JLG 660SJ Operator Manual

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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

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

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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

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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

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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

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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

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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-

• 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

Service Technician

Mechanic

Reference

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

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Machine Nomenclature - 600SJ/660SJ

1. Platform

2. Platform Control Box

3. Rotator

4. Articulating Jib

5. Fly Boom

6. Mid Boom

7. Base Boom

8. Boom Assembly

9. Telescope Cylinder ( I ns i de )

10. Ground Control Box

11. Turntable

12. Steer Wheels

13. Frame

14. Drive Wheels

15. Swing Bearing

16. Lift Cylinder

17. Slave Level Cylinder

18. Ar ticulating Jib L i ft C y li n de r

19. Footswitch

3121205 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Machine Nomenclature - 600S

1. Platform

2. Platform Control Box

3. Rotator

4. Fly Boom

5. Mid Boom

6. Base Boom

7. Boom Assembly

8. Telescope Cylinder (Inside)

9. Ground Control Box

10. Turntable

11. Steer Wheels

12. Frame

13. Drive Wheels

14. Swing Bearing

15. Lift Cylinder

16. Slave Level Cylinder

17. Footswitch

2-10 – JLG Lift – 3121205

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-3. Daily Walk-Around Inspection Diagram

3121205 – JLG Lift – 2-11

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 “Walk-Around Inspection Checklist”.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING "WALK-AROUND INSPECTION".

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missing

parts, that they are securely fastened and that no visible damage exists in addition to any other criteria mentioned.

1. Platform Assembly - Platform mounting pins secure. Footswitch in good working order; not modified, disabled or blocked.

2. Platform Control Console - Switches and levers return to neutral and are properly secured, decals/placards secure and legible, control marking legible.

3. Rotator - See Note.

4. Rotator Motion Control Valve - See Note.

5. Jib Boom (If Equipped) - See Note.

6. Dual Capacity Limit Switch - Arm free to move, and

free from dirt and grease.

7. Power Track - See Note.

8. Steer Cylinder Assembly (4 Wheel Steer) - See Note.

9. Spindle (4 Wheel Steer) - Evidence of proper lubrica-

tion.

10. Drive Motor and Brake - See Note.

11. Drive Hub - See Note.

Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1 of 3

2-12 – JLG Lift – 3121205

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Wheel/Tire Assembly - No loose or missing lug nuts. Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

13. Tie Rod and Steering Linkage (4 Wheel Steer) - Tie rod end studs locked.

14. Turntable Lock - Operable.

15. Auxiliary Power Pump - See Note.

16. Swing Drive Motor and Brake - See Note.

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

18. Turntable Bearing and Pinion - Evidence of proper

lubrication. No evidence of loose bolts or looseness between bearing and structure.

19. Manual Descent (Prior to S/N 70975) - See Note.

20. Hydraulic Oil Return Filter Housing - See Note.

21. LP Gas Tank (If Equipped) - See Note.

22. 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.

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

24. Ground Controls - Switches operable, decals secure and legible.

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

26. Door and Latches - Hood door and latches in working

condition.

27. Tie Rod and Steering Linkage, - Tie rod end studs locked.

28. Oscillating Cam Valve (If Equipped) - See Note

29. Oscillating Axle Cylinder (If Equipped) - See Note.

30. Oscillating Axle (If Equipped) - See Note.

31. Dual Capacity Limit Switch - Arm free to move, and

free from dirt and grease.

32. Engine Air Filter - Element clean.

Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2 of 3

3121205 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

33. Battery - Proper electrolyte levels; cables tight, no visible damage or corrosion.

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

35. Muffler and Exhaust System - See Note.

36. Hydraulic Pump - See Note.

37. Engine Tray Pivot - See Note.

38. Hydraulic Oil Medium Pressure Filter Housing - Hous-

ing secure.

39. Hydraulic Swivel - See Note.

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

Drive Cut-off Switch) Arm free to move, and free from dirt and grease.

41. LP Gas Tank (If Equipped) - See Note.

42. Flow Valves - See Note.

43. Frame - See Note.

44. Main Boom Sections - Wear pads secure. All cylinders

- rod end shafts and barrel-end shafts properly secured; evidence of proper lubrication.

45. Platform Pivot Pin - See Note.

Figure 2-6. Daily Walk-Around Inspection Points - Sheet 3 of 3

2-14 – JLG Lift – 3121205

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. On ANSI machines, 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.

Ground Control Station

(See Figure 3-1., Ground Control Station)

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.

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 compensate for any difference in the automatic self leveling system.

3121205 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706914 A

Figure 3-1. Ground Control Station

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 . J i b 4 . P o we r /E m er g e nc y St o p 5 . E n g in e St a r t /A u xi l ia r y Po w er or E ng i n e S t ar t / Au x i li a r y P ow e r /F un c ti o n En a bl e 6 . B o o m L i f t 7 . H o u rm e te r 8 . P l a tf o rm / Gr o u nd S el e ct S w it c h 9 . S w i ng

10. Boom Telescope

3-2 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Jib (If Equipped)

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.

