JLG 600AJ Operation And Safety Manual
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JLG 600AJ Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Model
600AJ
PVC 2001
AS/NZS
ANSI
31215030
®
September 24, 2019 - Rev A

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Model 600AJ PVC 2001 AS/NZS ANSI 31215030 ® September 24, 2019 - Rev A...
  • Page 2 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...
  • Page 3 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 4 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 5 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 A POTENTIONALLY HAZARDOUS SITUATION.
  • Page 6 FOREWORD REVISION LOG Original Issue A - September 24, 2019 31215030...

  • Page 7: Table Of Contents

    600AJ ........
  • Page 8 TABLE OF CONTENTS Air Shutoff Valve (ASOV) (If Equipped)....4-5 4.11 SHUT DOWN AND PARK......4-19 Fuel Reserve / Shut-Off System.
  • Page 9 TABLE OF CONTENTS Safety Precautions ....... . . 6-4 SOFT TOUCH........6-13 Preparation and Inspection .
  • Page 10 TABLE OF CONTENTS OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 7-30 PROPANE FUEL FILTER REPLACEMENT ....7-31 Removal ......... 7-31 Installation .
  • Page 11 600AJ Decal Installation - Sheet 2 of 4 ....4-27 4-10. 600AJ Decal Installation - Sheet 3 of 4 ....4-28 4-11.
  • Page 12 Inspection and Maintenance Table ....2-3 600AJ Decal Legend....... . .4-34 Available Accessories .

  • Page 13: Section 1. Safety Precautions

    This section contains the responsibilities of the owner, user, oper- ator, lessor, and lessee concerning safety, training, inspection, maintenance, application, and operation. If there are any ques- tions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“JLG”). 31215030...

  • Page 14: Workplace Inspection

    MEWP. The user shall deter- ment unless the application is approved in writing by JLG. mine if personnel are qualified to operate the MEWP prior to operation.

  • Page 15: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 16: Trip And Fall Hazards

    • Hydraulic cylinders are subject to thermal expansion and con- traction. This may result in changes to the platform position approved by JLG. while the machine is stationary. Factors affecting thermal • When two or more persons are in the platform, the operator movement can include the length of time the machine will shall be responsible for all machine operations.

  • Page 17: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards • Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform • This machine is not insulated and does not provide protection assembly is fully lowered. Face the platform when entering or from contact or proximity to electrical current.

  • Page 18: Minimum Approach Distances (M.a.d.)

    SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE (Phase to Phase) in Feet (Meters) 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)

  • Page 19: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS Tipping Hazards • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are • Ensure that the ground conditions are adequate to support rated for the voltage of the line being guarded. These barriers the maximum tire load indicated on the tire load decals shall not be part of (or attached to) the machine.
  • Page 20 Keep all loads within the confines of the plat- weather events, the time required to lower the platform, and form, unless authorized by JLG. methods to monitor current and potential wind conditions. • Keep the chassis of the machine a minimum of 2 ft. (0.6m) •...

  • Page 21: Beaufort Scale (For Reference Only)

    SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 7.2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLATFORM BILLBOARD. Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number...

  • Page 22: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 23: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING or property. A maintenance program must be established by a qualified person and must be followed to ensure that the • Never allow personnel in platform while towing, lifting, or machine is safe. hauling.
  • Page 24 • Use only replacement parts or components that are approved MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT- by JLG. To be considered approved, replacement parts or com- TEN PERMISSION FROM THE MANUFACTURER. ponents must be identical or equivalent to original parts or components.

  • Page 25: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- nents or when performing welding on the machine. • Do not allow smoking, open flame, or sparks near battery during charging or servicing. • Do not contact tools or other metal objects across the battery terminals.

  • Page 26: Section 2 - User Responsibilities, Machine Preparation, And Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The Mobile Elevating Work Platform (MEWP) is a personnel han- depressions, holes, and drop-offs exist.

  • Page 27: Operator Responsibility

    The following table covers machine inspections and mainte- familiarization shall operate a MEWP. The user shall determine if nance required by JLG Industries, Inc. Consult local regulations for personnel are qualified to operate the MEWP prior to operation. further requirements for MEWPs. Frequency of inspections and...

