JLG 600s Operation And Safety Manual
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JLG 600s Operation And Safety Manual

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See also: Service Maintenance Manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
600S
600SJ
660SJ
ANSI
3121205
®
May 1, 2012

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  • Page 1 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...
  • Page 2 ADE Identification All 600S, 600SJ, and 660SJ machines from S/N 61927 incorporate ADE (JLG Control System). The follow- ing 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.
  • Page 3 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.
  • Page 4 INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO- DECAL WILL HAVE AN ORANGE BACKGROUND. TECTION OF PROPERTY. – JLG Lift – 3121205...
  • Page 5 FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- • Accident Reporting • Standards and Regulations TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...

  • Page 6: Revision Log

    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 – JLG Lift – 3121205...

  • Page 7: Table Of Contents

    Function Check......2-5 Platform Level Adjustment ....4-7 3121205 – JLG Lift –...
  • Page 8 Critical Stability Weights ....6-10 Serial Number Locations ....6-12 – JLG Lift – 3121205...
  • Page 9 2-2. Machine Nomenclature - 600S ....2-9 Tire Damage ......6-33 2-3.
  • Page 10 4-11. Decal Installation - Sheet 3 of 4....4-22 600S Decal Legend - Prior to S/N XXXXXX ..4-24 4-12. Decal Installation - Sheet 4 of 4....4-23 600S Decal Legend - S/N XXXXXX to Present .
  • Page 11 PAGE 6-17 Critical Stability Weights - 600S ....6-10 6-18 Critical Stability Weights - 600SJ ... . . 6-11 6-19 Critical Stability Weights - 660SJ .

  • Page 12: Section - Paragraph, Subject

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally. – JLG Lift – 3121205...

  • Page 13: Section 1. Safety Precautions

    If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“ JLG”). • Do not operate this machine until complete training is per- formed by authorized persons.

  • Page 14: Workplace Inspection

    JLG. • Avoid any buildup of debris on the platform floor. Keep • Do not operate the machine in hazardous environments mud, oil, grease, and other slippery substances from foot- unless approved for that purpose by JLG.

  • Page 15: Operation

    • Do not carry materials directly on platform railing. Contact yard anchorage point. Attach only one (1) lanyard per lan- JLG for approved material handling accessories. yard anchorage point. • When two or more persons are in the platform, the opera- tor shall be responsible for all machine operations.

  • Page 16: Electrocution Hazards

    • 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 plat- form. – JLG Lift – 3121205...

  • Page 17: Minimum Approach Distances (M.a.d.)

    50,000 volts. One foot additional clearance is required for • Allow for machine movement and electrical line swaying. every additional 30,000 volts or less. 3121205 – JLG Lift –...

  • Page 18: Tipping Hazards

    DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. – JLG Lift – 3121205...

  • Page 19: Crushing And Collision Hazards

    Increase of the area exposed to the wind will decrease stability. • Do not increase the platform size with unauthorized deck • During operation, keep all body parts inside platform rail- extensions or attachments. ing. 3121205 – JLG Lift –...

  • Page 20: Towing, Lifting, And Hauling

    Disconnect power to overhead cranes. • Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if neces- sary. – JLG Lift – 3121205...

  • Page 21: Additional Hazards / Safety

    • When performing welding or metal cutting operations, • Charge batteries only in a well ventilated area. precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. 3121205 – JLG Lift –...

  • Page 22: Beaufort Scale (For Reference Only)

    13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. 1-10 – JLG Lift – 3121205...

  • Page 23: 2.1 Personnel Training

    4. Use of approved fall protection device. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 3121205 – JLG Lift –...

  • Page 24: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT and maintenance recommended by JLG Industries, Inc. MODEL.

  • Page 25: Inspection And Maintenance Table

    At intervals as specified in the Service and Main- Owner, Dealer, or User Qualified JLG Service and Maintenance tenance Manual. Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121205 – JLG Lift –...

  • Page 26: Pre-Start Inspection

    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 – JLG Lift – 3121205...

  • Page 27: Function Check

    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. 3121205 – JLG Lift –...

