JLG B300001393 Operation And Safety Manual
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JLG B300001393 Operation And Safety Manual

JLG B300001393 Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
600A
600AJ
S/N 0300177361 &
B300001393
to Present
AS/NZS
ANSI
3121615
®
November 5, 2018 - Rev M

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 600A 600AJ S/N 0300177361 & B300001393 to Present AS/NZS ANSI 3121615 ® November 5, 2018 - Rev M...
  • 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 NOTE: This manual also applies to a machine with the following Serial Number: 0300176207. 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.
  • 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 POTENTIALLY HAZARDOUS SITUATION.
  • Page 6 Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.
  • Page 7 FOREWORD REVISION LOG Original Issue A - November 6, 2013 Revised B - January 1, 2014 Revised C - July 4, 2014 Revised D - October 1, 2014 Revised E - January 5, 2015 Revised F - January 7, 2016 Revised G - June 13, 2016 Revised...

  • Page 8: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS SkyGuard® Function Test......2-6 LIMIT SWITCH FUNCTIONAL CHECK.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE STEERING......... . . 4-11 4.16 DUAL FUEL SYSTEM (GAS ENGINE ONLY) .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Accessory Ratings ....... . . 6-6 SECTION - 7 - GENERAL SPECIFICATIONS &...
  • Page 11 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally 3121615...
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature - 600A ......2-10 4-10.
  • Page 13 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121615...
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 Beaufort Scale (For Reference Only)....1-9 Inspection and Maintenance Table .
  • Page 15 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121615...

  • Page 16: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 17: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 18: 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 19: Trip And Fall Hazards

    • Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature, approved by JLG. ambient air temperature, and boom and platform position. • When two or more persons are in the platform, the operator Trip and Fall Hazards shall be responsible for all machine operations.

  • Page 20: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 21 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 22: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 23 Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind unless authorized by JLG. speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, •...
  • Page 24 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 25: 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 driving and swing operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 26: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 27 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 28: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 29 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121615...
  • Page 30 @ 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 31: 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 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The aerial platform is a personnel handling device; so it is neces- depressions, holes, dropoffs.

  • Page 32: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance recommended by JLG Industries, Inc.
  • Page 33 Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121615...

  • Page 34: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-3. thru Fig- ure 2-7. The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7.

  • Page 35: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the transport (stowed) position: a. Drive the machine on a grade, not to exceed the rated Perform the Function Check as follows: gradeability, and stop to ensure the brakes hold; 1.

  • Page 36: Skyguard® Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard® Function Test NOTE: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing. NOTE: Refer to Section 4.10 for additional information on SkyGuard 4. Disengage the SkyGuard sensor, release controls, then recy- operation.

  • Page 37: Limit Switch Functional Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION LIMIT SWITCH FUNCTIONAL CHECK 4. Swing turntable to LEFT and RIGHT a minimum of 45 degrees. Check for smooth motion. 5. Check the chassis out of level indicator located on the plat- form control console by driving, with the machine in level TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL position, up a suitable ramp of at least 5°...
  • Page 38 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION c. Mark wear pad location on the fly and mid booms. d. Lift boom up until 1000 lb. (454 kg for ANSI markets and 450 kg for CE and Australia markets) light comes on. d.
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Main Boom Angle Switch. d. Lift main boom down until 500 lb. (227 kg for ANSI mar- kets and 230 kg for CE and Australia markets) light a. Lift main boom to approximately horizontal. comes on.
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 5. Base Boom 9. Rear Drive Wheels 2. Platform Control Box 6. Upright 10. Footswitch 3. Rotator 7. Tower Boom 11. SkyGuard (If Equipped) 4. Fly Boom 8. Front Drive/Steer Wheels 12.
  • Page 41 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 5. Fly Boom 9. Front Drive/Steer Wheels 13. Foot Switch 2. Platform Control Box 6. Base Boom 10. Rear Drive Wheels 14. SkyGuard (If Equipped) 3. Rotator 7. Upright 11.
  • Page 42 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection Diagram - Deutz D2011L04 2-12 3121615...
  • Page 43 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-4. Daily Walk-Around Inspection Diagram - Deutz TD2.9 3121615 2-13...
  • Page 44 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-5. Daily Walk-Around Inspection Diagram - GM 3.0L 2-14 3121615...