  • Page 28: Inspection And Maintenance Table

    Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. IMPORTANT JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION BASIC NOMENCLATURE 1. Platform 5. Fly Boom 9. Front Drive/Steer Wheels 13. Jib Lift Cylinder 2. Platform Control Console 6. Base Boom 10. Ground Control Console 14. Foot Switch 3. Rotator 7.

  • Page 30: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection Walk-Around Inspection – Perform as instructed. Battery – Charge as required. The Pre-Start Inspection should include each of the following: Fuel (Combustion Engine Powered Machines) – Add the Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- proper fuel as necessary.
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Lanyard Attach Points - 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. IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI- ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL.
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION WALK-AROUND INSPECTION DIAGRAM 31215030...
  • Page 33 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General Platform Control Console - Switches and levers return to neutral when activated and released, decals/placards secure Begin the Walk-Around Inspection at Item 1, as noted on the dia- and legible, control markings legible. gram.

  • Page 34: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Ground Control Console - Switches and levers return to b. Ensure all functions stop when the function switch is neutral when activated and released, decals/placards secure released. and legible, control markings legible. c.
  • Page 35 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Swing the boom over either of the rear tires and ensure that the Drive Orientation indicator illuminates and that the Drive Orientation Override switch must be used for the drive function to operate. Place the machine in Transport Mode.

  • Page 36: Skyguard® Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard® Function Test Disengage the SkyGuard sensor, release controls, then recy- cle the footswitch. Ensure normal operation is available. NOTE: Refer to Section 4.10 for additional information on SkyGuard NOTE: On machines equipped with SkyLine, reattach magnetic end of operation.

  • Page 37: General

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL CONTROLS AND INDICATORS NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND arise.

  • Page 38: Ground Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS GROUND CONTROL STATION 600AJ 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power 6. Tower Boom Telescope 7. Hourmeter 8. Platform/Ground Select 9. Swing 10. Tower Boom Lift 11.

  • Page 39: 600Aj With Machine Safety System Override (Msso)

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 600AJ with Machine Safety System Override (MSSO) (CE ONLY) 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power 6. Tower Boom Telescope 7. Hourmeter 8. Platform/Ground Select 9.
  • Page 40 SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Leveling Override TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR A three position switch allows the operator to adjust the automatic self TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE leveling system.
  • Page 41 SECTION 3 - MACHINE CONTROLS AND INDICATORS Tower Boom Telescope ALWAYS POSITION EMERGENC Y STOP SWITCH TO THE ’OFF’ POSITION (PUSHED IN) This switch provides extending and WHEN MACHINE IS NOT IN USE. retracting of the tower boom. This function works only when the tower NOTE: On machines with diesel engines, when Glow Plug Indicator is boom is fully elevated (lift up).
  • Page 42 SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform/Ground Select Switch Tower Boom Lift The three position, key operated switch sup- This switch provides raising and low- plies power to the platform control console ering of the tower boom. This func- when positioned to Platform.

  • Page 43: (Ce Only)

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Machine Safety System Override (MSSO) (CE Only) Provides emergency override of function controls that are locked out in the event of Load Sense System activation. Air Shutoff Valve (ASOV) (If Equipped) The red LED ASOV light indicates when the valve has been actuated.

  • Page 44: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS GROUND CONTROL INDICATOR PANEL 1. Battery Charge 5. Capacity Zone Indicator 8. Platform Overload 2. Low Fuel (Ford DF 2.5L Only) 6. Glow Plug 9. Engine Error 3. System Distress 7. Generator 10. Emissions Temperature 4.
  • Page 45 System Distress Indicator Glow Plug Indicator The light indicates that the JLG Control System has detected an abnormal condition and a Indicates the glow plugs are on. The glow Diagnostic Trouble Code has been set in the plugs are automatically turned on with the system memory.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS Engine Error Indicator Indicates a fault with the engine and service is required. Emissions Temperature Indicator Icon illuminates when the engine emissions control sensor reaches a high temperature. 3-10 31215030...

  • Page 47: Platform Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS PLATFORM CONTROL CONSOLE 1702676 D 1001107677 A 1702566 B 1702565 B 1702567 B 1705170 A 1702938 11 10 1. Drive Speed/Torque Select 6. Drive Orientation Override 11. Soft Touch/SkyGuard Override 16. Function Speed Control 2.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS Horn TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR A push-type Horn switch supplies electrical power to an audible warning device when pressed. TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS Drive Orientation Override NOTE: To operate the Drive joystick, pull up on the lock- ing ring below the handle. When the boom is swung over the rear tires or further in either direction, the Drive Orienta- tion indicator will illuminate when the drive function is selected.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: The ignition switch does not have to be on to operate the lights, Tower Telescope so care must be taken to avoid draining the battery if left unat- tended. The master switch and/or the ignition switch at the This switch provides for extending and retract- ground control will turn off power to all lights.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Rotate NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. Provides rotation of the platform. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released.

