JLG 600A Operation And Safety Manual
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JLG 600A 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
600A
600AJ
ANSI
3121204
August 1, 2016
®

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Summary of Contents for JLG 600A

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 600A 600AJ ANSI 3121204 August 1, 2016 ®...
  • Page 2 ADE Identification All 600A and 600AJ machines from S/N 64249 incorporate ADE. The following machine serial numbers prior to S/N 64249 also utilize ADE: 63908, 63912, 63932, 63936, 63938, 63954, 63959, and 63963. A Machine that incorporates ADE (Advanced Design Elec-...
  • 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 – 3121204...
  • Page 5 FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions •...
  • Page 6 Revised - September 17, 2009 Revised - November 25, 2009 Revised - July 22, 2010 Revised - August 25, 2010 Revised - September 27, 2011 Revised - April 30, 2012 Revised - August 1, 2016 – JLG Lift – 3121204...

  • Page 7: Table Of Contents

    Pre-Start Inspection ..... . 2-4 Function Check......2-5 3121204 – JLG Lift –...
  • Page 8 Changing From LP Gas to Gasoline ..4-19 Hydraulic Oil ......6-9 – JLG Lift – 3121204...
  • Page 9 2-2. Machine Nomenclature - 600A ....2-11 TIRES & WHEELS ......6-33 2-3.

  • Page 10: Section - Paragraph, Subject Page

    Lifting Chart ......4-22 4-10. 600A & 600AJ Decal Installation - Sheet 1 of 4. . . 4-23 4-11.
  • Page 11 6-18 Quintolubric 888-46......6-11 600A Decal Legend - Prior to S/N 0300140401 . . 4-27 6-19 Critical Stability Weights ....6-12 600A Decal Legend - S/N 0300140401 6-20 Lubrication Specifications.
  • Page 12 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This page left blank intentionally. – JLG Lift – 3121204...

  • 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

    • Do not operate any machine on which safety or instruction placards or decals are missing or illegible. ment unless approved in writing by 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 – 3121204...

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

    • Allow for machine movement and electrical line swaying. to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less. 3121204 – 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 – 3121204...

  • 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. 3121204 – 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 – 3121204...

  • 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. 3121204 – 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 – 3121204...

  • Page 23: Section 2 - User Responsibilities, Machine Preparation, And Inspection

    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. 3121204 – JLG Lift –...

  • Page 24: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED 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 Maintenance tenance Manual. Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121204 – 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 – 3121204...

  • Page 27: Machine Nomenclature - 600Aj

    19. Tower Telescope Cylinder (Inside) 20. Boom Assembly 21. Upright Level Cylinder 22. Main Lift Cylinder 23. Slave Level Cylinder 24. Articulating Fly Lift Cylinder 25. Footswitch 26. SkyGuard (If Equipped) Figure 2-1. Machine Nomenclature - 600AJ 3121204 – JLG Lift –...

  • Page 28: Machine Nomenclature - 600A

    16. Swing Bearing 17. Turntable 18. Tower Telescope Cylinder Inside 19. Boom Assembly 20. Upright Level Cylinder 21. Main Lift Cylinder 22. Slave Level Cylinder 23. Footswitch 24. SkyGuard (If Equipped) Figure 2-2. Machine Nomenclature - 600A – JLG Lift – 3121204...

  • Page 29: Daily Walk-Around Inspection Diagram

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection Diagram 3121204 – JLG Lift –...

  • Page 30: Daily Walk-Around Inspection Points

    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 men- tioned. Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1 of 3 – JLG Lift – 3121204...

  • Page 31: Daily Walk-Around Inspection Points

    19. Hydraulic Oil Return Filter Housing - Housing secure. 20. Manual Descent - See Note. 21. LP Gas Tank (If Equipped) - See Note. Figure 2-5. Daily Walk-Around Inspection Points - Sheet 2 of 3 3121204 – JLG Lift –...

  • Page 32: Function Check

    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: 2-10 – JLG Lift – 3121204...

