JLG 600SC-660SJC Operator Manual

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Page 1

Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models 600SC 660SJC

S/N 74785 to Present

ANSI

3121156

May 4, 2012

Page 2

Page 3

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.

3121156 – JLG Lift – a

Page 4

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 DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

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.

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THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

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.

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:

3121156 – JLG Lift – c

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

Page 6

FOREWORD

REVISION LOG

Original Issue - October 28, 2003

Revised - May 4, 2005

Revised - July 18, 2006

Revised - September 13, 2006

Revised - July 30, 2009

Revised - August 19, 2009

Revised - December 1, 2009

Revised - April 3, 2012

Revised - May 4, 2012

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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 . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Indictor Panel . . . . . . . . . . . . . . 3-6

Platform Control Station . . . . . . . . . . . . . . . . . . . 3-9

Platform Control Indicator Panel . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3

4.3 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-3

Traveling Forward or Reverse . . . . . . . . . . . . . . . 4-6

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.5 PARKING AND STOWING . . . . . . . . . . . . . . . . . . 4-10

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Platform Level Adjustment . . . . . . . . . . . . . . . . 4-10

Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . 4-10

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-11

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

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

Telescoping the Main Boom . . . . . . . . . . . . . . 4-12

4.8 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-12

4.9 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . 4-12

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12

4.10 AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.11 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS

(OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

Tool Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 PLACARDS AND DECALS. . . . . . . . . . . . . . . . . . . 4-18

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Major Component Weights. . . . . . . . . . . . . . . . . 6-7

Serial Number Locations . . . . . . . . . . . . . . . . . . 6-8

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-14

6.4 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-19

SECTION - 7 - INSPECTION AND REPAIR LOG

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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 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-12

2-6. Daily Walkaround Inspection Points -

Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13

2-7. Daily Walkaround Inspection Points -

Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-14

3-1. Ground Control Station - 600SC . . . . . . . . . . . . . . .3-2

3-2. Ground Control Station - 660SJC . . . . . . . . . . . . . .3-3

3-3. Ground Control Indicator Panel - Sheet 1 of 2 . . . .3-7

3-4. Ground Control Indicator Panel - Sheet 2 of 2 . . . .3-8

3-5. Platform Control Console. . . . . . . . . . . . . . . . . . . .3-11

3-6. Platform Control Console w/Drive Orientation. . . .3-12

3-7. Platform Control Indicator Panel . . . . . . . . . . . . . .3-17

3-8. Platform Control Indicator Panel w/Drive

Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17

4-1. Grades and Sideslopes . . . . . . . . . . . . . . . . . . . . . .4-4

4-2. Machine Motion Hazard . . . . . . . . . . . . . . . . . . . . . .4-5

4-3. Position of Least Backward Stability . . . . . . . . . . . 4-8

4-4. Position of Least Forward Stability . . . . . . . . . . . . . 4-9

4-5. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-6. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-7. Decal Installation - Sheet 1 of 10 . . . . . . . . . . . . . 4-19

4-8. Decal Installation - Sheet 2 of 10 . . . . . . . . . . . . . 4-20

4-9. Decal Installation - Sheet 3 of 10 . . . . . . . . . . . . . 4-21

4-10. Decal Installation - Sheet 4 of 10 . . . . . . . . . . . . . 4-22

4-11. Decal Installation - Sheet 5 of 10 . . . . . . . . . . . . . 4-23

4-12. Decal Installation - Sheet 6 of 10 . . . . . . . . . . . . . 4-24

4-13. Decal Installation - Sheet 7 of 10 . . . . . . . . . . . . . 4-25

4-14. Decal Installation - Sheet 8 of 10 . . . . . . . . . . . . . 4-26

4-15. Decal Installation - Sheet 9 of 10 . . . . . . . . . . . . . 4-27

4-16. Decal Installation - Sheet 10 of 10 . . . . . . . . . . . . 4-28

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. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-11

6-5. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-12

6-6. Operator Maintenance and Lubrication Diagram. 6-13

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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 - Prior to S/N 0300148842 . 4-29 4-2 600SC Decal Legend - S/N 0300148842 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-3 660SJC Decal Legend - Prior to

S/N 0300148842 . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

4-4 660SJC Decal Legend - S/N 0300148842 to

Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37

6-1 Operating Specifications - Prior to

S/N 0300148842 . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Operating Specifications - S/N 0300148842

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Deutz F4M1011F/F4M2011 Specifications . . . . . . . 6-3

6-5 Caterpillar 3044C/3.4 . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-6 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-7 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . .6-5

6-8 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . 6-6

6-10 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . .6-6

6-11 Major Component Weights . . . . . . . . . . . . . . . . . . . 6-7

6-12 Lubrication Specifications . . . . . . . . . . . . . . . . . . . 6-14

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

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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 should not operate the machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an 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.

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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 – 3121156

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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 tie-down lugs on the chassis.

• Do not place boom or platform against any structure to steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

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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 – 3121156

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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-

• 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)

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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.

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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 tieoff machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

• Do not increase the platform size with unauthorized deck 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.

3121156 – JLG Lift – 1-7

Page 18

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 – 3121156

Page 19

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.

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Page 20

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 r ustle

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

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

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t 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

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121156

Page 21

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 over-

head obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

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.

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Page 22

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 – 3121156

Page 23

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Type Frequency

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 Service and Main-

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 Qualified JLG

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 Purchased used.

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

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory-Trained

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Service Technician (Recommended)

Mechanic

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

Reference

3121156 – JLG Lift – 2-3

Page 24

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

The Pre-Start Inspection should 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. Operators 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., Fig-

ure 2-6. and Figure 2-7.

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.

2-4 – JLG Lift – 3121156

Page 25

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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.

NOTE: Perform checks from ground controls first, then from plat-

form controls.

1. Operate machine from ground control.

NOTE: For adjustments see Service Manual, Limit Switch Adjust-

ments.

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.

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.

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Page 26

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

ANSI, ANSI Expor t, CSA, Japan 5°

CE, Australia 3°

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.

4. Drive Disable Switch (Refer to Figure 2-2., Drive Func-

tion 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 disen-

gage 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 surface, shut down the machine, and contact a qualified technician before resuming operation.

8. Check that platform automatic self-leveling system func-

tions properly during raising and lowering of the boom.

9. Check platform level adjustment system for proper oper-

ation.

10. Check platform rotator for smooth operation and assure

platform will rotate 90 degrees in both directions from centerline of boom.

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Page 27

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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 APP ROXIM ATELY AT ITS CEN TER OF TRAVEL. IF SWITCH 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 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

control. 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 foot-

switch. 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.

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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 – 3121156

Page 29

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

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

3121156 – JLG Lift – 2-9

Page 30

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

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 – 3121156

Page 31

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-4. Daily Walk-Around Inspection Diagram

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Page 32

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist.

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

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists 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. Rotator - See Inspection Note.

