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Oshkosh JLG 600S 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
600S
660SJ
S/N 0300235168 &
B300002655 to Present
* See inside front cover for exceptions.
ANSI
AS/NZS
3121727
®
November 5, 2018 - Rev F

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 600S 660SJ S/N 0300235168 & B300002655 to Present * See inside front cover for exceptions. ANSI AS/NZS 3121727 ® November 5, 2018 - Rev F...
  • Page 2 This manual also covers the following Serial Numbers. 0300224266 0300224756 0300233720 B300002216 0300224267 0300224757 0300233721 B300002217 0300224755 0300224758 0300233722 B300002383 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 3 FOREWORD FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose. Due to continuous product improvements, JLG Industries, Inc.
  • Page 4 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 5 FOREWORD For: • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG Compliance Information INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- • Product Safety Publica- TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue A - July 12, 2017 Revised B - January 11, 2018 Revised C - March 23, 2018 Revised D - May 30, 2018 Revised E - June 29, 2018 - Revised Covers, Prop 65 Revised F - November 5, 2018 3121727...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS Function Check........2-10 SkyGuard Function Test.
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE STEERING..........4-9 4.16 TIE DOWN AND LIFTING.
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE PIPE RACK ......... . . 6-8 OPERATOR MAINTENANCE .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally 3121727...
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature - 600S ......2-4 4-8.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121727...
  • Page 13 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE Minimum Approach Distances (M.A.D.) ....1-6 7-16 Lubrication Specifications......7-19 Beaufort Scale (For Reference Only).
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121727...

  • Page 15: Section 1 - Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR safe machine usage and maintenance.

  • Page 16: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS • An operator must not accept operating responsibilities until Workplace Inspection adequate training has been given by competent and autho- • Precautions to avoid all hazards in the work area must be rized persons. taken by the user before and during operation of the machine. •...

  • Page 17: Machine Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection OPERATION • Do not operate this machine until the inspections and func- General tional checks as specified in Section 2 of this manual have been performed. • Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e.

  • Page 18: Trip And Fall Hazards

    SECTION 1 - SAFETY PRECAUTIONS • 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 19: 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 20 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 21: 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 22 SECTION 1 - SAFETY PRECAUTIONS • Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions, including platform. 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.
  • Page 23 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 24: 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 25: 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 26 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 27: 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 CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND nents or when performing welding on the machine. SEEK MEDICAL ATTENTION.
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121727...

  • Page 29: 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, or drop-offs exist.

  • Page 30: 2.2 Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 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 required by JLG Industries, Inc.
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Pre-Start Inspection Before using each day; or User or Operator User or Operator Operation and Safety Manual whenever there’s an Operator change. Pre-Delivery Inspection (See Before each sale, lease, or rental delivery.
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 5. Mid Boom 10. Rear Drive Wheels 2. Platform Control Box 6. Base Boom 11. Ground Control Console 3. Rotator 7. Turntable 12. Powertrack 4. Fly Boom 8. Front Drive/Steer Wheels 13.
  • Page 33 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Platform 5. Fly Boom 9. Front Drive/Steer Wheels 13. Powertrack 2. Platform Control Box 6. Mid Boom 10. Rear Drive Wheels 14. SkyGuard (If Equipped) 3. Rotator 7. Base Boom 11.

  • 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. 6. Battery – Charge as required. The Pre-Start Inspection should include each of the following: 7. Fuel (Combustion Engine Powered Machines) – Add the 1.
  • Page 35 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection Diagram 3121727...

  • Page 36: Walk-Around Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Walk-Around Inspection 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.
  • Page 37 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 38: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check a. Ensure that the control console is firmly secured in the proper location; Perform the Function Check as follows: b. Check that all guards protecting the switches or locks are in place;...

  • Page 39: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test 4. 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 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 2-12 3121727...