  • Page 28: Limit Switch Functional Check

    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. – JLG Lift – 3121205...
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: Steps 7 & 8 cover 600S ANSI market machines with dual Boom Angle Switch. capacities (500 & 1000 lb. [227 kg for ANSI markets and a. Telescope boom to full extension.
  • Page 30 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). – JLG Lift – 3121205...
  • Page 31 6. Mid Boom 16. Lift Cylinder 7. Base Boom 17. Slave Level Cylinder 8. Boom Assembly 18. Articulating Jib 9. Telescope Cylinder Lift Cylinder (Inside) 19. Footswitch 10. Ground Control Box Figure 2-1. Machine Nomenclature - 600SJ/660SJ 3121205 – JLG Lift –...
  • Page 32 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 Figure 2-2. Machine Nomenclature - 600S 2-10 – JLG Lift – 3121205...
  • Page 33 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection Diagram 3121205 – JLG Lift – 2-11...
  • Page 34 10. Drive Motor and Brake - See Note. damage exists in addition to any other criteria men- tioned. 11. Drive Hub - See Note. Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1 of 3 2-12 – JLG Lift – 3121205...
  • Page 35 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. Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2 of 3 3121205 – JLG Lift – 2-13...
  • Page 36 38. Hydraulic Oil Medium Pressure Filter Housing - Hous- secured; evidence of proper lubrication. ing secure. 45. Platform Pivot Pin - See Note. 39. Hydraulic Swivel - See Note. Figure 2-6. Daily Walk-Around Inspection Points - Sheet 3 of 3 2-14 – JLG Lift – 3121205...

  • Page 37: 3.1 General

    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 compen- sate for any difference in the automatic self leveling sys- tem. 3121205 – JLG Lift –...
  • Page 38 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Boom Telescope 1706914 A Figure 3-1. Ground Control Station – JLG Lift – 3121205...

  • Page 39: Controls And Indicators

    OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.) 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. 3121205 – JLG Lift –...
  • Page 40 NOTE: With the Platform/Ground Select Switch in the center posi- Provides extension and retraction of the boom, when tion, power is shut off to controls at both operating sta- positioned to IN or OUT. tions. – JLG Lift – 3121205...

  • Page 41: Ground Control Indicator Panel

    Start the engine only after the light goes out. 3121205 – JLG Lift –...
  • Page 42 6. Low Fuel 10. Transmission Filter By-Pass 3. Engine Water Temp. 7. Glow Plug 11. Engine Air Filter By-Pass 4. Engine Oil Temp. 8. Platform Overload Figure 3-2. Ground Control Indicator Panel - Sheet 1 of 2 – JLG Lift – 3121205...
  • Page 43 3. Engine Water Temp. 8. Platform Overload 12. Not Used 4. Engine Oil Temp. 9. Not Used 13. Drive and Steer Disable 5. Engine Malfunction Indicator Figure 3-3. Ground Control Indicator Panel - Sheet 2 of 2 3121205 – JLG Lift –...
  • Page 44 13. Drive and Steer Disable Indicator (If equipped) front of the book) Indicates the Drive and Steer Disable function has been By pushing and holding the system test button on the activated. side of the ground control box, the Diagnostic Trouble – JLG Lift – 3121205...

  • Page 45: Platform Station

    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 maxi- mum displacement. 3121205 – JLG Lift –...
  • Page 46 12. Platform Rotate 2. Steer Select 6. Aux. Power 10. Telescope 13. Function Speed 3. Platform Leveling Override 7. Fuel Select 11. Jib 14. Main Lift/Swing 4. Horn 8. Lights Figure 3-5. Platform Control Console 3-10 – JLG Lift – 3121205...
  • Page 47 17. Soft Touch Indicator 3. Platform Leveling Override 8. Lights 13. Function Speed 4. Horn 9. Drive/Steer 14. Main Lift/Swing 5. Power/Emergency Stop 10. Telescope 15. Drive Orientation Override Figure 3-6. Platform Control Console - w/Drive Orientation 3121205 – JLG Lift – 3-11...
  • Page 48 ENGINE START/AUXILIARY POWER toggle steering function. 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...
  • Page 49 The master switch and / or the ignition switch at the ground control will turn off power to all lights. 3121205 – JLG Lift – 3-13...
  • Page 50 FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORI- ZONTAL. 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. 3-14 – JLG Lift – 3121205...
  • Page 51 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. 3121205 – JLG Lift – 3-15...