  • Page 33: Skyguard Function Test

    TO AVOID MACHINE UPSET DO NOT USE MACHINE IF TOWER BOOM SWITCHING IS OUT OF SEQUENCE. IF THE TOWER BOOM LIFTS ‘DOWN’ WITH THE TOWER BOOM TELE- SCOPED ‘OUT’, SHUT DOWN MACHINE AND CONTACT A CERTIFIED JLG TECHNICIAN. IF THE TOWER BOOM ‘TELESCOPES’ WITH THE TOWER BOOM LESS THAN FULLY ELEVATED ‘UP’, SHUT DOWN MACHINE AND CONTACT...
  • Page 34 TELESCOPE to ‘out’ position and hold until the TOWER TELESCOPE FUNCTIONS. BOOM is fully extended. — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH- 5. With TOWER BOOM completely extended, place NICIAN BEFORE CONTINUING USE OF MACHINE. TOWER LIFT in ‘down’ position. Tower boom should not LIFT ‘down’...
  • Page 35 #43 on the main terminal box. a. Lift boom up to 5 degrees above horizontal. Limit NOTE: Step 8 is only applicable for 600A ANSI market machines. switch should activate at this point. b. Lift main boom down until limit switch resets. This 8.
  • Page 36 OUT OF LEVEL indicator light on the platform control console, manually activate the indicator light by com- pressing any one of the three tilt indicator mounting springs. If the light does not illuminate, shut down 2-14 – JLG Lift – 3121204...

  • Page 37: General

    3121204 – JLG Lift –...

  • Page 38: Ground Controls

    Emergency Stop Switch. The keyed Master Switch can also be used for the same purpose. – JLG Lift – 3121204...

  • Page 39: Ground Control Station

    5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Tower Telescope 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Tower Lift 11. Main Boom Lift 12. Main Boom Telescope 1706913 A Figure 3-1. Ground Control Station 3121204 – JLG Lift –...
  • Page 40 TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Tele- ABOVE SEQUENCE. scope, Tower Telescope, Platform Rotator and Auxiliary Power control switches are spring-loaded and will auto- matically return to neutral (off) when released. – JLG Lift – 3121204...
  • Page 41 MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED. 10. Tower Lift This switch provides raising and lowering of the tower boom. This function works only when the tower boom is fully retracted (telescope in). 3121204 – JLG Lift –...

  • Page 42: Ground Control Indicator Panel

    Start the vice is required. engine only after the light goes out. – JLG Lift – 3121204...

  • Page 43: Ground Control Indicator Panel - Sheet 1 Of 2

    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 3121204 – JLG Lift –...

  • Page 44: Ground Control Indicator Panel - Sheet 2 Of 2

    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 – JLG Lift – 3121204...

  • Page 45: Malfunction Indicator Light And Test Button

    13. Drive and Steer Disable Indicator (If equipped) By pushing and holding the system test button on the Indicates the Drive and Steer Disable function has been side of the ground control box, the Diagnostic Trouble activated. 3121204 – JLG Lift –...

  • Page 46: Platform Control

    “ON” position and the ENGINE START switch is push forward. To re-synchronize the front and rear axles, position the 3-10 – JLG Lift – 3121204...

  • Page 47: Platform Control Console

    6. Aux. Power 10. Telescope 14. Platform Rotate 3. Platform Leveling Override 7. Fuel Select 11. Jib 15. Function Speed 4. Horn 8. Lights 12. Tower Telescope 16. Main Lift/Swing Figure 3-5. Platform Control Console 3121204 – JLG Lift – 3-11...

  • Page 48: Platform Control Console - W/Drive Orientation

    3. Platform Leveling Override 7. Fuel Select 11. Jib 15. Function Speed Override 4. Horn 8. Lights 12. Tower Telescope 16. Main Lift/Swing 19. Soft Touch/SkyGuard Indi- cator Figure 3-6. Platform Control Console - w/Drive Orientation 3-12 – JLG Lift – 3121204...
  • Page 49 NOTE: When boom is positioned above horizontal and any of the following switches, DRIVE SPEED/TORQUE SELECT or FUNCTION SPEED, are positioned to HIGH, high function speeds are automatically cut out and the machine contin- ues to operate at a lower speed. 3121204 – JLG Lift – 3-13...
  • Page 50 MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED. TO AVOID TIPPING OVER AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER PRESCRIBED IN (12) AND (13) ABOVE. 3-14 – JLG Lift – 3121204...
  • Page 51 Move right to swing right, move left to shutdown situation. swing left. If equipped with SkyGuard, the switch enables functions cut out by the Skyguard system to be operated again, allowing the operator to resume use of machine func- tions. 3121204 – JLG Lift – 3-15...