4. Rotator Motion Control Valve - See Inspection Note.

5. Articulating Jib Boom - See Inspection Note.

6. Dual Capacity Limit Switch, Transport Position Limit Switch - Switches operate properly.

7. Power Track - See Inspection Note.

8. Turntable Bearing and Pinion - No evidence of loose bolts or looseness between bearing and structure. See Inspection Note.

9. Right Track - Properly secured plates, no loose or missing track bolts, no dislocation of the track pins. Proper tension. See Inspection Note.

10. Final Drive, Both Sides - See Inspection Note.

11. Turntable Lock - Operable; See Inspection Note.

12. Auxiliary Power Pump - See Inspection Note.

13. Bottom Rollers, Right Side - See Inspection Note.

14. Track Carrier Roller, Both Sides - See Inspection

Note.

Figure 2-5. Daily Walkaround Inspection Points - Sheet 1 of 3

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Page 33

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

16. Control Valve (Tank Compartment) - See Inspection

Note.

17. Hydraulic Oil Return Filter - Housing secure; See

Inspection Note.

18. 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.

19. Hydraulic Oil Breather - Element in place, not

clogged, no sign of overflow.

20. Door and Latches, Right Side - Hood door and

latches in working condition. See Inspection Note.

21. Ground Controls - Switches and levers return to neu-

tral, decals/placards secure and legible, control markings legible.

22. Right Tension Mechanism - See Inspection Note.

23. Fuel Supply - Fuel filler cap secure. Tank - See

Inspection Note.

24. Idler, Right Front - See Inspection Note.

25. Dual Capacity Limit Switch - Switch operates prop-

erly.

26. Left Track - Properly secured plates, no loose or miss-

ing track bolts, no dislocation of the track pins. Proper tension. See Inspection Note.

27. Idler, Left Front - See Inspection Note.

28. Left Tension Mechanism - See Inspection Note.

29. Bottom Rollers, Left Side - See Inspection Note.

30. Battery - Proper electrolyte levels; cables tight, no vis-

ible damage or corrosion.

31. Door and Latches, Left Side - Hood door and latches

in working condition, see Inspection Note.

32. Engine Air Filter - See Inspection Note.; element

clean.

33. Engine Oil Supply - Full mark on dipstick; filler cap

secure.

Figure 2-6. Daily Walkaround Inspection Points - Sheet 2 of 3

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Page 34

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

34. Muffler and Exhaust System - See Inspection Note.

35. Hydraulic Pump - See Inspection Note.

36. Engine Tray Pivot - See Inspection Note.

37. Hydraulic Oil Medium Pressure Filter Housing -

Housing secure; See Inspection Note.

38. Horizontal Cutoff Limit Switch - (High Engine/High

Drive Cut-off Switch) Switch operates properly.

39. Frame - See Inspection Note.

40. Hydraulic Swivel - See Inspection Note.

41. Main Boom Sections - See Inspection Note.

Figure 2-7. Daily Walkaround Inspection Points - Sheet 3 of 3

2-14 – JLG Lift – 3121156

Page 35

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that use

symbols to indicate control functions. Refer to decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

Ground Control Station

(See Figure 3-1., Ground Control Station - 600SC, and Figure 3-2., Ground Control Station - 660SJC)

NOTE: If equipped, the Function Enable switch must

be held down in order to operate Telescope, Swing, Lift, Jib Lift, Platform Level Override, and Platform Rotate functions.

1. Platform Rotate

A three position switch permits rotation of the platform.

3121156 – JLG Lift – 3-1

Page 36

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-1. Ground Control Station - 600SC

1. Platform Rotate 2 . P l a tf o rm L e ve l in g Ov e r ri d e

3. Not Used

4. Power/Emergency Stop 5 . E n g in e St a r t /A u xi l ia r y Po w er or E n gi n e S t ar t / A ux i li a r y P o we r /F u nc t io n En a b le

6. Lift

7. Hourmeter

8. Platform/Ground Select Switch

9. Swing

10. Telescope

11. Indicator Panel

3-2 – JLG Lift – 3121156

Page 37

1 . P l a tf o rm R ot a te 2 . P l a tf o rm L e ve l in g Ov e r ri d e

3. Ar ticulating Jib

4. Power/Emergency Stop

5. Engine Start/Auxiliar y Power or E n gi n e S t ar t / A ux i li a r y P o we r /F u nc t io n En a b le

6. Lift

7. Hourmeter

8. Platform/Ground Select Switch

9. Swing

10. Telescope

11. Indicator Panel

Figure 3-2. Ground Control Station - 660SJC

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121156 – JLG Lift – 3-3

Page 38

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

2. Platform Leveling Override

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

3. Articulating Jib

This switch provides raising and lowering of the jib.

NOTE: When Power/Emergency Stop switch is in the “ON” posi-

tion and engine is not running, an alarm will sound, indicating Ignition is “ON”.

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

4. Power/Emergency Stop Switch

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

3-4 – JLG Lift – 3121156

Page 39

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Lift Control

WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.

5. Engine Start/Auxiliary Power Switch

or Engine 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. Aux power can only be used if the engine is not running.

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

Provides raising and lowering of the main boom.

7. Hourmeter

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

NOTE: With PLATFORM/GROUND SELECT switch in the center

position, power is shut off to controls at both operating stations.

8. Platform/Ground Select Switch

A three position, key operated switch supplies power to the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground controls are operable.

9. Swing Control

Provides 360 degrees continuous turntable rotation.

10. Tel e s c o p e C o n t r o l .

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

3121156 – JLG Lift – 3-5

Page 40

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indictor Panel

(See Figure 3-3., Ground Control Indicator Panel - Sheet 1 of

1. Battery Charging Indicator

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

2. Low Engine Oil Pressure Indicator

Indicates that engine oil pressure is below normal and service is required.

3. High Coolant Temperature Indicator (If equipped)

Indicates that engine coolant temperature is abnormally high and service is required.

4. Engine Oil Temperature Indicator (Deutz)

Indicates the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. System Distress Indicator

The light indicates that the JLG Control System has detected a malfunction and a Diagnostic Trouble Code

has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

6. Low Fuel Indicator

Indicates the fuel tank is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

7. Glow Plug Indicator

Indicates the glow plugs are operating. After turning on ignition, 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 in Section 2).

3-6 – JLG Lift – 3121156

Page 41

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 4125

8910

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. High Engine Oil Temp.

5. System Distress

6. Low Fuel

7. Glow Plug

8. Platform Overload

9. Drive Disabled

10. Hydraulic Oil Filter

11. Transmission Pump Oil Filter

12. Engine Air Filter

Figure 3-3. Ground Control Indicator Panel - Sheet 1 of 2

Prior to S/N 0300128000

3121156 – JLG Lift – 3-7

Page 42

SECTION 3 - MACHINE CONTROLS AND INDICATORS

S/N 0300128000 to Present

1. Battery Charging

2. Engine Oil Pressure

3. Engine Water Temp.

4. Engine Oil Temp.

5. Malfunction Indicator

6. Low Fuel

7. Glow Plug

8. Platform Overload

Figure 3-4. Ground Control Indicator Panel - Sheet 2 of 2

3-8 – JLG Lift – 3121156

Page 43

SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Hydraulic Oil Filter Indicator

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

11. Transmission Pump Oil Filter Indicator

When illuminated indicates that charge pump filter is too restrictive and needs to be replaced. This indicator has an integral temperature sensor (70 degrees F.) so that false signals are not generated when the hydraulic oil is below normal operating temperature.