  • Page 52: Platform Control Indicator Panel

    This indicator will be green with 2. Platform Overload (If equipped) the exception of the capacity indicator which will be green or yellow depending upon platform Indicates the platform has been overloaded. position. 3-16 – JLG Lift – 3121205...
  • Page 53 1. Tilt 5. Enable 9. AC Generator 2. Overload 6. Glow Plug 10. Soft Touch 3. Capacity 7. Low Fuel 11. Creep 4. Cable Service 8. Engine Malfunction Figure 3-7. Platform Control Indicator Panel 3121205 – JLG Lift – 3-17...
  • Page 54 9. AC Generator 2. Overload 6. Glow Plug 10. Not Used 3. Capacity 7. Low Fuel 11. Creep 4. Cable Service 8. Malfunction 12. Drive Orientation Figure 3-8. Platform Control Indicator Panel - w/Drive Orientation 3-18 – JLG Lift – 3121205...
  • Page 55 PLATFORM TO THE STOWED POSITION, SHUT DOWN THE MACHINE, AND HAVE THE BOOM CABLES INSPECTED. FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT- TOM. 3121205 – JLG Lift – 3-19...
  • Page 56 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 con- dition and a Diagnostic Trouble Code has been set in the system memory.
  • Page 57 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...
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 – JLG Lift – 3121205...

  • Page 59: Section 4. Machine Operation

    Swing, and are to be used in an emergency to lower the plat- 4. Proper tire pressure. form to the ground should the operator in the platform be unable to do so. 5. Machine is as originally equipped from JLG. 3121205 – JLG Lift –...

  • Page 60: Stability

    Ground Control station. 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. – JLG Lift – 3121205...

  • Page 61: Shutdown Procedure

    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 informa- tion. Figure 4-1. Position of Least Backward Stability 3121205 – JLG Lift –...
  • Page 62 SECTION 4 - MACHINE OPERATION Figure 4-2. Position of Least Forward Stability – JLG Lift – 3121205...

  • Page 63: Traveling (Driving)

    DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE travel. The indicator light will flash during the 3 second CONTROLS WILL BE REVERSED. interval until the drive function is selected. 3121205 – JLG Lift –...
  • Page 64 SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Sideslope – JLG Lift – 3121205...

  • Page 65: Steering

    LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE. 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. 3121205 – JLG Lift –...

  • Page 66: Swinging The Boom

    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. – JLG Lift – 3121205...

  • Page 67: Oscillating Axle Lockout Test (If Equipped)

    When steering the unit the valve knob is pushed IN. When towing the unit the valve knob is pulled OUT to the float position. 3121205 – JLG Lift –...
  • Page 68 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. Figure 4-4. Drive Disconnect Hub 4-10 – JLG Lift – 3121205...
  • Page 69 SECTION 4 - MACHINE OPERATION STEER SELECT VALVE Figure 4-5. Towbar Connecting Points - Prior to S/N 75606 3121205 – JLG Lift – 4-11...
  • Page 70 SECTION 4 - MACHINE OPERATION STEER SELECT VALVE Figure 4-6. Towbar Connecting Points - S/N 75606 to Present 4-12 – JLG Lift – 3121205...

  • Page 71: Auxiliary Power - Non Ade Equipped Machines

    6. Position POWER/EMERGENCY STOP switch to OFF. 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. 3121205 – JLG Lift – 4-13...

  • Page 72: Auxiliary Power - Ade Equipped Machines

    1. Position PLATFORM/GROUND SELECT KEY SWITCH to 6. Position POWER/EMERGENCY STOP switch to OFF. PLATFORM. 2. Position POWER/EMERGENCY STOP switch to ON. 3. Depress and hold footswitch. 4. Position AUXILIARY POWER switch to ON and hold. 4-14 – JLG Lift – 3121205...

  • Page 73: Dual Fuel System (Gas Engine Only)

    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 Sta- tion to GASOLINE position. 3121205 – JLG Lift – 4-15...
  • Page 74 1 GPM (ex. setting 2 = 2 GPM). At setting form rail. The male quick connect is the pressure feed seven (7) the pump has reached its maximum flow rate line. therefore any setting past 7 will produce no additional flow. 4-16 – JLG Lift – 3121205...