NOTE: On machines with diesel engines, when Glow Plug Indi-

cator is lighted (Yellow), wait until light goes out before cranking engine.

4. Power/Emergency Stop Switch

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

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.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)

3121205 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Lift Control

Provides raising and lowering of the main boom.

7. Hourmeter

Registers the amount of time the machine has been in use, with engine running. By connecting into the oil pressure circuit of the engine, only engine run hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset.

8. Platform/Ground Select

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

NOTE: With the Platform/Ground Select Switch in the center posi-

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

NOTE: Lift, Swing, Platform Level, Telescope, Platform Rotator

and Auxiliary control switches are spring-loaded and will automatically return to neutral (off) when released.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.

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.

9. Swing Control

Provides 360 degrees continuous turntable rotation.

10. Tel es co p e C o n tr ol

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

3-4 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel

(See Figure 3-2. and Figure 3-3.)

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 Engine Coolant Temperature (Ford and Continental) Indicator

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

4. High 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. Engine Malfunction Indicator Light (Ford Engines S/N 48907 to S/N 61927 - refer to ADE System Identification page at the front of the book)

Indicates that the Engine Control Module has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM. 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 Level Indicator

Indicates that the fuel level 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 (Diesel)

Indicates glow plugs are on. The glow plugs are automatically turned on with the ignition circuit and remain on for approximately about seven seconds. Start the engine only after the light goes out.

3121205 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Prior to S/N 0300099060

1. Batter y Charging

2. Engine Oil Pressure

3. Engine Water Temp.

4. Engine Oil Temp.

5. Engine Malfunction In dicator

6. Low Fuel

7. Glow Plug

8. Platform Overload

9. Hyd. Filter Bypass

10. Transmission Filter By-Pass

11. Engine Air Filter By-Pass

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

3-6 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

S/N 0300099060 to Present

1. Battery Charging

2. Engine Oil Pressure

3. Engine Water Temp.

4. Engine Oil Temp.

5. Engine Malfunction Indicator

6. Low Fuel

7. Glow Plug

8. Platform Overload

9. Not Used

10. Not Us ed

11. Not Us ed

12. Not Us ed

13. Drive and Steer Disable

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

3121205 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-4. Malfunction Indicator Light and Test Button

8. Platform Overload (If equipped)

Indicates the platform has been overloaded.

9. Hydraulic Oil Filter Indicator (Prior to S/N 84827).

Indicates the return oil filter is too restrictive and in the bypass mode and needs to be replaced.

10. Transmission Pump Oil Filter Indicator (Prior to S/N 84827)

Indicates that charge pump filter is too restrictive and needs to be replaced. This indicator has an integral temperature sensor (70° F [21° C].) so that false signals are not generated when the hydraulic oil is below normal operating temperature.

11. Engine Air Filter Indicator (Prior to S/N 84827)

Indicates that the air filter is too restrictive and needs to be replaced.

12. EFI System Test Button (Ford Engines S/N 48907 to S/N 61927 - refer to ADE System Identification page at the front of the book)

By pushing and holding the system test button on the side of the ground control box, the Diagnostic Trouble

Codes will be displayed on the Malfunction Indicator Light. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

13. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function has been activated.

3-8 – JLG Lift – 3121205

Platform Station

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

1. 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 and climbing grades by shifting the wheel motors to maximum displacement and giving high engine speed when 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.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121205 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Drive Speed

2. Steer Select

3. Platform Leveling Override

4. Horn

5. Power/Emergency Stop 6 . A u x . P ow e r 7 . F ue l S e le ct

8. Lights

9. Drive/Steer

10. Telescope

11. Jib

12. Platform Rotate

13. Function Speed

14. Main Lift/Swing

Figure 3-5. Platform Control Console

3-10 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1702567 A

1702676-B

1704997

1705170 A

1702938

14 13

12 111617

10 9

715

1. Drive Speed

2. Steer Select

3. Platfor m Leveling Override

4. Horn

5. Power/Emergency Stop

6. Aux. Power

7. Fuel Select

8. Lights

9. Drive/Steer

10. Telescope

11. Jib

12. Platfor m Rotate

13. Function Speed

14. Main Lift/Swing

15. Drive Orientation Override

16. Sof t Touch Override

17. Sof t Touch Indicator

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

3121205 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Steer Select (If Equipped)

When equipped with four wheel steering, the action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is for normal driving at maximum speeds. The forward position is for “crab” steering. When in this mode both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This can be used for positioning the machine in aisle ways or against buildings. The back switch position is for “coordinated” steering. In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas.

To re-synchronize the front and rear axles, position the rear drive wheels to the forward drive position by selecting either crab or compound steer, then select front steer (center switch position) to operate the normal steering function.

3. Platform Leveling Override

This switch allows the operator to adjust the level of the platform.

4. Travel Warning Horn

Supplies electrical power to an audible warning device when pressed.

5. Power/Emergency Stop

An ON-OFF POWER/EMERGENCY STOP switch and a separate ENGINE START/AUXILIARY POWER toggle switch on the platform console supply electrical power to the starter solenoid, when the ignition switch is placed in the “ON” position and the ENGINE START switch is push forward.