  • Page 52: Platform Control Indicator Panel

    If the boom is above horizontal and the machine is on a slope, the tilt alarm warning 3-16 – JLG Lift – 3121204...

  • Page 53: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Tilt 5. Glow Plug 9. Soft Touch 2. Overload 6. Low Fuel 10. Creep 3. Capacity 7. Engine Malfunction 4. Enable 8. AC Generator Figure 3-7. Platform Control Indicator Panel 3121204 – JLG Lift – 3-17...

  • Page 54: Platform Control Indicator Panel - W/Drive Orientation

    5. Glow Plug 9. Not Used 2. Overload 6. Low Fuel 10. Creep 3. Capacity 7. Malfunction 11. Drive Orientation 4. Enable 8. AC Generator Figure 3-8. Platform Control Indicator Panel - w/Drive Orientation 3-18 – JLG Lift – 3121204...
  • Page 55 On machines with Ford engines from S/N 48907 to S/N 64249, the light indicates that the Engine Control Sys- tem has detected a malfunction and a Diagnostic Trou- ble Code has been set in the system memory. 3121204 – JLG Lift – 3-19...
  • Page 56 On machines after S/N 64249, the light indicates that the 11. Drive Orientation Indicator JLG Control System has detected an abnormal condi- tion and a Diagnostic Trouble Code has been set in the When the boom is swung beyond the rear drive tires or system memory.

  • Page 57: Section 4 - Machine Operation

    4. Proper tire pressure. form to the ground should the operator in the platform be unable to do so. The Ground Control is also to be used in 5. Machine is as originally equipped from JLG. Pre-Start Inspection. 3121204 – JLG Lift –...

  • Page 58: Stability

    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. – JLG Lift – 3121204...

  • Page 59: Shutdown Procedure

    3-5 minutes; this allows further reduction of the depressed position, DO NOT OPERATE MACHINE. internal engine temperature. 2. Push POWER/EMERGENCY STOP switch in. 3. Turn MASTER switch to Off. Refer to Engine Manufacturer’s manual for detailed informa- tion. 3121204 – JLG Lift –...

  • Page 60: Position Of Least Forward Stability

    MAIN BOOM LEVEL AND FULLY EXTENDED UPRIGHT MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE 13 DEGREES FROM VERTICAL TOWER BOOM FULLY ELEVATED AND FULLY RETRACTED Figure 4-1. Position of Least Forward Stability – JLG Lift – 3121204...

  • Page 61: Traveling (Driving)

    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. Figure 4-2. Position of Least Backward Stability 3121204 – JLG Lift –...

  • Page 62: Traveling Forward And Reverse

    The indicator light will flash during the 3 second To rotate the platform to the left or right, use the Platform interval until the drive function is selected. Rotate control switch to select the direction and hold until desired position is reached. – JLG Lift – 3121204...

  • Page 63: Grade And Sideslope

    SECTION 4 - MACHINE OPERATION Figure 4-3. Grade and Sideslope 3121204 – JLG Lift –...

  • Page 64: Boom

    MENT 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. – JLG Lift – 3121204...

  • Page 65: Raising And Lowering The Tower Boom

    SCOPE FUNCTIONS. 1. Sequence while RAISING the TOWER BOOM from the fully lowered position. — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH- NICIAN BEFORE CONTINUING USE OF MACHINE. a. The TOWER BOOM must be fully elevated “up” (approximately 13 degrees from vertical) before the TOWER BOOM can be extended from the fully retracted position.

  • Page 66: Raising And Lowering The Main Boom

    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. 4-10 – JLG Lift – 3121204...
  • Page 67 SECTION 4 - MACHINE OPERATION 3121204 – JLG Lift – 4-11...
  • Page 68 SECTION 4 - MACHINE OPERATION 4-12 – JLG Lift – 3121204...

