JLG 600SC-660SJC Operator Manual
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
600SC
660SJC
S/N 0300174703 to Present
ANSI
3121606
November 27, 2013
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
3121606 – JLG Lift – a
FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
THIS DECAL WILL HAVE A YELLOW BACKGROUND.
INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
b – JLG Lift – 3121606
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.
For:
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding
Product Safety
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
or Your Local JLG Office
(See addresses on inside of manual cover)
In USA:
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com
FOREWORD
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Product Modifications
3121606 – JLG Lift – c
FOREWORD
Original Issue - November 27, 2013
REVISION LOG
d – JLG Lift – 3121606
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . . . 1-7
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . . 1-8
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Daily Functional Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Ground Control Indictor Panel . . . . . . . . . . . . . . . . . . . . . 3-7
Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-14
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Traveling Forward or Reverse . . . . . . . . . . . . . . . . . . . . . . 4-8
4.5 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Raising and Lowering the Main Boom . . . . . . . . . . . . 4-12
3121606 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12
4.8 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.9 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10 AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Activating from the Platform Control Station . . . . . . 4-13
Activating from the Ground Control Station . . . . . . . 4-15
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-2
Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-16
SECTION - 7 - INSPECTION AND REPAIR LOG
ii – JLG Lift – 3121606
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF FIGURES
2-1. Drive Function Operating Range Diagrams -
Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2-2. Drive Function Operating Range Diagrams -
Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2-3. Drive Function Operating Range Diagrams -
Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2-4. Daily Walk-Around Inspection Diagram . . . . . . . . . . . . . . 2-11
2-5. Daily Walkaround Inspection Points - Sheet 1 of 2 . . . . 2-12
2-6. Daily Walkaround Inspection Points - Sheet 2 of 2 . . . . 2-13
3-1. Ground Control Station - 600SC . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Ground Control Station - 660SJC . . . . . . . . . . . . . . . . . . . . . 3-4
3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-8
3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
3-4. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-15
4-1. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-2
4-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-3
4-3. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4. Machine Motion Hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-5. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4-6. Decal Installation - Sheet 1 of 6 . . . . . . . . . . . . . . . . . . . . . .4-16
4-7. Decal Installation - Sheet 2 of 6 . . . . . . . . . . . . . . . . . . . . . .4-17
4-8. Decal Installation - Sheet 3 of 6 . . . . . . . . . . . . . . . . . . . . . .4-18
4-9. Decal Installation - Sheet 4 of 6 . . . . . . . . . . . . . . . . . . . . . .4-19
4-10. Decal Installation - Sheet 5 of 6 . . . . . . . . . . . . . . . . . . . . . .4-20
4-11. Decal Installation - Sheet 6 of 6 . . . . . . . . . . . . . . . . . . . . . . 4-21
6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-2. Engine Operating Temperature Specifications - Deutz -
Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-3. Engine Operating Temperature Specifications - Deutz -
Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6-4. Operator Maintenance and Lubrication Diagram. . . . . 6-11
3121606 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-5
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . . . . . . . . 1-10
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 600SC Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-2 660SJC Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Deutz D2011L04 Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Hydraulic Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 Mobil DTE 10 Excel 32 Specs . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-8 Mobil EAL 224H Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-10 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-11 Major Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-12 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
iv – JLG Lift – 3121606
SECTION 1. SAFETY PRECAUTIONS
SECTION 1 - SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper and
safe machine operation and maintenance. For proper machine
use, it is mandatory that a daily routine is established based on
the content of this manual. A maintenance program, using the
information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and
followed to ensure the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine shall not
operate the machine until this manual has been read, training is
accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified
operator.
If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG
Industries, Inc. (“JLG”).
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
DEATH.
1.2 PRE-OPERATION
Operator Training and Knowledge
• Read and understand this manual before operating the
machine.
• Do not operate this machine until complete training is performed by authorized persons.
• Only authorized and qualified personnel can operate the
machine.
3121606 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, and operating instructions on the machine and in this
manual.
• Use the machine in a manner which is within the scope of its
intended application set by JLG.
• All operating personnel must be familiar with the emergency
controls and emergency operation of the machine as specified
in this manual.