12. Engine Air Filter Indicator

When illuminated indicates that the air filter is too restrictive and needs to be replaced.

Platform Control Station

(See Figure 3-6., Platform Control Console w/Drive Orientation)

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

1. Power/Emergency Stop

A two-position red mushroom shaped switch furnishes power to PLATFORM Controls when pulled out (on). When pushed in (off), power is shut off to the platform functions.

Within about 2 seconds of pulling the switch out, the machine will perform a diagnostic check of the various electrical circuits, and if everything is OK, the platform alarm will beep once. During this time the lights on the indicator panel will also blink once as a bulb check.

3121156 – JLG Lift – 3-9

Page 44

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Start/Auxiliary Power

When pushed forward, the switch energizes the starter motor to start the engine.

When pushed back, it energizes the electrically operated hydraulic pump, when actuated. (Switch must be held ON for duration of auxiliary pump use.)

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

3. Lights (If Equipped)

This switch operates accessory light packages if the machine is so equipped.

4. Drive/Steer Enable

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

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

698

123

1. Power/Emergency Stop

2. Star t / Aux Power

3. Light

4. Drive/Steer Enable

5. Drive Steer

6. Telescope

7. Ar ticulating Jib

8. Platform Rotate

9. Function Speed Control

10. Main Lif t / Swing

11. Drive Speed / Torque Select

12. Platform Level Override

13. Horn

Figure 3-5. Platform Control Console

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

1705170 A

698

1702938

1. Power/Emergency Stop

2. Star t / Aux Power

3. Lights

4. Drive/Steer Enable

5. Drive Steer

6. Telescope

7. Ar ticulating Jib

8. Platform Rotate

9. Function Speed Control

10. Main Lif t / Swing

11. Drive Speed / Torque Select

12. Platform Level Override

13. Horn

14. Drive Orientation Override

15. Sof t Touch Override

16. Sof t Touch Indicator

Figure 3-6. Platform Control Console w/Drive Orientation

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Drive/Steer

Proportional dual axis joystick is provided to control drive and steer. Push forward to drive straight forward. The joystick is proportional, with the drive speed increasing as the joystick is moved further from its neutral position. Moving the joystick forward and to the side steers the machine in the direction of the side displacement of the joystick. With the joystick positioned all the way to the side and slightly forward, the machine will turn in place with one track stopped and the other one turning the machine around the center of the stopped track.

Moving the joystick to the side (no dislocation in the forward or aft direction) will turn the machine by counterrotation around the center of the machine by powering the tracks in opposite directions.

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

NOTE: Both drive and steer functions work in the opposite direc-

tion when the boom is positioned over front of the chassis (over idler wheels).

NOTE: When boom is positioned above horizontal and any of the

following switches, DRIVE SPEED/TORQUE SELECT or FUNCTION SPEED, are positioned to HIGH, high function speeds are automatically cut out and the machine continues to operate at a lower speed.

NOTE: The drive/steer control joystick on machines equipped

with JLG Control System software version p6.1 or higher can only command counter-rotate by being moved in the joystick's left - to - right axis, after first achieving the joystick neutral position. For machines equipped with version p5.12 and lower, the drive/steer joystick can be positioned into the counter-rotate command position without first achieving joystick neutral.

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

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Main Telescope

This control allows extension and retraction of the main boom.

7. Articulating Jib

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

8. Platform Rotate

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

9. 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.

10. Main Lift/Swing Controller

An infinitely proportional dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lift down. Move right to swing right, move left to swing left.

NOTE: Main lift and swing functions may be selected in combina-

tion. The handle features a round gate so that maximum speed is reduced when multiple functions are selected.

11. Drive Speed/Torque Select

The machine has a three position switch.

The forward position gives maximum drive speed by shifting the drive motors to minimum the displacement and giving high engine when drive controller is moved.

The back position gives maximum torque for rough terrain, climbing grades, and sharp turns. In this position, the motors are shifted to maximum displacement and the engine in high speed when the drive controller is moved.

The center position allows the machine to be driven as quietly as possible by leaving the engine at mid speed and the drive motors in maximum displacement.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

14. Drive Orientation Override

12. Platform Leveling Override

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

13. Travel Warning Horn

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

When the boom is swung over the rear in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction.

15. Soft Touch Override Switch (If equipped)

This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed, allowing the operator to move the platform away from the obstacle that caused the shutdown situation.

16. Soft Touch Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

(See Figure 3-8., Platform Control Indicator Panel w/Drive Orientation)

NOTE: The platform control indicator panel uses different shaped

symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below.

Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

1. Tilt Alarm Warning Light and Alarm

Indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation. If the boom is above horizontal and the machine is on a slope, the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated.

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

2. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Tilt Alarm Warning

2. Platform Overload 3 . P l a tf o rm C a pa c it y

4. Drive Disabled

5. Footswitch/Enable 6 . G l o w P l ug

7. Low Fuel

8. System Distress

9. AC Generator

10. Soft Touch

11. Creep Speed

Figure 3-7. Platform Control Indicator Panel

1001107926 A

611 8

1. Tilt Alarm Warning

2. Platform O verload

3. Platform C apacity

4. Drive Disabled

5. Footswitch/Enable

6. Glow Plug

7. Low Fuel

8. System Distress

9. AC Generator

10. Not Used

11. Creep Speed

12. Drive Orientation

Figure 3-8. Platform Control Indicator Panel w/Drive

Orientation

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Platform Capacity Indicator (If equipped)

Indicates the maximum platform capacity selected for the platform.

One of the capacity lights should be on at all times. Both lights will flash and an alarm will sound if the platform is out of the operating envelope for the selected capacity.

4. Drive Disabled Indicator

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

5. Footswitch/Enable Indicator

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next function, the enable light will go out and the footswitch must be released and depressed again to enable the controls.

Releasing the footswitch removes power from all controls and applies the drive brakes.

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

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

6. Glow Plug Indicator

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

7. Low Fuel Indicator.

Indicates the fuel tank is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. System Distress Indicator

The light indicates that the JLG Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

9. AC Generator

Indicates the generator is in operation.

10. Soft Touch Indicator

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep mode.

11. Creep Speed Indicator

When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed. The light flashes if the control system puts the machine into creep speed and will be on continuously if the operator selects creep speed.

12. Drive Orientation Indicator

When the boom is swung beyond the rear in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

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SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

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

The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the boom to the left or right. Standard boom swing is 360 degree continuous left and right of the stowed position. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so.

The JLG Lift is a crawler track type machine with drive power being supplied by a hydraulic motor for each final drive and sprocket. Each final drive is equipped with a spring applied, hydraulically released brake. The swing drive is also equipped with such a brake. These brakes are automatically applied any time the Drive or Swing control levers are returned to the neutral position.

