JLG 600A Operation And Safety Manual Download

Page: 11 / 142

3121615

– JLG Lift –

LIST OF FIGURES

FIGURE NUMBER - TITLE

PAGE

FIGURE NUMBER - TITLE

PAGE

2-1.

Basic Nomenclature - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

2-2.

Basic Nomenclature - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

2-3.

Daily Walk-Around Inspection Diagram -

Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

2-4.

Daily Walk-Around Inspection Diagram -

Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-5.

Daily Walk-Around Inspection Diagram - GM 3.0L . . . . 2-14

2-6.

Daily Walk-Around Inspection Points - Sheet 1 of 2 . . . 2-15

2-7.

Daily Walk-Around Inspection Points - Sheet 2 of 2 . . . 2-16

3-1.

Ground Control Station - 600AJ. . . . . . . . . . . . . . . . . . . . . . . 3-3

3-2.

Ground Control Station - 600AJ with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-4

3-3.

Ground Control Station - 600A . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4.

Ground Control Station - 600A with Machine Safety

System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-6

3-5.

Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . 3-11

3-6.

Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

3-7.

Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-19

4-1.

Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-2

4-2.

Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-3

4-3.

Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4-4.

Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4-5.

Boom Upright Positioning - Sheet 1 of 2 . . . . . . . . . . . . . 4-14

4-6.

Boom Upright Positioning - Sheet 2 of 2 . . . . . . . . . . . . . 4-15

4-7.

Towbar Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

4-8.

Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-9.

Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

4-10.

600A & 600AJ Decal Installation - Sheet 1 of 4 . . . . . . . . 4-25

4-11.

600A & 600AJ Decal Installation - Sheet 2 of 4 . . . . . . . . 4-26

4-12.

600A & 600AJ Decal Installation - Sheet 3 of 4 . . . . . . . . 4-27

4-13.

600A & 600AJ Decal Installation - Sheet 4 of 4 . . . . . . . . 4-28

6-1.

Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

6-2.

Engine Operating Temperature Specifications -

Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11

6-3.

Engine Operating Temperature Specifications -

Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-4.

Engine Operating Temperature Specifications -

GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-5.

Engine Operating Temperature Specifications -

GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-6.

Operator Maintenance & Lubrication Diagram -

Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-7.

Operator Maintenance & Lubrication Diagram -

Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16

6-8.

Operator Maintenance & Lubrication Diagram -

GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-9.

Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

6-10.

Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31

Summary of Contents for 600A

Page 1: ...ANSI 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 3121615 January 7 2016 ...

Page 2: ...NOTE This manual also applies to a machine with the following Serial Number 0300176207 ...

Page 3: ...e owners users operators lessors and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose Due to continuous product improvements JLG Industries Inc reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information ...

Page 4: ...LL HAVE AN ORANGE BACK GROUND INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY This is the Safety Alert Symbol It is used to alert you ...

Page 5: ...CTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER SONAL PROPERTY OR THE JLG PRODUCT Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 USA or Your Local JLG Office See addresses on inside of manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside U...

Page 6: ...FOREWORD d JLG Lift 3121615 REVISION LOG Original Issue November 6 2013 Revised January 1 2014 Revised July 4 2014 Revised October 1 2014 Revised January 5 2015 Revised January 7 2016 ...

Page 7: ...NG 2 1 Operator Training 2 1 Training Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function Check 2 5 SkyGuard Function Test 2 6 2 3 LIMIT SWITCH FUNCTIONAL CHECK 2 7 General 2 15 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground Control Station 3 2 Ground Control Indicator Panel 3...

Page 8: ...6 4 11 SHUT DOWN AND PARK 4 17 4 12 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 4 17 4 13 STEER TOW SELECTOR IF EQUIPPED 4 17 4 14 TOWING IF EQUIPPED 4 18 4 15 AUXILIARY POWER 4 21 Activating from the Platform Control Station 4 21 Activating from the Ground Control Station 4 21 4 16 DUAL FUEL SYSTEM GAS ENGINE ONLY 4 22 Changing From Gasoline to LP Gas 4 22 Changing From LP Gas to Gasoline 4 22 4 17...

