Charge batteries only in a well ventilated area.


1-1 3121156

nally.

0 – JLG Lift –

This page left blank intentio

CHINE PREPARATION, AND INSPECTION

2-1

PREPARATION, AND INSPECTION

e safest means to operate the machine where over-ad obstructions, other moving equipment, and obsta-

es, depressions, holes, drop-offs.

eans to avoid the hazards of unprotected electrical nductors.

ecific job requirements or machine application.

Supervisiong must be done under the supervision of a qualified in an open area free of obstructions until the traineeveloped the ability to safely control and operate the

ne.

Responsibilityerator must be instructed that he/she has the respon-

and authority to shut down the machine in case of action or other unsafe condition of either the machinejob site.

SECTION 2 - USER RESPONSIBILITIES, MA

3121156 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

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

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal-function.

6. Thhecl

7. Mco

8. Sp

Training Traininpersonhas demachi

OperatorThe opsibilitymalfunor the

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121156

2.2 IMPORTANT, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICEA PERSON WHO HAS SUCCESSFULLY COMPLETEDE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD-

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for further requirements for aerial work plat-forms. The frequency of inspections and maintenance mustbe increased as necessary when the machine is used in aharsh or hostile environment, if the machine is used withincreased frequency, or if the machine is used in a severemanner.

JLG INDUSTRIESTECHNICIAN AS THE JLG SERVICUCT MODEL.


2-3

nce Table

rybility

Service Qualification

Reference

or User or Operator Operator and Safety Manual

or User Qualified JLG Mechanic

Service and Maintenance Manual and applicable JLG inspection form



or User Factory-Certified Service Technician(Recommended)



Service and Maintenance Manual

ance Manual to perform inspections.


3121156 – JLG Lift –

Table 2-1.Inspection and Maintena

Type FrequencyPrima

Responsi

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

User or Operat

Pre-Delivery Inspection (See Note)

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

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,

Annual Machine Inspection(See Note)

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

Owner, Dealer,

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

Owner, Dealer,

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


2-4 3121156

Pre stic only) is enclosed in the weather resistant e container.

-Around” Inspection – Refer to Figure 2-3., Fig-. and Figure 2-6.

y – Charge as required.

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

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

ulic Oil – Check the hydraulic oil level. Ensure lic oil is added as required.

sories/Attachments - Reference the Operator fety Manual of each attachment or accessory d upon the machine for specific inspection, oper-

and maintenance instructions.

on Check – Once the “Walk-Around” Inspection plete, perform a functional check of all systems in a free of overhead and ground level obstructions. o Section 4 for more specific operating instruc-

– JLG Lift –

-Start InspectionThe Pre-Start Inspection should include each of the follow-ing:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents,damage, weld or parent metal cracks or other discrep-ancies.

3. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities

(Domestorag

5. “Walkure 2-5

6. Batter

7. Fuel (Cproper

8. EnginFull m

9. Hydrahydrau

10. Accesand Sainstalleation,

11. Functiis coman areRefer ttions.

Parent Metal Crack Weld Crack


2-5

rform checks from ground controls first, then from plat-m controls.

perate machine from ground control.

r adjustments see Service Manual, Limit Switch Adjust-nts.

heck elevation limit switch as follows:

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

heck capacity limit switch as follows:

. Boom Length Switch.

Raise boom to horizontal. Telescope boom out until500 lb. light comes on. Make sure the switch resetsand the 1000 lb. light comes back on when tele-scoping 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.


3121156 – JLG Lift –

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THEMACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPERMAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTILIT IS DECLARED SAFE FOR OPERATION.

Daily Functional CheckA functional check of all systems should be performed, oncethe walk-around inspection is complete, in an area free ofoverhead and ground level obstructions. First, using theground controls, check all functions controlled by the groundcontrols. Next, using the platform controls, check all func-tions controlled by the platform controls.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMMOVEMENTS DO NOT RETURN TO THE OFF OR NEUTRAL POSITIONWHEN RELEASED.

TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOPWHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOTFROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THEMACHINE.

NOTE: Pefor

1. O

NOTE: Fome

2. C

WmTh

3. C

a

b


2-6 3121156

NOT

NOT

turntable. Return snap pin to lock pin to hold lockthe disengaged position. Reverse procedure to turntable lock.

turntable to LEFT and RIGHT a minimum of 45 s. Check for smooth motion.

the chassis out of level indicator located on the m control console by driving, with the machine in osition, up a suitable ramp of at least 5° slope. the out of level indicator, with the machine on the If the light does not illuminate, return the machine el surface, shut down the machine, and contact a d technician before resuming operation.

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

platform level adjustment system for proper oper-

platform rotator for smooth operation and assure m will rotate 90 degrees in both directions from line of boom.

SI, ANSI Export, CSA, Japan 5°

, Australia 3°

– JLG Lift –

light comes on. Boom angle must be approximately45 to 50 degrees

Lift boom up until 1000 lb. light comes on. Theswitch should reset when the boom angle is about55 degrees to 64 degrees.

E: If limit switch settings need to be changed, you will needto recheck that the 500 lb. light comes on at 45 degrees to50 degrees when lifting down.

4. Drive Disable Switch (Refer to Figure 2-2., Drive Func-tion Operating Range Diagrams - Sheet 2 of 2).

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 for delayed movement of fly section, indicating loose cables.

E: Turntable lock is on turntable facing platform. To disen-gage lock, pull snap pin from lock pin, lift lock pin up to

unlock pin in engage

6. Swingdegree

7. Checkplatforlevel pCheckramp. to a levqualifie

8. Checktions p

9. Checkation.

10. Checkplatforcenter

AN

CE


2-7

. With engine power shut down, depress the foot-switch. Attempt to start engine. Engine should notattempt to start when footswitch is depressed. Ifstarter engages or engine turns over, shut downmachine and contact a certified JLG service techni-cian.

xiliary Power.

perate each function control switch (e.g. TELE, LIFT d SWING) to assure that they function in both direc-ns using auxiliary power instead of engine power.

round Controls.

ace GROUND/PLATFORM SELECT switch to ROUND. Start engine. Platform controls should not erate.


3121156 – JLG Lift –

11. Drive forward and reverse; check for proper operation.

12. Steer left and right; check for proper operation.

13. Raise and lower Articulating Jib Boom. Check for smooth operation.

14. Footswitch.

IMPORTANTFOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER-ATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IFSWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM,IT SHOULD BE ADJUSTED.

a. Activate hydraulic system. By depressing foot-switch. Operate MAIN TELESCOPE and hold con-trol. Remove foot from footswitch, motion shouldstop. If it does not, shut down machine and contacta certified JLG service technician.

b. With footswitch depressed, operate LIFT and holdcontrol. Remove foot from footswitch, motionshould stop. If it does not, shut down machine andcontact a certified JLG service technician.

c

15. Au

Oantio

16. G

PlGop


2-8 3121156

ams - Sheet 1 of 2

E: In the Transport Mode, High Drive willbe disabled above 10° elevation orpast 3 feet (1 m) of boom extension.

– JLG Lift –

Figure 2-1. Drive Function Operating Range Diagr

NOT


2-9

agrams - Sheet 2 of 2

NOTE: In the Transport Mode, High Drive willbe disabled above 10° elevation orpast 3 feet (1 m) of boom extension.


3121156 – JLG Lift –

Figure 2-2. Drive Function Operating Range Di


2-1 3121156

agram

0 – JLG Lift –

Figure 2-3. Daily Walk-Around Inspection Di


2-11

otator - See Inspection Note.

otator Motion Control Valve - See Inspection Note.

rticulating Jib Boom - See Inspection Note.