  • Page 41: 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 42: Ground Control Station

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Station NOTE: The Function Enable switch must be held down in order to operate Telescope, Swing, Lift, Jib Lift, Platform Level Override, and Platform Rotate (See Figure 3-1., Figure 3-2., Figure 3-3., and Figure 3-4.) functions.
  • Page 43 SECTION 3 - MACHINE CONTROLS AND INDICATORS Swing Boom Lift Boom Telescope Not Used Platform Rotate Platform Leveling Override 7. Power/Emergency Stop Platform/Ground Select Switch 9. Not Used 10. Engine Start/Auxiliary Power/Function Enable 11. Display Gauge 12. Indicator Panel 13. Air Shutoff Valve (ASOV) (If Equipped) Figure 3-1.
  • Page 44 SECTION 3 - MACHINE CONTROLS AND INDICATORS Swing Boom Lift Boom Telescope Not Used Platform Rotate Platform Leveling Override 7. Power/Emergency Stop Platform/Ground Select Switch 9. Machine Safety System Override (MSSO) 10. Engine Start/Auxiliary Power/Function Enable 11. Display Gauge 12. Indicator Panel 1001192264 G Figure 3-2.
  • Page 45 SECTION 3 - MACHINE CONTROLS AND INDICATORS Swing Boom Lift Boom Telescope Platform Rotate Platform Leveling Override 7. Power/Emergency Stop Platform/Ground Select Switch 9. Not Used 10. Engine Start/Auxiliary Power/Function Enable 11. Display Gauge 12. Indicator Panel 13. Air Shutoff Valve (ASOV) (If Equipped) Figure 3-3.
  • Page 46 SECTION 3 - MACHINE CONTROLS AND INDICATORS Swing Boom Lift Boom Telescope Platform Rotate Platform Leveling Override 7. Power/Emergency Stop Platform/Ground Select Switch 9. Machine Safety System Override (MSSO) 10. Engine Start/Auxiliary Power/Function Enable 11. Display Gauge 12. Indicator Panel Figure 3-4.
  • Page 47 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Jib (If Equipped) This switch provides raising and lower- ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF ing of the jib. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL.
  • Page 48 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When Power/Emergency Stop switch is in the “On” position and NOTE: When the Platform/Ground Select Switch is in the engine is not running, an alarm will sound, indicating Ignition is center position, power is shut off to the controls at “On”.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: On machines with diesel engines, when Glow Plug Indicator is 11. Display Gauge lighted (Yellow), wait until light goes out before cranking engine. Registers the amount of time the machine 10. Engine Start/ Auxiliary Power Switch /Function has been in use, with engine running.

  • Page 50: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel 3. System Distress Indicator The light indicates that the JLG Control System (See Figure 3-5., Ground Control Indicator Panel) has detected an abnormal condition and a Diagnostic Trouble Code has been set in the 1.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Battery Malfunction 2. Engine Malfunction/Check Engine 3. System Distress 4. Low Fuel 5. Glow Plug 6. Platform Overload (If Equipped) 7. Drive and Steer Disable (If Equipped) Figure 3-5. Ground Control Indicator Panel 3121727 3-11...
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Glow Plug Indicator 7. Drive and Steer Disable Indicator (If Equipped) Indicates the glow plugs are operating. After Indicates the Drive and Steer Disable function turning on ignition, wait until light goes out has been activated.

  • Page 53: Ground Control Console Display Gauge

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Console Display Gauge (See Figure 3-9., Ground Control Console Display Gauge) The Display Gauge shows engine hours, fuel level (if applicable), and Diagnostic Trouble Codes (DTCs) from both the JLG Control System and the engine control system.
  • Page 54 SECTION 3 - MACHINE CONTROLS AND INDICATORS The Diagnostic Screen will show active and inactive faults from The Engine Diagnostics Screen will show SPN (Suspect Parameter the JLG Control System on the screen. An asterisk (*) will be dis- Number), FMI (Failure Mode Identifier), and Occurrence count played to show active faults.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS INDICATOR LAMP FUEL LEVEL ENGINE HOURS NAVIGATE FORWARD ARROW NAVIGATE BACK ARROW NAVIGATION BUTTONS Figure 3-9. Ground Control Console Display Gauge 3121727 3-15...