Page 9: ...Hydraulic Oil 6 5 Critical Stability Weights 6 9 Serial Number Locations 6 10 6 3 OPERATOR MAINTENANCE 6 18 6 4 TIRES WHEELS 6 27 Tire Inflation 6 27 Tire Damage 6 27 Tire Replacement 6 28 Wheel Replacement 6 28 Wheel Installation 6 28 6 5 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED 6 30 6 6 PROPANE FUEL FILTER REPLACEMENT 6 31 Removal 6 31 Installation 6 32 6 7 PROPANE FUEL SYSTEM PRESSURE RELIEF 6...

Page 10: ...iv JLG Lift 3121615 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE This Page Left Blank Intentionally ...

Page 11: ...sition of Least Forward Stability 4 3 4 3 Grade and Sideslope 4 7 4 4 Traveling on a Grade 4 9 4 5 Boom Upright Positioning Sheet 1 of 2 4 14 4 6 Boom Upright Positioning Sheet 2 of 2 4 15 4 7 Towbar Connecting Points 4 19 4 8 Drive Disconnect Hub 4 20 4 9 Lifting Chart 4 24 4 10 600A 600AJ Decal Installation Sheet 1 of 4 4 25 4 11 600A 600AJ Decal Installation Sheet 2 of 4 4 26 4 12 600A 600AJ De...

Page 12: ...vi JLG Lift 3121615 LIST OF FIGURES FIGURE NUMBER TITLE PAGE FIGURE NUMBER TITLE PAGE This Page Left Blank Intentionally ...

Page 13: ...ifications 6 1 6 2 Dimensional Data 6 2 6 3 Capacities 6 3 6 4 Deutz D2011L04 Specifications 6 3 6 5 Deutz TD 2 9 Specifications 6 4 6 6 GM 3 0L 6 4 6 7 Tire Specifications 6 5 6 8 Hydraulic Oil 6 5 6 9 Mobilfluid 424 Specs 6 6 6 10 Mobil DTE 13M Specs 6 6 6 11 Mobil EAL H 46 Specs 6 7 6 12 Exxon Univis HVI 26 Specs 6 7 6 13 Mobil EAL 224H Specs 6 8 6 14 Quintolubric 888 46 6 8 6 15 Critical Stabi...

Page 14: ...viii JLG Lift 3121615 LIST OF TABLES TABLE NUMBER TITLE PAGE TABLE NUMBER TITLE PAGE This Page Left Blank Intentionally ...

Page 15: ...aining is accomplished and operation of the machine has been completed under the supervision of an experienced and quali fied operator This section contains the responsibilities of the owner user oper ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any ques tions with regard to safety training inspection maintenance application and op...

Page 16: ...overnmental regulations as they pertain to your utilization and application of the machine Workplace Inspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equip ment unless the application is approved in...

Page 17: ...m floor Keep mud oil grease and other slippery substances from footwear and plat form floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any device i e cell phones two way radios etc that will distract your attention from safely operating the machine Do not use the machine for any purpose other than position ing personnel their ...

Page 18: ...quip ment Persons under the influence of drugs or alcohol or who are subject to seizures dizziness or loss of physical control must not operate this machine Hydraulic cylinders are subject to thermal expansion and con traction This may result in changes to the boom and or plat form position while the machine is stationary Factors affecting thermal movement can include the length of time the machin...

Page 19: ... positioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slippery substances cleaned from footwear and the platform floor Electrocution Hazards This machine is not insulated and does not provide protection from contact or proximity to electrical current ...

Page 20: ...nd its occupants their tools and their equip ment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less Table 1 1 Minimum Approach Distances M A D Voltage Range Phase to Phase MINIMUM APPROACH DISTANCE in Feet Meters 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KV...

