JLG 660SJ Operator Manual
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
600S
600SJ
660SJ
ANSI
3121205
May 1, 2012
A Machine that incorporates ADE (JLG Control System) can be outwardly identified by
the analyzer connection at the base of the
platform control box as shown by the arrow.
ADE Identification
All 600S, 600SJ, and 660SJ machines from S/N 61927 incorporate ADE (JLG Control System). The following machine serial numbers prior to S/N 61927 also utilize ADE: 58993, 58998, 59222, 59223, 59275,
59281, 59315, 59319, 59352, 59358, 59631, 59769, 60253, 60254, 60286, 60642, 60645, 61120, 61257,
61402, 61440, 61491, 61833, 61840, 61875, and 61878.
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
3121205 – JLG Lift – a
FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL
WILL HAVE A RED BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD
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.
b – JLG Lift – 3121205
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:
3121205 – JLG Lift – c
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: ProductSafety@JLG.com
FOREWORD
REVISION LOG
Original Issue - April 1, 2005
Revised - February 27, 2006
Revised - May 3, 2006
Revised - September 25, 2007
Revised - February 22, 2008
Revised - June 5, 2008
Revised - September 21, 2009
Revised - December 1, 2009
Revised - October 31, 2011
Revised - May 1, 2012
d – JLG Lift – 3121205
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
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . 2-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
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 Indicator Panel . . . . . . . . . . . . . 3-5
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Platform Control Indicator Panel . . . . . . . . . . . . 3-14
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5
Traveling Forward and Reverse . . . . . . . . . . . . . 4-5
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7
3121205 – JLG Lift – i
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8
Raising and Lowering the Boom . . . . . . . . . . . . 4-8
Telescoping the Boom. . . . . . . . . . . . . . . . . . . . 4-8
4.8 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . . 4-8
4.9 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4.10 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . . 4-9
4.11 TOWING (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . 4-9
4.12 AUXILIARY POWER - NON ADE EQUIPPED MA-
CHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Activating from the Platform Control Station . . 4-13
Activating from the Ground Control Station . . 4-13
4.13 AUXILIARY POWER - ADE EQUIPPED
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Activating from the Platform Control Station . . 4-14
Activating from the Ground Control Station . . 4-14
4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-15
Changing From Gasoline to LP Gas . . . . . . . . 4-15
Changing From LP Gas to Gasoline . . . . . . . . 4-15
4.15 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS . . . 4-15
Tool Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4.16 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-17
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1
5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1
Operator Unable to Control Machine . . . . . . . . . 5-1
Platform or Boom Caught Overhead . . . . . . . . . 5-2
5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2
5.5 MANUAL DESCENT (MACHINES PRIOR TO S/N
70975). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Torque Requirements. . . . . . . . . . . . . . . . . . . . . 6-7
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-10
Serial Number Locations . . . . . . . . . . . . . . . . . 6-12
ii – JLG Lift – 3121205
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-23
6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-33
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-33
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-34
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.5 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
6.6 DRAINING OIL BUILD UP FROM THE PROPANE REG-
ULATOR (PRIOR TO S/N 0300132529) . . . . . . . .6-38
6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-39
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-41
6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-42
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Machine Nomenclature - 600SJ/660SJ . . . . . . . . . 2-8
2-2. Machine Nomenclature - 600S . . . . . . . . . . . . . . . . 2-9
2-3. Daily Walk-Around Inspection Diagram . . . . . . . . 2-10
2-4. Daily Walk-Around Inspection Points -
Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2-5. Daily Walk-Around Inspection Points -
Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2-6. Daily Walk-Around Inspection Points -
Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-2
3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . 3-5
3-3. Malfunction Indicator Light and Test Button . . . . . 3-7
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . 3-8
3-5. Platform Control Console - w/Drive Orientation . . . 3-9
3-6. Platform Control Indicator Panel . . . . . . . . . . . . . 3-15
3-7. Platform Control Indicator Panel -
w/Drive Orientation . . . . . . . . . . . . . . . . . . . . . . . 3-16
4-1. Position of Least Backward Stability . . . . . . . . . . . 4-3
4-2. Position of Least Forward Stability . . . . . . . . . . . . . 4-4
4-3. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-6
4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-10
4-5. Towbar Connecting Points - Prior to S/N 75606 . 4-11
4-6. Towbar Connecting Points - S/N 75606
to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
3121205 – JLG Lift – iii
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4-7. Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-8. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-9. Decal Installation - Sheet 1 of 4. . . . . . . . . . . . . . . 4-20