3-12 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Auxiliary Power

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 tower boom lift, tower telescope, main boom lift, main telescope and swing.

7. Fuel Select (Dual Fuel Engine Only) (If Equipped)

Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position. It is unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is running.

8. Lights (If Equipped)

This switch operates control console panel lights and head lights if the machine is so equipped. The ignition switch does not have to be on to operate the lights, so care must be taken to avoid draining the battery if left unattended. The master switch and / or the ignition switch at the ground control will turn off power to all lights.

NOTE: LIFT, SWING, and DRIVE control levers are spring-loaded

and will automatically return to neutral (OFF) position when released.

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.

9. Drive/Steer

The DRIVE joystick provides for driving either forward or backward. The controller is ‘ramped’ to allow variable drive speed.

Steering is controlled by a thumb operated switch on top of the joystick.

10. Tel es co p e C o n tr ol

This control allows extension and retraction of the main boom.

3121205 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

11. Jib (If Equipped)

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

12. Platform Rotate

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

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

13. Function Speed

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.

14. 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. 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.

3-14 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

15. Drive Orientation Override

When the boom is swung over the rear tires or further 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.

16. 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.

17. 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.

3121205 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

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

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

This orange illuminator 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 (If equipped)

Indicates the platform has been overloaded.

3-16 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Tilt

2. Overload

3. Capacity

4. Cable Se rvice

5. Enable

6. Glow Plug

7. Low Fuel

8. Engine Malfunction

9. AC Generator

10. Sof t Touch

11. Creep

Figure 3-7. Platform Control Indicator Panel

3121205 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

* UNRESTRICTED CAPACITY

** RESTRICTED CAPACITY

1001107927 A

611 8912

1. Tilt

2. Overload

3. Capacity

4. Cable Service

5. Enable

6. Glow Plug

7. Low Fuel

8. Malfunction

9. AC Generator

10. Not Used

11. Creep

12. Drive Orientation

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

3-18 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Capacity Indicator

Indicates the maximum platform capacity for the current position of the platform. Restricted capacities are permitted at restricted platform positions (shorter boom lengths and higher boom angles).

NOTE: Refer to the capacity decals on the machine for restricted

and unrestricted platform capacities.

4. Cable Service Indicator (If Equipped)

When illuminated, the light indicates the boom cables are loose or broken and must be repaired or adjusted immediately.

IF THE CABLE SERVICE INDICATOR IS ILLUMINATED, RETURN THE PLATFORM TO THE STOWED POSITION, SHUT DOWN THE MACHINE, AND HAVE THE BOOM CABLES INSPECTED.

5. Enable Indicator/Footswitch

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.

3121205 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Glow Plug Indicator (Diesel Only)

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

7. Low Fuel Indicator (Yellow)

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.

8. Malfunction Indicator

On all machines prior to S/N 48907 and machines with a Deutz engine prior to S/N 61927, the light turns on and an alarm sounds when machine’s power system requires immediate service. Any of the following conditions will turn on light and alarm: low engine oil pressure, high engine coolant temperature, clogged engine air filter, low alternator output, clogged hydraulic oil return filter, or clogged charge pump filter.

On machines with Ford engines from S/N 48907 to S/N 61927, the light indicates that the Engine Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory.

On machines after S/N 6T1927, the light indicates that the JLG Control System has detected an abnormal condition 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.

3-20 – JLG Lift – 3121205

SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. AC Generator (Green)

Indicates the generator is in operation.

10. 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.

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.

12. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or further 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.

3121205 – JLG Lift – 3-21

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-22 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic personnel 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 main or tower 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.

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

The boom can be raised above horizontal with or without any load in platform, if:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG.

3121205 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

Stability

Machine stability is based on two positions which are called FORWARD and BACKWARD stability. The machines position of least FORWARD stability is shown in Figure 4-2., Position of Least Forward Stability, and its position of least BACKWARD stability is shown in Figure 4-1., Position of Least Backward Stability.

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

4.3 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure

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

NOTE: Diesel engines only: After turning on ignition, operator

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

1. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch until engine starts.

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

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

3. Turn SELECT switch to PLATFORM.

4-2 – JLG Lift – 3121205

4. From Platform, pull POWER/EMERGENCY STOP switch

Figure 4-1. Position of Least Backward Stability

out, then push the ENGINE START switch 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.

Shutdown Procedure

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

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

2. Push POWER/EMERGENCY STOP switch in.

3. Turn Select switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

SECTION 4 - MACHINE OPERATION

3121205 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Forward Stability

4-4 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

4.4 TRAVELING (DRIVING)

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

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED TRAVELING.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED.

Traveling Forward and Reverse

1. At Platform Controls, pull out Emergency Stop switch and activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as desired.

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 drive tires 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 platform 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.

3121205 – JLG Lift – 4-5

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Sideslope

4-6 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

4.5 STEERING

Position thumb switch on Drive/Steer controller to RIGHT for steering right, or to LEFT for steering left.