  • Page 75: 4.16 Tie Down And Lifting

    NOTE: With the foot switch released to operate the tool circuit all drive and boom functions are cut out. SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER. 3121205 – JLG Lift – 4-17...

  • Page 76: Machine Tie Down

    This prevents the boom from bouncing up and down preventing possible damage while transporting. Figure 4-7. Machine Tie Down 4-18 – JLG Lift – 3121205...

  • Page 77: Lifting Chart

    SECTION 4 - MACHINE OPERATION Figure 4-8. Lifting Chart 3121205 – JLG Lift – 4-19...

  • Page 78: Decal Installation - Sheet 1 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 1 of 4 4-20 – JLG Lift – 3121205...

  • Page 79: Decal Installation - Sheet 2 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 2 of 4 3121205 – JLG Lift – 4-21...

  • Page 80: Decal Installation - Sheet 3 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 3 of 4 4-22 – JLG Lift – 3121205...

  • Page 81: Decal Installation - Sheet 4 Of 4

    SECTION 4 - MACHINE OPERATION 27,22 Figure 4-12. Decal Installation - Sheet 4 of 4 3121205 – JLG Lift – 4-23...
  • Page 82 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend - Prior to S/N 0300099060 Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Australian Chinese Chinese 0273867-8 0273872-6 0273870-9 0273882-6 0273888-8 0273885-6 1001114385-1 0273875-3 0275099-8 1001116839-2 1701499...
  • Page 83 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend - Prior to S/N 0300099060 Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Australian Chinese Chinese 0273867-8 0273872-6 0273870-9 0273882-6 0273888-8 0273885-6 1001114385-1 0273875-3 0275099-8 1001116839-2 1703953...
  • Page 84 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend - Prior to S/N 0300099060 Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Australian Chinese Chinese 0273867-8 0273872-6 0273870-9 0273882-6 0273888-8 0273885-6 1001114385-1 0273875-3 0275099-8 1001116839-2 1704096...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend - Prior to S/N 0300099060 Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Australian Chinese Chinese 0273867-8 0273872-6 0273870-9 0273882-6 0273888-8 0273885-6 1001114385-1 0273875-3 0275099-8 1001116839-2 4420051...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-2. 600S Decal Legend - S/N 0300099060 to Present Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Chinese Chinese 0273867-9 0273872-7 0273875-3 0273870-10 0273882-7 0273888-9 0273885-7 1001114385-1 0275099-9 1001116839-3 1701499 1701499...
  • Page 87 SECTION 4 - MACHINE OPERATION Table 4-2. 600S Decal Legend - S/N 0300099060 to Present Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Chinese Chinese 0273867-9 0273872-7 0273875-3 0273870-10 0273882-7 0273888-9 0273885-7 1001114385-1 0275099-9 1001116839-3 1001117034 1001117035...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-2. 600S Decal Legend - S/N 0300099060 to Present Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Chinese Chinese 0273867-9 0273872-7 0273875-3 0273870-10 0273882-7 0273888-9 0273885-7 1001114385-1 0275099-9 1001116839-3 1001121800 1001121802...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-2. 600S Decal Legend - S/N 0300099060 to Present Traditional Simplified Item # ANSI French Korean Spanish Japanese Portuguese Australian Chinese Chinese 0273867-9 0273872-7 0273875-3 0273870-10 0273882-7 0273888-9 0273885-7 1001114385-1 0275099-9 1001116839-3 4420051 4420051...