  • Page 52: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS PLATFORM CONTROL INDICATOR PANEL 1. Low Fuel (Ford DF 2.5L Only) 5. Tilt Alarm/Warning 9. Engine Emissions System Failure 13. Diesel Particulate Filter Indicator 6. Creep 10. Generator 14. Emissions Temperature 2. System Distress 3.
  • Page 53 System Distress Indicator restricted platform positions (shorter boom lengths and higher boom angles). The light indicates that the JLG Control System has detected an abnormal condition and a NOTE: Refer to the capacity decals on the machine for Diagnostic Trouble Code has been set in the restricted and unrestricted platform capacities.
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS. RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE BEFORE EXTENDING Glow Plug Indicator BOOM OR RAISING BOOM ABOVE HORIZONTAL.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS Engine Error Indicator Indicates a fault with the engine and service is required. Diesel Particulate Filter (DPF) Indicator Icon will illuminate when standstill exhaust system cleaning is required. Emissions Temperature Indicator Icon illuminates when the engine emissions control sensor reaches a high temperature.

  • Page 56: Section 4 - Machine Operation

    All machine systems are functioning properly. The primary operator control station is in the platform. From this Machine is as originally equipped from JLG. control station, the operator can drive and steer the machine in Platform Load Sensing System (LSS) both forward and reverse directions.

  • Page 57: Stability

    SECTION 4 - MACHINE OPERATION Stability Position of Least Backward Stability Machine stability is based on two positions which are called FOR- WARD and BACKWARD stability. The machines position of least FORWARD stability is shown in “Position of Least Forward Stabil- ity”...
  • Page 58 SECTION 4 - MACHINE OPERATION Position of Least Forward Stability 31215030...

  • Page 59: Engine Operation

    MANUAL. coolant temperature may occur. NOTE: Diesel engines only: After turning on ignition, NOTE: Contact JLG Customer Service for operation under abnormal operator must wait until glow plug indicator light conditions. goes out before cranking engine. NOTE: Initial starting should always be performed from the Ground Control station.

  • Page 60: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION Push the Engine Start switch until engine starts. ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD. NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed posi- After engine has had sufficient time to warm tion, DO NOT OPERATE MACHINE.

  • Page 61: Air Shutoff Valve (Asov) (If Equipped)

    SECTION 4 - MACHINE OPERATION Air Shutoff Valve (ASOV) (If Equipped) DO NOT USE ASOV AS AN ALTERNATIVE TO SHUTTING DOWN MACHINE PROPERLY. Air Shutoff Valve (ASOV ) is an overspeed protection device mounted to the engine’s air intake system. When the valve is actuated, it obstructs airflow intake and stops the engine.

  • Page 62: Fuel Reserve / Shut-Off System

    The Fuel Shutoff System monitors the fuel in the tank and senses more fuel available. when the fuel level is getting low. The JLG Control System auto- matically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

  • Page 63: Grade And Sideslope

    SECTION 4 - MACHINE OPERATION Figure 4-2. Grade and Sideslope 31215030...

  • Page 64: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM SUR- See Figure 4-2., Grade and Sideslope FACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE. NOTE: Refer to the Operating Specifications table for Gradeability and Sideslope ratings.

  • Page 65: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse Push and release the Drive Orientation Over- ride switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the At Platform Controls, pull out Emergency Stop intended direction of machine travel. The indi- switch and activate footswitch.

  • Page 66: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION Traveling on a Grade STEERING Position thumb switch on Drive/Steer controller to When traveling a grade, maximum braking and traction are obtained Right for steering right, or to Left for steering left. with the boom stowed, in position over the rear (drive) axle, and in line with the direction of travel.

  • Page 67: Boom

    SECTION 4 - MACHINE OPERATION BOOM TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER- GENCY STOP SWITCH TO STOP THE MACHINE. A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE.