4.6 PLATFORM

Platform Level Adjustment

To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level.

Platform Rotation

To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached.

4.7 BOOM

DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE.

3121205 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

Swinging the Boom

To swing boom, use SWING control switch to select RIGHT or LEFT direction.

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

NOTE: When boom functions are being operated there is an

interlock that prevents the use of DRIVE and STEER functions.

Raising and Lowering the Boom

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

Telescoping the Boom

To extend or retract the 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 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 minutes 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.

4-8 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

4.9 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

Refer to Section 6.5, Oscillating Axle Lockout Test (If Equipped) for procedure.

4.10 STEER/TOW SELECTOR (IF EQUIPPED)

DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COMPLETE TOW PACKAGE FROM MANUFACTURER.

A push-pull type selector valve located adjacent to the steer cylinder and linkage regulates oil flow in the steer circuit for steering and towing. When steering the unit the valve knob is pushed IN. When towing the unit the valve knob is pulled OUT to the float position.

4.11 TOWING (IF EQUIPPED)

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 8 M.P.H. (13 K.M.H.)

MAXIMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

1. Retract, lower and position boom over rear drive wheels in line with direction of travel; lock turntable.

3121205 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

Figure 4-4. Drive Disconnect Hub

2. Connect tow bar to front of frame with attach pins, and

tow bar to towing vehicle.

3. Disconnect drive hubs by inverting disconnect cap.Refer to Figure 4-4., Drive Disconnect Hub.

4. Actuate steer/tow selector valve for towing; pull valve knob OUT to float position. (This opens the steer circuit to reservoir, allowing the steer cylinder rod free travel.) The machine is now in the towing mode.

After towing the machine, complete the following:

1. Actuate steer/tow selector valve for steering; push valve

knob IN to the actuated position.

2. Reconnect drive hubs by inverting disconnect cap.

3. Disconnect tow bar from steering hitch and from towing

vehicle. The machine is now in the driving mode.

4-10 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Figure 4-5. Towbar Connecting Points - Prior to S/N 75606

STEER SELECT

VALVE

3121205 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

STEER SELECT

VALVE

Figure 4-6. Towbar Connecting Points - S/N 75606 to Present

4-12 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

4.12 AUXILIARY POWER - NON ADE EQUIPPED MACHINES

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)

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:

Activating from the Platform Control Station

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.

Activating 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.

3121205 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

4.13 AUXILIARY POWER - ADE EQUIPPED MACHINES

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)

Activating from the Platform Control Station

1. Position PLATFORM/GROUND SELECT KEY SWITCH to PLATFORM.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Depress and hold footswitch.

4. Position AUXILIARY POWER switch to ON and hold.

5. Operate appropriate control switch, lever or controller

for desired function and hold.

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

7. Position POWER/EMERGENCY STOP switch to OFF.

Activating from the Ground Control Station

1. Position PLATFORM/GROUND SELECT KEY SWITCH to GROUND.

2. Position POWER/EMERGENCY STOP switch to ON.

3. Position AUXILIARY POWER switch to ON and hold.

4. Operate appropriate control switch or controller for

desired function and hold.

5. Release AUXILIARY POWER switch, and appropriate control switch or controller.

6. Position POWER/EMERGENCY STOP switch to OFF.

4-14 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.

Changing From Gasoline to LP Gas

1. Start engine from Ground Control Station.

2. Open hand valve on LP gas supply tank by turning

counterclockwise.

3. While engine is operating on GASOLINE under a noload condition, place FUEL SELECT switch at Platform Control to LP position.

Changing From LP Gas to Gasoline

1. With engine operating on LP under a no-load condition, position FUEL SELECT switch at Platform Control Station to GASOLINE position.

2. Close hand valve on LP gas supply tank by turning clockwise.

4.15 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS

Tool Circuit

Operate with engine running and foot switch released.

1. Be sure hydraulic switch is “OFF”. It is located on the left side of platform below console box.

3121205 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

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

3. Plug tool 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.

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.

4-16 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

5. Turn hydraulic power tool switch “ON”. 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 “OFF”.

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 (179 Bar). 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.

4.16 TIE DOWN AND LIFTING

When transporting machine, boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck. Four tie down eyes are provided in the frame slab, one at each corner of the machine. (See Figure 4-3. Machine Tie Down.)

If it becomes necessary to lift the machine using an overhead or mobile crane, it is very important that the lifting devices are attached only to the designated lifting eyes, and that the turntable lock pin is engaged. (See Figure 4-4. Lifting Chart.)

NOTE: If not equipped, front lifting eyes on the S Models

machines are available. (P/N 3539590)

NOTE: Lifting eyes are provided at the front and rear in the frame

slab. Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated.

SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER.

3121205 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-7. 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.