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

ower Track - See Inspection Note.

urntable Bearing and Pinion - No evidence of loose olts or looseness between bearing and structure. See spection Note.

ight Track - Properly secured plates, no loose or issing track bolts, no dislocation of the track pins. roper tension. See Inspection Note.

inal Drive, Both Sides - See Inspection Note.

urntable Lock - Operable; See Inspection Note.

uxiliary Power Pump - See Inspection Note.

P Gas Tank - See Inspection Note. (If Equipped)

ottom Rollers, Right Side - See Inspection Note.

rack Carrier Roller, Both Sides - See Inspection ote.

Points -Sheet 1


3121156 – JLG Lift –

GeneralBegin the "Walk-Around Inspection" at Item 1, as noted onthe diagram. Continue to the right (counterclockwiseviewed from top) checking each item in sequence for theconditions listed in the following checklist.

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEENCORRECTED.

INSPECTION NOTE: On all components, make sure thereare no loose or missing parts, that they are securely fas-tened, and no visible damage, leaks or excessive wearexists in addition to any other criteria mentioned.

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

2. Platform Control Console - Switches and levers return to neutral, decals/placards secure and legible, control markings legible.

3. R

4. R

5. A

6. DL

7. P

8. TbIn

9. RmP

10. F

11. T

12. A

13. L

14. B

15. TN

Figure 2-4. Daily Walkaround Inspection


2-1 3121156

Right Front - See Inspection Note.

Capacity Limit Switch - Switch operates prop-

rack - Properly secured plates, no loose or miss-ck bolts, no dislocation of the track pins. Proper n. See Inspection Note.

Left Front - See Inspection Note.

ension Mechanism - See Inspection Note.

m Rollers, Left Side - See Inspection Note.

ry - Proper electrolyte levels; cables tight, no vis-amage or corrosion.

and Latches, Left Side - Hood door and latches rking condition, see Inspection Note.

e Air Filter - See Inspection Note.; element .

e Oil Supply - Full mark on dipstick; filler cap e.

ts -Sheet 1

2 – JLG Lift –

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

17. Control Valve (Tank Compartment) - See Inspection Note.

18. Manual Descent - See Inspection Note.

19. Hydraulic Oil Return Filter - Housing secure; See Inspection Note.

20. Hydraulic Oil Supply - Recommended oil level sight gauge. (Check level with cold oil, systems shut down, machine in stowed position) Cap in place and secure.

21. Hydraulic Oil Breather - Element in place, not clogged, no sign of overflow.

22. Door and Latches, Right Side - Hood door and latches in working condition. See Inspection Note.

23. Ground Controls - Switches and levers return to neu-tral, decals/placards secure and legible, control mark-ings legible.

24. Right Tension Mechanism - See Inspection Note.

25. Fuel Supply - Fuel filler cap secure. Tank - See Inspection Note.

26. Idler,

27. Dual erly.

28. Left Ting tratensio

29. Idler,

30. Left T

31. Botto

32. Batteible d

33. Doorin wo

34. Enginclean

35. Enginsecur

Figure 2-5. Daily Walkaround Inspection Poin


2-13

orizontal Cutoff Limit Switch - (High Engine/High rive Cut-off Switch) Switch operates properly.

rame - See Inspection Note.

ydraulic Swivel - See Inspection Note.

ain Boom Sections - See Inspection Note.

latform Pivot Pin - See Inspection Note.

n Points - Sheet 2


3121156 – JLG Lift –

36. Muffler and Exhaust System - See Inspection Note.

37. Hydraulic Pump - See Inspection Note.

38. Engine Tray Pivot - See Inspection Note.

39. Hydraulic Oil Medium Pressure Filter Housing - Housing secure; See Inspection Note.

40. LP Gas Tank - See Inspection Note. (If Equipped)

41. Flow Valves - See Inspection Note.

42. HD

43. F

44. H

45. M

46. P

Figure 2-6. Daily Walkaround Inspectio


2-1 3121156

ally.

4 – JLG Lift –

This page left blank intention

MACHINE CONTROLS AND INDICATORS

3-1

AND INDICATORS

ontrol Stationigure 3-1., Ground Control Station - 600SC, and Figureround Control Station - 660SJC)

quipped, the Function Enable switch must held down in order to operate Telescope,ing, Lift, Jib Lift, Platform Level Override,d Platform Rotate functions.

atform Rotate

three position switch permits rotation of the platform.

atform Leveling Override

three position switch allows the operator to compen-te for any difference in the automatic self leveling sys-m.

ticulating Jib

is switch provides raising and lowering of the jib.

en Power/Emergency Stop switch is in the “ON” posi- and engine is not running, an alarm will sound, indi-ing Ignition is “ON”.

SECTION 3 -

3121156 – JLG Lift –

SECTION 3. MACHINE CONTROLS

3.1 GENERAL

IMPORTANTTHE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that usesymbols to indicate control functions. Refer to decallocated on the control box guard in front of the control boxor by the ground controls for these symbols and the corre-sponding functions.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMMOVEMENT DO NOT RETURN TO THE OFF POSITION WHENRELEASED.

Ground C(See F3-2., G

NOTE: If ebeSwan

1. Pl

A

2. Pl

A sate

3. Ar

Th

NOTE: Whtioncat

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121156

WHESWIDRA

ILIARY POWER, DO NOT OPERATE MORE THAN ONETIME. (SIMULTANEOUS OPERATION CAN OVERLOADUMP.

Start/Auxiliary Power Switch or Start/ Auxiliary Power Switch /Function Enable.

To start the engine, the switch must be held "UP"until the engine starts.

To use auxiliary power, the switch must be held“DOWN” for duration of auxiliary pump use. Auxpower can only be used if the engine is not run-ning.

If equipped, the enable switch must be held"DOWN" to enable all boom controls when theengine is running.

– JLG Lift –

N THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOPTCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENTINING THE BATTERY.

4. Power/Emergency Stop Switch

A two-position red mushroom shaped switch furnishespower to PLATFORM/GROUND SELECT switch whenpulled out (on). When pushed in (off), power is shut offto the PLATFORM/GROUND SELECT switch.

WHEN USING AUXFUNCTION AT A THE AUXILIARY P

5. Engine Engine


3-3

- 600SC

SECTION 3 -

3121156 – JLG Lift –

Figure 3-1. Ground Control Station

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


3-4 3121156

0SJC

– JLG Lift –

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

Figure 3-2. Ground Control Station - 66


3-5

ontrol Indictor Paneligure 3-3., Ground Control Indicator Panel)

ttery Charging Indicator

dicates a problem in the battery or charging circuit,d service is required.

w Engine Oil Pressure Indicator

dicates that engine oil pressure is below normal andrvice is required.

igh Coolant Temperature Indicator (If equipped)

dicates that engine coolant temperature is abnormallygh and service is required.

gine Oil Temperature Indicator (Deutz)

dicates the temperature of the engine oil, which alsorves as engine coolant, is abnormally high and ser-

ce is required.

stem Distress Indicator

e light indicates that the JLG Control System hastected a malfunction and a Diagnostic Trouble Codes been set in the system memory. Refer to the Service

SECTION 3 -

3121156 – JLG Lift –

6. Lift Control

Provides raising and lowering of the main boom.

7. Hourmeter

Registers the amount of time the machine has been inuse with engine running.

NOTE: With PLATFORM/GROUND SELECT switch in the centerposition, power is shut off to controls at both operatingstations.

8. Platform/Ground Select Switch

A three position, key operated switch supplies power tothe platform control console when positioned to PLAT-FORM. With the switch key held in the GROUND posi-tion, power is shut off to platform and only groundcontrols are operable.