  • Page 68: Raising And Lowering The Tower Boom

    TIONS. (approximately 13 degrees from vertical) before the Tower Boom can be extended — HAVE CONDITION CORRECTED BY A QUALIFIED JLG SERVICE TECHNICIAN BEFORE from the fully retracted position. CONTINUING USE OF MACHINE. b. The Tower Telescope “out” or “in” will only...

  • Page 69: Re-Synchronize The Lower Lift Cylinder

    SECTION 4 - MACHINE OPERATION RE-SYNCHRONIZE THE LOWER LIFT CYLINDER To Operate: Pull the red knob Level Override Valve Using the ground control raise the lower boom 6 feet. A pull type control valve allows the operator to adjust the tower Release the knob.
  • Page 70 SECTION 4 - MACHINE OPERATION 31215030 4-15...
  • Page 71 SECTION 4 - MACHINE OPERATION 4-16 31215030...

  • Page 72: Machine Safety System Override (Msso)

    SECTION 4 - MACHINE OPERATION MACHINE SAFETY SYSTEM OVERRIDE (MSSO) SkyGuard (CE ONLY) The Machine Safety System Override (MSSO) is used to override function controls for Emergency Platform Retrieval only. Refer to Section 5.5, Machine Safety System Override (MSSO) (CE Only) for operating procedures.

  • Page 73: Skyguard - Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- Operator passes through path of sensor beam. nected. SkyGuard Function Table Tower Boom Drive Drive Tower Tower Tower Boom Boom Boom Basket Basket Steer...

  • Page 74: 4.11 Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) The preferred procedures to shut down and park the machine are as follows: LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- Drive machine to a reasonably well protected area.
  • Page 75 SECTION 4 - MACHINE OPERATION Towbar Connecting Points STEER SELECT VALVE 4-20 31215030...

  • Page 76: Towing (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.14 TOWING (IF EQUIPPED) After towing the machine, complete the following: Actuate steer/tow selector valve for steering; push valve RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOW- knob IN to the actuated position. ING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED.

  • Page 77: 4.15 Auxiliary Power

    SECTION 4 - MACHINE OPERATION 4.15 AUXILIARY POWER WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC- TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXIL- IARY 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.

  • Page 78: Activating From The Ground Control Station

    SECTION 4 - MACHINE OPERATION Depress and hold footswitch. Position Auxiliary Power switch to On and hold. Position Auxiliary Power switch to On and hold. Operate appropriate control switch or control- ler for desired function and hold. Operate appropriate control switch, lever or controller for Release Auxiliary Power switch, and appropriate control desired function and hold.

  • Page 79: Changing From Gasoline To Lp Gas

    SECTION 4 - MACHINE OPERATION Changing From Gasoline to LP Gas 4.17 TIE DOWN AND LIFTING Start engine from Ground Control Sta- When transporting machine, boom must be in the stowed mode tion. with turntable lock pin engaged and machine securely tied down to truck or trailer deck.

  • Page 80: Lifting Chart

    SECTION 4 - MACHINE OPERATION Figure 4-7. Lifting Chart 31215030 4-25...
  • Page 81 SECTION 4 - MACHINE OPERATION Figure 4-8. 600AJ Decal Installation - Sheet 1 of 4 4-26 31215030...
  • Page 82 SECTION 4 - MACHINE OPERATION 57 253 Figure 4-9. 600AJ Decal Installation - Sheet 2 of 4 31215030 4-27...
  • Page 83 SECTION 4 - MACHINE OPERATION Figure 4-10. 600AJ Decal Installation - Sheet 3 of 4 4-28 31215030...
  • Page 84 SECTION 4 - MACHINE OPERATION 105 45 Figure 4-11. 600AJ Decal Installation - Sheet 4 of 4 31215030 4-29...