• Read, understand, and obey all applicable employer, local, and
governmental regulations as they pertain to operation of the
machine.
Workplace Inspection
• The operator is to take safety measures to avoid all hazards in
the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers,
railway cars, floating vessels, scaffolds or other equipment
unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the machine.
Machine Inspection
• Before machine operation, perform inspections and functional
checks. Refer to Section 2 of this manual for detailed instructions.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the Service
and Maintenance Manual.
• Be sure the footswitch and all other safety devices are operating properly. Modification of these devices is a safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE
ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep mud,
oil, grease, and other slippery substances from footwear and
platform floor.
1-2 – JLG Lift – 3121606
SECTION 1 - SAFETY PRECAUTIONS
1.3 OPERATION
General
• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.
• Never operate a machine that is not working properly. If a malfunctions occurs, shut down the machine.
• Never slam a control switch or lever through neutral to an
opposite direction. Always return switch to neutral and stop
before moving the switch to the next function. Operate controls with slow and even pressure.
• Hydraulic cylinders should never be left fully extended or fully
retracted before shutdown or for long periods of time.
• Do not allow personnel to tamper with or operate the
machine from the ground with personnel in the platform,
except in an emergency.
• Do not carry materials directly on platform railing. Contact JLG
for approved material handling accessories.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and never
left hanging by their cord from the platform work area.
• Supplies or tools which extend outside the platform are prohibited unless approved by JLG.
• When driving, always position boom over rear axle in line with
the direction of travel. Remember, if boom is over the front
axle, steer and drive functions will be reversed.
• Do not assist a stuck or disabled machine by pushing, pulling,
or by using boom functions. Only pull the unit from the tiedown lugs on the chassis.
• Do not place boom or platform against any structure to steady
the platform or to support the structure.
• Stow boom and shut off all power before leaving machine.
Trip and Fall Hazards
During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard anchorage point.
3121606 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all gates are closed
and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar items
on platform to provide additional reach.
• Never use the boom assembly to enter or leave the platform.
• Use extreme caution when entering or leaving platform. Be
sure that the boom is fully lowered. It may be necessary to
telescope out to position the platform closer to the ground for
entry/exit. Face the machine, maintain “three point contact”
with the machine, using two hands and one foot or two feet
and one hand during entry and exit.
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.
1-4 – JLG Lift – 3121606
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Approach Distances (M.A.D.)
• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum
Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part of
the machine and its occupants, their tools, and their equipment
from any electrical line or apparatus carrying up to 50,000 volts.
One foot additional clearance is required for every additional
30,000 volts or less.
MINIMUM APPROACH DISTANCE
in Feet (Meters)
3121606 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
• The minimum approach distance may be reduced if insulating
barriers are installed to prevent contact, and the barriers are rated
for the voltage of the line being guarded. These barriers shall not
be part of (or attached to) the machine. The minimum approach
distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall
be made by a qualified person in accordance with the employer,
local, or governmental requirements for work practices near
energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).
ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• The user should be familiar with the surface before driving. Do
not exceed the allowable sideslope and grade while driving.
1-6 – JLG Lift – 3121606
SECTION 1 - SAFETY PRECAUTIONS
• Do not elevate platform or drive with platform elevated while
on a sloping, uneven, or soft surface.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor.
• Do not raise the platform or drive from an elevated position
unless the machine is on firm, level and smooth surfaces.
• Keep the chassis of the machine at least 2 ft. (0.6m) from holes,
bumps, drop-offs, obstructions, debris, concealed holes, and
other potential hazards on the floor/surface.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tie-off
machine to any adjacent structure.
• Do not elevate the machine when wind conditions exceed 28
mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).
• Do not increase the surface area of the platform or the load.
Increase of the area exposed to the wind will decrease stability.
• Do not increase the platform size with unauthorized deck
extensions or attachments.
• If boom assembly or platform is in a position that one or more
wheels are off the ground, all persons must be removed before
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine.
Crushing and Collision Hazards
• Approved head gear must be worn by all operating and
ground personnel.
• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.