9. Swing Control

Provides 360 degrees continuous turntable rotation.

10. Telescope Control.

Provides extension and retraction of the boom whenpositioned to IN or OUT.

Ground C(See F

1. Ba

Inan

2. Lo

Inse

3. H

Inhi

4. En

Insevi

5. Sy

Thdeha


3-6 3121156

arginge Oil Pressuree Coolant Temp.e Oil Temp.tress

7. Glow Plug 8. Platform Overload9. Drive Disabled10. Hydraulic Oil Filter11. Transmission Pump Oil Filter12. Engine Air Filter

3-3. Ground Control Indicator Panel

– JLG Lift –

Manual for instructions concerning the trouble codesand trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 sec-onds when the key is positioned to the on position to actas a self test.

6. Low Fuel Indicator

Indicates the fuel tank is 1/8 full or less. When the lightfirst turns on, there are approximately four usable gal-lons of fuel remaining.

7. Glow Plug Indicator

Indicates the glow plugs are operating. After turning onignition, wait until light goes out before cranking engine.

8. Platform Overload Indicator (If equipped)

Indicates the platform has been overloaded.

9. Drive Disabled Indicator

When illuminated, the drive function has been disabled.(Refer to Drive Function Operating Range Diagrams inSection 2).

1. Battery Ch2. Low Engin3. High Engin4. High Engin5. System Dis6. Low Fuel

Figure


3-7

Control Stationigure 3-4., Platform Control Console)

RIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-RS OR TOGGLE SWITCHES CONTROLLING PLATFORMDO NOT RETURN TO THE OFF OR NEUTRAL POSITION

ASED.

wer/Emergency Stop

two-position red mushroom shaped switch furnisheswer to PLATFORM Controls when pulled out (on).hen pushed in (off), power is shut off to the platformnctions.

ithin about 2 seconds of pulling the switch out, theachine will perform a diagnostic check of the variousectrical circuits, and if everything is OK, the platformarm will beep once. During this time the lights on thedicator panel will also blink once as a bulb check.

SECTION 3 -

3121156 – JLG Lift –

10. Hydraulic Oil Filter Indicator

When illuminated indicates that the return oil filter is toorestrictive and needs to be replaced.

11. Transmission Pump Oil Filter Indicator

When illuminated indicates that charge pump filter is toorestrictive and needs to be replaced. This indicator hasan integral temperature sensor (70 degrees F.) so thatfalse signals are not generated when the hydraulic oil isbelow normal operating temperature.

12. Engine Air Filter Indicator

When illuminated indicates that the air filter is too restric-tive and needs to be replaced.

Platform(See F

TO AVOID SETROL LEVEMOVEMENT WHEN RELE

1. Po

A poWfu

Wmelalin


3-8 3121156

elect (Dual Fuel Engine Only) (If Equipped)

ne or liquid propane fuel may be selected by mov- switch to the appropriate position. It is unneces- purge the fuel system before switching fuels, so

s no waiting period when switching fuels while the is running.

– JLG Lift –

2. Start/Auxiliary Power

When pushed forward, the switch energizes the startermotor to start the engine.

When pushed back, it energizes the electrically oper-ated hydraulic pump, when actuated. (Switch must beheld ON for duration of auxiliary pump use.)

The auxiliary pump functions to provide sufficient oil flowto operate the basic machine functions should the mainpump or engine fail. The auxiliary pump will operateplatform rotate, jib lift, jib swing, platform level override,main boom lift, main telescope and swing.

3. Fuel S

Gasoliing thesary tothere iengine


3-9

ontrol

que Select

13. Platform Level Override14. Horn

sole

SECTION 3 -

3121156 – JLG Lift –

1. Power/Emergency Stop2. Start / Aux Power3. Fuel Select4. Lights

5. Drive/Steer Enable6. Drive Steer7. Telescope8. Articulating Jib

9. Platform Rotate10. Function Speed C11. Main Lift / Swing12. Drive Speed / Tor

Figure 3-4. Platform Control Con


3-1 3121156

r aft direction) will turn the machine by counter-n around the center of the machine by poweringcks in opposite directions.

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

ive and steer functions work in the opposite direc-en the boom is positioned over front of the chassisler wheels).

oom is positioned above horizontal and any of theg switches, DRIVE SPEED/TORQUE SELECT orION SPEED, are positioned to HIGH, high func-eeds are automatically cut out and the machinees to operate at a lower speed.

E MACHINE IF DRIVE SPEED /TORQUE SELECT OR SWITCHES OPERATE WHEN BOOM IS ABOVE HORI-

elescope

ontrol allows extension and retraction of the main

0 – JLG Lift –

4. Lights (If Equipped)

This switch operates accessory light packages if themachine is so equipped.

5. Drive/Steer Enable

Located on the top of the Drive Steer Joystick, the but-ton must be pushed in for the Drive/Steer control tofunction. If at any time the Enable Switch is pushed inand no function is operated for a period of 3 seconds,the switch will "time-out" and the switch must be cycledagain to renew normal functions.

6. Drive/Steer

Proportional dual axis joystick is provided to controldrive and steer. Push forward to drive straight forward.The joystick is proportional, with the drive speedincreasing as the joystick is moved further from its neu-tral position. Moving the joystick forward and to the sidesteers the machine in the direction of the side displace-ment of the joystick. With the joystick positioned all theway to the side and slightly forward, the machine willturn in place with one track stopped and the other oneturning the machine around the center of the stoppedtrack.

Moving the joystick to the side (no dislocation in the for-

ward orotatiothe tra

Pullingand di

NOTE: Both drtion wh(over id

NOTE: When bfollowinFUNCTtion spcontinu

DO NOT OPERATFUNCTION SPEEDZONTAL.

7. Main T

This cboom.


3-11

rive Speed/Torque Select

e machine has a three position switch.

e forward position gives maximum drive speed byifting the drive motors to minimum the displacementd giving high engine when drive controller is moved.

e back position gives maximum torque for rough ter-in, climbing grades, and sharp turns. In this position,e motors are shifted t maximum displacement and thegine in high speed when the drive controller is moved.

e center position allows the machine to be driven asietly as possible by leaving the engine at mid speedd the drive motors in maximum displacement.

atform Leveling Override

e Platform Level switch allows the operator to adjuste level of the platform by positioning the switch to Up Down.

avel Warning Horn

push-type HORN switch supplies electrical power to audible warning device when pressed.

SECTION 3 -

3121156 – JLG Lift –

8. Articulating Jib

Push forward to lift up, pull back to lift down. Variable liftspeed is using the Function Speed Control.

9. Platform Rotate

This switch allows the operator to rotate the basket tothe left or right.

10. Function Speed Control

Controls the speed of Boom and Swing Functions.Rotate CCW for slower speed and CW for faster speed.To adjust to creep, turn knob fully CCW until it clicks.

11. Main Lift/Swing Controller

An infinitely proportional dual axis joystick is providedfor main lift and swing. Push forward to lift up, pull back-ward to lift down. Move right to swing right, move left toswing left.

NOTE: Main lift and swing functions may be selected in combina-tion. The handle features a round gate so that maximumspeed is reduced when multiple functions are selected.

12. D

Th

Thshan

Thrathen

Thquan

13. Pl

Ththor

14. Tr

A an


3-1 3121156

Pla

NOT

rm Warning Light

tes that the chassis is on a slope greater than thesor setting. If the boom is above horizontal andchine is on a slope greater than the tilt sensor set-n alarm will sound and CREEP is automaticallyed.