  • Page 85: 600Aj Decal Legend

    SECTION 4 - MACHINE OPERATION Table 4-1. 600AJ Decal Legend Eng/ Chinese Chinese Item # ANSI Eng/French Eng/Spanish Japanese Australian Korean Portuguese Simplified Traditional 1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B 1001243640-B 1001243648-B 1001243647-B 3252347 1705828 3251813 3251813 3251813 3251813...
  • Page 86 SECTION 4 - MACHINE OPERATION Table 4-1. 600AJ Decal Legend Eng/ Chinese Chinese Item # ANSI Eng/French Eng/Spanish Japanese Australian Korean Portuguese Simplified Traditional 1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B 1001243640-B 1001243648-B 1001243647-B 0100011 0100011 0100011 0100011 0100011 0100011...
  • Page 87 SECTION 4 - MACHINE OPERATION Table 4-1. 600AJ Decal Legend Eng/ Chinese Chinese Item # ANSI Eng/French Eng/Spanish Japanese Australian Korean Portuguese Simplified Traditional 1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B 1001243640-B 1001243648-B 1001243647-B 1001231801 2902303 2902303 2902303 2902303 2902303...
  • Page 88 SECTION 4 - MACHINE OPERATION Table 4-1. 600AJ Decal Legend Eng/ Chinese Chinese Item # ANSI Eng/French Eng/Spanish Japanese Australian Korean Portuguese Simplified Traditional 1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B 1001243640-B 1001243648-B 1001243647-B 1703953 1703942 1701518 1703941 1705903 1703944...
  • Page 89 @ www.discount-equipment.com Select an option below to find your Equipment We sell worldwide for the brands: Genie, Terex, JLG, MultiQuip, Mikasa, Essick, Whiteman, Mayco, Toro Stone, Diamond Products, Generac Magnum, Airman, Haulotte, Barreto, Power Blanket, Nifty Lift, Atlas Copco, Chicago Pneumatic, Allmand, Miller Curber, Skyjack, Lull,...

  • Page 90: Section 5 - Emergency Procedures

    BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR- RECTLY. JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is EMERGENCY OPERATION evident, the factory should be contacted by telephone and pro- vided with all necessary details.

  • Page 91: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead EMERGENCY TOWING PROCEDURES Towing this machine is prohibited, unless properly equipped. If the platform or boom becomes jammed or snagged in over- However, provisions for moving the machine have been incorpo- head structures or equipment, do the following: rated.

  • Page 92: Machine Safety System Override (Msso)

    NOTE: If the MSSO functionality is used, the fault indicator is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician. NOTE: No functional checks of the MSSO system are necessary. The JLG Control system will set a Diagnostic Trouble Code if the control switch is faulty.

  • Page 93: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Fall Arrest Platform (36" x 72")      Fall Arrest Platform (36" x 96")     Pipe Racks ...

  • Page 94: Options/Accessories Relationship Table

    SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Platform MMR**, Platform MTR*, SkyGlazier™, SkyCutter™, Pipe Racks SkyPower™ Soft Touch SkyWelder™, 4’ Platform, Pipe Racks, Platform SkyCutter™ SkyPower™...

  • Page 95: Fall Arrest Platform

    FALL ARREST PLATFORM PIPE RACKS NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform.

  • Page 96: Capacity Specifications (Australia Only)

    SECTION 6 - ACCESSORIES Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform. • Do not exit platform over rails or stand on rails. Max. Platform Capacity Max. Capacity in Racks • Do not drive machine without material secured (With Max.

  • Page 97: Skycutter

    SECTION 6 - ACCESSORIES SKYCUTTER™ Safety Precautions DO NOT OVERLOAD PLATFORM. DE-RATE THE PLATFORM BY 70 LB (32 KG) WHEN ACCESSORY IS IN THE PLATFORM. • Check for cracked welds and damage to plasma supports. • Check for secure installation of cutter and bracket. •...

  • Page 98: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Amperes Input @ Plasma Gas Flow/ Rated Cutting Spec. Rated Output Rated Output, 60 kVa/kW Plasma Gas Max. OCV Pressure Capacity @ 10 IPM Hz, 1-Phase 120 Volts ±10% 27 A @ 91 VDC @ 20% 28.8 max;...

  • Page 99: Skyglazier

    SECTION 6 - ACCESSORIES SKYGLAZIER™ Capacity Specifications Max. Platform Capacity Capacity Zone * Max. Tray Capacity (With Max. Weight in Tray) 500 lb 150 lb 250 lb (227 kg) (68 kg) (113 kg) 550 lb 150 lb 250 lb (250 kg) (68 kg) (113 kg) 600 lb...

  • Page 100: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions Preparation and Inspection • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. ENSURE PANEL IS SECURED WITH STRAP. • Ensure strap is not torn or frayed. Operation DO NOT OVERLOAD TRAY OR PLATFORM.