  • Page 45: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 4. Jib (If Equipped) - See Inspection Note. Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the con- ditions listed in the following checklist. TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF.
  • Page 46 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11. Auxiliary Power Pump - See Inspection Note. 17. Battery - Proper electrolyte levels if adjustable; cables tight, no visible damage or corrosion. 12. Swing Drive Motor and Brake - See Inspection Note. 18.
  • Page 47 @ 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 48: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Indicates a potentially hazardous situation, which if THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 49: Ground Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Station ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF (See Figure 3-1., Figure 3-2., Figure 3-3. and Figure 3-4.) THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR NOTE: If equipped, the Function Enable switch must be FALL.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Tower Lift 11. Main Boom Lift 12.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power/Function Enable 6. Boom Lift 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Tower Lift 11. Main Boom Lift 12.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Not Used 4. Power/Emergency Stop 5. 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.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Not Used 4. Power/Emergency Stop 5. 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.
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When Power/Emergency Stop switch is in the “On” position and 5. Engine Start/ Auxiliary Power Switch /Function engine is not running, an alarm will sound, indicating Ignition is Enable “On”. To start the engine, the switch must be held "Up" until the engine starts.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Tower Telescope NOTE: When the Platform/Ground Select Switch is in the center position, power is shut off to the controls at This switch provides extending and both operating stations. Remove the key to pre- retracting of the tower boom.
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope, 10. Tower Lift Tower Telescope, Platform Rotator and Auxiliary Power control switches are spring-loaded and will automatically return to neu- This switch provides raising and low- tral (off) when released.

  • Page 57: Ground Control Indicator Panel

    5. System Distress Indicator Ground Control Indicator Panel The light indicates that the JLG Control System (See Figure 3-5.) has detected an abnormal condition and a 1. No Alternator Output Indicator Diagnostic Trouble Code has been set in the system memory.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. No Alternator Output 5. System Distress 2. Low Engine Oil Pressure 6. Glow Plug Wait to Start 3. High Engine Coolant Temp. 7. Platform Overload 4. Engine Oil Temp. 8. Drive and Steer Disable Figure 3-5.

  • Page 59: Platform Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Glow Plug/ Wait to Start Indicator Platform Station Indicates the glow plugs are on. The glow (See Figure 3-6.) plugs are automatically turned on with the ignition circuit and remain on for approxi- mately seven seconds.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Steer Select (If Equipped) When equipped with four wheel steering, the ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF action of the steering system is operator THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR selectable.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Drive Speed 6. Start/Aux. Power 11. Lights 16. Soft Touch/SkyGuard Indicator 2. Steer Select 7. Fuel Select 12. Jib 17. Platform Rotate 3. Platform Leveling Override 8. Drive Orientation Override 13. Soft Touch/SkyGuard Override 18.
  • Page 62 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Power/Emergency Stop Switch 7. Fuel Select (Dual Fuel Engine Only) (If Equipped) A two-position red mushroom shaped switch furnishes power to Platform Controls when Gasoline or liquid propane fuel may be pulled out (on). When pushed in (off ), power is selected by moving the switch to the appropriate position.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Lift, Swing, and Drive control levers are spring-loaded and will 10. Main Boom Telescope automatically return to neutral (off) position when released. Provides extension and retraction of the main boom. 11. Lights (If Equipped) TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE This switch operates control console panel...
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS If equipped with Soft Touch, the switch enables the functions that were cut out by the Soft Touch system to operate TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT again at creep speed, allowing the AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE.

  • Page 65: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS swing right, move left to swing left. Moving the joystick acti- vates switches to provide the functions selected. DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEED Platform Control Indicator Panel SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL.
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Tilt 5. Glow Plug 8. AC Generator 2. Overload 6. Low Fuel 9. Drive Orientation 3. Capacity 7. System Distress 10. Creep 4. Enable Figure 3-7. Platform Control Indicator Panel 3121615 3-19...
  • Page 67 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Platform Overload (If equipped) 4. Footswitch/Enable Indicator Indicates the platform has been overloaded. To operate any function, the footswitch must be depressed and the function selected within 3. Capacity Indicator seven seconds. The enable indicator shows that the controls are enabled.
  • Page 68 7. System Distress Indicator the proper direction (i.e. controls reversed situations). The light indicates that the JLG Control System 10. Creep Speed Indicator has detected an abnormal condition and a...
  • Page 69 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 3121615...
  • Page 70 @ 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 71: Section 4 - Machine Operation

    4. Proper tire pressure. Controls operate Boom Lift and Swing, and are to be used in an 5. Machine is as originally equipped from JLG. emergency to lower the platform to the ground should the oper- ator in the platform be unable to do so.