WHEN BOOM IS RAISED OR EXTENDED, RETRACTELOW HORIZONTAL THEN REPOSITION MACHINE SOL BEFORE EXTENDING BOOM OR RAISING BOOM

TAL.

m Overload Indicator (If Equipped)

tes the platform has been overloaded.

m Capacity Indicator (If equipped)

tes the maximum platform capacity selected fortform.

f the capacity lights should be on at all times. Bothwill flash and an alarm will sound if the platform isthe operating envelope for the selected capacity.

2 – JLG Lift –

tform Control Indicator Panel(See Figure 3-5., Platform Control Indicator Panel)

E: The platform control indicator panel uses different shapedsymbols to alert the operator to different types of opera-tional situations that could arise. The meaning of thosesymbols are explained below.

1. Tilt Ala

Indicatilt senthe mating, aactivat

IF ILLUMINATED AND LOWER TO BTHAT IT IS LEVEABOVE HORIZON

2. Platfor

Indica

3. Platfor

Indicathe pla

One olights out of

Indicates a potentially hazardous situation, whichif not corrected, could result in serious injury ordeath. This indicator will be red.

Indicates an abnormal operating condition,which if not corrected, may result in machineinterruption or damage. This indicator will be yel-low.

Indicates important information regarding theoperating condition, i.e. procedures essential forsafe operation. This indicator will be green withthe exception of the capacity indicator which willbe green or yellow depending upon platformposition.


3-13

otswitch/Enable Indicator

operate any function, the footswitch must bepressed and the function selected within seven sec-ds. The enable indicator shows that the controls areabled. If a function is not selected within seven sec-ds, or if a seven second lapse between ending one

nction and beginning the next function, the enableht will go out and the footswitch must be released andpressed again to enable the controls.

leasing the footswitch removes power from all con-ls and applies the drive brakes.

ERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLEITCH BY BLOCKING OR ANY OTHER MEANS.

H MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHENY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT-

SECTION 3 -

3121156 – JLG Lift –

4. Drive Disabled Indicator

When illuminated, the drive function has been disabled.(Refer to Drive Function Operating Range Diagrams inSection 2).

5. Fo

Todeonenonfuligde

Retro

TO AVOID STHE FOOTSW

FOOTSWITCSWITCH ONLTOM.

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

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

9. AC Generator10. Soft Touch11. Creep Speed

Figure 3-5. Platform Control Indicator Panel


3-1 3121156

nerator

tes the generator is in operation.

uch Indicator

tes the Soft Touch bumper is against an object. Allls are cut out until the override button is pushed,h time controls are active in the Creep mode.

Speed Indicator

the Function Speed Control is turned to the creepn, the indicator acts as a reminder that all func-re set to the slowest speed. The light flashes if thel system puts the machine into creep speed and on continuously if the operator selects creep

.

4 – JLG Lift –

6. Glow Plug Indicator

Indicates the glow plugs are operating. After turning onignition, wait until light goes out before cranking engine.

7. Low Fuel Indicator.

Indicates the fuel tank is 1/8 full or less. When the lightfirst turns on, there are approximately four usable gal-lons of fuel remaining.

8. System Distress Indicator

The light indicates that the JLG Control System hasdetected a malfunction and a Diagnostic Trouble Codehas been set in the system memory. Refer to the ServiceManual for instructions concerning the trouble codesand trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 sec-onds when the key is positioned to the on position to actas a self test.

9. AC Ge

Indica

10. Soft To

Indicacontroat whic

11. Creep

When positiotions acontrowill bespeed

SECTION 4 - MACHINE OPERATION

4-1

PERATION

G Lift is a crawler track type machine with drive powersupplied by a hydraulic motor for each final drive andet. Each final drive is equipped with a spring applied,ulically released brake. The swing drive is alsoed with such a brake. These brakes are automaticallyd any time the Drive or Swing control levers ared to the neutral position.

3121156 – JLG Lift –

SECTION 4. MACHINE O

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating and rotating boom.Vibrations emitted by these machines are not hazardous toan operator in the work platform. The equivalent continuousA-Weighted sound pressure level at the work platform is lessthan 70dB(A).

The primary operator control station is in the platform. Fromthis control station, the operator can drive and steer themachine in both forward and reverse directions. The opera-tor can raise or lower the upper or lower boom or swing theboom to the left or right. Standard boom swing is 360 degreecontinuous left and right of the stowed position. The machinehas a Ground Control Station which will override the PlatformControl Station. Ground Controls operate Boom Lift andSwing, and are to be used in an emergency to lower the plat-form to the ground should the operator in the platform beunable to do so.

The JLbeing sprockhydraequippappliereturne


4-2 3121156

4.2

NOT

Sta

IF EEXTALLAFTUAL

NOT

key of SELECT switch to GROUND. PositionR/EMERGENCY STOP switch to ON, then pushGINE START switch to the upward position until starts.

TO WARM-UP FOR A FEW MINUTES AT LOW SPEEDG ANY LOAD.

ngine has had sufficient time to warm up, shut off.

ey of SELECT switch to PLATFORM.

Platform position POWER/EMERGENCY STOP to ON, then push the ENGINE START switch toward position until engine starts.

itch must be in released (up) position beforewill operate. If starter operates with footswitch inressed position, DO NOT OPERATE MACHINE.

– JLG Lift –

ENGINE OPERATION

E: Initial starting should always be performed from theGround Control station.

rting Procedure

1. Check engine oil. If necessary, add oil in accordancewith the Engine Manufacturer’s manual.

2. Check fuel level. Add fuel if necessary.

3. Check that air cleaner components are in place andsecurely fastened.

NGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR ANENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE AGAIN,OW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILSER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MAN-.

E: Machines with diesel engines. After turning on ignition,operator must wait until glow plug indicator light goes outbefore cranking engine.

4. Turn POWEthe ENengine

ALLOW ENGINE BEFORE APPLYIN

5. After eengine

6. Turn k

7. From switchthe for

NOTE: Footswstarter the dep


4-3

THE FRAME.

T TURNTABLE LOCK IS ENGAGED BEFORE BEGINNINGED TRAVELING. AVOID ANY TERRAIN FEATURES WHICH

SE THE MACHINE TO UPSET.

D/TORQUE SELECT SWITCH SHOULD BE IN THE BACK-ION FOR:

VELING GRADES

VELING IN DIFFICULT CONDITIONS

RP TURNS (ESPECIALLY WITH ONE TRACK STOPPED

NTERROTATION

E CAUTION WHEN DRIVING IN REVERSE AND AT ALL DRIVING WITH THE PLATFORM ELEVATED AND SPE-

N DRIVING WITH ANY PART OF THE MACHINE WITHIN 6F AN OBSTRUCTION. DO NOT USE DRIVE TO MANEUVERCLOSE TO AN OBSTRUCTION. USE ONE OF THE BOOM

3121156 – JLG Lift –

Shutdown Procedure

IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUT-DOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANYOPERATION.

1. Remove all load and allow engine to operate at lowspeed setting for 3-5 minutes; this allows for furtherreduction of internal engine temperature.

2. Position POWER/EMERGENCY STOP switch to OFF.

3. Turn key of MASTER switch to OFF position.

Refer to Engine Manufacturer’s manual for detailed informa-tion.

4.3 TRAVELING (DRIVING)

DO NOT DRIVE WITH BOOM EXTENDED OR ABOVE HORIZONTALEXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES ANDSIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPESEXCEEDING THOSE SPECIFIED ON MANUFACTURERS NAMEPLATE

LOCATED ON

ASSURE THAANY EXTENDCOULD CAU

DRIVE SPEEWARD POSIT

• TRA

• TRA

• SHA

• COU

USE EXTREMTIMES WHENCIALLY WHEFEET (2M) OPLATFORM FUNCTIONS.