  • Page 101: Skypower

    SECTION 6 - ACCESSORIES SKYPOWER™ All power regulation components are located in a watertight box connected by cable to the generator. The generator supplies power when running at the specified speed with the power switch on (switch is located on platform). A three-pole, 30 Amp circuit breaker protects the generator from overload.

  • Page 102: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions SKYWELDER™ DO NOT OVERLOAD PLATFORM. • Ensure no personnel are beneath platform. • This factory-installed option is available only on specified models. • Keep lanyard attached at all times. • Do not use electrical tools in water. •...

  • Page 103: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Welding Amps Input At Rated Load Output (50/60 Hz) Maximum Open Welding Mode Input Power Rated Output Amperage Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2 V, 15.7 35% Duty Cycle 3- phase 5-250 A 79 VDC...

  • Page 104: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Do not ground through the platform. • Do not use a high frequency arc starter with TIG welder. Preparation and Inspection DO NOT OVERLOAD PLATFORM. • Connect ground clamp to metal being welded. •...

  • Page 105: Soft Touch

    SECTION 6 - ACCESSORIES SOFT TOUCH BOLT-ON EXTERNAL FALL ARREST A padding kit is mounted to the platform rails and to a frame sus- The bolt-on external fall arrest system is designed to provide a lan- pended below the platform. Limit switches deactivate platform yard attach point while allowing the operator to access areas outside functions when the padded framework contacts an adjacent the platform.

  • Page 106: Inspection Before Use

    SECTION 6 - ACCESSORIES Bolt-On External Fall Arrest Cable Tension THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTI- GAP SHOWING: FICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A INCORRECT QUALIFIED PERSON OTHER THAN THE USER. Inspection Before Use The external fall arrest system must be inspected before each use of the machine.

  • Page 107: Bolt-On External Fall Arrest System

    SECTION 6 - ACCESSORIES Bolt-On External Fall Arrest System 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal 31215030 6-15...

  • Page 108: Section - 7 - General Specifications & Operator Mainte

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications mation to the operator for proper operation and maintenance of this machine.

  • Page 109: Dimensional Data

    7ft chassis Maximum Drive Speed 4.25 MPH (6.84 Km/hr.) Platform Height 600AJ 60 ft. 7 in. (18.47 m) Gross Machine Weight --600AJ (Approximate) 22,240 lb (10,088 kg) Horizontal Reach 22,740 lb (10,315 kg) 600AJ 39 ft. 9 in. (12.10 m)

  • Page 110: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Data Table 7-3. Capacities Table 7-4. Deutz D2011L04 Specifications Fuel Tank 30 Gallons (113.6 L) Fuel Diesel Oil Capacity Hydraulic Oil Tank 30.6 Gallons (115.8 L) Cooling System 5 Quarts (4.5 L) Hydraulic System (Including Tank) 40 Gallons (151.4 L) Crankcase...

  • Page 111: Deutz Td 2.9L Specifications

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-5. Deutz TD 2.9L Specifications Table 7-6. Ford DF 2.5L, MSG 425 Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline/LP Gas Output 67 hp (50 kW) Oil Capacity 7 qt (6.6L) Torque 173 ft.lbs.

  • Page 112: Tires

    When temperatures remain below 20° F (-7 degrees C), JLG Industries recommends the use of Mobil DTE 13M. Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.

  • Page 113: Mobilfluid 424 Specs

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-9. Mobilfluid 424 Specs Table 7-10. Mobil DTE 10 Excel 32 Specs SAE Grade 10W30 ISO Viscosity Grade Gravity, API 29.0 Specific Gravity 0.877 Density, lb./Gal. 60°F 7.35 Pour Point, Max -40°F (-40°C) Pour Point, Max -46°F (-43°C)

  • Page 114: Mobil Eal H 46 Specs

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-11. Mobil EAL H 46 Specs Table 7-12. Mobil EAL 46 Specs Type Synthetic Biodegradable Type Synthetic Biodegradable ISO Viscosity Grade ISO Viscosity Grade Density at 15° C .874 Density at 15° C Pour Point -49°F (-45°C) Pour Point...

  • Page 115: Exxon Univis Hvi 26 Specs

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-13. Exxon Univis HVI 26 Specs Table 7-14. Mobil EAL 224H Specs Specific Gravity 32.1 Type Synthetic Biodegradable Pour Point -76°F (-60°C) ISO Viscosity Grade 32/46 Flash Point 217°F (103°C) Specific Gravity .922 Viscosity Pour Point, Max...
  • Page 116 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-15. Quintolubric 888-46 Density 0.92 g/cm Pour Point <-30°C (<-22°F) Flash Point 300°C (572°F) Fire Point 360°C (680°F) Autoignition Temperature >450°C (842°F) Viscosity at 0° C (32°F) 320 cSt at 20° C (68°F) 109 cSt at 40°...