  • Page 72: Stability

    SECTION 4 - MACHINE OPERATION 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 Figure 4-2., Position of Least For- ward Stability, and its position of least BACKWARD stability is shown in Figure 4-1., Position of Least Backward Stability.
  • Page 73 SECTION 4 - MACHINE OPERATION Figure 4-2. Position of Least Forward Stability 3121615...

  • Page 74: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION 2. Pull the Power/Emergency Stop switch to On. NOTE: Initial starting should always be performed from the Ground Control station. 3. Push the Engine Start switch until engine starts. Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

  • Page 75: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION 7. Push the Engine Start switch until engine starts. Air Shutoff Valve (ASOV) (If Equipped) Air Shutoff Valve (ASOV ) is an overspeed protection device mounted to the engine’s air intake system. When the valve is NOTE: Footswitch must be in released (up) position before starter will actuated, it obstructs airflow intake and stops the engine.

  • Page 76: Fuel Reserve / Shut-Off System

    JLG Mechanic to verify your machine setup. The Fuel Shutoff System monitors the fuel in the tank and senses 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 77: Traveling (Driving)

    All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted. CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE. Traveling is limited by two factors: •...
  • Page 78 SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Sideslope 3121615...

  • Page 79: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND 1. At Platform Controls, pull out Emergency Stop LEVEL SURFACE. switch and activate footswitch. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

  • Page 80: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION 1. Match the black and Traveling on a Grade white direction arrows on both platform con- When traveling a grade, maximum braking and traction are obtained trol panel and the chas- with the boom stowed, in position over the rear (drive) axle, and in sis to determine the line with the direction of travel.

  • Page 81: Steering

    SECTION 4 - MACHINE OPERATION STEERING BOOM Position thumb switch on Drive/Steer controller to Right for steering right, or to Left for steering left. DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL. PLATFORM DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. Platform Level Adjustment TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL.

  • Page 82: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom Raising and Lowering the Tower Boom To swing boom, use Swing control switch to select This machine has two controls for the tower boom (two toggle Right or Left direction. switches), one controls tower lift, the other tower telescope. The switching system will sequence its Lift and Telescope functions as follows: 1.

  • Page 83: Raising And Lowering The Main Boom

    — LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNC- To extend or retract the main boom, use the Main TIONS. Telescope Control Switch to select In or Out move- ment. — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE. 3121615 4-13...

  • Page 84: Re-Synchronize The Lower Lift Cylinder

    SECTION 4 - MACHINE OPERATION RE-SYNCHRONIZE THE LOWER LIFT CYLINDER To Operate: 1. Pull the red knob Level Override Valve 2. Using the ground control raise the lower boom 6 feet. A pull type control valve allows the operator to adjust the tower 3.
  • Page 85 SECTION 4 - MACHINE OPERATION 3121615 4-15...
  • Page 86 SECTION 4 - MACHINE OPERATION 4-16 3121615...

  • Page 87: Machine Safety System Override (Msso)(Ce Only)

    SECTION 4 - MACHINE OPERATION MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE SkyGuard 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. 4.10 SKYGUARD OPERATION SkyGuard provides enhanced control panel protection.

  • Page 88: 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 89: 4.11 Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.11 SHUT DOWN AND PARK 4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 1. Drive machine to a protected area. 2. Assure boom is fully retracted and lowered over rear (Drive) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- axle;...

  • Page 90: Towing (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.14 TOWING (IF EQUIPPED) Prior to towing the machine, complete the following: DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED. RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT 1.
  • Page 91 SECTION 4 - MACHINE OPERATION STEER SELECT VALVE Figure 4-8. Towbar Connecting Points 3121615 4-21...
  • Page 92 SECTION 4 - MACHINE OPERATION 3. Disconnect drive hubs by inverting disconnect cap.Refer to Figure 4-9., Drive Disconnect Hub. 4. Actuate steer/tow selector valve for towing; pull valve knob OUT to float position. (This opens the steer circuit to reser- voir, allowing the steer cylinder rod free travel.) The machine is now in the towing mode.

  • Page 93: 4.15 Auxiliary Power

    SECTION 4 - MACHINE OPERATION 4.15 AUXILIARY POWER 4. Position Auxiliary Power switch to On and hold. WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC- 5. Operate appropriate control switch, lever or controller for TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXIL- desired function and hold.