4-4 3121156
– JLG Lift –
Figure 4-1. Grades and Sideslopes


4-5

zard

3121156 – JLG Lift –

Figure 4-2. Machine Motion Ha


4-6 3121156

USERAINTERMACTHEAN EING

BEFREATHEWHEDIRE

Tra

e), move DRIVE/STEER control to RIGHT forh turn to right and LEFT for smooth turn to left.

tain sharp turns, move DRIVE SPEED/TORQUET switch to the back position, slow down the

speed and move the DRIVE control lever to RIGHTurn to the right and to LEFT for a turn to the left.arpest possible turn is achieved when the joysticke position to command one track to stop and theo move slowly.

ONLY IN AN AREA FREE OF OBSTACLES AND ONLY FULLY RETRACTED. USE SLOW, GENTLE CONTROL DO NOT OPERATE ANY OTHER FUNCTIONS DURINGION.

tain counter-rotation (turn in place), stop thene, move the DRIVE/STEER control lever directlyHT to get clockwise rotation and to LEFT to getrclockwise rotation.

tain maximum travel speed, position the DRIVEller to FAST and activate the following switches:

sition DRIVE SPEED/TORQUE SELECT switch toST. (Forward Position)

– JLG Lift –

EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TER- OBSTACLE. CHECK FOR CURBS, LARGE STONES, OR OTHER

RAIN OBSTACLES INCLUDING OVERHEAD OBSTACLES AS THEHINE WILL MAKE UNCONTROLLED PIVOTING MOTIONS WHEN

CENTER OF GRAVITY (CENTER OF TRACK FRAME) SHIFTS OVERDGE. SLOW DOWN TO MINIMIZE ACCELERATION DURING PIVOT-

MOVEMENT.

ORE DRIVING, MAKE SURE THE BOOM IS POSITIONED OVER THER OF THE CHASSIS (OVER FINAL DRIVES AND SPROCKETS). IF BOOM IS OVER THE FRONT OF THE CHASSIS (OVER THE IDLERELS) STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITECTIONS TO MACHINE CONTROLS.

veling Forward or Reverse

1. With engine running, depress footswitch and positionDRIVE control to FORWARD and hold for the duration offorward travel desired.

2. Depress footswitch and position DRIVE control toREVERSE and hold for duration of reverse traveldesired.

3. Depress footswitch, move joystick (DRIVE/STEER CON-TROL) to select desired direction of travel (forward or

reverssmoot

4. To obSELECtravel for a tThe shis in thother t

TURN IN PLACE WITH THE BOOMMOVEMENTS ANDCOUNTER-ROTAT

5. To obmachito RIGcounte

6. To obcontro

a. PoFA


4-7

ure 4-3. Position of Least Backward Stability

ORM ROTATED DEGREES

MACHINE WILL UPSETIN THIS DIRECTION IF

OVERLOADED OR OPERATED ON AN

OUT-OF-LEVEL SURFACE

BOOM FULLYRACTED ANDLEVATED

3121156 – JLG Lift –

7. Prior to stopping the machine, position switches as fol-lows:

a. Position DRIVE SPEED/TORQUE SELECT switch toLOW. (Backward Position)

8. For traveling up grades, position switches as follows:

a. Position DRIVE SPEED/TORQUE SELECT switch toHIGH. (Backward position)

NOTE: For smoother operation when driving with fully extendedboom, place DRIVE control to SLOW before stopping.

Stability

Machine stability is based on two positions which are calledFORWARD STABILITY and BACKWARD STABILITY. Themachines position of least forward stability is shown in Fig-ure 4-4., and its position of least backward stability is shownin Figure 4-3.

TO AVOID FORWARD OR BACKWARD UPSET, DO NOT OVERLOADMACHINE OR OPERATE ON AN OUT-OF-LEVEL SURFACE.

Fig

PLATF90

MAINRET

E


4-8 3121156

bility

LEVEL SURFACE

– JLG Lift –

Figure 4-4. Position of Least Forward Sta

MACHINE WILL UPSET IN THISDIRECTION IF OVERLOADED

OR OPERATED ON ANOUT-OF-LEVEL SURFACE

BOOM FULLY EXTENDED@ HORIZONTAL (O DEGREES)


4-9

ATFORM

Level Adjustment

veling UP. Depress footswitch To raise platform, posi-n PLATFORM LEVEL control switch UP and hold untilatform is level.

veling DOWN. Depress footswitch To lower platform,sition PLATFORM LEVEL control switch to DOWN andld until platform is level.

Rotation

epress footswitch to rotate platform to the left, PLAT-RM ROTATE control is positioned to the LEFT andld until desired position is reached.

epress footswitch to rotate platform to the right, PLAT-RM ROTATE control is positioned to the RIGHT andld until desired position is reached.

3121156 – JLG Lift –

4.4 STEERINGDepress footswitch. Move the DRIVE/STEER control lever toRIGHT for a turn to the right and to LEFT for a turn to the left.

BEFORE OPERATING MACHINE, MAKE SURE BOOM IS POSITIONEDOVER REAR OF CHASSIS. IF BOOM IS OVER FRONT OF THE CHASSIS,STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTIONTHAN INDICATED ON MACHINE PLACARDS.

4.5 PARKING AND STOWINGPark and stow machine as follows:

1. Park machine in travel position; boom lowered over rear,all access panels and doors closed and secured, igni-tion off, turntable locked.

2. Check that brakes hold machine in position.

3. Chock tracks front and rear.

4. Turn off SELECT switch and remove key.

5. When parking on frozen ground overnight, drive themachine up on boards to prevent freezing to theground.

4.6 PL

Platform

1. Letiopl

2. Lepoho

Platform

1. DFOhe

2. DFOhe


4-1 3121156

4.7

AN TRO(5 DBOO

DO CHADEGING,

TO WHERETREPING

TRAIS PTION

TO CONMOVWHE

LISION AND INJURY IF PLATFORM DOES NOT STOPL SWITCH OR LEVER IS RELEASED, REMOVE FOOT

TCH OR USE EMERGENCY STOP TO STOP THE

e Boom

IMPORTANTRNTABLE LOCK IS DISENGAGED BEFORE STARTINGATION.

otswitch. To swing boom, position SWING controlontroller to RIGHT or LEFT for direction desired.

oom functions are being operated there an inter-vents the use of DRIVE and STEER functions.

Lowering the Main Boom

d lower Main Boom, position MAIN LIFT controlontroller to UP OR DOWN and hold until desiredached.

0 – JLG Lift –

BOOM

ORANGE TILT ALARM WARNING LIGHT, LOCATED ON THE CON-L CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPEEGREES OR GREATER). DO NOT SWING, EXTEND OR RAISE MAINM ABOVE HORIZONTAL WHEN LIT.

NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THESSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5REES OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWING- EXTENDING OR RAISING BOOM ABOVE HORIZONTAL.

AVOID UPSET, IF ORANGE TILT ALARM WARNING LIGHT LIGHTSN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL,

RACT AND LOWER PLATFORM TO NEAR GROUND LEVEL. THENOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTEND-OR RAISING MAIN BOOM.

VELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTALERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON CAU- PLACARD AT PLATFORM.

AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANYTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITIONN RELEASED.

TO AVOID A COLWHEN A CONTROFROM FOOTSWIMACHINE.