  • Page 117: Serial Number Locations

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Serial Number Locations A serial number plate is affixed to the left 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. 7-10 31215030...

  • 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

    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 TE : AMBIENT AIR TEMPERATURES 110°...
  • Page 120 -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 121 (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: Operator Maintenance And Lubrication

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE AND LUBRICATION DIAGRAM DEUTZ D2011L04 31215030 7-15...

  • Page 123: Deutz Td 2.9

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Deutz TD 2.9L 7-16 31215030...

  • Page 124: Ford Df 2.5L, Msg 425

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Ford DF 2.5L, MSG 425 31215030 7-17...

  • Page 125: Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE Swing Bearing NOTE: The following numbers correspond to those in Figure 7.3, Opera- tor Maintenance and Lubrication Diagram Deutz D2011L04. Table 7-16. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel- lent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 126 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Bearings (If equipped) Swing Drive Hub Lube Point(s) - Repack Lube Point(s) - Level/Fill Plug Capacity - A/R Capacity - 43 oz. (1.3 L) Lube - MPG Lube - 90w80 Gear Oil Interval - Every 2 years or 1200 hours of operation Interval - Check level every 3 months or 150 hrs of operation;...
  • Page 127 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Drive Hub Hydraulic Return Filter Lube Point(s) - Level/Fill Plug Capacity - 20 oz. (0.6 L) Lube - EPGL Interval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation Interval - Change after first 50 hrs.
  • Page 128 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Charge Filter Hydraulic Tank NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION Interval - Change after first 50 hrs. and every 6 months or Lube Point(s) - Fill Cap 300 hrs. thereafter or as indicated by Condition Indicator. Capacity - 30.6 gal.
  • Page 129 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE A. Oil Change w/Filter - Deutz 2011 B. Oil Change w/Filter - Deutz TD2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Capacity - 9.6 Quarts (9.0 L) Lube - EO Lube - EO...

  • Page 130: Deutz 2011 Engine Dipstick

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD MAXIMUM LEVEL OIL LEVEL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 7-3.
  • Page 131 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Oil Change w/Filter - Ford A. Fuel Filter - Deutz Lube Point(s) - Fill Cap/Spin-on Element On Engine: Capacity - 4.5 qt. (4.25 L) w/filter Lube Point(s) - Replaceable Element Lube - EO Interval - Change in accordance with engine manual Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with...
  • Page 132 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Fuel Filter - Deutz TD2.9 (On Turntable) C. Fuel Filter - Deutz TD2.9 (On Engine) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual Interval - Change in accordance with engine manual Fuel Filter (Gasoline) - Ford Lube Point(s) - Replaceable Element...
  • Page 133 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE A. Air Filter (Deutz 2011 and Ford) B. Air Filter (Deutz TD 2.9) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator indicated by the condition indicator...

  • Page 134: Tires & Wheels

    For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly.

  • Page 135: Tire Replacement

    JLG recommends a replacement tire be the same size, ply and brand Wheel Installation as originally installed on the machine. Please refer to the JLG Parts...

  • Page 136: Oscillating Axle Lockout Test (If Equipped)

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tighten nuts in the following sequence: Table 7-17. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage 3rd Stage 40 ft. lbs. 95 ft. lbs. 170 ft. lbs. (55 Nm) (130 Nm) (230 Nm) OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-...

  • Page 137: Propane Fuel Filter Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Carefully activate Swing control lever and position boom should release and allow wheel to rest on ground, it may be necessary activate Drive to release cylinders. over right side of machine. With boom over right side of machine, place Drive control If lockout cylinders do not function properly, have qualified lever to Reverse and drive machine off of block and ramp.

  • Page 138: Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Installation BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL Install the housing seal. Drop the magnet into the bottom of the filter housing. Install the filter into the housing. Install the filter up to the bottom of the electric lock off.

  • Page 139: Propane Fuel System Pressure Relief

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL SYSTEM PRESSURE RELIEF SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO and is only applicable to CE machines.
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