4-10. Decal Installation - Sheet 2 of 4. . . . . . . . . . . . . . . 4-21
4-11. Decal Installation - Sheet 3 of 4. . . . . . . . . . . . . . . 4-22
4-12. Decal Installation - Sheet 4 of 4. . . . . . . . . . . . . . . 4-23
6-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . 6-12
6-2. Engine Operating Temperature Specifications - Deutz
- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-3. Engine Operating Temperature Specifications - Deutz
- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-4. Engine Operating Temperature Specifications - Ford -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5. Engine Operating Temperature Specifications - Ford -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-6. Engine Operating Temperature Specifications -
Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18
6-7. Engine Operating Temperature Specifications -
Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19
6-8. Engine Operating Temperature Specifications - GM -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-9. Engine Operating Temperature Specifications - GM -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-10. Operator Maintenance & Lubrication Diagram . . . 6-22
6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-40
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 600S Decal Legend - Prior to S/N XXXXXX . . . . . 4-24
4-2 600S Decal Legend - S/N XXXXXX to Present. . . 4-28
4-3 600SJ Decal Legend . . . . . . . . . . . . . . . . . . . . . . 4-32
4-4 660SJ Decal Legend - Prior to S/N XXXXXX . . . . 4-36
4-5 660SJ Decal Legend - S/N XXXXXX to Present . . 4-40
6-1 Operating Specifications - Prior to S/N XXXXXX . . 6-2
6-2 Operating Specifications - S/N XXXXXX to Present 6-3
6-3 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-4 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-4
6-5 Deutz F4M1011F/F4M2011 Specifications . . . . . . 6-5
6-6 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . 6-5
6-7 Caterpillar 3044C / 3.4 . . . . . . . . . . . . . . . . . . . . . . 6-6
6-8 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-9 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-10 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . 6-7
6-11 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-12 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-13 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-14 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-9
6-15 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . 6-9
6-16 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . 6-10
iv – JLG Lift – 3121205
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-17 Critical Stability Weights - 600S . . . . . . . . . . . . . . 6-10
6-18 Critical Stability Weights - 600SJ . . . . . . . . . . . . . 6-11
6-19 Critical Stability Weights - 660SJ . . . . . . . . . . . . . 6-11
6-20 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-23
6-22 Wheel Torque Chart - 10 Lug. . . . . . . . . . . . . . . . 6-36
6-21 Wheel Torque Chart - 9 Lug. . . . . . . . . . . . . . . . . 6-36
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
3121205 – JLG Lift – v
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This page left blank intentionally.
vi – JLG Lift – 3121205
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.
3121205 – JLG Lift – 1-1
SECTION 1 - SAFETY PRECAUTIONS
• Read, understand, and obey all DANGERS, WARNINGS,
CAUTIONS, and operating instructions on the machine
and in this manual.
• Use the machine in a manner which is within the scope of
its intended application set by JLG.
• All operating personnel must be familiar with the emergency controls and emergency operation of the machine
as specified in this manual.
• Read, understand, and obey all applicable employer,
local, and governmental regulations as they pertain to
operation of the machine.
Workplace Inspection
• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.
• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.
• Do not operate the machine in hazardous environments
unless approved for that purpose by JLG.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.
Machine Inspection
• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for
detailed instructions.
• Do not operate this machine until it has been serviced and
maintained according to requirements specified in the
Service and Maintenance Manual.
• Be sure the footswitch and all other safety devices are
operating properly. Modification of these devices is a
safety violation.
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER
• Do not operate any machine on which safety or instruction
placards or decals are missing or illegible.
• Avoid any buildup of debris on the platform floor. Keep
mud, oil, grease, and other slippery substances from footwear and platform floor.
1-2 – JLG Lift – 3121205
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.
• 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.
3121205 – JLG Lift – 1-3
SECTION 1 - SAFETY PRECAUTIONS
• Before operating the machine, make sure all gates are
closed and fastened in their proper position.
• Keep both feet firmly positioned on the platform floor at all
times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the boom assembly to enter or leave the platform.
• Use extreme caution when entering or leaving platform.
Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.
Electrocution Hazards
• This machine is not insulated and does not provide protection from contact or proximity to electrical current.
1-4 – JLG Lift – 3121205
SECTION 1 - SAFETY PRECAUTIONS
Table 1-1. Minimum Approach Distances (M.A.D.)
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the
Minimum Approach Distance (MAD) as shown in Table 1-
1.
• Allow for machine movement and electrical line swaying.