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SECTION 4 - MACHINE OPERATION

4.2 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure

1. Check engine oil. If necessary, add oil in accordance

with the Engine Manufacturer’s manual.

2. Check fuel level. Add fuel if necessary.

3. Check that air cleaner components are in place and

securely fastened.

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

NOTE: Machines with diesel engines. After turning on ignition,

operator must wait until glow plug indicator light goes out before cranking engine.

4. Turn key of SELECT switch to GROUND. Position

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

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

5. After engine has had sufficient time to warm up, shut

engine off.

6. Turn key of SELECT switch to PLATFORM.

7. From Platform position POWER/EMERGENCY STOP

switch to ON, then push the ENGINE START switch to the forward position until engine starts.

NOTE: Footswitch must be in released (up) position before

starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.

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SECTION 4 - MACHINE OPERATION

Shutdown Procedure

IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION.

1. Remove all load and allow engine to operate at low

speed setting for 3-5 minutes; this allows for further reduction 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 information.

4.3 TRAVELING (DRIVING)

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

TO AVOID LOSS OF TRAVEL CONTROL OR UPSET ON GRADES AND SIDESLOPES, DO NOT DRIVE MACHINE ON GRADES OR SIDESLOPES EXCEEDING THOSE SPECIFIED ON MANUFACTURERS NAMEPLATE

LOCATED ON THE FRAME.

ASSURE THAT TURNTABLE LOCK IS ENGAGED BEFORE BEGINNING ANY EXTENDED TRAVELING. AVOID ANY TERRAIN FEATURES WHICH COULD CAUSE THE MACHINE TO UPSET.

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

• TRAVELING GRADES

• TRAVELING IN DIFFICULT CONDITIONS

• SHARP TURNS (ESPECIALLY WITH ONE TRACK STOPPED

• COUNTERROTATION

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN DRIVING WITH THE PLATFORM ELEVATED AND SPECIALLY WHEN DRIVING WITH ANY PART OF THE MACHINE WITHIN 6 FEET (2M) OF AN OBSTRUCTION. DO NOT USE DRIVE TO MANEUVER PLATFORM CLOSE TO AN OBSTRUCTION. USE ONE OF THE BOOM FUNCTIONS.

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SECTION 4 - MACHINE OPERATION

Figure 4-1. Grades and Sideslopes

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SECTION 4 - MACHINE OPERATION

Figure 4-2. Machine Motion Hazard

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SECTION 4 - MACHINE OPERATION

USE EXTREME CAUTION WHEN APPROACHING A CREST OF ANY TERRAIN OBSTACLE. CHECK FOR CURBS, LARGE STONES, OR OTHER TERRAIN OBSTACLES INCLUDING OVERHEAD OBSTACLES AS THE MACHINE WILL MAKE UNCONTROLLED PIVOTING MOTIONS WHEN THE CENTER OF GRAVITY (CENTER OF TRACK FRAME) SHIFTS OVER AN EDGE. SLOW DOWN TO MINIMIZE ACCELERATION DURING PIVOTING MOVEMENT.

BEFORE DRIVING, MAKE SURE THE BOOM IS POSITIONED OVER THE REAR OF THE CHASSIS (OVER FINAL DRIVES AND SPROCKETS). IF THE BOOM IS OVER THE FRONT OF THE CHASSIS (OVER THE IDLER WHEELS) STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTIONS TO MACHINE CONTROLS.

Traveling Forward or Reverse

1. With engine running, depress footswitch and position

DRIVE control to FORWARD and hold for the duration of forward travel desired.

2. Depress footswitch and position DRIVE control to

REVERSE and hold for duration of reverse travel desired.

3. Depress footswitch, move joystick (DRIVE/STEER CON-

TROL) to select desired direction of travel (forward or

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

4. To obtain sharp turns, move DRIVE SPEED/TORQUE

SELECT switch to the back position, slow down the travel speed and move the DRIVE control lever to RIGHT for a turn to the right and to LEFT for a turn to the left. The sharpest possible turn is achieved when the joystick is in the position to command one track to stop and the other to move slowly.

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

5. To obtain counter-rotation (turn in place), stop the

machine, move the DRIVE/STEER control lever directly to RIGHT to get clockwise rotation and to LEFT to get counterclockwise rotation.

6. To obtain maximum travel speed, position the DRIVE

controller to FAST and activate the following switches:

a. Position DRIVE SPEED/TORQUE SELECT switch to

FAST. (Forward Position)

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SECTION 4 - MACHINE OPERATION

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

lows:

a. Position DRIVE SPEED/TORQUE SELECT switch to

LOW. (Backward Position)

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

a. Position DRIVE SPEED/TORQUE SELECT switch to

HIGH. (Backward position)

NOTE: For smoother operation when driving with fully extended

boom, place DRIVE control to SLOW before stopping.

This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond the rear and the machine may Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner:

1. Match the black and white direction arrows on both plat-

form control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch.

Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

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SECTION 4 - MACHINE OPERATION

Figure 4-3. Position of Least Backward Stability

PLATFORM ROTATED

90 DEGREES

MACHINE WILL UPSET

IN THIS DIRECTION IF

OVERLOADED OR OPERATED ON AN

OUT-OF-LEVEL SURFACE

MAIN BOOM FULLY

RETRACTED AND

ELEVATED

Stability

Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machines position of least forward stability is shown in Figure 4-4., and its position of least backward stability is shown in Figure 4-3.

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

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Figure 4-4. Position of Least Forward Stability

MACHINE WILL UPSET IN THIS

DIRECTION IF OVERLOADED

OR OPERATED ON AN

OUT-OF-LEVEL SURFACE

LEVEL SURFACE

BOOM FULLY EXTENDED

@ HORIZONTAL (O DEGREES)

SECTION 4 - MACHINE OPERATION

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SECTION 4 - MACHINE OPERATION

4.4 STEERING

Depress footswitch. Move the DRIVE/STEER control lever to RIGHT for a turn to the right and to LEFT for a turn to the left.

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

4.5 PARKING AND STOWING

Park and stow machine as follows:

1. Park machine in travel position; boom lowered over rear,

all access panels and doors closed and secured, ignition off, turntable locked.

2. Check that brakes hold machine in position.

3. Chock tracks front and rear.

4. Turn off SELECT switch and remove key.

5. When parking on frozen ground overnight, drive the

machine up on boards to prevent freezing to the ground.

4.6 PLATFORM

Platform Level Adjustment

1. Leveling UP. Depress footswitch. To raise platform, posi-

tion PLATFORM LEVEL control switch UP and hold until platform is level.

2. Leveling DOWN. Depress footswitch. To lower platform,

position PLATFORM LEVEL control switch to DOWN and hold until platform is level.

Platform Rotation

1. Depress footswitch to rotate platform to the left, PLAT-

FORM ROTATE control is positioned to the LEFT and held until desired position is reached.

2. Depress footswitch to rotate platform to the right, PLAT-

FORM ROTATE control is positioned to the RIGHT and held until desired position is reached.