  • Page 94: Dual Fuel System (Gas Engine Only)

    SECTION 4 - MACHINE OPERATION 4. Operate appropriate control switch or controller for desired Changing From Gasoline to LP Gas function and hold. 1. Start engine from Ground Control Sta- 5. Release Auxiliary Power switch, and appropriate control tion. switch or controller. 6.

  • Page 95: 4.17 Tie Down And Lifting

    SECTION 4 - MACHINE OPERATION 4.17 TIE DOWN AND LIFTING NOTE: Lifting eyes are provided at the front and rear in the frame slab. Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated. When transporting machine, boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck.
  • Page 96 SECTION 4 - MACHINE OPERATION Figure 4-10. Lifting Chart 4-26 3121615...
  • Page 97 SECTION 4 - MACHINE OPERATION A us 36 28 Figure 4-11. 600A & 600AJ Decal Installation - Sheet 1 of 4 3121615 4-27...
  • Page 98 SECTION 4 - MACHINE OPERATION Figure 4-12. 600A & 600AJ Decal Installation - Sheet 2 of 4 4-28 3121615...
  • Page 99 SECTION 4 - MACHINE OPERATION 22 67 Figure 4-13. 600A & 600AJ Decal Installation - Sheet 3 of 4 3121615 4-29...
  • Page 100 SECTION 4 - MACHINE OPERATION Figure 4-14. 600A & 600AJ Decal Installation - Sheet 4 of 4 4-30 3121615...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-1. 600A Decal Legend Canadian Chinese Chinese Item # ANSI CE/AUS Spanish Portuguese Japanese Korean French Simplified Traditional 1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B 1001156985-B 1001156980-B 1001156979-B 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509...
  • Page 102 SECTION 4 - MACHINE OPERATION Table 4-1. 600A Decal Legend Canadian Chinese Chinese Item # ANSI CE/AUS Spanish Portuguese Japanese Korean French Simplified Traditional 1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B 1001156985-B 1001156980-B 1001156979-B 1704007 1705901 1703953 1703942 1703941 1705903 1703944 1001116845 1703943 1703945...
  • Page 103 SECTION 4 - MACHINE OPERATION Table 4-1. 600A Decal Legend Canadian Chinese Chinese Item # ANSI CE/AUS Spanish Portuguese Japanese Korean French Simplified Traditional 1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B 1001156985-B 1001156980-B 1001156979-B 1001121813 1001121815 1705978 1001121817 1001121819 1001121820 1001121824 1001121822 1001122201 1001121800...
  • Page 104 SECTION 4 - MACHINE OPERATION Table 4-1. 600A Decal Legend Canadian Chinese Chinese Item # ANSI CE/AUS Spanish Portuguese Japanese Korean French Simplified Traditional 1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B 1001156985-B 1001156980-B 1001156979-B 1001131269 1001131269 1700584 1700584 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493...
  • Page 105 SECTION 4 - MACHINE OPERATION Table 4-2. 600AJ Decal Legend Canadian Chinese Chinese Item # ANSI Spanish Portuguese Japanese Australian Korean French Simplified Traditional 1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B 1001156986-B 1001156982-B 1001156981-B 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499...
  • Page 106 SECTION 4 - MACHINE OPERATION Table 4-2. 600AJ Decal Legend Canadian Chinese Chinese Item # ANSI Spanish Portuguese Japanese Australian Korean French Simplified Traditional 1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B 1001156986-B 1001156982-B 1001156981-B 1001117034 1001117035 1703953 1703942 1703941 1705903 1703944 1001116845 1703943...
  • Page 107 SECTION 4 - MACHINE OPERATION Table 4-2. 600AJ Decal Legend Canadian Chinese Chinese Item # ANSI Spanish Portuguese Japanese Australian Korean French Simplified Traditional 1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B 1001156986-B 1001156982-B 1001156981-B 1001121814 1001121816 1705978 1001121818 1001121655 1001121821 1705978 1001121825 1001121823...
  • Page 108 SECTION 4 - MACHINE OPERATION Table 4-2. 600AJ Decal Legend Canadian Chinese Chinese Item # ANSI Spanish Portuguese Japanese Australian Korean French Simplified Traditional 1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B 1001156986-B 1001156982-B 1001156981-B 1001131269 1001131269 1702573 1001131269 1001108493 1001108493 1001108493 1001108493 1001108493...
  • Page 109 @ 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 110: 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 111: 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 112: Machine Safety System Override (Msso)(Ce Only)

    NOTE: If the MSSO functionality is used, the fault indicator will flash and a fault code is set 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 113 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121615...