  • Page 56: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF (See Figure 3-10., Platform Control Console) THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. 2.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1001184626 A 1001195947 A 1702566 B 1702565 B 1702567 B 1705170 A 1. Drive Speed/Torque Select 6. Start/Auxiliary Power 10. Telescope 14. Soft Touch/SkyGuard Indicator (If Equipped) 2. Platform Leveling Override 7. Capacity Select 11.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Power/Emergency Stop Switch 7. Capacity Select A two-position red mushroom shaped switch On 600S models, this switch allows the operator furnishes power to PLATFORM Controls when to select between an operating envelope with a pulled out (on).
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Drive joystick, pull up on the lock- 11. Lights (If Equipped) ing ring below the handle. This switch operates the chassis lights if NOTE: The Drive joystick is spring loaded and will auto- the machine is so equipped.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS 13. Soft Touch/SkyGuard Override Switch (If equipped) 14. Soft Touch/SkyGuard Indicator (If Equipped) The machine can be equipped with one of three options. It Indicates the Soft Touch bumper is against an object or the may have Soft Touch, SkyGuard, or both Soft Touch and Sky- SkyGuard sensor has been activated.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. 17.

  • Page 62: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel 3. Platform Overload Indicator (If Equipped) Indicates the platform has been overloaded. (See Figure 3-11., Platform Control Indicator Panel) NOTE: The indicator lights will illuminate for approximately 1 second 4.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1001170083 C * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. Level System 5. Tilt 9. Creep 2. AC Generator (If Equipped) 6. Glow Plug/Wait to Start 10. System Distress 3. Platform Overload (If Equipped) 7.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS 5. Tilt Alarm Warning Light and Alarm 6. Glow Plug/Wait to Start Indicator Indicates the glow plugs are operating. After This red illuminator indicates that the chassis is turning on ignition, wait until light goes out on a slope.
  • Page 65 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Fuel Level Indicator 9. Creep Speed Indicator Indicates the level of fuel in the tank. When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slow- est speed.
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS 11. Wire Rope Service Indicator 12. Drive Orientation Indicator When illuminated, the light indicates the When the boom is swung beyond the rear boom wire ropes are loose or broken and drive tires or further in either direction, the must be repaired or adjusted immediately.

  • Page 67: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a mobile elevating work platform used to posi- Capacities tion personnel, along with their necessary tools and materials at work locations. The boom can be raised above horizontal with or without any The primary operator control station is in the platform.

  • Page 68: 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- MACHINE WILL TIP OVER IN THIS MACHINE WILL TIP OVER IN THIS ward Stability, and its position of least BACKWARD stability is DIRECTION IF OVERLOADED...
  • Page 69 SECTION 4 - MACHINE OPERATION BOOM FULLY EXTENDED BOOM FULLY EXTENDED @ HORIZONTAL (0 DEGREES) @ HORIZONTAL (0 DEGREES) MACHINE WILL TIP OVER IN THIS MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED DIRECTION IF OVERLOADED OR OPERATED ON AN OR OPERATED ON AN OUT-OF-LEVEL SURFACE OUT-OF-LEVEL SURFACE...

  • Page 70: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION NOTE: Diesel engines only: After turning on ignition, operator must wait until glow plug indicator light goes out before cranking engine. NOTE: When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air den- sity.

  • Page 71: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION 4. After engine has had sufficient time to warm Shutdown Procedure up, push in the Power/Emergency Stop switch and shut engine off. 5. Turn Platform/Ground Select switch to Plat- IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE form.

  • Page 72: Air Shutoff Valve (Asov) (If Equipped)

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

  • Page 73: Fuel Reserve / Shut-Off System

    SECTION 4 - MACHINE OPERATION Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera- tor will be permitted to cycle power and restart the engine for approximately 2 minutes of run time. After the 2 min- NOTE: Reference the Service and Maintenance Manual along with a utes of run time is complete, the operator may cycle power...

  • Page 74: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION 1. Gradeability, which is the percent of grade of the incline the Traveling Forward and Reverse machine can climb. 1. At Platform Controls, pull out Emergency Stop 2. Sideslope, which is the angle of the slope the machine can switch, start engine, and activate footswitch.

  • Page 75: Steering

    SECTION 4 - MACHINE OPERATION 1. Match the black and STEERING white direction arrows on both platform con- Position thumb switch on Drive/Steer controller to trol panel and the chas- Right for steering right, or to Left for steering left. sis to determine the direction the machine will travel.
  • Page 76 SECTION 4 - MACHINE OPERATION LEVEL LEVEL Figure 4-4. Grade and Sideslope 4-10 3121727...