Swinging th

ASSURE THAT TUANY SWING OPER

Depress foswitch or c

NOTE: When block pre

Raising and

To raise answitch or cheight is re


4-11

DOWN AND LIFTING

IMPORTANTSPORTING THE MACHINE, THE BOOM MUST BE FULLYTO THE BOOM REST.

ace the boom in the stowed position with the turntablecked.

move all loose items from the machine.

cure the chassis and the platform using straps orains of adequate strength and attached to the desig-ted tie down points. (See Figure 4-5., Machine Tie

own.)

re 4-6., Lifting Chart)

eigh the individual unit, refer to the Serial Numberate or call JLG Industries to find out the Gross Vehicleeight.

3121156 – JLG Lift –

Telescoping the Main Boom

To extend or retract Main Boom, position MAIN TELESCOPEcontrol switch to IN or OUT and hold until platform reachesdesired position.

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

2. Assure main boom is fully retracted and lowered overrear (Drive) axle; all access panels and doors closedand secured.

3. Remove all load and allow engine to operate 3-5 min-utes at LOW setting to permit reduction of engine inter-nal temperatures.

4. At Ground Controls, turn KEY SELECT switch to (center)OFF. Position, POWER/EMERGENCY STOP switch(down) to OFF. Remove key.

5. Cover Platform Control console to protect instructionplacards, warning decals and operating controls fromhostile environment.

4.9 TIE

Tie Down

WHEN TRANLOWERED IN

1. Pllo

2. Re

3. SechnaD

Lifting

(See Figu

1. WplW


4-1 3121156

4.1

e AUXILIARY POWER switch, selected control, lever or controller, and footswitch.

n POWER/EMERGENCY STOP switch to OFF.

auxiliary power from the ground control station:

n PLATFORM/GROUND SELECT KEY SWITCH toND.

n POWER/EMERGENCY STOP switch to ON.

te appropriate control switch or controller ford function and hold.

n AUXILIARY POWER switch to ON and hold.

e AUXILIARY POWER switch, and appropriatel switch or controller.

n POWER/EMERGENCY STOP switch to OFF.

2 – JLG Lift –

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

3. Remove all loose items from the machine.

4. Attach lifting device and equipment only to the desig-nated lifting points.

5. Properly adjust the rigging to prevent damage to themachine and so the machine remains level.

0 AUXILIARY POWERA toggle type auxiliary power control switch is located on theplatform control station and another is located on the groundcontrol station. Operation of either switch turns on the electri-cally driven auxiliary hydraulic pump. This should be used incase of failure of the main power plant. The auxiliary pumpwill operate boom lift, telescope and swing. To activate auxil-iary power:

1. Position PLATFORM/GROUND SELECT KEY SWITCH toPLATFORM.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Depress and hold footswitch.

4. Operate appropriate control switch, lever or controllerfor desired function and hold.

5. Position AUXILIARY POWER switch to ON and hold.

6. Releasswitch

7. Positio

To activate

1. PositioGROU

2. Positio

3. Operadesire

4. Positio

5. Releascontro

6. Positio


4-13
3121156 – JLG Lift –
Figure 4-5. Machine Tie Down

NOTE: When transporting machine over rough terrain or long distance the boom needs to be chocked and strapped whenever the base boom is unable to rest onits pad. This prevents the boom from "Bouncing"up and down preventing possible damage while transporting.


4-1 3121156
4 – JLG Lift –
Figure 4-6. Lifting Chart


4-15

ug tool it into quick-disconnect fittings mounted onatform rail. The male quick connect is the pressureed line.

t flow control knob to desired setting.

3121156 – JLG Lift –

4.11 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS (OPTIONAL)

Tool Circuit

To Operate: (with engine running and foot switch released).

1. Be sure hydraulic switch is in the “OFF” position.Located on the left side of platform below console box.

2. Make sure the hydraulic tool about to be operated is at a“safe” setting.

3. Plplfe

4. Se


4-1 3121156

NOT ydraulic powertool switch to the “ON” position. Oilw flow to the tool. It is possible to adjust the flowl knob during operation to achieve desired tool

ance.

finished, turn the hydraulic tool switch to the position.

nect tool from the quick-disconnects.

C TOOL SWITCH TO THE “OFF” POSITION IN ORDERS.

ol circuit will not work with the foot switched. If the foot switch is depressed during tool cir-ration the tool circuit will stop functioning until the

itch is released.

l is designed to operate at 2600 psi. If necessary be adjusted for a higher or lower pressure.

e foot switch released to operate the tool circuit alld boom functions are cut out.

6 – JLG Lift –

E: Each notch in the flow control knob corresponds toapproximately 1 GPM (ex. setting 2 = 2 GPM). At settingseven (7) the pump has reached its maximum flow ratetherefore any setting past 7 will produce no additionalflow.

5. Turn hwill nocontroperform

6. When “OFF”

7. Discon

TURN HYDRAULITO SWITCH TOOL

NOTE: The todepresscuit opefoot sw

NOTE: The toothis can

NOTE: With thdrive an


4-17
3121156 – JLG Lift –
4.12 PLACARDS AND DECALSRead and understand all placards and decals. Do not oper-ate any machine on which DANGER, WARNING, CAUTIONOR INSTRUCTION PLACARDS OR DECALS ARE MISSINGOR ILLEGIBLE. Replace placards and decals if damaged,missing or illegible.

Decals are made of Lexan Pressure Sensitive Adhesive witha protective film on the front. Remove the damaged decaland thoroughly clean surface before installing a new decal.Simply peel off, press on to surface.

NOTE: Placards and Decals can be ordered by using part num-bers located by each placard or decal. (See Figure 4-7.,Figure 4-9., and Figure 4-11.)