  • Page 69: Oscillating Axle Lockout Test (If Equipped)

    2. Connect tow bar to front of frame with attach pins, and steering and towing. When steering the unit the valve knob is tow bar to towing vehicle. pushed IN. When towing the unit the valve knob is pulled OUT to the float position. 3121204 – JLG Lift – 4-13...

  • Page 70: Towbar Connecting Points - Prior To S/N 81836

    SECTION 4 - MACHINE OPERATION STEER SELECT VALVE Figure 4-6. Towbar Connecting Points - Prior to S/N 81836 4-14 – JLG Lift – 3121204...

  • Page 71: To Present

    SECTION 4 - MACHINE OPERATION STEER SELECT VALVE Figure 4-7. Towbar Connecting Points - S/N 81836 to Present 3121204 – JLG Lift – 4-15...

  • Page 72: Drive Disconnect Hub

    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 4-8. Drive Disconnect Hub 4-16 – JLG Lift – 3121204...

  • Page 73: 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. 3121204 – JLG Lift – 4-17...

  • Page 74: 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. 4-18 – JLG Lift – 3121204...

  • Page 75: Dual Fuel System (Gas Engine Only)

    Control to LP position. To Operate: 1. Pull the red knob 2. Using the ground control raise the lower boom 6 feet. 3. Release the knob. 4. Fully lower the boom. 5. Repeat if necessary. 3121204 – JLG Lift – 4-19...

  • Page 76: 4.16 Tie Down And Lifting

    (See Figure 4-10. Lift- ing Chart.) 4-20 – JLG Lift – 3121204...

  • Page 77: 4.17 Skyguard Operation

    C = Indicates Cutout is Activated * Disregard when boom is in line and driving forward with or without steering and no other function active Note: When Soft Touch is enabled with SkyGuard all functions are cut out only. 3121204 – JLG Lift – 4-21...

  • Page 78: Lifting Chart

    SECTION 4 - MACHINE OPERATION Figure 4-9. Lifting Chart 4-22 – JLG Lift – 3121204...

  • Page 79: A & 600Aj Decal Installation - Sheet 1 Of 4

    SECTION 4 - MACHINE OPERATION A us 36 28 Figure 4-10. 600A & 600AJ Decal Installation - Sheet 1 of 4 3121204 – JLG Lift – 4-23...

  • Page 80: A & 600Aj Decal Installation - Sheet 2 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-11. 600A & 600AJ Decal Installation - Sheet 2 of 4 4-24 – JLG Lift – 3121204...

  • Page 81: A & 600Aj Decal Installation - Sheet 3 Of 4

    SECTION 4 - MACHINE OPERATION 22 67 Figure 4-12. 600A & 600AJ Decal Installation - Sheet 3 of 4 3121204 – JLG Lift – 4-25...

  • Page 82: A & 600Aj Decal Installation - Sheet 4 Of 4

    SECTION 4 - MACHINE OPERATION Figure 4-13. 600A & 600AJ Decal Installation - Sheet 4 of 4 4-26 – JLG Lift – 3121204...
  • Page 83 SECTION 4 - MACHINE OPERATION Table 4-2. 600A Decal Legend - Prior to S/N 0300140401 Canadian Australian Item # ANSI Spanish Portuguese Japanese French 1001114388- 0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 0273893-9 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509...
  • Page 84 SECTION 4 - MACHINE OPERATION Table 4-2. 600A Decal Legend - Prior to S/N 0300140401 Canadian Australian Item # ANSI Spanish Portuguese Japanese French 1001114388- 0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 0273893-9 3251243 3251243 3251243 3251243 1704006 1704007 1705901 1703953 1703942...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-2. 600A Decal Legend - Prior to S/N 0300140401 Canadian Australian Item # ANSI Spanish Portuguese Japanese French 1001114388- 0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 0273893-9 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1707014 1707046...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-2. 600A Decal Legend - Prior to S/N 0300140401 Canadian Australian Item # ANSI Spanish Portuguese Japanese French 1001114388- 0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 0273893-9 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1001108493 1001108493...