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4.7 BOOM

A TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE (5 DEGREES OR GREATER). DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. TILT ALARM INDICATES CHASSIS IS ON A SEVERE SLOPE (5 DEGREES OR GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING, EXTENDING OR RAISING BOOM ABOVE HORIZONTAL.

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

TRAVELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON CAUTION PLACARD AT PLATFORM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

TO AVOID A 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.

Swinging the Boom

ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTING ANY SWING OPERATION.

Depress footswitch. To swing boom, position SWING control switch or controller to RIGHT or LEFT for direction desired.

NOTE: When boom functions are being operated there an inter-

lock prevents the use of DRIVE and STEER functions.

Raising and Lowering the Main Boom

To raise and lower Main Boom, position MAIN LIFT control switch or controller to UP OR DOWN and hold until desired height is reached.

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SECTION 4 - MACHINE OPERATION

Telescoping the Main Boom

To extend or retract Main Boom, position MAIN TELESCOPE control switch to IN or OUT and hold until platform reaches desired position.

4.8 SHUT DOWN AND PARK

1. Drive machine to a protected area.

2. Assure main boom is fully retracted and lowered over

rear (Drive) axle; all access panels and doors closed and secured.

3. Remove all load and allow engine to operate 3-5 min-

utes at LOW setting to permit reduction of engine internal 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 instruction

placards, warning decals and operating controls from hostile environment.

4.9 TIE DOWN AND LIFTING

Tie Down

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

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

locked.

2. Remove all loose items from the machine.

3. Secure the chassis and the platform using straps or

chains of adequate strength and attached to the designated tie down points. (See Figure 4-5., Machine Tie Down.)

Lifting

(See Figure 4-6., Lifting Chart)

1. Weigh the individual unit, refer to the Serial Number

plate or call JLG Industries to find out the Gross Vehicle Weight.

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

locked.

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SECTION 4 - MACHINE OPERATION

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 the

machine and so the machine remains level.

4.10 AUXILIARY POWER

A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station. Operation of either switch turns on the electrically driven auxiliary hydraulic pump. This should be used in case of failure of the main power plant. The auxiliary pump will operate boom lift, telescope and swing. To activate auxiliary power:

1. Position PLATFORM/GROUND SELECT KEY SWITCH to

PLATFORM.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Depress and hold footswitch.

4. Operate appropriate control switch, lever or controller

for desired function and hold.

5. Position AUXILIARY POWER switch to ON and hold.

6. Release AUXILIARY POWER switch, selected control

switch, lever or controller, and footswitch.

7. Position POWER/EMERGENCY STOP switch to OFF.

To activate auxiliary power from the ground control station:

1. Position PLATFORM/GROUND SELECT KEY SWITCH to

GROUND.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Operate appropriate control switch or controller for

desired function and hold.

4. Position AUXILIARY POWER switch to ON and hold.

5. Release AUXILIARY POWER switch, and appropriate

control switch or controller.

6. Position POWER/EMERGENCY STOP switch to OFF.

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SECTION 4 - MACHINE OPERATION

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 on its pad. This prevents the boom from "Bouncing" up and down preventing possible damage while transporting.

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SECTION 4 - MACHINE OPERATION

Figure 4-6. Lifting Chart

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SECTION 4 - MACHINE OPERATION

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. Plug tool it into quick-disconnect fittings mounted on

platform rail. The male quick connect is the pressure feed line.

4. Set flow control knob to desired setting.

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SECTION 4 - MACHINE OPERATION

NOTE: Each notch in the flow control knob corresponds to

approximately 1 GPM (ex. setting 2 = 2 GPM). At setting seven (7) the pump has reached its maximum flow rate therefore any setting past 7 will produce no additional flow.

5. Turn hydraulic power tool switch to the “ON” position.

Oil will now flow to the tool. It is possible to adjust the flow control knob during operation to achieve desired tool performance.

6. When finished, turn the hydraulic tool switch to the

“OFF” position.

7. Disconnect tool from the quick-disconnects.

TURN HYDRAULIC TOOL SWITCH TO THE “OFF” POSITION IN ORDER TO SWITCH TOOLS.

NOTE: The tool circuit will not work with the foot switch

depressed. If the foot switch is depressed during tool circuit operation the tool circuit will stop functioning until the foot switch is released.

NOTE: The tool is designed to operate at 2600 psi. If necessary

this can be adjusted for a higher or lower pressure.

NOTE: With the foot switch released to operate the tool circuit all

drive and boom functions are cut out.

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SECTION 4 - MACHINE OPERATION

4.12 PLACARDS AND DECALS

Read and understand all placards and decals. Do not operate any machine on which DANGER, WARNING, CAUTION OR INSTRUCTION PLACARDS OR DECALS ARE MISSING OR ILLEGIBLE. Replace placards and decals if damaged, missing or illegible.

Decals are made of Lexan Pressure Sensitive Adhesive with a protective film on the front. Remove the damaged decal and 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 4-13., and Figure 4-15.)

4-18 – JLG Lift – 3121156

Page 73

SECTION 4 - MACHINE OPERATION

WARNING

CRUSHING HAZARD

1703953 A

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

Keep all body parts away from any moving components.

Failure to follow these instructions could result in death or serious in ju ry .

DANGER

ELECTROCUTION HAZARD

1703805 B

This machine is not insulated. Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or appar tus charged up to 50,000 volts. One footaddtional clearance is required foreach addtional 30,00 volts or less. Allowances must be made for error, machine deflection and electrical line swaying.

Failure to follow these instructions could

result in death or serious injury.

61 55

Figure 4-7. Decal Installation - Sheet 1 of 10

3121156 – JLG Lift – 4-19

Page 74

SECTION 4 - MACHINE OPERATION

VIEW A-A

CE/AUS

1705961

1701518

WARNING

CRUSHING HAZARD

1703804 B

Do not stand under a raised platform or boom, or between a rotating platform and t he boom.

Keep all body parts away from any moving components.

Failure to follow these instructions could result in death or serious injury.

DANGER

ELECTROCUTION HAZARD

1703805 B

This machine is not insulated. Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or a ppartus charged up to 50,000 volts. One footaddtional clearance is requi red foreach ad dtional 30,00 volts or less. Allowances must be made for error, m achine deflection and electrical line swaying.

Failure to follow these instructions could result in death or serious injury.

CE ONLY

1701518

40 55

DANGER

ELECTROCUTION HAZARD

1703805 B

This machine is not insulated.

Maintain a clearance of at least 10 ft. between any part of machine

or load and any electrical line or appartus charged up to 50 ,000 volts.

One footaddtional clearance is required foreach addtional 30,00 volts or less. Allowances must be made for error, machine deflection and electrical line swaying.

Failure to follow these instructions could result in death or serious injury.

WARNING

CRUSHING HAZARD

1703953 A

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

Keep all body parts away from any moving components.

Failure to follow these ins t r uc ti o n s cou ld result in death or serious injury.