Voltage Range
(Phase to Phase)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain a clearance of at least 10 ft. (3m) between any part
of the machine and its occupants, their tools, and their
equipment from any electrical line or apparatus carrying up
to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
MINIMUM APPROACH DISTANCE
in Feet (Meters)
3121205 – JLG Lift – 1-5
SECTION 1 - SAFETY PRECAUTIONS
• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers
are rated for the voltage of the line being guarded. These
barriers shall not be part of (or attached to) the machine. The
minimum approach distance shall be reduced to a distance
within the designed working dimensions of the insulating
barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental
requirements for work practices near energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED
ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
Tipping Hazards
• The user must be familiar with the surface before driving.
Do not exceed the allowable sideslope and grade while
driving.
1-6 – JLG Lift – 3121205
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.
3121205 – JLG Lift – 1-7
SECTION 1 - SAFETY PRECAUTIONS
• Use the boom functions, not the drive function, to position
the platform close to obstacles.
• Always post a lookout when driving in areas where vision
is obstructed.
• Keep non-operating personnel at least 6 ft. (1.8m) away
from machine during all driving and swing operations.
• Limit travel speed according 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 – 3121205
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.
3121205 – JLG Lift – 1-9
SECTION 1 - SAFETY PRECAUTIONS
DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28
MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort
Number
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves ru stle
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 – 3121205
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING
The aerial platform is a personnel handling device; so it is
necessary that it be operated and maintained only by trained
personnel.
Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.
Operator Training
Operator training must cover:
1. Use and limitations of the controls in the platform and at
the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
machine.
3. Rules of the employer and government regulations.
4. Use of approved fall protection device.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunction.
6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, dropoffs.
7. Means to avoid the hazards of unprotected electrical
conductors.
8. Specific job requirements or machine application.
Training Supervision
Training must be done under the supervision of a qualified
person in an open area free 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.
3121205 – JLG Lift – 2-1
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.2 PREPARATION, INSPECTION, AND MAINTENANCE
The following table covers the periodic machine inspections
and maintenance recommended 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-QUALIFIED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT
MODEL.
2-2 – JLG Lift – 3121205
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 In ser vice for 3 months or 150 hours, whichever
Annual Machine Inspection Annually, no later than 13 months from the date of
Preventative Maintenance At intervals as specified in the Ser vice 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
comes first;
or
Out of service for a period of more than 3 months;
or
Purchased used.
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-Qualified
Owner, Dealer, or User Qualified JLG
Service
Qualification
Mechanic
Mechanic
Service Technician
Mechanic
Reference
Service and Maintenance
Manual and applicable JLG
inspection form
Service and Maintenance
Manual and applicable JLG
inspection form
Service and Maintenance
Manual and applicable JLG
inspection form
Service and Maintenance
Manual
3121205 – JLG Lift – 2-3
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Pare nt Metal C rack 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, EMI 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 2-3. thru
Figure 2-6.
6. Battery – Charge as required.
7. Fuel (Combustion Engine Powered Machines) – Add the
proper fuel as necessary.
8. Hydraulic Oil – Check the hydraulic oil level. Ensure
hydraulic oil is added as required.
9. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems in
an area free of overhead and ground level obstructions.
Refer to Section 4 for more specific instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE
MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER
MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT
IS DECLARED SAFE FOR OPERATION.
2-4 – JLG Lift – 3121205
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
Function Check
Perform the Function Check as follows:
1. From the ground control panel with no load in the platform:
a. Check that all guards protecting the switches or
locks are in place;
b. Operate all functions and check all limiting and cut-
out switches;
c. Check auxiliary power (or manual descent);
d. Ensure that all machine functions are disabled
when the Emergency Stop Button is activated.
2. From the platform control console:
a. Ensure that the control console is firmly secured in
the proper location;
b. Check that all guards protecting the switches or
locks are in place;
c. Operate all functions and check all limiting and cut-
out switches;
d. Ensure that all machine functions are disabled
when the Emergency Stop Button is pushed in.
3. With the platform in the transport (stowed) position:
a. Drive the machine on a grade, not to exceed the
rated gradeability, and stop to ensure the brakes
hold;
b. Check the tilt sensor alarm to ensure proper opera-
tion.
3121205 – JLG Lift – 2-5
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
2.3 LIMIT SWITCH FUNCTIONAL CHECK
TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP
WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT
FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE
MACHINE.
NOTE: Perform checks from ground controls first, then from plat-
form controls.
1. Operate machine from ground control.
NOTE: For adjustments see Service Manual - Limit Switch Adjust-
ments.