• During operation, keep all body parts inside platform railing.
3121606 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
• Use the boom functions, not the drive function, to position the
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Limit travel speed according to conditions of ground surface,
congestion, visibility, slope, location of personnel, and other
factors which may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel
grades in low speed only.
• Do not use high speed drive in restricted or close quarters or
when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if necessary.
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 of
emergency, malfunction, power failure, or loading/unloading.
Refer to the Emergency Procedures section of this manual for
emergency towing procedures.
• Ensure boom is in the stowed position and the turntable
locked prior to towing, lifting or hauling. The platform must be
completely empty of tools.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity.
• Refer to the Machine Operation section of this manual for lifting information.
1-8 – JLG Lift – 3121606
SECTION 1 - SAFETY PRECAUTIONS
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 from direct
exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin and
clothing at all times.
• Charge batteries only in a well ventilated area.
3121606 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/
S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches be gin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires. Umbrella use
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
Wind Speed
mph m/s
Description Land Conditions
becomes difficult.
1-10 – JLG Lift – 3121606
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.
Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not
operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and at the
ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunction.
6. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
depressions, holes, or drop-offs exist.
7. Means to avoid the hazards of unprotected electrical conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has
developed the ability to safely control and operate the machine.
Operator Responsibility
The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job
site.
3121606 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table covers the periodic machine inspections and
maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as
necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the
machine is used in a severe manner.
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A
PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL
FOR THE SPECIFIC JLG PRODUCT MODEL.
2-2 – JLG Lift – 3121606
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Table 2-1.Inspection and Maintenance Table
Type Freq uenc y
Pre-Start Inspection Before using each day; or
whenever there’s an Operator change.
Pre-Delivery Inspection (See
Note)
Frequent Inspection
(See Note)
Annual Machine Inspection
(See Note)
Preventative Maintenance At intervals as specified in the Ser vice and Maintenance
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualif ied JLG Mechanic Service and Maintenance Ma nual
In service for 3 months or 150 hours, whichever comes first;
o r
Out of service for a period of more than 3 months;
o r
Purchase d used.
Annually, no later than 13 months from the date of prior
inspection.
Manual.
Primary
Responsibility
User or Operator User or Operator Operator and Safety Manual
Owner, Dealer, or User Q ualified JLG Mechanic Serv ice and Maintenance Manual
Owner, Dealer, or User Factory-Trained
Owner, Dealer, or User Q ualified JLG Mechanic Serv ice and Maintenance Manual
Service
Qualification
Service Technician
(Recommended)
Reference
and applicable JLG inspection form
and applicable JLG inspection form
Service and Maintenance Manual
and applicable JLG inspection form
3121606 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Parent Metal Crack Weld Crack
Pre-Start Inspection
The Pre-Start Inspection shall include each of the following:
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or battery fluid) or foreign objects. Report any leakage to the
proper maintenance personnel.
2. Structure - Inspect the machine structure for dents, damage, weld or parent metal cracks or other discrepancies.
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. Operation and Safety Manuals – Make sure a copy of the
Operator and Safety Manual, AEM Safety Manual (Domestic
only), and ANSI Manual of Responsibilities (Domestic only) is
enclosed in the weather resistant storage container.
5. “Walk-Around” Inspection – Refer to Figure 2-4., Figure 2-
5. and Figure 2-6.
6. Battery – Charge as required.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Engine Oil Supply - Ensure the engine oil level is at the Full
mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.
10. Accessories/Attachments - Reference the Operator and
Safety Manual of each attachment or accessory installed
upon the machine for specific inspection, operation, and
maintenance instructions.
11. Function Check – Once the “Walk-Around” Inspection is
complete, perform a functional check of all systems in an
area free of overhead and ground level obstructions. Refer to
Section 4 for more specific operating instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
2-4 – JLG Lift – 3121606
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Daily Functional Check
A functional check of all systems should be performed, once the
walk-around inspection is complete, in an area free of overhead
and ground level obstructions. First, using the ground controls,
check all functions controlled by the ground controls. Next, using
the platform controls, check all functions controlled by the platform controls.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENTS DO NOT RETURN TO THE
OFF OR NEUTRAL POSITION WHEN RELEASED.
TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL
SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE.
NOTE: Perform checks from ground controls first, then from platform
controls.
1. Operate machine from ground control.
NOTE: For adjustments see Service Manual, Limit Switch Adjustments.
2. Check elevation limit switch as follows:
While driving in high drive, elevate the boom to approximately 10 degrees. Drive should cut back to low speed. The
switch should reset when the boom is fully lowered.
3. Check capacity limit switch as follows:
a. Boom Length Switch.
Raise boom to horizontal. Telescope boom out until 500
lb. light comes on. Make sure the switch resets and the
1000 lb. light comes back on when telescoping in.
b. 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. light
comes on. Boom angle must be approximately 45 to 50
degrees
Lift boom up until 1000 lb. light comes on. The switch
should reset when the boom angle is about 55 degrees
to 64 degrees.
NOTE: If limit switch settings need to be changed, you will need to
recheck that the 500 lb. light comes on at 45 degrees to 50
degrees when lifting down.
3121606 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
ANSI, ANSI Export, CSA, Japan 5°
CE, Australia 3°
4. Drive Disable Switch (Refer to Figure 2-2., Drive Function
Operating 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 on
again.
5. Raise main boom, extend and retract telescope. Check for
delayed movement of fly section, indicating loose cables.
NOTE: Turntable lock is on turntable facing platform. To disengage
lock, pull snap pin from lock pin, lift lock pin up to unlock turntable. Return snap pin to lock pin to hold lock pin in the disengaged 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 platform control console by driving, with the machine in level
position, up a suitable ramp of at least 5° slope. Check the
out of level indicator, with the machine on the ramp. If the
light does not illuminate, return the machine to a level sur-
face, shut down the machine, and contact a qualified technician before resuming operation.
8. Check that platform automatic self-leveling system functions properly during raising and lowering of the boom.
9. Check platform level adjustment system for proper operation.
10. Check platform rotator for smooth operation and assure
platform will rotate 90 degrees in both directions from centerline of boom.
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.
FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL
IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/
4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.
2-6 – JLG Lift – 3121606
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
a. Activate hydraulic system. By depressing footswitch.
Operate Main Telescope and hold control. Remove foot
from footswitch, motion should stop. If it does not, shut
down machine and contact a certified JLG service technician.
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 certified JLG service technician.
c. With engine power shut down, depress the footswitch.
Attempt to start engine. Engine should not attempt to
start when footswitch is depressed. If starter engages or
engine turns over, shut down machine and contact a
certified JLG service technician.
15. Auxiliary Power.
Operate each function control switch (e.g. Tele, Lift and
Swing) to assure that they function in both directions using
auxiliary power instead of engine power.
16. Ground Controls.
Place Ground/Platform Select switch to Ground. Start
engine. Platform controls should not operate.
3121606 – JLG Lift – 2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Figure 2-1. Drive Function Operating Range Diagrams - Sheet 1 of 3
NOTE: In the Transport Mode, High Drive will be
disabled above 10° elevation or past 3
feet (1 m) of boom extension.
2-8 – JLG Lift – 3121606
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
CHASSIS
TILTED> 1.8°
NO DRIVE IF
CHASSIS
TILTED> 1.8°
DRIVE CUTOUT
PER
PERSONALITY
SETTING
55 DEGREES
Figure 2-2. Drive Function Operating Range Diagrams - Sheet 2 of 3
NOTE: In the Transport Mode, High Drive will be
disabled above 10° elevation or past 3 feet
(1 m) of boom extension.
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
3121606 – JLG Lift – 2-9
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
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
CHASSIS
TILTED
CREEP CUTOUTS
PER PERSONALITY
SETTING
CREEP IF
TILTED > 1.8°
CUTOUTS PER
PERSONALITY SETTING
Figure 2-3. Drive Function Operating Range Diagrams - Sheet 3 of 3
NOTE: In the Transport Mode, High Drive will be
disabled above 10° elevation or past 3 feet
(1 m) of boom extension.
2-10 – JLG Lift – 3121606
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