  • Page 87: To Present

    SECTION 4 - MACHINE OPERATION Table 4-3. 600A Decal Legend - S/N 0300140401 to Present Chinese Chinese Canadian Australian Item # ANSI Spanish Portuguese Japanese Simplified Traditional French 1001114388- 0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001116840- 1001116841- 0273893-9 1701499 1701499 1701499...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-3. 600A Decal Legend - S/N 0300140401 to Present Chinese Chinese Canadian Australian Item # ANSI Spanish Portuguese Japanese Simplified Traditional French 1001114388- 0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001116840- 1001116841- 0273893-9 3251243 3251243 3251243...
  • Page 89 SECTION 4 - MACHINE OPERATION Table 4-3. 600A Decal Legend - S/N 0300140401 to Present Chinese Chinese Canadian Australian Item # ANSI Spanish Portuguese Japanese Simplified Traditional French 1001114388- 0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001116840- 1001116841- 0273893-9 1703469 1703469 1703469...
  • Page 90 SECTION 4 - MACHINE OPERATION Table 4-3. 600A Decal Legend - S/N 0300140401 to Present Chinese Chinese Canadian Australian Item # ANSI Spanish Portuguese Japanese Simplified Traditional French 1001114388- 0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001116840- 1001116841- 0273893-9 1700584 1700584 1700584...
  • Page 91 SECTION 4 - MACHINE OPERATION Table 4-3. 600A Decal Legend - S/N 0300140401 to Present Chinese Chinese Canadian Australian Item # ANSI Spanish Portuguese Japanese Simplified Traditional French 1001114388- 0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001116840- 1001116841- 0273893-9 1705351 1705429 1705910...

  • Page 92: 600Aj Decal Legend - Prior To S/N 0300140401

    1703811 1703811 1703811 1703811 1703811 1703811 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705514 3251243 3251243 3251243 3251243 3251243 4-36 – JLG Lift – 3121204...
  • Page 93 1703938 1705961 1703984 1705828 1703983 1705902 1703980 1705828 3251813 3251813 3251813 3251813 3251813 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702819 1702819 1702819 1702819 1702819 1702819 1702819 3121204 – JLG Lift – 4-37...
  • Page 94 French 1001114389- 0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 0273894-9 1707013 1707046 1705978 1707049 1707052 1707054 1705978 1701645 1703996 1705978 1707056 1707057 1707059 1705978 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1706948 1706948 1706948 1706948 1706948 4-38 – JLG Lift – 3121204...
  • Page 95 1702573 1700584 1700584 1700584 1001108493 1001108493 1001108493 1001108493 1001108493 1706941 1706941 1706941 1706941 1706941 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1705351 1705429 1705910 1705905 1705426 1001112551 3121204 – JLG Lift – 4-39...

  • Page 96: 600Aj Decal Legend - S/N 0300140401

    1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705084 1705084 1705514 1705514 1705514 3251243 3251243 3251243 3251243 3251243 4-40 – JLG Lift – 3121204...
  • Page 97 1001116851 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982 3251813 3251813 3251813 3251813 3251813 3251813 3251813 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 3121204 – JLG Lift – 4-41...
  • Page 98 1702818 1702818 1001121814 1001121816 1705978 1001121818 1001121655 1001121821 1705978 1001121825 1001121823 1001121801 1001121803 1705978 1001121805 1001121656 1001121808 1705978 1001121812 1001121810 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1706948 1706948 1706948 1706948 1706948 4-42 – JLG Lift – 3121204...
  • Page 99 1001108493 1706941 1706941 1706941 1706941 1706941 1706941 1706941 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862 1705351 1705429 1705910 1705905 1705426 1705430 1001116863 1001112551 3121204 – JLG Lift – 4-43...
  • Page 100 SECTION 4 - MACHINE OPERATION 4-44 – JLG Lift – 3121204...

  • Page 101: Section 5 - Emergency Procedures

    JLG Industries, Inc. must be notified immediately of any inci- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE dent involving a JLG product. Even if no injury or property AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS, damage is evident, the factory should be contacted by tele- THEN FROM THE PLATFORM CONTROLS.