Figure 4-8. Decal Installation - Sheet 2 of 10

4-20 – JLG Lift – 3121156

Page 75

SECTION 4 - MACHINE OPERATION

VIEW

D-D

GRADALL UNDERCARRIAGE

38 55

VIEW

E-E

Figure 4-9. Decal Installation - Sheet 3 of 10

3121156 – JLG Lift – 4-21

Page 76

SECTION 4 - MACHINE OPERATION

CATERPILLAR UNDERCARRIAGE

600 SC ANSI

VIEW D - D

600SC BOTH SIDES

VIEW E - E

600SC BOTH SIDES

TYPICAL ON ALL CAT MODELS

Figure 4-10. Decal Installation - Sheet 4 of 10

4-22 – JLG Lift – 3121156

Page 77

SECTION 4 - MACHINE OPERATION

CATERPILLAR UNDERCARRIAGE

600SC CE/AUS

* NOTE: TYPICAL FOR ALL THREE MODELS OF CAT UNDERCARRIAGE

* CAT S/N

NAMETAG

VIEW D - D

600SC BOTH SIDES

VIEW E - E

600SC BOTH SIDES

Figure 4-11. Decal Installation - Sheet 5 of 10

3121156 – JLG Lift – 4-23

Page 78

SECTION 4 - MACHINE OPERATION

CATERPILLAR UNDERCARRIAGE

660SC

FORWARD

REVERSE

TYP.

VIEW D - D

600SC BOTH SIDES

VIEW E - E

600SC BOTH SIDES

Figure 4-12. Decal Installation - Sheet 6 of 10

4-24 – JLG Lift – 3121156

Page 79

SECTION 4 - MACHINE OPERATION

TYPICAL BOTH SIDES

Figure 4-13. Decal Installation - Sheet 7 of 10

3121156 – JLG Lift – 4-25

Page 80

SECTION 4 - MACHINE OPERATION

CALLED OUT ON MACHINE

LIFTING ATTACH INSL'L

3251243

120V - 60HZ

ANSI

WARNING

CRUSHING HAZARD

1703953 A

Do not stand under a raised platform or boom,

or between a rotating platform and the boom.

Keep all body parts away from any moving components.

Failure to follow these instruct io ns c ou ld result in death or serious injury.

1701518

CE/AUS ONLY

1700584

ANSI

DANGER

ELECTROCUTION HAZARD

1703805 B

This machine is not insulated. Maintain a clearance of at least 10 ft. between any part of machine or load and any electrical line or a ppartus charged up to 50,000 volts. One footaddtional clearance is requi red foreach addtional 30,00 volts or less. Allowances must be made for error, m achine deflection and electrical line swaying.

Failure to follow these instruct io ns could result in death or serious injury.

Figure 4-14. Decal Installation - Sheet 8 of 10

4-26 – JLG Lift – 3121156

Page 81

SECTION 4 - MACHINE OPERATION

Figure 4-15. Decal Installation - Sheet 9 of 10

3121156 – JLG Lift – 4-27

Page 82

SECTION 4 - MACHINE OPERATION

Figure 4-16. Decal Installation - Sheet 10 of 10

4-28 – JLG Lift – 3121156

Page 83

SECTION 4 - MACHINE OPERATION

Table 4-1. 600SC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273906-6

1- - - - - - - -

2 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529

7- - - - - - - -

8- - - - - - - -

9- - - - - - - -

10 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243

Canadian

French

0273982-7

CE/

Australian

0273985-5

English/

Portuguese

1001093424-4

Table 4-1. 600SC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273906-6

18- -- -- - - -

19 - - - - - - 1705904

20 - - - - - - 1705906

21 - - - - - - 1705901

22 170 3953 1703942 - - 1705903

23- -- -- - - -

24 170 2868 1704000 - - 1705967

25 1703797 1703924 1705921 1705895

26 1705336 1705347 1705822 1705896

27 1703804 1703948 1701518 1705898

28 1703805 1703936 1705961 1705897

29 - - 1703984 170582 8 1705902

30 325 1813 3251813 - - 3251813

31- -- -- - - -

32 1702631 1702631 1702631 1702631

33 1704434 1703165 1704434 1704434

34- -- -- - - -

35 1704096 1704099 1705978 1706380

Canadian

French

0273982-7

CE/ Australian 0273985-5

English/

Portuguese

1001093424-4

3121156 – JLG Lift – 4-29

Page 84

SECTION 4 - MACHINE OPERATION

Table 4-1. 600SC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273906-6

36 1707014 1707046 1705978 1707051

37 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948

39 1705177 1705177 1705177 1705177

40 - - - - - - - -

41 - - - - - - - -

42 - - - - - - - -

43 - - - - - - - -

44 - - - - - - - -

45 - - - - - - - -

46 - - - - - - - -

47 - - - - - - - -

48 - - - - - - - -

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -

53 - - - - - - - -

Canadian

French

0273982-7

CE/ Australian 0273985-5

English/

Portuguese

1001093424-4

Table 4-1. 600SC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273906-6

54- -- -- - - -

55- -- -- - - -

56- -- -- - - -

57 1704468 1001093684 1704468 1001093439

58 1001108494 1001108494 - - 1001108494

59 170 6943 1706943 - - 1706943

60- -- -- - - -

61- -- -- - - -

62 1700584 1700584 1700584 1700584

Canadian

French

0273982-7

CE/ Australian 0273985-5

English/

Portuguese

1001093424-4

4-30 – JLG Lift – 3121156

Page 85

SECTION 4 - MACHINE OPERATION

Table 4-2. 600SC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273906-9

1- -- -- - - - - - - -

2 1701499 1701499 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529

7- -- -- - - - - - - -

8- -- -- - - - - - - -

9- -- -- - - - - - - -

10 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243 3251243 3251243

18- -- -- - - - - - - -

Canadian

French

0273982-9

CE/ Australian 0273985-6

English/

Portuguese

1001093424-7

Simplified

Chinese

1001116970-3

Traditional

Chinese

1001116971-3

3121156 – JLG Lift – 4-31

Page 86

SECTION 4 - MACHINE OPERATION

Table 4-2. 600SC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273906-9

19 - - - - - - 1705904 1705342 1001117034

20 - - - - - - 1705906 1705507 1001117035

21- -- -- - - - - - - -

22 1703 953 1703942 - - 1705903 1001116845 1703943

23- -- -- - - - - - - -

24 1702868 1704000 - - 1705967 1705968 1001116846

25 1703797 1703924 1705921 1705895 1001116847 1703925

26 1705336 1705347 1705822 1705896 1001116848 1001116849

27 1703804 1703948 1701518 1705898 1001116850 1703949

28 1703805 1703936 1705961 1705897 1703937 1001116851

29 - - 1703984 1705828 1705902 1001116852 1703982

30- -- -- - - - - - - -

31- -- -- - - - - - - -

32 - - 1702631 - - - - - - - -

33 1704434 1703165 1704434 1704434 1704434 1704434

34- -- -- - - - - - - -

35 1001121800 1001121802 1705978 1001121806 1001121811 1001121809

36 1001121813 1001121815 1705978 1001121819 1001121824 1001121822

Canadian

French

0273982-9

CE/ Australian 0273985-6

English/

Portuguese

1001093424-7

Simplified

Chinese

1001116970-3

Traditional

Chinese

1001116971-3

4-32 – JLG Lift – 3121156

Page 87

SECTION 4 - MACHINE OPERATION

Table 4-2. 600SC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273906-9

37 1704885 1704885 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948 1706948 1706948