4-1 3121156

f 6

8 – JLG Lift –

Figure 4-7. Decal Installation - Sheet 1 o


4-19

t 2 of 6

3121156 – JLG Lift –

Figure 4-8. Decal Installation - Shee


4-2 3121156

f 6

0 – JLG Lift –

Figure 4-9. Decal Installation - Sheet 3 o


4-21

t 4 of 6

3121156 – JLG Lift –

Figure 4-10. Decal Installation - Shee


4-2 3121156

of 6

2 – JLG Lift –

Figure 4-11. Decal Installation - Sheet 5


4-23

et 6 of 6

3121156 – JLG Lift –

Figure 4-12. Decal Installation - She


4-2 3121156

- - - - - -

- - - - - -

- - - - - -

1702153 - - 1704006

1703953 - - 1703942

- - - - - -

1702868 - - 1704000

1703797 1703924 1703924

1705336 1705822 1705347

1703804 1701518 1703948

1703805 1705961 1703936

- - 1705828 1703984

3251813 - - 3251813

- - - - - -

1702631 1702631 1702631

1704434 1704434 1704434

- - - - - -

1704096 1705978 1704099

Table 4-1. 600SC Decal Legend

ANSI0273906-2

CE/Australian0273985-3

CanadianFrench

0273982-2

4 – JLG Lift –


Item # ANSI0273906-2


CanadianFrench

0273982-2

1 - - - - - -

2 - - 1701499 1701499

3 1701502 1701502 1701502

4 1701503 1701503 1701503

5 1701509 1701509 1701509

6 1701529 1701529 1701529

7 - - - - - -

8 - - - - - -

9 - - - - - -

10 1703811 1703811 1703811

11 1703814 1703814 1703814

12 1704277 1704277 1704277

13 1704412 1704412 1704412

14 - - 1705084 - -

15 - - - - 1705514

16 - - - - - -

17 3251243 3251243 3251243

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

Item #


4-25

54 - - - - - -

55 - - - - - -

56 - - - - - -

57 1704468 1704468 1704468

58 1704502 - - 1704502

59 1706943 - - 1706943

60 - - - - - -

61 - - - - - -

62 1700584 1700584 1700584


tem # ANSI0273906-2


CanadianFrench

0273982-2

3121156 – JLG Lift –

36 1704104 1705978 1704107

37 1704885 1704885 1704885

38 3252342 - - 3252342

39 1705177 1705177 1705177

40 - - - - - -

41 - - - - - -

42 - - - - - -

43 - - - - - -

44 - - - - - -

45 - - - - - -

46 - - - - - -

47 - - - - - -

48 - - - - - -

49 - - - - - -

50 - - - - - -

51 - - - - - -

52 - - - - - -

53 - - - - - -




CanadianFrench

0273982-2

I


4-2 3121156

- - - - - -

- - - - - -

- - - - - -

1702153 - - 1704006

1703953 - - 1703942

- - - - - -

1702868 - - 1704000

1703797 1705921 1703924

1705336 1705822 1705347

1703804 1701518 1703948

1703805 1705961 1703936

- - 1705828 1703984

3251813 - - 3251813

- - - - - -

1702631 1702631 1702631

1703165 1703165 1703165

- - - - - -

1701645 1705978 1703996

Table 4-2. 660SJC Decal Legend

ANSI0273908-2


CanadianFrench

0273984-2

6 – JLG Lift –




CanadianFrench

0273984-2

1 - - - - - -

2 1701499 1701499 1701499

3 1701502 1701502 1701502

4 1701503 1701503 1701503

5 1701509 1701509 1701509

6 1701529 1701529 1701529

7 - - - - - -

8 - - - - - -

9 - - - - - -

10 1703811 1703811 1703811

11 1703814 1703814 1703814

12 1704277 1704277 1704277

13 1704412 1704412 1704412

14 - - 1705084 1705084

15 - - - - 1705514

16 - - - - - -

17 3251243 3251243 3251243

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

Item #


4-27

54 - - - - - -

55 - - - - - -

56 - - - - - -

57 1704468 1704468 1704468

58 1704502 - - 1704502

59 1706943 - - 1706943

60 - - - - - -

61 - - - - - -

62 1700584 1700584 1700584


tem # ANSI0273908-2


CanadianFrench

0273984-2

3121156 – JLG Lift –

36 1702688 1705978 1704112

37 1704885 1704885 1704885

38 3252342 - - 3252342

39 1705177 1705177 1705177

40 - - - - - -

41 - - - - - -

42 - - - - - -

43 - - - - - -

44 - - - - - -

45 - - - - - -

46 - - - - - -

47 - - - - - -

48 - - - - - -

49 - - - - - -

50 - - - - - -

51 - - - - - -

52 - - - - - -

53 - - - - - -




CanadianFrench

0273984-2

I


4-2 3121156

nally.

8 – JLG Lift –

This page left blank intentio

SECTION 5 - EMERGENCY PROCEDURES

5-1

ROCEDURES

IMPORTANT ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINELL FUNCTIONS FIRST FROM THE GROUND CONTROLS,

THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10OU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED,D, AND THAT ALL CONTROLS ARE OPERATING COR-

3121156 – JLG Lift –

SECTION 5. EMERGENCY P

5.1 GENERALThis section explains the steps to be taken in case of anemergency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any inci-dent involving a JLG product. Even if no injury or propertydamage is evident, the factory should be contacted by tele-phone and provided with all necessary details.

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

Outside USA:717-485-5161

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving aJLG Industries product within 48 hours of such an occur-rence may void any warranty consideration on that particularmachine.

FOLLOWINGAND TEST ATHEN FROMFT.) UNTIL YIF REQUIRERECTLY.

SECTION 5 - EMERGENCY PROCEDURES

5-2 3121156

5.3

Op

Boom Caught Overheadorm or boom becomes jammed or snagged instructures or equipment, rescue platform occu- to freeing the machine.

– JLG Lift –

EMERGENCY OPERATION

erator Unable to Control MachineIF THE PLATFORM OPERATOR IS PINNED, TRAPPED ORUNABLE TO OPERATE OR CONTROL MACHINE:

1. Other personnel should operate the machine from ground controls only as required.

2. Other qualified personnel on the platform may use the platform controls. DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY.

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

Platform or If the platfoverhead pants prior

FICATIONS & OPERATOR MAINTENANCE

6-1

OPERATOR MAINTENANCE

ERATING SPECIFICATIONSTable 6-1. Operating Specifications

ork Load (Capacity)icted:ted - 600SCted - 660SJC

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

500 lb. (230 kg)

ravel Grade (Gradeability)* 55%

ravel Grade (Side Slope)* 5°

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

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

56 ft. 9 in. (17.3 m)

dius 0

round Bearing Pressure5.45 psi (0.383 kg/cm2)

6.5 psi (0.457 kg/cm2)

Drive Speed: 1.6 mph (2.6 kph)

ulic System Pressure 4500 psi (310 Bar)

SECTION 6 - GENERAL SPECI

3121156 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS &

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machine.

The maintenance portion of this section is intended as infor-mation to assist the machine operator to perform daily main-tenance tasks only, and does not replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual ............................ 3121157

Illustrated Parts Manual ............................................ 3121158

6.2 OP

Maximum W Unrestr Restric Restric

Maximum T

Maximum T

Max.Vertic 600SC 660SJC

Max.Horizo 600SC 660SJC

Turning Ra

Maximum G 600SC

660SJC

Maximum

Max. Hydra

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121156

Ca

M

M

E

G

*

F

H

H

E

Deutz F4M1011F/F4M2011 Specifications

Diesel

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

16 Quarts (15 L)

1000

1800

2800

60 Amp, belt drive

1000 Cold Cranking Amps, 210Minutes Reserve Capacity, 12 VDC

on1.90 GPH (7.19 lph)2.50 GPH (9.46 lph)

65 @ 3000 RPM, full load

– JLG Lift –

pacities

Engine Data aximum Wind Speed 28 mph (12.5 m/s)

aximum Manual Force 101 lb. (450 N)

lectrical 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 6-2. Capacities

uel Tank 39 US. Gallons (147.6 L)

ydraulic Oil Tank 31 U.S. Gallons (117.3 L)

ydraulic System (Including Tank) 37.2 U.S. Gallons (140.8 L)

ngine Crankcase Deutz w/Filter Caterpillar (w/filter)

11 quarts (10.5 L)10.6 quarts (10 L)

Table 6-1. Operating Specifications

Table 6-3.

Fuel

Oil Capacity Cooling Syste Crankcase Total Capacity

Idle RPM

Low RPM

High RPM

Alternator

Battery

Fuel Consumpti Low RPM High RPM

Horsepower


6-3

c Oil

draulic oils must have anti-wear qualities at least to APIrvice Classification GL-3, and sufficient chemical stabil-for mobile hydraulic system service. JLG Industriesommends Mobilfluid 424 hydraulic oil, which has anE viscosity index of 152.

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

from JLG recommendations, it is not advisable to mix different brands or types, as they may not contain therequired additives or be of comparable viscosities. If hydraulic oil other than Mobilfluid 424 is desired, con-G Industries for proper recommendations.