  • Page 114: 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 115 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 116: 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 117: 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 118: Skycutter

    SECTION 6 - ACCESSORIES SKYCUTTER™ Safety Precautions DO NOT OVERLOAD PLATFORM. DE-RATE THE PLATFORM BY 70 LBS (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 119: 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 120: Skyglazier

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

  • Page 121: 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 122: 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 123: 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 124: 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 125: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Use correct rod size and current settings. • Do not use electrical cords without ground. • Do not use electrical tools in water. DO NOT OVERLOAD PLATFORM. • Do not weld to the platform. •...

  • Page 126: 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 127: Inspection Before Use

    SECTION 6 - ACCESSORIES Inspection Before Use The external fall arrest system must be inspected before each use of IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE the aerial work platform. Replace components if there are any signs DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY of wear or damage.
  • Page 128 SECTION 6 - ACCESSORIES • Cable: Inspect cable for proper tension, broken strands, kinks, or • Attaching Hardware: Inspect all attaching hardware to ensure any signs of corrosion. there are no missing components and hardware is properly tight- ened. GAP SHOWING: GAP SHOWING: •...
  • Page 129 SECTION 6 - ACCESSORIES 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 Figure 6-2. Bolt-On External Fall Arrest System 6-16 3121615...
  • Page 130 @ 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 131: 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 132: Dimensional Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications Dimensional Data Turning Radius - (inside) narrow chassis Table 7-2. Dimensional Data 12 ft. 2 in. (3.71 m) 5 ft. 7 in. (1.7 m) Machine Height (Stowed) Maximum Tire Load: 11,700 lbs.

  • Page 133: 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 134 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-5. Deutz TD 2.9 Specifications Table 7-6. GM 3.0L Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline or Gasoline/LP Gas Output 67 hp (50 kW) No. of Cylinders Torque 173 ft.lbs. (234 Nm) @ 1800rpm Gasoline 83 hp @ 3000 rpm Oil Capacity (Crankcase)

  • Page 135: Tires

    Industries recommends the use of Mobil DTE 13M. ** Load Capacity - 11,800 lb. (4404 kg) - Static 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 136 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 137 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 138 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 139 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 140: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-16. Critical Stability Weights Platform 30x48 30x60 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, 36x72 ENGINE &...

  • Page 141: Serial Number Locations

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 7-1.
  • Page 142 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 143 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 144 -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 145 (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 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-6. Operator Maintenance & Lubrication Diagram - Deutz D2011L04 7-16 3121615...
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-7. Operator Maintenance & Lubrication Diagram - Deutz TD2.9 3121615 7-17...
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-8. Operator Maintenance & Lubrication Diagram - GM 3.0L 7-18 3121615...

  • Page 149: Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE 1. Swing Bearing NOTE: The following numbers correspond to those in Figure 7-6., Oper- ator Maintenance & Lubrication Diagram - Deutz D2011L04. Table 7-17. 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 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Bearings (If equipped) 3. 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 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Wheel Drive Hub 5. 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 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Charge Filter 7. 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.
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. 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 154 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD LEVEL MAXIMUM LEVEL OIL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 7-9.
  • Page 155 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Oil Change w/Filter - GM 10. 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...
  • Page 156 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 11.
  • Page 157 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. A. Air Filter (Deutz 2011 and GM) 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 158: Tires & Wheels

    TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pres- sure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.

  • Page 159: Tire Replacement

    Tire Replacement dations, may result in an unsafe condition regarding stability. 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 160 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1. Start all nuts by hand to prevent cross threading. DO NOT Table 7-18. Wheel Torque Chart use a lubricant on threads or nuts. TORQUE SEQUENCE 2. Tighten nuts in the following sequence: 1st Stage 2nd Stage 3rd Stage...

  • Page 161: Oscillating Axle Lockout Test (If Equipped)

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders. 8.

  • Page 162: Propane Fuel Filter Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL FILTER REPLACEMENT Removal 1. Relieve the propane fuel system pressure. Refer to Propane Fuel System Pressure Relief. 2. Disconnect the negative battery cable. 3. Slowly loosen the Filter housing and remove it. 4.

  • Page 163: Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Installation PROPANE FUEL SYSTEM PRESSURE RELIEF BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO NEW SEAL MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL...

  • Page 164: Supplemental Information

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A) For combustion engine powered machines, guaranteed Sound...

  • Page 165: Section 8 - Inspection And Repair Log

    SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121615...
  • Page 166 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121615...
  • Page 168 @ 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,...

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