  • Page 102: Platform Or Boom Caught Overhead

    #1, #2, and #4 should be open (counter- pump until tight. When this operation has been com- clockwise) 3 turns. Knob #3 should be closed pleted, turn #1 and #4 counterclockwise 3 turns. (clockwise). – JLG Lift – 3121204...

  • Page 103: Section 6. General Specifications & Operator Maintenance

    Illustrated Parts Manual - ANSI Spec (s/n 0300068000 to s/n 0300087000) ....3121177 Illustrated Parts Manual - Euro Spec (s/n 0300068000 to s/n 0300087000) ....3121855 Illustrated Parts Manual - Global Spec (s/n 0300087000 to Present)........3121206 3121204 – JLG Lift –...

  • Page 104: Operating Specifications

    75 psi (5.3 kg/cm Maximum Work Load (Capacity) 600AJ 500 lb (230 kg) Unrestricted: 94 psi (6.6 kg/cm 600A - narrow chassis 1000 lb (450 kg) Restricted: 94 psi (6.6 kg/cm 600AJ - narrow chassis Maximum Travel Grade (Gradeabil- Maximum Drive Speed - A Models ity) 3.6 MPH (5.80 Km/hr.)

  • Page 105: Operating Specifications - S/N 0300140401

    1000 lb (450 kg) Unrestricted: 75 psi (5.3 kg/cm 600AJ Restricted: 94 psi (6.6 kg/cm 600A - narrow chassis Maximum Travel Grade (Gradeabil- 94 psi (6.6 kg/cm 600AJ - narrow chassis ity) Maximum Drive Speed - A Models 3.6 MPH (5.80 Km/hr.) 4 MPH (6.44 Km/hr.)

  • Page 106: Capacities

    2.30 GPH (8.71 lph) 10.6 quarts (10 L) 4.5 qts. (4.25 L) w/Filter Horsepower 66.5 @ 3000 RPM Cooling System 16 Quarts (15.14 L.) Coolant 3.8 Gallons (3.6 l) Torque hubs should be one half full of lubricant. – JLG Lift – 3121204...

  • Page 107: Ford Lrg-423 Specifications

    16 Quarts (15.14 L.) Horsepower 54 @ 2400 RPM, full load Spark Plug AWSF-52-C Cooling System 16 Quarts (15.14 L.) Spark Plug Gap 0.044 in. (1.117 mm) Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) 3121204 – JLG Lift –...

  • Page 108: 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 – JLG Lift – 3121204...

  • Page 109: 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 3121204 – JLG Lift –...

  • Page 110: Tires

    14 x 17.5 Machine Height (Stowed) 8 ft. 3.75 in. (2.53 m) Load Range Machine Length (Stowed) Ply Rating 600A Over Drive Axle 26 ft. 5 in. (8.05 m) Tire Pressure 90 PSI (6 Bar) Air-Boss 600AJ Over Drive Axle 28 ft.

  • Page 111: Torque Requirements

    SAE viscosity index of 152. *Check swing bearing bolts for security after first 50 hours of operation and NOTE: When temperatures remain below 20° F (-7° C), JLG every 600 hours thereafter. (See Swing Bearing in Section 3.) Industries recommends the use of Mobil DTE 13M.
  • Page 112 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Aside from JLG recommendations, it is not advisable to mix Table 6-16. Mobil DTE 13M Specs oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities. If...
  • Page 113 NOTE: Mobil/Exxon recommends that this oil be checked at 20° C (68°F) 102 cSt on a yearly basis for viscosity. at 40° C (104°F) 46 cSt at 100° C (212°F) 10 cSt Viscosity Index 3121204 – JLG Lift – 6-11...