4-18 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Figure 4-8. Lifting Chart

3121205 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Installation - Sheet 1 of 4

4-20 – JLG Lift – 3121205

612228

33 62

AUS

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

SECTION 4 - MACHINE OPERATION

3121205 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Installation - Sheet 3 of 4

4-22 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

27,22

4115304445

101

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

3121205 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Table 4-1. 600S Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273867-8

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- - - - - -

4- -- -- -- -- -- -- -- - - - - -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

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

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

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

10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

14 - - 1705084 1705084 - - - - - - 1705084 - - - - 1705084

15 - - 1705514 - - - - - - - - 1705514 - - - - - -

16- -- -- -- -- -- -- -- -- - - -

17 3251243 3251243 3251243 - - 3251243 3251243 3251243 3251243 3251243 3251243

French

0273872-6

CE Australian 0273875-3

Korean

0273870-9

Spanish

0273882-6

Japanese

0273888-8

Portuguese

0273885-6

Traditi onal

Chinese

0275099-8

Simplified

Chinese

1001116839-2

Australian

1001114385-1

4-24 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-1. 600S Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273867-8

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

19- -- -- -- -- -- -- -- -- - - -

20- -- -- -- -- -- -- -- -- - - -

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

22 1703 953 1703942 - - 1703945 1703941 1703944 1705903 1703943 1001116845 - -

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

24 1702 868 1704000 - - 1705969 1704001 - - 1705967 1001116846 1705 968 - -

25 1703797 1703924 1705921 1703927 1703923 1703926 1705895 1703925 1001116847 1705921

26 1705336 1705347 1705822 1705345 1705917 1705344 1705896 1001116849 1001116848 1705822

27 1703804 1703948 1701518 1703951 1703947 1703950 1705898 1703949 1001116850 1701518

28 1703805 1703936 1705961 1703939 1703935 1703938 1705897 1001116851 1703937 1705961

29 3252347 1703984 1705828 1703981 1703983 1703980 1705902 1703982 1001116852 1705828

30 3251813 3251813 - - - - 3251813 3251813 3251813 3251813 3251813 - -

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

32- -- -- -- -- -- -- -- -- - - -

33 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470

34 1702631 1702631 1702631 - - 1702631 - - 1702631 - - 1702631 1702631

35 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815

French

0273872-6

CE Australian 0273875-3

Korean

0273870-9

Spanish

0273882-6

Japanese

0273888-8

Portuguese

0273885-6

Traditional

Chinese

0275099-8

Simplified

Chinese

1001116839-2

Australian

1001114385-1

3121205 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. 600S Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273867-8

36- -- -- -- -- -- -- -- -- - - -

37 1704096 1704099 1705978 1704103 1704098 1704102 1706380 1704101 1001116853 1705978

38 1707014 1704107 1705978 1707043 1707048 1707053 1707051 1707045 1001116854 1705978

39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 - - 1704885

40 - - 1706948 - - 1706948 170694 8 - - 1706948 - - - - - -

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

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

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

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

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

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

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

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

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

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

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

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

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

French

0273872-6

CE Australian 0273875-3

Korean

0273870-9

Spanish

0273882-6

Japanese

0273888-8

Portuguese

0273885-6

Traditi onal

Chinese

0275099-8

Simplified

Chinese

1001116839-2

Australian

1001114385-1

4-26 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-1. 600S Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273867-8

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

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

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

57- -- -- -- -- -- -- -- -- - - -

58- -- -- -- -- -- -- -- -- - - -

59- -- -- -- -- -- -- -- -- - - -

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

61- -- -4420051- -- -- -- -- -- -4420051

62 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584

63 1001108493 10 01108 493 - - 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 - -

64 1706 941 1706941 - - 170694 1 1706941 1706941 1 706941 1706941 1706941 - -

65 1705 351 1705429 - - 170542 7 1705910 1705426 1 705905 1001116863 1705430 - -

66- -- -- -- -- -- -- -- -- -1001112551

French

0273872-6

CE Australian 0273875-3

Korean

0273870-9

Spanish

0273882-6

Japanese

0273888-8

Portuguese

0273885-6

Traditional

Chinese

0275099-8

Simplified

Chinese

1001116839-2

Australian

1001114385-1

3121205 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-2. 600S Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273867-9

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- - - - - -

4- -- -- -- -- -- -- -- - - - - -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

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

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

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

10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

14 - - 1705084 1705084 - - - - - - 1705084 - - - - 1705084

15 - - 1705514 - - - - - - - - 1705514 - - - - - -

16- -- -- -- -- -- -- -- -- - - -

17 3251243 3251243 3251243 - - 3251243 3251243 3251243 3251243 3251243 3251243

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

French

0273872-7CE0273875-3

Korean

0273870-10

Spanish

0273882-7

Japanese

0273888-9

Portuguese

0273885-7

Traditi onal

Chinese

0275099-9

Simplified

Chinese

1001116839-3

Australian

1001114385-1

4-28 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-2. 600S Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273867-9

19- -- -- -- -- -- -- -1001117034- - - -

20- -- -- -- -- -- -- -1001117035- - - -

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

22 1703 953 1703942 - - 170394 5 1703941 1703944 170 5903 1703943 1001116845 - -

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

24 1702 868 1704000 - - 170596 9 1704001 - - 1705967 1001116846 1705968 - -

25 1703797 1703924 1705921 1703927 1703923 1703926 1705895 1703925 1001116847 1705921