Page 21: ... or governmental require ments for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH ERWISE Tipping Hazards The user must be familiar with the surface before driving Do not exceed the allowable sideslope and grade while driving Do not elevate platform or drive with platform e...

Page 22: ...before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions including gusts may exceed 28 mph 12 5 m s Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Refer to Table 1 2 Beaufort scale For Reference Only or use other me...

Page 23: ...e Windfeltonexposedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effo...

Page 24: ...operator must limit travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driv ing in high speed switch to low speed before stopping Travel grades in low speed only Do not use high speed drive in restricted or close quarters o...

Page 25: ...ring machine maintenance are inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the mac...

Page 26: ...he machine Do not use machine as a ground for welding When performing welding or metal cutting operations pre cautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine with the engine running Use only approved non flammable cleaning solvents Do not replace items critical to stability such as batteries or solid tires with items of...

Page 27: ...cts across the battery terminals Always wear hand eye and face protection when servicing batteries Ensure that battery acid does not come in contact with skin or clothing BATTERY FLUID IS HIGHLY CORROSIVE AVOID CONTACT WITH SKIN AND CLOTHING AT ALL TIMES IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION Charge batteries only in a well ventilated area Avoid overfillin...

Page 28: ...SECTION 1 SAFETY PRECAUTIONS 1 14 JLG Lift 3121615 NOTES ...

Page 29: ... of the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc tion 6 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes dropoffs 7 Means to avoid the hazards of unprotected electrical con ductors...

Page 30: ...tions for further requirements for aerial work platforms The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment if the machine is used with increased fre quency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE ...

Page 31: ...form FrequentInspection Inservicefor3monthsor150hours whichevercomesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended ServiceandMaintenan...

Page 32: ...t storage container 5 Walk Around Inspection Refer to Figure 2 3 thru Fig ure 2 7 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Engine Oil Supply Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure 9 Hydraulic Oil Check the hydraulic oil level Ensure hydrau lic oil is added as required 10 Accessori...

Page 33: ...ons are disabled when the Emergency Stop Button is activated 2 From the platform control console a Ensure that the control console is firmly secured in the proper location b Check that all guards protecting the switches or locks are in place c Operate all functions and check all limiting and cut out switches d Ensure that all machine functions are disabled when the Emergency Stop Button is pushed ...

Page 34: ...horn will sound until the SkyGuard sensor and footswitch are disengaged NOTE If the machine is equipped with both SkyGuard and Soft Touch functions will not reverse only stop NOTE If equipped ensure the blue beacon illuminates when SkyGuard is activated Disengage the SkyGuard sensor release controls recycle the foot switch make sure normal operation is available If SkyGuard remains activated after...

Page 35: ...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 position up a suitable ramp of at least 5 slope Check the out of level indicator with the machine on the ramp If the light does not illuminate return the machine to a level sur face shut down the...

Page 36: ...ce angle indicator on base boom between boom pivot pin and lift cylinder attach pin d Lift boom up until 1000 lb 454 kg for ANSI markets and 450 kg for CE and Australia markets light comes on Boom angle should be 55 degrees to 64 degrees NOTE If limit switch settings need to be changed you will need to recheck that the 500 lb 227 kg for ANSI markets and 230 kg for CE and Australia markets light co...

Page 37: ... until 1000 lb 454 kg for ANSI mar kets and 450 kg for CE and Australia markets light comes on The boom angle at this point should be 55 degrees to 60 degrees d Lift main boom down until 500 lb 227 kg for ANSI mar kets and 230 kg for CE and Australia markets light comes on The boom angle at this point should be 45 degrees to 50 degrees NOTE If limit switch settings need to be changed you will need...