39 1705177 1705177 1705177 1705177 1705177 1705177

40- -- -- - - - - - - -

41- -- -- - - - - - - -

42- -- -- - - - - - - -

43- -- -- - - - - - - -

44- -- -- - - - - - - -

45- -- -- - - - - - - -

46- -- -- - - - - - - -

47- -- -- - - - - - - -

48- -- -- - - - - - - -

49- -- -- - - - - - - -

50- -- -- - - - - - - -

51- -- -- - - - - - - -

52- -- -- - - - - - - -

53- -- -- - - - - - - -

54- -- -- - - - - - - -

Canadian

French

0273982-9

CE/ Australian 0273985-6

English/

Portuguese

1001093424-7

Simplified

Chinese

1001116970-3

Traditional

Chinese

1001116971-3

3121156 – JLG Lift – 4-33

Page 88

SECTION 4 - MACHINE OPERATION

Table 4-2. 600SC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273906-9

55- -- -- - - - - - - -

56- -- -- - - - - - - -

57 1704468 1001093684 1704468 1001093439 1001116963 1001116964

58 1001108494 1001108494 - - 1001108494 1001108494 1001108494

59 1706943 1706943 - - 1706943 1706943 1706943

60- -- -- - - - - - - -

61- -- -- - - - - - - -

62 1001131269 1001131269 - - - - - - - -

Canadian

French

0273982-9

CE/ Australian 0273985-6

English/

Portuguese

1001093424-7

Simplified

Chinese

1001116970-3

Traditional

Chinese

1001116971-3

4-34 – JLG Lift – 3121156

Page 89

SECTION 4 - MACHINE OPERATION

Table 4-3. 660SJC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273908-7

1- - - - - - - -

2 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529

7- - - - - - - -

8- - - - - - - -

9- - - - - - - -

10 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243

Canadian

French

0273984-7

CE/

Australian

0273987-6

English/

Portuguese

1001103292-3

Table 4-3. 660SJC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273908-7

18- -- -- - - -

19 - - - - - - 1705904

20 - - - - - - 1705906

21 - - - - - - 1705901

22 170 3953 1703942 - - 1705903

23- -- -- - - -

24 170 2868 1704000 - - 1705967

25 1703797 1703924 1705921 1705895

26 1705336 1705347 1705822 1705896

27 1703804 1703948 1701518 1705898

28 1703805 1703936 1705961 1705897

29 - - 1703984 170582 8 1705902

30 325 1813 3251813 - - 3251813

31- -- -- - - -

32 1702631 1702631 1702631 1702631

33 1703165 1703165 1703165 1703165

34- -- -- - - -

35 1701645 1707055 1705978 1701645

Canadian

French

0273984-7

CE/ Australian 0273987-6

English/

Portuguese

1001103292-3

3121156 – JLG Lift – 4-35

Page 90

SECTION 4 - MACHINE OPERATION

Table 4-3. 660SJC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273908-7

36 1707013 1707047 1705978 1707052

37 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948

39 1705177 1705177 1705177 1705177

40 - - 1001093553 - - - -

41 - - - - - - - -

42 - - - - - - - -

43 - - - - - - - -

44 - - - - - - - -

45 - - - - - - - -

46 - - - - - - - -

47 - - - - - - - -

48 - - - - - - - -

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -

53 - - - - - - - -

Canadian

French

0273984-7

CE/

Australian

0273987-6

English/

Portuguese

1001103292-3

Table 4-3. 660SJC Decal Legend - Prior to S/N 0300148842

Item # ANSI

0273908-7

54- -- -- - - -

55- -- -- - - -

56- -- -- - - -

57 1704468 1001093684 1704468 1001093439

58 1001108494 1001108494 - - 1001108494

59 170 6943 1706943 - - 1706943

60- -- -- - - -

61- -- -- - - -

62 1700584 1700584 1700584 1700584

Canadian

French

0273984-7

CE/ Australian 0273987-6

English/

Portuguese

1001103292-3

4-36 – JLG Lift – 3121156

Page 91

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273908-10

1- - - - - - - -

2 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529

7- - - - - - - -

8- - - - - - - -

9- - - - - - - -

10 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412

14 1705084 1705084 1705084 1705084

15 1705514 1705514 1705514 1705514

16 1704461 1704461 1704461 1704461

17 3251243 3251243 3251243 3251243

Canadian

French

0273984-9

CE/

Australian

0273987-7

English/

Portuguese

1001103292-6

Table 4-4. 660SJC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273908-10

18- -- -- - - -

19 - - - - - - 1705904

20 - - - - - - 1705906

21- -- -- - - -

22 170 3953 1703942 - - 1705903

23- -- -- - - -

24 170 2868 1704000 - - 1705967

25 1703797 1703924 1705921 1705895

26 1705336 1705347 1705822 1705896

27 1703804 1703948 1701518 1705898

28 1703805 1703936 1705961 1705897

29 3532347 1703984 1705828 1705902

30 - - - - - - 3251813

31- -- -- - - -

32 - - 1702631 - - - -

33 1703165 1703165 1703165 1703165

34- -- -- - - -

35 1001121801 1001121803 1705978 1001121801

Canadian

French

0273984-9

CE/ Australian 0273987-7

English/

Portuguese

1001103292-6

3121156 – JLG Lift – 4-37

Page 92

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273908-10

36 1001121814 1001121816 1705978 1001121655

37 1704885 1704885 1704885 1704885

38 1706948 1706948 - - 1706948

39 1705177 1705177 1705177 1705177

40 - - 1001093553 - - 1001093553

41 - - - - - - - -

42 - - - - - - - -

43 - - - - - - - -

44 - - - - - - - -

45 - - - - - - - -

46 - - - - - - - -

47 - - - - - - - -

48 - - - - - - - -

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -

53 - - - - - - - -

Canadian

French

0273984-9

CE/

Australian

0273987-7

English/

Portuguese

1001103292-6

Table 4-4. 660SJC Decal Legend - S/N 0300148842 to Present

Item # ANSI

0273908-10

54- -- -- - - -

55- -- -- - - -

56- -- -- - - -

57 1704468 1001093684 1704468 1001093439

58 1001108494 1001108494 - - 1001108494

59 170 6943 1706943 - - 1706943

60- -- -- - - -

61- -- -- - - -

62 1001131269 100113126 9 - - - -

Canadian

French

0273984-9

CE/ Australian 0273987-7

English/

Portuguese

1001103292-6

4-38 – JLG Lift – 3121156

Page 93

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL

This section explains the steps to be taken in case of an emergency situation while operating.