  • Page 77: Platform

    SECTION 4 - MACHINE OPERATION PLATFORM BOOM Platform Level Adjustment DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. THE PLATFORM.

  • Page 78: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom SHUT DOWN AND PARK 1. Drive machine to a protected area. To swing boom, use Swing control switch to select Right or Left direction. 2. Assure boom is fully retracted and lowered over rear (Drive) axle;...

  • Page 79: 4.10 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.10 SKYGUARD OPERATION SkyGuard SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- ation will reverse or cutout. The SkyGuard Function Table pro- vides more details on these functions. During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

  • Page 80: Skyguard Skyeye

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

  • Page 81: Oscillating Axle Lockout Test (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.11 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 4.13 TOWING (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES.
  • Page 82 SECTION 4 - MACHINE OPERATION STEER STEER SELECT SELECT VALVE VALVE RUNAWAY VEHICLE/ RUNAWAY VEHICLE/ MACHINE HAZARD MACHINE HAZARD MACHINE HAS NO TOWING BRAKES. TOWING MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO VEHICLE MUST BE ABLE TO CONTROL MACHINE AT CONTROL MACHINE AT ALL TIMES.
  • Page 83 SECTION 4 - MACHINE OPERATION 2. Connect tow bar to front of frame with attach pins, and tow bar to towing vehicle. 3. Disconnect drive hubs by inverting disconnect cap. Refer to Figure 4-6., Drive Disconnect Hub. 4. Actuate steer/tow selector valve for towing; pull valve knob OUT to float position.

  • Page 84: 4.14 Auxiliary Power

    SECTION 4 - MACHINE OPERATION 4.14 AUXILIARY POWER 3. Depress and hold footswitch. 4. Position Auxiliary Power switch to On and hold. 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.) 5.

  • Page 85: Dual Fuel System (Gas Engine Only)

    SECTION 4 - MACHINE OPERATION 3. Position Auxiliary Power switch to On and Changing From Gasoline to LP Gas hold. 1. Start engine from Ground Control Sta- 4. Operate appropriate control switch or control- tion. ler for desired function and hold. 5.

  • Page 86: 4.16 Tie Down And Lifting

    SECTION 4 - MACHINE OPERATION 4.16 TIE DOWN AND LIFTING NOTE: Lifting eyes are provided at the rear in the frame slab and at the top of the turntable near the boom pivot. Each of the four or slings used for lifting machine must be adjusted individually so When transporting machine, boom must be in the stowed mode machine remains level when elevated.
  • Page 87 SECTION 4 - MACHINE OPERATION MODELS 600S 1190 mm [46.9”] 1860 mm [73.2”] 660SJ 1330 mm [52.4”] 1720 mm [67.7”] 1001215615 D Figure 4-7. Lifting Chart 3121727 4-21...
  • Page 88 SECTION 4 - MACHINE OPERATION ANSI ANSI CE,AUS ANSI 63 62 61 DUAL LANGUAGE ONLY DETAIL G SEE DETAIL G 51 53 Figure 4-8. Decal Installation - Sheet 1 of 6 4-22 3121727...
  • Page 89 SECTION 4 - MACHINE OPERATION BOTH SIDES OF MACHINE SEE DETAIL E DETAIL E HOOD NOT SHOWN ANSI ANSI DUAL LANGUAGE ONLY Figure 4-9. Decal Installation - Sheet 2 of 6 3121727 4-23...
  • Page 90 SECTION 4 - MACHINE OPERATION ANSI ANSI ANSI Figure 4-10. Decal Installation - Sheet 3 of 6 4-24 3121727...
  • Page 91 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 4 of 6 3121727 4-25...
  • Page 92 SECTION 4 - MACHINE OPERATION ANSI ANSI (FOR CE,AUS) (FOR ANSI) Figure 4-12. Decal Installation - Sheet 5 of 6 4-26 3121727...
  • Page 93 SECTION 4 - MACHINE OPERATION 3 2 27 25 ANSI ANSI ANSI ANSI ANSI FALL ARREST PLATFORM ANSI ANSI Figure 4-13. Decal Installation - Sheet 6 of 6 3121727 4-27...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194213-E 1001194215-C 1001194221-C 1001194223-C 1001194225-C 1001194227-F 1001194229-C 1001194231-E 1001194217-C 1001194219-C 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194213-E 1001194215-C 1001194221-C 1001194223-C 1001194225-C 1001194227-F 1001194229-C 1001194231-E 1001194217-C 1001194219-C 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194213-E 1001194215-C 1001194221-C 1001194223-C 1001194225-C 1001194227-F 1001194229-C 1001194231-E 1001194217-C 1001194219-C 1701518 1701518 1705828 1705828 1001112551 1001215615 1001215615 1001215615 1001215615 1001215615...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-1. 600S Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194213-E 1001194215-C 1001194221-C 1001194223-C 1001194225-C 1001194227-F 1001194229-C 1001194231-E 1001194217-C 1001194219-C 1001159323 1702773 3121727 4-31...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-2. 660SJ Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194214-E 1001194216-C 1001194222-C 1001194224-C 1001194226-C 1001194228-F 1001194230-C 1001194232-E 1001194218-C 1001194220-C 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-2. 660SJ Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194214-E 1001194216-C 1001194222-C 1001194224-C 1001194226-C 1001194228-F 1001194230-C 1001194232-E 1001194218-C 1001194220-C 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-2. 660SJ Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194214-E 1001194216-C 1001194222-C 1001194224-C 1001194226-C 1001194228-F 1001194230-C 1001194232-E 1001194218-C 1001194220-C 1701518 1701518 1705828 1705828 1001112551 1001215615 1001215615 1001215615 1001215615 1001215615...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-2. 660SJ Decal Legend Traditional Simplified Item # ANSI Korean Portuguese Spanish French Japanese Australian Chinese Chinese 1001194214-E 1001194216-C 1001194222-C 1001194224-C 1001194226-C 1001194228-F 1001194230-C 1001194232-E 1001194218-C 1001194220-C 1001159323 1702773 3121727 4-35...
  • Page 102 SECTION 4 - MACHINE OPERATION NOTES: 4-36 3121727...