Page 38: ...N AND INSPECTION 2 10 JLG Lift 3121615 1 Platform 2 PlatformControlBox 3 Rotator 4 FlyBoom 5 BaseBoom 6 Upright 7 TowerBoom 8 FrontDrive SteerWheels 9 RearDriveWheels 10 Footswitch 11 SkyGuard IfEquipped 12 CrossRail Figure 2 1 Basic Nomenclature 600A ...

Page 39: ...G Lift 2 11 1 Platform 2 PlatformControlBox 3 Rotator 4 Jib 5 FlyBoom 6 BaseBoom 7 Upright 8 TowerBoom 9 FrontDrive SteerWheels 10 RearDriveWheels 11 PlatformLevelingCylinder 12 JibLiftCylinder 13 FootSwitch 14 SkyGuard IfEquipped 15 CrossRail Figure 2 2 Basic Nomenclature 600AJ ...

Page 40: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 12 JLG Lift 3121615 Figure 2 3 Daily Walk Around Inspection Diagram Deutz D2011L04 ...

Page 41: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121615 JLG Lift 2 13 Figure 2 4 Daily Walk Around Inspection Diagram Deutz TD2 9 ...

Page 42: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 14 JLG Lift 3121615 Figure 2 5 Daily Walk Around Inspection Diagram GM 3 0L ...

Page 43: ...embly and Gate Footswitch works properly not modified disabled or blocked Latch and hinges in working condition 2 Platform Ground Control Consoles Switches and levers return to neutral decals placards secure and legible con trol markings legible 3 Rotator See Inspection Note 4 Jib If Equipped See Inspection Note 5 Power Track See Inspection Note 6 All Hydraulic Cylinders See Inspection Note 7 Driv...

Page 44: ... evi dence of loose bolts or looseness between bearing and structure 15 Fuel Tank See Inspection Note 16 Hood Assemblies See Inspection Note 17 Battery Proper electrolyte levels if adjustable cables tight no visible damage or corrosion 18 Hydraulic Pump See Inspection Note 19 Turntable See Inspection Note 20 Frame See Inspection Note 21 Main Boom Sections See Inspection Note 22 SkyGuard If Equippe...

Page 45: ... by the ground controls for these symbols and the corresponding functions 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 not corrected could result in serious injury or death This indicator will be red Indi...

Page 46: ...latform Rotate Provides rotation of the platform ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 2 Platform Leveling Override A three position switch allows the operator to adjust the automatic self leveling system This switch is used to adjust ...

Page 47: ... 3 Figure 3 1 Ground Control Station 600AJ 1 PlatformRotate 2 PlatformLevelingOverride 3 Jib 4 Power EmergencyStop 5 EngineStart AuxiliaryPower FunctionEnable 6 BoomLift 7 Hourmeter 8 Platform GroundSelectSwitch 9 Swing 10 TowerLift 11 MainBoomLift 12 Telescope ...

Page 48: ... with Machine Safety System Override MSSO CE Only 1 PlatformRotate 2 PlatformLevelingOverride 3 Jib 4 Power EmergencyStop 5 EngineStart AuxiliaryPower FunctionEnable 6 BoomLift 7 Hourmeter 8 Platform GroundSelectSwitch 9 Swing 10 TowerLift 11 MainBoomLift 12 Telescope 13 MachineSafetySystemOverride MSSO ...

Page 49: ...e 3 3 Ground Control Station 600A 1 PlatformRotate 2 PlatformLevelingOverride 3 NotUsed 4 Power EmergencyStop 5 EngineStart AuxiliaryPower FunctionEnable 6 TowerTelescope 7 Hourmeter 8 Platform GroundSelectSwitch 9 Swing 10 TowerLift 11 MainBoomLift 12 MainBoomTelescope ...

Page 50: ...ine Safety System Override MSSO CE Only 1 PlatformRotate 2 PlatformLevelingOverride 3 NotUsed 4 Power EmergencyStop 5 EngineStart AuxiliaryPower FunctionEnable 6 TowerTelescope 7 Hourmeter 8 Platform GroundSelectSwitch 9 Swing 10 TowerLift 11 MainBoomLift 12 MainBoomTelescope 13 MachineSafetySystemOverride MSSO ...