  • Page 90: 600Sj Decal Legend

    1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705084 1705084 1705514 1705514 1705514 3251243 3251243 3251243 3251243 3251243 3251243 3251243 4-32 – JLG Lift – 3121205...
  • Page 91 1703980 1705902 1703981 1705828 3251813 3251813 3251813 3251813 3251813 1705494 1703471 1703471 1703471 1703471 1703471 1703471 1703471 1703471 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702816 1702816 1702816 1702816 1702816 1702816 1702816 1702816 3121205 – JLG Lift – 4-33...
  • Page 92 1001114386-1 0273876-4 0273889-7 0273886-7 1701645 1705978 1707055 1707056 1707058 1707057 1707058 1705978 1707013 1705978 1707047 1707049 1707054 1707052 1707042 1705978 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1706948 1706948 1706948 1706948 1706948 1706948 4-34 – JLG Lift – 3121205...
  • Page 93 1001112941-2 1001114386-1 0273876-4 0273889-7 0273886-7 4420051 4420051 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1706941 1706941 1706941 1706941 1706941 1706941 1705351 1705429 1705910 1705426 1705095 1705427 1001112551 3121205 – JLG Lift – 4-35...
  • Page 94 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705084 1705084 1705084 1705084 1705514 1705514 1705514 1705514 3251243 3251243 3251243 3251243 3251243 3251243 3251243 4-36 – JLG Lift – 3121205...
  • Page 95 1703983 1703980 1705902 1705828 3251813 3251813 3251813 3251813 3251813 3251813 1703472 1703472 1703472 1703470 1703472 1703472 1703472 1703472 1703472 1702631 1702631 1702631 1702631 1702631 1702631 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 3121205 – JLG Lift – 4-37...
  • Page 96 1001114387-1 0273874-6 0273877-4 0273871-10 1701645 1707055 1705978 1707058 1707060 1707056 1707059 1707057 1705978 1707013 1707047 1705978 1707042 1707044 1707049 1707054 1707052 1705978 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1706948 1706948 1706948 4-38 – JLG Lift – 3121205...
  • Page 97 0273871-10 4420051 4420051 1700584 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1706941 1706941 1706941 1706941 1706941 1706941 1706941 1705351 1705429 1705427 1001116863 1705910 1705426 1705905 1001112551 3121205 – JLG Lift – 4-39...
  • Page 98 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705084 1705084 1705084 1705084 1705514 1705514 1705514 1705514 3251243 3251243 3251243 3251243 3251243 3251243 3251243 4-40 – JLG Lift – 3121205...
  • Page 99 1705828 3251813 3251813 3251813 3251813 3251813 3251813 3251813 1703472 1703472 1703472 1703470 1703472 1703472 1703472 1703472 1703472 1703472 1702631 1702631 1702631 1702631 1702631 1702631 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 1702817 3121205 – JLG Lift – 4-41...
  • Page 100 1001117939-3 1001121801 1001121803 1705978 1001121918 1001121810 1001121812 1001121805 1001121808 1001121656 1705978 1001121814 1001121816 1705978 1001121921 1001121823 1001121825 1001121818 1001121821 1001121655 1705978 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1706948 1706948 1706948 4-42 – JLG Lift – 3121205...
  • Page 101 1700584 1700584 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1706941 1706941 1706941 1706941 1706941 1706941 1706941 1706941 1705351 1705429 1705427 1001116863 1705430 1705910 1705426 1705905 1001112551 3121205 – JLG Lift – 4-43...
  • Page 102 SECTION 4 - MACHINE OPERATION NOTES: 4-44 – JLG Lift – 3121205...

  • Page 103: Section 5. Emergency Procedures

    REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY. JLG Industries, Inc. must be notified immediately of any inci- dent involving a JLG product. Even if no injury or property EMERGENCY OPERATION damage is evident, the factory should be contacted by tele- phone and provided with all necessary details.

  • Page 104: Platform Or Boom Caught Overhead

    When the boom is completely retracted, go to STEP #2. (If no movement is observed, go to step #2). 2. To lower boom: Open knob #1 (counterclockwise), knob #2 must remain open. – JLG Lift – 3121205...

  • Page 105: Section 6. General Specifications & Operator Maintenance

    Illustrated Parts Manual - ANSI Spec (s/n 0300068000 to 0300087000) ......3121178 Illustrated Parts Manual - Euro Spec (s/n 0300068000 to 0300087000) ......3121856 Illustrated Parts Manual - Global Spec (s/n 0300087000 to Present)........3121207 3121205 – JLG Lift –...