  • Page 103: Section 5 - Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL This section explains the steps to be taken in case of an emer- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON- TROLS.

  • Page 104: 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 105: Machine Safety System Override (Msso)(Ce Only)

    SECTION 5 - EMERGENCY PROCEDURES MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE To operate the MSSO: ONLY) 1. From the ground control console, place the Platform/ Ground Select switch in the Ground position. The Machine Safety System Override (MSSO) is 2. Pull out the Power/Emergency Stop control. only to be used to retrieve an operator that is pinned, trapped, or unable to operate the 3.
  • Page 106 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121727...

  • Page 107: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) SkyPower™ (7500W) √ √ √ √ √ √ √ SkyPower™ (4000W) √ √ √ √ √ √ √ SkyWelder™ √ √ √...
  • Page 108 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH INTERCHANGABLE ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH ( note 1) WITH (note 2) SkyPower (7500 watt generator SkyGlazier, SkyWelder, and Air line to platform) SkyCutter SkyWelder ( Stick welder) SkyPower SkyCutter Soft Touch, Pipe Jacks/Racks, SkyGlazier...

  • Page 109: Skypower

    SECTION 6 - ACCESSORIES CE Specs: 3-phase, 240-volt, 7.5kw, 18.3-amps, 1.0-pf INSTALLING OR REMOVING APPROVED ACCESSORIES OR CHANGING PLATFORM SIZE REQUIRES RECALIBRATION OF THE BOOM CONTROL SYSTEM (SEE SERVICE AND MAIN- 1-phase, 240 volt, 6.0kw, 26-amps, 1.0-pf TENANCE MANUAL). 1-phase, 120 volt, 6.0kw, 50-amps, 1.0-pf SKYPOWER™...

  • Page 110: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions SKYWELDER™ • Do not over load platform. The welder is capable of TIG and Stick welding and is capable at producing 200 Amps at 100% duty cycle or 250 Amps at 50% • Make sure no personnel are beneath platform. duty cycle.
  • Page 111 SECTION 6 - ACCESSORIES WELDER WELDER SUPPORT FIRE EXTINGUISHER WELD LEADS Figure 6-1. SkyWelder™ - Sheet 1 of 2 3121727...
  • Page 112 SECTION 6 - ACCESSORIES ON/OFF SWITCH OUTPUT LIGHT OVERTEMP LIGHT WELD PROCESS REMOVE COVER SELECTOR SWITCH TO SELECT VOLTAGE. AMPERAGE ADJUSTMENT VOLTAGE TO BE SET CONTROL (5-250 AMPS) AT 220/230 VAC REMOTE AMPERAGE CONTROL RECEPTACLE Figure 6-2. SkyWelder™ - Sheet 2 of 2 3121727...