Page 51: ...ine 4 Power Emergency Stop Switch A two position red mushroom shaped switch supplies power to Platform Ground Select switch when pulled out on When pushed in off power is shut off to the Platform Ground Select switch 5 Engine Start Auxiliary Power Switch Function Enable To start the engine the switch must be held Up until the engine starts To use auxiliary power the switch must be held Down for du...

Page 52: ...f the engine only engine run hours are recorded The hourmeter registers up to 9 999 9 hours and cannot be reset NOTE When the Platform Ground Select Switch is in the center position power is shut off to the controls at both operating stations Remove the key to pre vent the controls from being actuated The key is removable in the platform position on CE specifi cation machines The key must be avail...

Page 53: ... UNDER PLATFORM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED 9 Swing Control Provides 360 degrees continuous turntable rotation 10 Tower Lift This switch provides raising and low ering of the tower boom This func tion works only when the tower boom is fully retracted 11 Main Boo...

Page 54: ...perature Indicator Liquid Cooled Engines Indicates that engine coolant temperature is abnormally high and service is required 4 Engine Oil Temperature Indicator Deutz Indicates that the temperature of the engine oil which also serves as engine coolant is abnormally high and service is required 5 System Distress Indicator The light indicates that the JLG Control System has detected an abnormal cond...

Page 55: ...ICATORS 3121615 JLG Lift 3 11 1 NoAlternatorOutput 2 LowEngineOilPressure 3 HighEngineCoolantTemp 4 EngineOilTemp 5 SystemDistress 6 GlowPlugWaittoStart 7 PlatformOverload 8 DriveandSteerDisable Figure 3 5 Ground Control Indicator Panel ...

Page 56: ...s the platform has been overloaded 8 Drive and Steer Disable Indicator If equipped Indicates the Drive and Steer Disable function has been activated Platform Station See Figure 3 6 TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED 1 Drive Speed Torque Select The machine ha...

Page 57: ...rear axles steer in the opposite directions to produce the tightest turning cir cle for maneuvering in confined areas To re synchronize the front and rear axles position the rear drive wheels to the forward drive position by selecting either crab or compound steer then select front steer cen ter switch position to operate the normal steering function ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTIO...

Page 58: ...4 Horn 5 Power EmergencyStop 6 Start Aux Power 7 FuelSelect 8 DriveOrientationOverride 9 Drive Steer 10 MainBoomTelescope 11 Lights 12 Jib 13 SoftTouch SkyGuardOverride 14 TowerTelescope 15 TowerLift 16 SoftTouch SkyGuardIndicator 17 PlatformRotate 18 FunctionSpeed 19 MainLift Swing Figure 3 6 Platform Control Console ...

Page 59: ...ary pump will operate tower boom lift tower telescope main boom lift main telescope and swing 7 Fuel Select Dual Fuel Engine Only If Equipped Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position It is unnecessary to purge the fuel system before switching fuels so there is no waiting period when switching fuels while the engine is running 8 Drive Orientat...

Page 60: ...in reverse Steering is accomplished via a thumb activated rocker switch on the end of the steer handle 10 Main Boom Telescope Provides extension and retraction of the main boom 11 Lights If Equipped This switch operates control console panel lights and head lights if the machine is so equipped The ignition switch does not have to be on to operate the lights so care must be taken to avoid draining ...

Page 61: ... positioned to in or out Tower Telescope must be fully retracted before operating Tower Lift Tower Telescope should not function when Tower Lift is not fully elevated up TO AVOID UPSET AND SERIOUS INJURY DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE 15 Tower Lift This switch provides for raising and lowering of the tower boom when positioned to up o...