5.2 INCIDENT NOTIFICATION

JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

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

Outside USA: 240-420-2661

E-mail:

ProductSafety@JLG.com

Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occurrence may void any warranty consideration on that particular machine.

SECTION 5 - EMERGENCY PROCEDURES

FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

3121156 – JLG Lift – 5-1

Page 94

SECTION 5 - EMERGENCY PROCEDURES

5.3 EMERGENCY OPERATION

Operator Unable to Control Machine

IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO OPERATE OR CONTROL MACHINE:

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

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

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

Platform or Boom Caught Overhead

If the platform or boom becomes jammed or snagged in overhead structures or equipment, rescue platform occupants prior to freeing the machine.

5-2 – JLG Lift – 3121156

Page 95

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION

This section of the manual provides additional necessary information to the operator for proper operation and maintenance of this machine.

The maintenance portion of this section is intended as information to assist the machine operator to perform daily maintenance tasks only, and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual.

Other Publications Available:

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

Illustrated Parts Manual (Prior to S/N - 128000

Gradall Chassis)..................................................... 3121158

Illustrated Parts Manual (S/N - 128000 to Present) .. 3121251

6.2 OPERATING SPECIFICATIONS

Table 6-1. Operating Specifications - Prior to S/N 0300148842

Maximum Work Load (Capacity) U n re s tr i ct e d: R es t r ic t ed - 60 0 SC R es t r ic t ed - 66 0 SJ C

Maximum Travel Grade (Gradeability)* Maximum Travel Grade (Side Slope)*

Max.Vertical Platform Height: 600SC 660SJC

Max.Horizontal Platform Reach: 600SC 660SJC

Tu rn in g R ad iu s 0

Maximum Ground Bearing Pressure 600SC 660SJC

Maximum Drive Speed: 1.6 mph (2.6 kph)

500 lb. (230 kg)

1000 lb. (450 kg)

500 lb. (230 kg)

55%

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

49 ft. 6 in. (15.09 m)

56 ft. 9 in. ( 17.3 m)

5.45 psi (0.383 kg/cm2)

6.5 psi (0.457 kg/cm

5°

)

3121156 – JLG Lift – 6-1

Page 96

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications - Prior to S/N 0300148842

Max. Hydraulic System Pressure 4500 psi (310 Bar)

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 101 lb. (450 N)

Electrical System Voltage 12 Volts

Gross Machine Weight 6 0 0S C 6 6 0S J C

(Platform Empty)

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

* W it h bo o m in s to w ed p o si t io n .

Table 6-2. Operating Specifications - S/N 0300148842 to

Present

Maximum Work Load (Capacity) - ANSI U n re s tr i ct e d: R es t r ic t ed - 60 0 SC R es t r ic t ed - 66 0 SJ C

Maximum Work Load (Capacity) - CE & Australia U n re s tr i ct e d: R es t r ic t ed - 60 0 SC R es t r ic t ed - 66 0 SJ C

Maximum Travel Grade (Gradeability)

500 lb. (227 kg)

1000 lb. (454 kg)

500 lb. (227 kg)

500 lb. (230 kg)

1000 lb. (450 kg)

500 lb. (230 kg)

55%

Table 6-2. Operating Specifications - S/N 0300148842 to

Present

Maximum Travel Grade (Side Slope)*

Max.Vertical Platform Height: 600SC 660SJC

Max.Horizontal Platform Reach: 600SC 660SJC

Tu rn in g R ad iu s 0

Maximum Ground Bearing Pressure 600SC 660SJC

Maximum Drive Speed: 1.6 mph (2.6 kph)

Max. Hydraulic System Pressure 4500 psi (310 Bar)

Maximum Wind Speed 28 mph (12.5 m/s)

Maximum Manual Force 101 lb. (450 N)

Electrical System Voltage 12 Volts

Gross Machine Weight 6 0 0S C 6 6 0S J C

(Platform Empty)

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

49 ft. 6 in. (15.09 m)

56 ft. 9 in. ( 17.3 m)

5.45 psi (0.383 kg/cm2)

6.5 psi (0.457 kg/cm

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

* With boom in stowed position.

5°

)

6-2 – JLG Lift – 3121156

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Capacities Engine Data

Table 6-3. Capacities

Fuel Tank 39 US. Gallons (147.6 L)

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

Hydraulic System (Includi ng Tank) 37.2 U.S. Gallons (140.8 L)

Engine Crankcase D eu t z w/ F il t er Caterpillar (w/filter)

11 quarts (10.5 L)

10.6 quarts (10 L)

Table 6-4. Deutz F4M1011F/F4M2011 Specifications

Fuel Diesel

Oil Capacity C oo l i ng S ys t em Crankcase To t al C ap a ci t y

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 60 Amp, belt drive

Battery 1000 Cold Cranking Amps, 210

Fuel Consumption L ow R P M H ig h R PM

Horsepower 65 @ 3000 RPM, full load

5 Quar ts (4.5 L)

11 Quar ts (10.5 L) w/Filter

16 Quarts (15 L)

Minutes Reserve Capacity, 12

VDC

1.90 GPH (7.19 lph)

2.50 GPH (9.46 lph)

3121156 – JLG Lift – 6-3

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-5. Caterpillar 3044C/3.4

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

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 - 3044C 1000

Idle RPM - 3.4 1200

Low RPM 1800

High RPM 2600

Alternator 60 Amp, belt drive

203 in3 (3.33 L)

Hydraulic Oil

Table 6-6. Hydraulic Oil

HYDRAULIC SYSTEM OPERATING

TEMPERATURE RANGE

+0° to +180° F (-18° C to +83° C) 10W

+0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30

+50° F to +210° F (+10° C to +210° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least to API

Service Classification GL-3, and sufficient chemical stability for mobile hydraulic system service. JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152.

NOTE: When temperatures remain below 20° F (-7 degrees C),

JLG Industries recommends the use of Mobil DTE 13M.

Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If use of hydraulic oil other than Mobilfluid 424 is desired, contact JLG Industries for proper recommendations.

SAE VISCOSITY GRADE

6-4 – JLG Lift – 3121156

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-7. 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

Table 6-8. Mobil DTE 13M Specs

ISO Viscosity Grade #32

Specific Gravity 0.877

Pour Point, Max -40?F (-40?C)

Flash Point, Min. 330?F (166?C)

Viscosity

at 40° C 33cSt

at 100° C 6.6 cSt

at 100° F 169 SUS

at 210° F 48 SUS

cp at -20° F 6,200

Viscosity Index 140

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SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-9. 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 checked

on a yearly basis for viscosity.

Table 6-10. Quintolubric 888-46

Density

0.91 @ 15°C (59°F)

Pour Poin t

<-20°C (<-4°F)

Flash Point

275°C (527°F)

Fire Point

325°C (617°F)

Autoignition Te mpe ra tu re

450°C (842°F)

Viscosity

at 0° C (32°F) 360 cSt

at 20° C (68°F) 102 cSt

at 40° C (104°F) 46 cSt

at 100° C (212°F) 10 cSt

Viscosity Index 220

6-6 – JLG Lift – 3121156