  • Page 113: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Table 6-3. Welding Characteristics Welding Amps Input At Rated Load Output. 50/60 Hz Welding Maximum Open Input Power Rated Output Amperage Mode Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2V. 30.5 15.7 35% Duty Cycle...

  • Page 114: Preparation And Inspection

    SECTION 6 - ACCESSORIES • Do not weld to platform. PIPE RACK • Do not ground through the platform. Pipe Racks provide a means of storage of pipe or conduit inside • Do not use a high frequency arc starter with TIG welder. the platform to help prevent rail damage and optimize platform utility.

  • Page 115: Soft Touch

    SECTION 6 - ACCESSORIES SOFT TOUCH Table 6-4. Maximum Work Load Capacity with Soft Touch A padding kit is mounted to the platform rails and to a frame sus- Maximum Work Load (Capacity) -600S ANSI pended below the platform. Limit switches deactivate platform Unrestricted: 500 lb (227 kg) functions when the padded framework contacts an adjacent...
  • Page 116 SECTION 6 - ACCESSORIES NOTE: Platform shown in phantom OVERRIDE SWITCH for clarity. OVERRIDE INDICATOR LIGHT RAIL BUMPER LIMIT SWITCH SOFT TOUCH RAIL & BUMPER SOFT TOUCH FRAME LIMIT SWITCH Figure 6-3. Soft Touch 6-10 3121727...

  • Page 117: 6.10 Skyglazier

    SECTION 6 - ACCESSORIES 6.10 SKYGLAZIER™ The SkyGlazier™ allows glaziers to efficiently position panels. The WITH THE SKYGLAZIER INSTALLED, THE ORIGINAL PLATFORM CAPACITY RATINGS glazier package consists of a tray that extends from the bottom of ARE REDUCED AS SHOWN IN TABLE 6-5, SPECIFICATIONS FOR SKYGLAZIER™. DO NOT the platform.

  • Page 118: Specifications

    SECTION 6 - ACCESSORIES Specifications Table 6-5. Specifications for SkyGlazier™ Rated Table 6-5. Specifications for SkyGlazier™ Rated Manua Capacity Wind Capacity Zone Capacity SkyGlazier Rating Rated Platform Force Rated Manua ™ Capacity Wind Capacity Zone Capacity SkyGlazier Rating Max. Dimensions of Platform Force / 32 sq ft...

  • Page 119: Preparation And Inspection

    SECTION 6 - ACCESSORIES Preparation and Inspection Check for cracked welds and damage to tray. Make sure tray is properly secured to platform. Check to ensure strap is not torn or frayed. Operation Load SkyGlazier™ with panel and secure with strap. Position panel to its desired location.

  • Page 120: 6.11 Skycutter

    SECTION 6 - ACCESSORIES 6.11 SKYCUTTER duty cycle or 14A at 92 VDC @ 60% duty cycle. The Plasma Cutter will be capable of cutting up to a thickness of Accessory Ratings 3/8 in. metal and is capable of producing 27A at 92 VDC @ 35% Table 6-6.

  • Page 121: Safety Precautions

    SECTION 6 - ACCESSORIES Safety Precautions • Do not cut platform. • Do not ground through the platform. • Wear proper cutting apparel. DO NOT OVER LOAD PLATFORM. • Do not drive machine while connecting external air/gas sources. • Preparation and Inspection DE RATE THE PLATFORM BY 70LBS/32KG WHEN PLASMA CUTTER IS IN THE PLAT- •...

  • Page 122: 6.12 Fall Arrest Platform

    SECTION 6 - ACCESSORIES 6.12 FALL ARREST PLATFORM 6.13 BOLT-ON EXTERNAL FALL ARREST NOTE: Refer to JLG External Fall Arrest System manual (P/N-3128935) The bolt-on external fall arrest system is designed to provide a lan- for more detailed information. yard attach point while allowing the operator to access areas outside the platform.