2. Check elevation limit switch as follows:
a. Lift boom up to 2 degrees to 7 degrees above hori-
zontal. The switch should activate at this point.
b. Lift boom down to 2.5 degrees to 7.5 degrees
below horizontal. The switch should reset at this
point.
3. Raise main boom, extend and retract telescope. Check
for delayed movement of fly section, indicating loose
cables.
4. Swing turntable to LEFT and RIGHT a minimum of 45
degrees. Check for smooth motion.
NOTE: Step 5 is only applicable for machines with an external tilt
sensor.
5. With the aid of an assistant to monitor the CHASSIS
OUT OF LEVEL indicator light on the platform control
console, manually activate the indicator light by compressing any one of the three tilt indicator mounting
springs. If the light does not illuminate, shut down
machine and contact a qualified service technician
before continuing operation.
NOTE: Step 6 is applicable for machines with an internal tilt sen-
sor.
6. Check the chassis out of level indicator located on the
platform control console by driving, with the machine in
level position, up a suitable ramp of at least 5° slope.
Check the out of level indicator, with the machine on the
ramp. If the light does not illuminate, return the machine
to a level surface, shut down the machine, and contact a
qualified technician before resuming operation.
2-6 – JLG Lift – 3121205
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
NOTE: Steps 7 & 8 cover 600S ANSI market machines with dual
capacities (500 & 1000 lb. [227 kg for ANSI markets and
230 kg for CE and Australia markets & 454 kg for ANSI
markets and 450 kg for CE and Australia markets]).
7. Check capacity limit switch as follows:
Boom Length Switch.
a. Raise boom to horizontal (place angle indicator on
base boom between boom pivot pin and lift cylinder
attach pin).
b. Telescope boom out until 500 lb. (227 kg for ANSI
markets and 230 kg for CE and Australia markets)
light comes on (may need to used auxiliary power
to position boom correctly).
c. Mark wear pad location on the fly and mid booms.
d. Telescope boom out to full extension.
e. Measure from the mark on the fly boom to the wear
pad and measure from mark on the mid boom to
the wear pad.
f. Add These two numbers together (they should be
approximately equal) they should measure 137" to
139" (348 to 353 cm).
Boom Angle Switch.
a. Telescope boom to full extension.
b. Lift boom up until 1000 lb. (454 kg for ANSI markets
and 450 kg for CE and Australia markets) light
comes on.
c. Lift boom down using auxiliary power until 500 lb.
(227 kg for ANSI markets and 230 kg for CE and
Australia markets) light comes on. Boom angle
must be 45 degrees to 50 degrees (place angle
indicator on base boom between boom pivot pin
and lift cylinder attach pin).
d. Lift boom up until 1000 lb. (454 kg for ANSI markets
and 450 kg for CE and Australia markets) light
comes on. Boom angle should be 55 degrees to 64
degrees.
NOTE: If limit switch settings need to be changed, you will need
to recheck that the 500 lb. (227 kg for ANSI markets and
230 kg for CE and Australia markets) light comes on at 45
degrees to 50 degrees when lifting down.
3121205 – JLG Lift – 2-7
SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
8. Check capacity limit switch as follows:
Main Boom Length Switch.
a. Lift main boom to approximately horizontal.
b. Telescope boom out until 500 lb. (227 kg for ANSI
markets and 230 kg for CE and Australia markets)
light comes on (may need to used auxiliary power
to position boom correctly).
c. Mark the wear pad location on the main fly boom.
d. Telescope the main boom to full extension.
e. Measure from the mark on the fly boom to the wear
pad. The dimension should be 125" to 127" (317.5
to 322.5 cm).
Main Boom Angle Switch.
a. Lift main boom to approximately horizontal.
b. Telescope boom out until 500 lb. (227 kg for ANSI
markets and 230 kg for CE and Australia markets)
light comes on (may need to used auxiliary power
to position boom correctly).
c. Lift main boom up until 1000 lb. (454 kg for ANSI
markets and 450 kg for CE and Australia markets)
light comes on. The boom angle at this point should
be 55 degrees to 60 degrees.
d. Lift main boom down until 500 lb. (227 kg for ANSI
markets and 230 kg for CE and Australia markets)
light comes on. The boom angle at this point should
be 45 degrees to 50 degrees.
NOTE: If limit switch settings need to be changed, you will need
to recheck that the 500 lb. (227 kg for ANSI markets and
230 kg for CE and Australia markets) light comes on at 45
degrees to 50 degrees when lifting down.
2-8 – JLG Lift – 3121205
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