Table 6-5. Hydraulic Oil

ULIC SYSTEM OPERATING MPERATURE RANGE

SAE VISCOSITY GRADE

+180° F (-18° C to +83° C) 10W

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

+210° F (+10° C to +210° C) 20W-20


3121156 – JLG Lift –

Hydrauli

NOTE: HySeity recSA

NOTE: WhJLG

Aside oils ofsame use oftact JL

Table 6-4. Caterpillar 3044C

Type Four Stroke Cycle

Cylinders 4 in-line

Bore 3.70 inch (94 mm)

Stroke 4.72 inch (120 mm)

Aspiration turbocharged

Compression ratio 19:1

Displacement 203 in3 (3.33 L)

Firing Order 1-3-4-2

Rotation (viewed from flywheel) Counterclockwise

Oil Capacity (w/filter) 10.6 quarts (10 L)

Cooling System (Engine Only) 5.8 quarts (5.5 L)

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 60 Amp, belt drive

Battery 930 Cold Cranking Amps, 205Minutes Reserve Capacity, 12 VDC

HYDRATE

+0° to

+0° F to

+50° F to


6-4 3121156

Table 6-7. Mobil DTE 13M Specs

osity Grade #32

fic Gravity 0.877

oint, Max -40°F (-40°C)

oint, Min. 330°F (166°C)

Viscosity

40° C 33cSt

100° C 6.6 cSt

100° F 169 SUS

210° F 48 SUS

t -20° F 6,200

sity Index 140

– JLG Lift –

Table 6-6. 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

ISO Visc

Speci

Pour P

Flash P

at

at

at

at

cp a

Visco


6-5

mponent Weights

Table 6-9. Major Component Weights

660SJ 600S

LB. KG. LB. KG.

ontrol Console 250 113 250 113

evel Cylinder 60 27 46 21

(Includes Lift Cyl., Rotator, rt)

3783 1716 3527 1600

Complete (including engine) 9065 4112 7315 3318


3121156 – JLG Lift –

Major CoTable 6-8. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

NOTE: Mobil/Exxon recommends that this oil be checkedon a yearly basis for viscosity.

Platform C

Platform L

Main Boomand Suppo

Turntable


6-6 3121156

Ser erial number is stamped on the left side of the

ns

SERIAL NUMBER(STAMPED ON FRAME)

– JLG Lift –

ial Number LocationsA serial number plate is affixed to the left rear side of theframe. If the serial number plate is damaged or missing, the

machine sframe.

Figure 6-1. Serial Number Locatio

SERIAL NUMBERPLATE


6-7

ns - Deutz - Sheet 1 of 2


3121156 – JLG Lift –

Figure 6-2. Engine Operating Temperature Specificatio


6-8 3121156

- Deutz - Sheet 2 of 24150548-C

– JLG Lift –

Figure 6-3. Engine Operating Temperature Specifications


6-9

s - Caterpillar - Sheet 1 of 2


3121156 – JLG Lift –

Figure 6-4. Engine Operating Temperature Specification


6-1 3121156

Caterpillar - Sheet 2 of 24150548-C

0 – JLG Lift –

Figure 6-5. Engine Operating Temperature Specifications -


6-11

ication Diagram


3121156 – JLG Lift –

Figure 6-6. Operator Maintenance and Lubr


6-1 3121156

6.3

NOT

LUBUNDOPECONACC

Bearing

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

K

M

E

2 – JLG Lift –

OPERATOR MAINTENANCE

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

IMPORTANTRICATION INTERVALS ARE BASED ON MACHINE OPERATIONER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFTRATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS ORDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASEDORDINGLY.

1. Swing

Lube PoCapacityLube - MInterval -Comme

Table 6-10. Lubrication Specifications

EY SPECIFICATIONS

PG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

PGL Extreme Pressure Gear Lube (oil) meeting API service classifica-tion GL-5 or MIL-Spec MIL-L-2105

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

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

ydraulic Return Filter

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


3121156 – 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 opera-tion; 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 opera-tion; change every 2 years or 1200 hours of operation

4. H

Inte300


6-1 3121156

ulic Tank

int(s) - Fill Cap - 30.6 gal. Tank; 32.7 gal. SystemO Check Level daily; Change every 2 years or 1200 operation.

NORMAL OPERATINGRANGE WITH BOOMIN STOWED POSITION

4 – JLG Lift –

5. Hydraulic Charge Filter

Interval - Change after first 50 hrs. and every 6 months or300 hrs. thereafter or as indicated by Condition Indicator.

6. Hydra

Lube PoCapacityLube - HInterval -hours of


6-15

il Change w/Filter - Deutz

e Point(s) - Fill Cap/Spin-on Elementacity - 11 Quarts Crankcase; 5 Quarts Coolere - EOrval - Every Year or 1200 hours of operationments - Check level daily/Change in accordance with

ine manual.


3121156 – JLG Lift –

7. Suction Strainers (in tank)

Lube Point(s) - 2Interval - Every 2 years or 1200 hours of operation, removeand clean at time of hydraulic oil change.

8. O

LubCapLubInteComeng

REMOVE FILL CAP PLATE FROM TANK TO GAIN ACCESS TO STRAINERS


6-1 3121156

ilter - Caterpillar

int(s) - Replaceable Element Every Year or 600 hours of operation

er

int(s) - Replaceable Element- Every 6 months or 300 hours of operation or as by the condition indicator

6 – JLG Lift –

9. Oil Change w/Filter - Caterpillar

Lube Point(s) - Fill Cap/Spin-on ElementCapacity - 10.6 QuartsLube - EOInterval - 3 Months or 150 hours of operationComments - Check level daily/Change in accordance withengine manual.

10. Fuel Filter - Deutz

Lube Point(s) - Replaceable ElementInterval - Every Year or 600 hours of operation

11. Fuel F

Lube PoInterval -

12. Air Filt

Lube PoInterval indicated

TION 7 - INSPECTION AND REPAIR LOG

7-1

D REPAIR LOG

ir Log

nts

SEC

3121156 – JLG Lift –

SECTION 7. INSPECTION ANMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121156

og

– JLG Lift –

Table 7-1. Inspection and Repair L

Date Comments

JLG Worldwide LocationsJLG Industries (UK)

Unit 12, Southside

Bredbury Park Industrial Estate

Bredbury

Stockport

SK6 2sP

England

Phone: (44) 870 200 7700

Fax: (44) 870 200 7711

JLG Industries (Europe)

Kilmartin Place,

Tannochside Park

Uddingston G71 5PH

Scotland

Phone: (44) 1 698 811005

Fax: (44) 1 698 811055

JLG Industries (Australia)

P.O. Box 5119

11 Bolwarra Road

Port Macquarie

N.S.W. 2444

Australia

Phone: (61) 2 65 811111

Fax: (61) 2 65 810122

JLG Industries (Pty) Ltd.

Unit 1, 24 Industrial Complex

Herman Street

Meadowdale

Germiston

South Africa

Phone: (27) 11 453 1334

Fax: (27) 11 453 1342

JLG Europe B.V.

Jupiterstraat 234

2132 HJ Foofddorp

The Netherlands

Phone: (31) 23 565 5665

Fax: (31) 23 557 2493

JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson,

80-Suite 71

13092-310 Campinas-SP

Brazil

Phone: (55) 19 3295 0407

Fax: (55) 19 3295 1025

JLG Polska

UI. Krolewska

00-060 Warsawa

Poland

Phone: (48) 91 4320 245

Fax: (48) 91 4358 200

JLG Industries (Sweden)

Enkopingsvagen 150

Box 704

SE - 175 27 Jarfalla

Sweden

Phone: (46) 8 506 59500

Fax: (46) 8 506 59534

JLG Deutschland GmbH

Max Planck Strasse 21

D-27721 Ritterhude/lhlpohl

Bei Bremen

Germany

Phone: (49) 421 693 500

Fax: (49) 421 693 5035

JLG Industries (Italia)

Via Po. 22

20010 Pregnana Milanese - MI

Italy

Phone: (39) 02 9359 5210

Fax: (39) 02 9359 5845

Plataformas Elevadoras

JLG Iberica, S.L.

Trapadella, 2

P.I. Castellbisbal Sur

08755Castellbisbal

Spain

Phone: (34) 93 77 24700

Fax: (34) 93 77 11762

www.jlg.com

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Fax: (717) 485-6417

Documents

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