  • Page 123: 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 124 SECTION 6 - ACCESSORIES • Cable: Inspect cable for proper tension, broken strands, kinks, or • Attachment Ring: No cracks or signs of wear are acceptable. Any any signs of corrosion. signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure GAP SHOWING: GAP SHOWING: there are no missing components and hardware is properly tight-...
  • Page 125 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 6-5. Bolt-On External Fall Arrest System 3121727 6-19...
  • Page 126 SECTION 6 - ACCESSORIES NOTES: 6-20 3121727...

  • Page 127: Section 7 - General Specifications & Operator Maintenance

    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 128: Dimensional Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications Dimensional Data Ground Bearing Pressure Table 7-2. Dimensional Data Foam-Filled 86.4 psi (6.07 kg/cm Pneumatic 85.1 psi (5.98 kg/cm Machine Height (Stowed) 8 ft. 2.4 in. (2.5 m) Maximum Drive Speed (4WD) 3.8 MPH (6.3 Km/hr.) Machine Length (Stowed)

  • Page 129: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-2. Dimensional Data Table 7-3. Capacities Horizontal Reach 600lb (272 kg) Zone 24 ounces (0.7 L) Torque Hub, Drive 600S 50 ft. 2 in. (15.29 m) Engine Crankcase Horizontal Reach 1000 lb (454 kg) Zone 10 quarts (9.4 L) Deutz D2011L04 600S...

  • Page 130: Engine Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-5. Deutz D2.9L4 Type Liquid Cooled Table 7-4. Deutz D2011L04 Specifications Number of Cylinders Fuel Diesel Bore 3.6 in (92 mm) Oil Capacity Stroke 4.3 in (110 mm) Cooling System 5 Quarts (4.5 L) Total Displacement 178 cu.

  • Page 131: Tires

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Table 7-6. Ford MSG425-DF Type Liquid Cooled Table 7-7. Tire Specifications Number of Cylinders Size 355/55D625 355/55D625 41/18LLx22.5 41/18LLx22.5 Displacement 2.5L Load Range Max Rated Output (Gas) 84 hp (62 kW) Ply Rating Max Rated Output (LP) 80 hp (59 kW)
  • Page 132 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTE: When temperatures remain below 20° F (-7 degrees C), JLG Table 7-10. Mobil DTE 10 Excel 32 Specs Industries recommends the use of Mobil DTE 10. ISO Viscosity Grade NOTE: Aside from JLG recommendations, it is not advisable to mix oils Specific Gravity 0.877 of different brands or types, as they may not contain the same...
  • Page 133 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-11. Quintolubric 888-46 Table 7-12. Mobil EAL 224H Specs Density Type Synthetic Biodegradable 0.92 g/cm ISO Viscosity Grade 32/46 Pour Point <-30°C (<-22°F) Specific Gravity .922 Flash Point 300°C (572°F) Pour Point, Max -25°F (-32°C) Fire Point 360°C (680°F)
  • Page 134 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-13. Mobil EAL H 46 Specs Table 7-14. Exxon Univis HVI 26 Specs Specific Gravity 32.1 Type Synthetic Biodegradable Pour Point -76°F (-60°C) ISO Viscosity Grade Flash Point 217°F (103°C) Specific Gravity .910 Viscosity Pour Point...

  • Page 135: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-15. Critical Stability Weights Counterweight Chassis 205.5 Turntable (600S) 4922 2233 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, Turntable (660SJ) 5844 2653...