  • Page 106: Operating Specifications

    Maximum Travel Grade (Gradeability) 4.5 MPH (7.25 Km/hr.) 4 MPH (6.44 Km/hr.) Gross Machine Weight (Approximate) Maximum Travel Grade (Side Slope) 5° 600S - 2WD 22,000 lbs. (9,979.2 kg) Turning Radius (outside) 600SJ - 2WD 23,500 lbs. (10,660 kg) 2WS/2WD 17 ft.
  • Page 107 Table 6-2. Operating Specifications - S/N 0300099060 to Table 6-2. Operating Specifications - S/N 0300099060 to Present Present Maximum Work Load (Capacity) Maximum Tire Load: ANSI 600S & 600SJ 11,800 lbs. (5352 kg) Unrestricted: 500 lb (227 kg) 660SJ 14,200 lbs. (6441 kg) Restricted:...

  • Page 108: Capacities

    54 @ 2400 RPM, full load 4.5 qts. (4.25 L) w/Filter Cooling System 16 Quarts (15.14 L) Torque hubs should be one half full of lubricant. Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) – JLG Lift – 3121205...

  • Page 109: Deutz F4M1011F/F4M2011 Specifications

    Minutes Reserve Capacity, 12 VDC Fuel Consumption Fuel Consumption Low RPM 1.90 GPH (7.19 lph) Low RPM 1.90 GPH (7.19 lph) High RPM 2.50 GPH (9.46 lph) High RPM 2.50 GPH (9.46 lph) Horsepower Horsepower 3121205 – JLG Lift –...

  • Page 110: Gm 3.0L

    Idle RPM - 3044C 1000 Firing Order 1-3-4-2 Idle RPM - 3.4 1200 Max. RPM 2800 Low RPM 1800 High RPM 2600 Alternator 60 Amp, belt drive Battery 930 Cold Cranking Amps, 205 Minutes Reserve Capacity, 12 VDC – JLG Lift – 3121205...

  • Page 111: Dimensional Data

    8 ft. 4.75 in. (2.56 m) Interval Description Torque Value (Dry) Hours Machine Length (Stowed) 600S Over Drive Axle 27 ft. 11.125 in. (8.51 m) Bearing To Chassis See Note 50/600* 600SJ Over Drive Axle 32 ft. 11.75 in. (10.05 m)

  • Page 112: Tires

    NOTE: When temperatures remain below 20° F (-7 degrees C), JLG Industries recommends the use of Mobil DTE 13M. Table 6-11. Tire Specifications Aside from JLG recommendations, it is not advisable to mix Size 15 x 19.5 15 x 19.5 18 x 625 39x15-22.5 39x15-22.5 oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 113 6.6 cSt Viscosity Index at 100° F 169 SUS NOTE: Mobil/Exxon recommends that this oil be checked on a yearly basis for viscosity. at 210° F 48 SUS cp at -20° F 6,200 Viscosity Index 3121205 – JLG Lift –...

  • Page 114: Critical Stability Weights

    FILLED TIRES, COUNTERWEIGHT, ENGINE & PLATFORM) DO NOT MOD- Fire Point 325°C (617°F) IFY UNIT IN ANY WAY TO AFFECT STABILITY. Autoignition Temperature 450°C (842°F) Table 6-17. Critical Stability Weights - 600S Viscosity at 0° C (32°F) 360 cSt at 20° C (68°F) 102 cSt Tire and Wheel (Ballasted Only) Size (15 - 19.5)

  • Page 115: Critical Stability Weights - 600Sj

    Engine Ford Engine Ford Deutz Deutz Continental Continental Counterweight Weight 3500 1588 Counterweight Weight 4650 2109 Platform 6 ft. (1.83 M) Platform 6 ft. (1.83 M) 8 ft. (2.44 M) 8 ft. (2.44 M) 3121205 – JLG Lift – 6-11...

  • Page 116: Serial Number Locations

    A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame. Figure 6-1. Serial Number Locations 6-12 – JLG Lift – 3121205...
  • Page 117 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE This page left blank intentionally. 3121205 – JLG Lift – 6-13...

  • Page 118: Engine Operating Temperature Specifications - Deutz

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)

  • Page 119: Engine Operating Temperature Specifications - Deutz

    (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS NOTE: AMBIENT AIR TEMPERATURES 110°...

  • Page 120: Engine Operating Temperature Specifications - Ford

    WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 0 F(-18 C) -10 F(-23 C) A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 121: Engine Operating Temperature Specifications - Ford

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR TEMPERATURE THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...

  • Page 122: Engine Operating Temperature Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND...

  • Page 123: Engine Operating Temperature Specifications

    (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...