Page 62: ...joystick activates switches to provide the functions selected Platform Control Indicator Panel See Figure 3 7 Platform Control Indicator Panel 1 Tilt Alarm Warning Light and Alarm This illuminator indicates that the chassis is on a slope An alarm will also sound when the chassis is on a slope and the boom is above horizontal If lit when boom is raised or extended retract and lower to below horizon...

Page 63: ...CHINE CONTROLS AND INDICATORS 3121615 JLG Lift 3 19 1 Tilt 2 Overload 3 Capacity 4 Enable 5 GlowPlug 6 LowFuel 7 SystemDistress 8 ACGenerator 9 DriveOrientation 10 Creep Figure 3 7 Platform Control Indicator Panel ...

Page 64: ...ny function the footswitch must be depressed and the function selected within seven seconds The enable indicator shows that the controls are enabled If a function is not selected within seven seconds or if a seven second lapse between ending one function and beginning the next function the enable light will go out and the footswitch must be released and depressed again to enable the controls Relea...

Page 65: ...Code has been set in the system memory Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval 8 AC Generator If Equipped Indicates the generator is in operation 9 Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation indicator will illuminate when the drive function is select...

Page 66: ...SECTION 3 MACHINE CONTROLS AND INDICATORS 3 22 JLG Lift 3121615 NOTES ...

Page 67: ...d boom swing is 360 degree continuous left and right of the stowed position The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Boom Lift and Swing and are to be used in an emergency to lower the platform to the ground should the oper ator in the platform be unable to do so 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS Capacities The bo...

Page 68: ...nes 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 TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT OF LEVEL SURFACE Figure 4 1 Position of Least Backward Stability ...

Page 69: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 3 Figure 4 2 Position of Least Forward Stability ...

Page 70: ...MANUAL NOTE Diesel engines only After turning on ignition operator must wait until glow plug indicator light goes out before cranking engine 1 Turn key of Platform Ground Select switch to Ground 2 Pull the Power Emergency Stop switch to On 3 Push the Engine Start switch until engine starts ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 4 After engine has had suffic...

Page 71: ...hutoff 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 If fuel level reaches the Empty range the Low Fuel light will begin to flash once a second and there will be approximately 60 minutes of engine run time left If the syste...

Page 72: ...ANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE Engine Stop When the engine shuts down no restarts will be permitted until fuel is added to the tank 4 4 TRAVELING DRIVING See Figure 4 3 Grade and Sideslope NOTE Refer to the Operating Specifications table for Gradeability and Sideslope ratings All ratings for Gradeability and Sideslope are based upon the machine s boom being in ...

Page 73: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 7 Figure 4 3 Grade and Sideslope ...

Page 74: ... ELEVATED BEFORE DRIVING MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE IF BOOM IS OVER FRONT WHEELS STEER AND DRIVE CONTROLS WILL BE REVERSED Traveling Forward and Reverse 1 At Platform Controls pull out Emergency Stop switch and activate footswitch 2 Position Drive controller to FORWARD or REVERSE as desired This machine is equipped with a Drive Orientation Indicator The yellow light on the p...

Page 75: ...cator light will flash during the 3 second inter val until the drive function is selected Traveling on a Grade When traveling a grade maximum braking and traction are obtained with the boom stowed in position over the rear drive axle and in line with the direction of travel Drive the machine forward when climbing a grade and in reverse when descending a grade Do not exceed the machine s maximum ra...

Page 76: ...ation To rotate the platform to the left or right use the Platform Rotate control switch to select the direc tion and hold until desired position is reached 4 7 BOOM DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS TO AVOID TIP OVER LOWER PLATFORM TO GROUND LEVEL THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RA...

Page 77: ...oom two toggle switches one controls tower lift the other tower telescope The switching system will sequence its Lift and Telescope functions as follows 1 Sequence while raising the Tower Boom from the fully low ered position a The Tower Boom must be fully elevated up approximately 13 degrees from vertical before the Tower Boom can be extended from the fully retracted position b The Tower Telescop...