  • Page 114: Critical Stability Weights

    Table 6-19. Critical Stability Weights 600AJ 600A Tire and Wheel (Ballasted Only) Size (14-17.5) Engine Ford Deutz Figure 6-1. Serial Number Locations Continental Counterweight Weight 6200 2812 5700 2586 Platform 6 ft. (1.83 M) 8 ft. (2.44 M) 6-12 – JLG Lift – 3121204...
  • Page 115 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE This page left blank intentionally 3121204 – JLG Lift – 6-13...
  • Page 116 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 117 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 N O T E : AMBIENT AIR TEMPERATURES 110°...
  • Page 118 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 119 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 120: Caterpillar - Sheet 1 Of 2

    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 121: Caterpillar - Sheet 2 Of 2

    (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 122 -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 123 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 124: Lubrication And Maintenance Point Location

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-10. Lubrication and Maintenance Point Location 6-22 – JLG Lift – 3121204...

  • Page 125: Operator Maintenance

    Comments - Remote Access 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. 3121204 – JLG Lift – 6-23...
  • Page 126 Lube - EPGL Interval - Every 2 years or 1200 hours of operation Interval - Check level every 3 months or 150 hrs of oper- ation; change every 2 years or 1200 hours of operation 6-24 – JLG Lift – 3121204...
  • Page 127 300 hrs. thereafter or as indicated by Condition Indi- Lube - EPGL cator. Interval - Check level every 3 months or 150 hrs of oper- ation; change every 2 years or 1200 hours of operation 3121204 – JLG Lift – 6-25...
  • Page 128 300 hrs. thereafter or as indicated by Condition Indi- Capacity - 31 gal. (117.3 L) Tank; 37.2 gal. (140.8 L) cator. System Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 6-26 – JLG Lift – 3121204...
  • Page 129 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. 3121204 – JLG Lift – 6-27...
  • Page 130 Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Lube - EO Interval - Every Year or 1200 hours of operation Comments - Check oil level, fill oil to max marking on the dipstick. Check level daily/Change in accordance with engine manual. 6-28 – JLG Lift – 3121204...
  • Page 131 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. 3121204 – JLG Lift – 6-29...
  • Page 132 Interval - Every Year or 600 hours of operation Interval - Every Year or 600 hours of operation 19. Fuel Filter (Gasoline) - GM Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 6-30 – JLG Lift – 3121204...
  • Page 133 Comments - Drain oil build up. Refer to Section 6.6, Interval - Every 6 months or 300 hours of operation or as DRAINING OIL BUILD UP FROM THE PROPANE REG- indicated by the condition indicator ULATOR (Prior to S/N 0300132529) 3121204 – JLG Lift – 6-31...
  • Page 134 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 22. Fuel Filter (Propane) - GM Engine Interval - 3 Months or 150 hours of operation Comments - Replace filter. Refer to Section 6.7, Propane Fuel Filter Replacement 6-32 – JLG Lift – 3121204...

  • Page 135: 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 136: 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 137 2. Tighten nuts in the following sequence: 8 LUG PATTERN 9 LUG PATTERN 3. The tightening of the nuts should be done in stages. Fol- lowing the recommended sequence, tighten nuts per wheel torque chart. 3121204 – JLG Lift – 6-35...

  • Page 138: Oscillating Axle Lockout Test (If Equipped)

    2. From platform control station, start engine 3. Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block. 6-36 – JLG Lift – 3121204...
  • Page 139 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. 3121204 – JLG Lift – 6-37...

  • Page 140: 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 – 3121204...

  • Page 141: 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. 3121204 – JLG Lift – 6-39...

  • Page 142: Filter Lock Assembly

    7. Electrical Connec- 11. Fuel Inlet 2. Mounting Plate 12. Retaining Bolt 3. Housing Seal 8. Fuel Outlet 13. Ring 4. Filter Magnet 9. O-ring 5. Filter Housing Figure 6-11. Filter Lock Assembly 6-40 – JLG Lift – 3121204...

  • Page 143: 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. 3121204 – JLG Lift – 6-41...

  • Page 144: 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 – 3121204...

  • Page 145: 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 3121204 – JLG Lift –...
  • Page 146 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121204...
  • Page 150 +33 (0) 553 84 85 74 +(852) 2639 5797 Email:german-parts@jlg.com Email: pieces@jlg.com Email: emeaservice@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & Services JLG Industries Via Po. 22 Polaris Avenue 63 2B Fisher Cresent Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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