  • Page 124: Engine Operating Temperature Specifications - Gm

    -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)

  • Page 125: Engine Operating Temperature Specifications - Gm

    IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...

  • Page 126: Operator Maintenance & Lubrication Diagram

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-10. Operator Maintenance & Lubrication Diagram 6-22 – JLG Lift – 3121205...

  • Page 127: Operator Maintenance

    90 degree intervals until bearing is completely lubricated. LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON- DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD- INGLY. 3121205 – JLG Lift – 6-23...
  • Page 128 Lube Point(s) - 4 Grease Fittings Capacity - A/R Lube - MPG Interval - Every 3 months or 150 hrs of operation * Machines after S/N 38047 will have composite bushings and no grease fittings. 6-24 – JLG Lift – 3121205...
  • Page 129 Interval - Check level every 3 months or 150 hrs of opera- Interval - Check level every 3 months or 150 hrs of opera- tion; change every 2 years or 1200 hours of operation tion; change every 2 years or 1200 hours of operation 3121205 – JLG Lift – 6-25...
  • Page 130 Interval - Change after first 50 hrs. and every 6 months or Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 300 hrs. thereafter or as indicated by Condition Indicator. 6-26 – JLG Lift – 3121205...
  • Page 131 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 3121205 – JLG Lift – 6-27...
  • Page 132 13. Oil Change w/Filter - Ford LRG425 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 Quarts Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 6-28 – JLG Lift – 3121205...
  • Page 133 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with engine manual. 3121205 – JLG Lift – 6-29...
  • Page 134 Lube - EO Interval - 3 Months or 150 hours of operation Lube Point(s) - Replaceable Element Comments - Check level daily/Change in accordance Interval - Every Year or 600 hours of operation with engine manual. 6-30 – JLG Lift – 3121205...
  • Page 135 Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 22. Fuel Filter (Gasoline) - GM Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 3121205 – JLG Lift – 6-31...
  • Page 136 Comments - Replace filter. Refer to Section 6.7, Propane Comments - Drain oil build up. Refer to Section 6.6, Fuel Filter Replacement DRAINING OIL BUILD UP FROM THE PROPANE REGU- LATOR (Prior to S/N 0300132529) 6-32 – JLG Lift – 3121205...

  • Page 137: Tires & Wheels

    Tire Damage brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a For pneumatic tires, JLG Industries, Inc. recommends that when particular machine model. If not using a JLG approved replace-...

  • Page 138: Wheel Replacement

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque.
  • Page 139 2. Tighten nuts in the following sequence: 9 LUG PATTERN 10 LUG PATTERN 3. The tightening of the nuts should be done in stages. Fol- lowing the recommended sequence, tighten nuts per wheel torque chart. 3121205 – JLG Lift – 6-35...

  • Page 140: Oscillating Axle Lockout Test (If Equipped)

    3. Place the Drive control lever to the forward position and every 3 months or 150 hours of operation. carefully drive machine up ascension ramp until left front wheel is on top of block. 6-36 – JLG Lift – 3121205...
  • Page 141 8. Place the 6 inches (15.2 cm) high block with ascension ramp in front of right front wheel. 9. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block. 3121205 – JLG Lift – 6-37...

  • Page 142: Draining Oil Build Up From The Propane Regulator (Prior To S/N 0300132529)

    1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 6-38 – JLG Lift – 3121205...

  • Page 143: Propane Fuel Filter Replacement

    8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 3121205 – JLG Lift – 6-39...
  • Page 144 10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13. Ring 5. Filter Housing Figure 6-11. Filter Lock Assembly 6-40 – JLG Lift – 3121205...

  • Page 145: Installation

    TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS- 9. Open manual shut-off valve. Start the vehicle and leak CONNECTING ANY FUEL LINE. check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 3121205 – JLG Lift – 6-41...

  • Page 146: Supplemental Information

    The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s 6-42 – JLG Lift – 3121205...

  • Page 147: Section 7. Inspection And Repair Log

    SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121205 – JLG Lift –...
  • Page 148 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121205...
  • Page 150 1 JLG Drive McConnellsburg PA. 17233-9533 (717) 485-5161 3121205 (717) 485-6417 JLG Worldwide Locations JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu...

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