26 1705336 1705347 1705822 1705345 1705917 1705344 1705896 1001116849 1001116848 1705822

27 1703804 1703948 1701518 1703951 1703947 1703950 1705898 1703949 1001116850 1701518

28 1703805 1703936 1705961 1703939 1703935 1703938 1705897 1001116851 1703937 1705961

29 3252347 1703984 1705828 1703981 1703983 1703980 1705902 1703982 1001116852 1705828

30 3251813 3251813 - - - - 3251813 3251813 3251813 3251813 3251813 - -

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

32- -- -- -- -- -- -- -- -- - - -

33 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470 1703470

34 1702631 1702631 1702631 - - 1702631 - - 1702631 - - 1702631 1702631

35 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815 1702815

36- -- -- -- -- -- -- -- -- - - -

French

0273872-7CE0273875-3

Korean

0273870-10

Spanish

0273882-7

Japanese

0273888-9

Portuguese

0273885-7

Traditional

Chinese

0275099-9

Simplified

Chinese

1001116839-3

Australian

1001114385-1

3121205 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

Table 4-2. 600S Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273867-9

37 1001121800 1001121802 1705978 1001122200 1001121804 1001121807 1001121806 1001121809 1001121811 1705978

38 1001121813 1001121815 1705978 1001122201 1001121817 1001121820 1001121819 1001121822 1001121824 1705978

39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 - - 1704885

40 - - 1706948 - - - - 1706948 - - 1706948 - - - - - -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

French

0273872-7CE0273875-3

Korean

0273870-10

Spanish

0273882-7

Japanese

0273888-9

Portuguese

0273885-7

Traditi onal

Chinese

0275099-9

Simplified

Chinese

1001116839-3

Australian

1001114385-1

4-30 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-2. 600S Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273867-9

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

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

57- -- -- -- -- -- -- -- -- - - -

58- -- -- -- -- -- -- -- -- - - -

59- -- -- -- -- -- -- -- -- - - -

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

61- -- -4420051- -- -- -- -- -- -4420051

62 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584

63 1001108493 10 01108 493 - - 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 - -