  • Page 136: 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. Figure 7-1.
  • Page 137 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE This Page Left Blank Intentionally 3121727 7-11...
  • Page 138 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-2. Engine Operating Temperature Specifications - Deutz 2.9L 7-12 3121727...
  • Page 139 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1001151190-B Figure 7-3. Engine Operating Temperature Specifications - Deutz 2011 3121727 7-13...
  • Page 140 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1001206353 A Figure 7-4. Hydraulic Oil Operation Chart - Sheet 1 of 2 7-14 3121727...
  • Page 141 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fluid Base Properties Classi?cation Mobilfluid 424 Mobil DTE 10 Excel 32 UNIVIS HVI 26 Mobil EAL 224 H Mobil Envirosyn H 46 Quintolubric 888-46 Readily biodegradable classi?cation indicates NOTICE: one of the following: MACHINE OPERATION USING NON-JLG APPROVED CO2 Conversion>60% per EPA 560/6-82-003 HYDRAULIC FLUIDS OR OPERATION OUTSIDE OF...
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 600SJ 600S Figure 7-6. Operator Maintenance & Lubrication Diagram - Deutz 2011 Engine 7-16 3121727...
  • Page 143 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 600SJ 600S Figure 7-7. Operator Maintenance & Lubrication Diagram - Deutz 2.9L Engine 3121727 7-17...
  • Page 144 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 600S 600SJ Figure 7-8. Operator Maintenance & Lubrication Diagram - Ford Engine 7-18 3121727...

  • Page 145: Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OPERATOR MAINTENANCE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL NOTE: The following numbers correspond to those in Figure 7-6., Oper- CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED ator Maintenance & Lubrication Diagram - Deutz 2011 Engine. TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY.
  • Page 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Swing Drive Hub 3. Wheel Drive Hub FILL PORT Lube Point(s) - Level/Fill Plug Capacity - 24 oz. (0.7 L) Lube - 80w90 Gear Oil Interval - Check level every 3 months or 150 hrs of operation; Lube Point(s) - Level/Fill Plug change every 2 years or 1200 hours of operation Capacity - 32 oz.
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Charge Filter 5. Hydraulic Return Filter Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or whenever Charge Filter is replaced Interval - Change after first 50 hrs. and every 6 months or 300 hrs.
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank Breather 7. Hydraulic Tank Interval - Change after first 50 hrs. and every 6 months or 300 Lube Point(s) - Fill Cap hrs. thereafter. Capacity - 34 gal tank (129 L) 40.0 gal system (151 L) Comments - Remove wing nut and cover to replace.
  • Page 149 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Deutz 2011 9. Fuel Filter - Deutz 2011 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element Capacity - 10 Quarts (9.4 L) Crankcase; 5 Quarts (4.8L) Interval - Every Year or 600 hours of operation Cooler Lube - EO...
  • Page 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 10. Oil Change w/Filter - Deutz 2.9 11. Fuel Filter - Deutz 2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element Capacity - 10 Quarts (9.4 L) Crankcase; 5 Quarts (4.8L) Interval - Every Year or 600 hours of operation Cooler Lube - EO...
  • Page 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Fuel Pre-Filter - Deutz D2.9 13. Engine Coolant - Deutz D2.9 Lube Point(s) - Fill Cap Capacity (Deutz 2.9L)- 13.2 quart (12.5 L) Lube - Anti-Freeze Interval - Check level daily; change every 1000 hours or two years, whichever comes first.
  • Page 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 14. Oil Change w/Filter - Ford MSG425-DF 17. Air Filter Lube Point(s) - Fill Cap/Spin-on Element Capacity - 7 Quarts (6.6 L) Lube - EO Interval - Change in accordance with engine manual Comments - Check level daily 15.
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indi- cated by the condition indicator 18. Platform Filter 600SJ Lube Point - Replaceable Element 600S Interval - Change after first 50 hours and then every year or 600 hours of operation, whichever comes first...

  • Page 154: Tires & Wheels

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 19. Optional Fuel Filter - Deutz 2011 - China Market 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.

  • Page 155: Tire Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE • any damage to the bead area cords of the tire Wheel Replacement If a tire is damaged but is within the above noted criteria, the tire The rims installed on each product model have been designed for must be inspected on a daily basis to insure the damage has not stability requirements which consist of track width, tire pressure, and propagated beyond the allowable criteria.

  • Page 156: Wheel Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE.
  • Page 157 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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) 4. Wheel nuts should be torqued after first 50 hours of opera- tion and after each wheel removal.

  • Page 158: Oscillating Axle Lockout Test (If Equipped)

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 5. Place Drive control lever to Reverse and drive machine off of block and ramp. 6. Have an assistant check to see that left front wheel remains locked in position off of ground.

  • Page 159: 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.
  • Page 160 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 7-34 3121727...
  • Page 161 SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121727...
  • Page 162 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121727...
  • Page 164 3121727 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations www.jlg.com...

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