64 1706 941 1706941 - - 170694 1 1706941 1706941 1 706941 1706941 1706941 - -

65 1705 351 1705429 - - 170542 7 1705910 1705426 1 705905 1001116863 1705430 - -

66- -- -- -- -- -- -- -- -- -1001112551

French

0273872-7CE0273875-3

Korean

0273870-10

Spanish

0273882-7

Japanese

0273888-9

Portuguese

0273885-7

Traditional

Chinese

0275099-9

Simplified

Chinese

1001116839-3

Australian

1001114385-1

3121205 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

Table 4-3. 600SJ Decal Legend

Item # ANSI

0273868-6

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- - - - - -

4- -- -- -- -- -- - - - - -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

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

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

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

10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

14 - - 1705084 1705084 - - - - - - - - 1705084

15 - - 1705514 1705514 - - - - - - - - 1705514

16- -- -- -- -- -- -- - - -

17 - - 3251243 3251243 3251 243 3251243 3251243 32512 43 3251243

CE Australian 0273876-4

French

0273873-6

Spanish

0273883-7

Japanese

600SJ

0273889-7

Portuguese

600SJ

0273886-7

Korean

1001112941-2

Australian

1001114386-1

4-32 – JLG Lift – 3121205

Table 4-3. 600SJ Decal Legend

SECTION 4 - MACHINE OPERATION

Item # ANSI

0273868-6

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

19- -- -- -- -- -- -- - - -

20- -- -- -- -- -- -- - - -

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

22 1703 953 - - 1703942 170394 1 1703944 1705903 170 3945 - -

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

24 1702 868 - - 1704000 170400 1 - - 1705967 17059 69 - -

25 1703797 1705921 1703924 1703923 1703926 1705895 1703927 1705921

26 1705336 1705822 1705347 1705917 1705344 1705896 1705345 1705822

27 1703804 1701518 1703948 1703947 1703950 1705898 1703951 1701518

28 1703805 1705961 1703936 1703935 1703938 1705897 1703939 1705961

29 - - 1705828 1703984 1703 983 1703980 1705902 17039 81 1705828

30 3251 813 - - 3251813 325181 3 3251813 3251813 - - - -

31 - - - - - - - - 1705494 - - - - - -

32- -- -- -- -- -- -- - - -

33 1703471 1703471 1703471 1703471 1703471 1703471 1703471 1703471

34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

35 1702816 1702816 1702816 1702816 1702816 1702816 1702816 1702816

CE Australian 0273876-4

French

0273873-6

Spanish

0273883-7

Japanese

600SJ

0273889-7

Portuguese

600SJ

0273886-7

Korean

1001112941-2

Australian

1001114386-1

3121205 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

Table 4-3. 600SJ Decal Legend

Item # ANSI

0273868-6

36- -- -- -- -- -- -- - - -

37 1701645 1705978 1707055 1707056 1707058 1707057 1707058 1705978

38 1707013 1705978 1707047 1707049 1707054 1707052 1707042 1705978

39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

40 1706 948 - - 1706948 170694 8 1706948 1706948 170 6948 - -

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

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

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

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

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

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

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

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

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

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

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

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

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

CE Australian 0273876-4

French

0273873-6

Spanish

0273883-7

Japanese

600SJ

0273889-7

Portuguese

600SJ

0273886-7

Korean

1001112941-2

Australian

1001114386-1

4-34 – JLG Lift – 3121205

Table 4-3. 600SJ Decal Legend

SECTION 4 - MACHINE OPERATION

Item # ANSI

0273868-6

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

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

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

57- -- -- -- -- -- -- - - -

58- -- -- -- -- -- -- - - -

59- -- -- -- -- -- -- - - -

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

61 - - 4420051 - - - - - - - - - - 44200 51

62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584

63 1001108493 - - 1001108493 1001108493 1001108493 1001108493 1001108493 - -

64 1706 941 - - 1706941 170694 1 1706941 1706941 170 6941 - -

65 1705 351 - - 1705429 170591 0 1705426 1705095 170 5427 - -

66- -- -- -- -- -- -- -1001112551

CE Australian 0273876-4

French

0273873-6

Spanish

0273883-7

Japanese

600SJ

0273889-7

Portuguese

600SJ

0273886-7

Korean

1001112941-2

Australian

1001114386-1

3121205 – JLG Lift – 4-35

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJ Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273869-7

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- - - -

4- -- -- -- -- -- -- -- - - -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

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

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

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

10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

14 - - - - 1705084 - - - - 1705084 1705084 1705084 1705084

15 - - 1705514 - - - - - - 1705514 1705514 1705514 - -

16- -- -- -- -- -- -- -- - - -

17 3251243 3251243 3251243 - - - - 3251243 3251243 3251243 3251243

Canadian

French

0273874-6

CE Australian 0273877-4

Korean

0274925-9

Tradit ional

Chinese

0273871-10

Spanish

0273884-7

Japanese

0273890-9

Portuguese

0273887-7

Australian

1001114387-1

4-36 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJ Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273869-7

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

19- -- -- -- -1001117034- -- -- - - -

20- -- -- -- -1001117035- -- -- - - -

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

22 1703953 1703942 - - 1703945 1703943 1703941 1703944 1705903 - -

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

24 170 2868 1704000 - - 1705969 1001116846 1704001 - - 1705967 - -

25 1703797 1703924 1705921 1703927 1703925 1703923 1703926 1705895 1705921

26 1705336 1705347 1705822 1705345 1001116849 1705917 1705344 1705896 1705822

27 1703804 1703948 1701518 1703951 1703949 1703947 1703950 1705898 1701518

28 1703805 1703936 1705961 1703939 1001116851 1703935 1703938 1705897 1705961

29 - - 1703984 1705828 1703981 1703982 1703983 1703980 1705902 1705828

30 325 1813 3251813 - - - - 3251813 32 51813 3251813 3251813 - -

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

32- -- -- -- -- -- -- -- - - -

33 1703472 1703472 1703472 1703470 1703472 1703472 1703472 1703472 1703472

34 1702631 1702631 1702631 - - - - 1702631 - - 1702631 1702631

35 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817

Canadian

French

0273874-6

CE Australian 0273877-4

Korean

0274925-9

Tradit ional

Chinese

0273871-10

Spanish

0273884-7

Japanese

0273890-9

Portuguese

0273887-7

Australian

1001114387-1

3121205 – JLG Lift – 4-37

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJ Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273869-7

36- -- -- -- -- -- -- -- - - -

37 1701645 1707055 1705978 1707058 1707060 1707056 1707059 1707057 1705978

38 1707013 1707047 1705978 1707042 1707044 1707049 1707054 1707052 1705978

39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

40 - - 1706948 - - - - - - 1706948 - - 1706948 - -

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

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

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

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

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

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

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

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

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

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

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

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

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

Canadian

French

0273874-6

CE Australian 0273877-4

Korean

0274925-9

Tradit ional

Chinese

0273871-10

Spanish

0273884-7

Japanese

0273890-9

Portuguese

0273887-7

Australian

1001114387-1

4-38 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-4. 660SJ Decal Legend - Prior to S/N 0300099060

Item # ANSI

0273869-7

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

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

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

57- -- -- -- -- -- -- -- - - -

58- -- -- -- -- -- -- -- - - -

59- -- -- -- -- -- -- -- - - -

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

61 - - - - 4420051 - - - - - - - - - - 4420051

62 1700584 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584

63 1001108493 1 0011084 93 - - 1001108493 1001108493 10011 08493 1001108493 1001108493 - -

64 1706941 1706941 - - 1706941 1706941 1706941 1706941 1706941 - -

65 170 5351 1705429 - - 1705427 1001116863 1705910 1705426 1705905 - -

66- -- -- -- -- -- -- -- -1001112551

Canadian

French

0273874-6

CE Australian 0273877-4

Korean

0274925-9

Tradit ional

Chinese

0273871-10

Spanish

0273884-7

Japanese

0273890-9

Portuguese

0273887-7

Australian

1001114387-1

3121205 – JLG Lift – 4-39

SECTION 4 - MACHINE OPERATION

Table 4-5. 660SJ Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273869-8

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

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- - - - - -- -- - - -

4- -- -- -- -- - - - - -- -- - - -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529

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

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

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

10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

14 - - - - 1705084 - - - - - - 1705084 1705084 1705084 1705084

15 - - 1705514 - - - - - - - - 1705514 1705514 170 5514 - -

16- -- -- -- -- - - - - -- -- - - -

17 3251243 3251243 3251243 - - - - - - 3251243 3251243 3251243 3251243

Canadian

French

0273874-7

CE Australian 0273877-4

Korean

0274925-10

Tradit ional

Chinese

0273871-11

Simplified

Chinese

1001117939-3

Spanish

0273884-8

Japanese

0273890-10

Portuguese

0273887-8

Australian

1001114387-1

4-40 – JLG Lift – 3121205

SECTION 4 - MACHINE OPERATION

Table 4-5. 660SJ Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273869-8

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

19- -- -- -- -1001117034- - - -- -- - - -

20- -- -- -- -1001117035- - - -- -- - - -

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

22 170 3953 1703942 - - 1703945 1703943 1001116845 170394 1 1703944 1705903 - -

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

24 170 2868 1704000 - - 1705969 1001116846 17059 68 1704001 - - 1705967 - -

25 1703797 1703924 1705921 1703927 1703925 1001116847 1703923 1703926 1705895 1705921

26 1705336 1705347 1705822 1705345 1001116849 1001116848 1705917 1705344 1705896 1705822

27 1703804 1703948 1701518 1703951 1703949 1001116850 1703947 1703950 1705898 1701518

28 1703805 1703936 1705961 1703939 1001116851 1703937 1703935 1703938 1705897 1705961

29 - - 1703984 1705828 1703981 1703982 1001116852 1703983 1703980 1705902 1705828

30 325 1813 3251813 - - - - 3251813 32518 13 3251813 3251813 3251813 - -

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

32- -- -- -- -- - - - - -- -- - - -

33 1703472 1703472 1703472 1703470 1703472 1703472 1703472 1703472 1703472 1703472

34 1702631 1702631 1702631 - - - - - - 1702631 - - 1702631 1702631

35 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817

Canadian

French

0273874-7

CE Australian 0273877-4

Korean

0274925-10

Tradit ional

Chinese

0273871-11

Simplified

Chinese

1001117939-3

Spanish

0273884-8

Japanese

0273890-10

Portuguese

0273887-8

Australian

1001114387-1

3121205 – JLG Lift – 4-41

SECTION 4 - MACHINE OPERATION

Table 4-5. 660SJ Decal Legend - S/N 0300099060 to Present

Item # ANSI

0273869-8

36- -- -- -- -- - - - - -- -- - - -

37 1001121801 1001121803 1705978 1001121918 1001121810 1001121812 1001121805 1001121808 1001121656 1705978

38 1001121814 1001121816 1705978 1001121921 1001121823 1001121825 1001121818 1001121821 1001121655 1705978

39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

40 - - 1706948 - - - - - - - - 1706948 - - 1706948 - -

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

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

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

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

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

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

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

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

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

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

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

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

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

Canadian

French

0273874-7

CE Australian 0273877-4

Korean

0274925-10

Tradit ional

Chinese

0273871-11

Simplified

Chinese

1001117939-3

Spanish

0273884-8

Japanese

0273890-10

Portuguese

0273887-8

Australian

1001114387-1

4-42 – JLG Lift – 3121205

JLG 660SJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 ADDITIONAL HAZARDS / SAFETY

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

Function Check

2.3 LIMIT SWITCH FUNCTIONAL CHECK

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Ground Control Indicator Panel

Platform Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 ENGINE OPERATION

Starting Procedure

Shutdown Procedure

4.4 TRAVELING (DRIVING)

Traveling Forward and Reverse

4.5 STEERING

4.6 PLATFORM

Platform Level Adjustment

Platform Rotation

4.7 BOOM

Swinging the Boom

Raising and Lowering the Boom

Telescoping the Boom

4.8 SHUT DOWN AND PARK

4.9 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

4.10 STEER/TOW SELECTOR (IF EQUIPPED)

4.11 TOWING (IF EQUIPPED)

4.12 AUXILIARY POWER - NON ADE EQUIPPED MACHINES

Activating from the Platform Control Station

Activating from the Ground Control Station

4.13 AUXILIARY POWER - ADE EQUIPPED MACHINES

Activating from the Platform Control Station

Activating from the Ground Control Station

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Changing From Gasoline to LP Gas

Changing From LP Gas to Gasoline

4.15 HYDRAULIC TOOL CIRCUIT INSTRUCTIONS

Tool Circuit

4.16 TIE DOWN AND LIFTING