Page 78: ...ING MAIN BOOM LIFT AND TELESCOPE FUNC TIONS HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE CONTINUING USE OF MACHINE Raising and Lowering the Main Boom To raise or lower the Main Boom position the Main Boom Lift switch to Up or Down until the desired height is reached Telescoping the Main Boom To extend or retract the main boom use the Main Telescope Control Switch to select...

Page 79: ...operator to adjust the tower lift cylinder and the upright cylinder if the upright cylinder is not fully retracted when boom is in the stowed position This valve is located in the engine compartment area To Operate 1 Pull the red knob 2 Using the ground control raise the lower boom 6 feet 3 Release the knob 4 Fully lower the boom 5 Repeat if necessary ...

Page 80: ...SECTION 4 MACHINE OPERATION 4 14 JLG Lift 3121615 Figure 4 5 Boom Upright Positioning Sheet 1 of 2 ...

Page 81: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 15 Figure 4 6 Boom Upright Positioning Sheet 2 of 2 ...

Page 82: ...d sensor is activated functions that were in use at the time of actuation will reverse or cutout The table below outlines these functions Table 4 1 Skyguard Function Table Main Lift Main Tele In Main Tele Out Swing Drive Forward Drive Reverse Tower Lift Up Tower Lift Down Platform Level Platform Rotate Jib Lift DOS Enabled DOS Not Enabled DOS Enabled DOS Not Enabled R C R R R C R R R C C C C R Ind...

Page 83: ...ds warning decals and operating controls from hostile environment 4 12 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COM PONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED Refer to Section 6 5 Oscillating Axle Lockout Test If Equipped for procedure 4 13 STEER TOW SELECTOR IF EQUIPPED DO NOT ATTEMPT TO TOW MACHINE UNLESS E...

Page 84: ...AILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 8 M P H 13 K M H MAXIMUM TOWING GRADE 25 Prior to towing the machine complete the following DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower and position boom over rear drive wheels in line with direction of travel lock turntable 2 Connect tow bar to front of frame with attach pins ...

Page 85: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 19 Figure 4 7 Towbar Connecting Points STEERSELECT VALVE ...

Page 86: ...the steer circuit to reser voir allowing the steer cylinder rod free travel The machine is now in the towing mode After towing the machine complete the following 1 Actuate steer tow selector valve for steering push valve knob IN to the actuated position 2 Reconnect drive hubs by inverting disconnect cap 3 Disconnect tow bar from steering hitch and from towing vehicle The machine is now in the driv...

Page 87: ...iary pump will oper ate boom lift telescope and swing To activate auxiliary power Activating from the Platform Control Station 1 Position Platform Ground Select Key Switch to Platform 2 Position Power Emergency Stop switch to On 3 Depress and hold footswitch 4 Position Auxiliary Power switch to On and hold 5 Operate appropriate control switch lever or controller for desired function and hold 6 Rel...

Page 88: ...RCE TO THE OTHER WITHOUT ALLOW ING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 Start engine from Ground Control Sta tion 2 Open hand valve on LP gas supply tank by turning counter clockwise 3 While engine is operating on Gasoline under a no load condition place Fuel Select switch at Platform Control to LP position...

Page 89: ...ry to lift the machine using an overhead or mobile crane it is very important that the lifting devices are attached only to the designated lifting eyes and that the turnta ble lock pin is engaged See Figure 4 9 Lifting Chart 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 rema...

Page 90: ...SECTION 4 MACHINE OPERATION 4 24 JLG Lift 3121615 Figure 4 9 Lifting Chart ...

Page 91: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 25 33 10 11 43 17 16 7 49 48 64 36 36 28 22 27 26 68 Aus 6 10 11 21 22 34 35 44 39 62 61 Figure 4 10 600A 600AJ Decal Installation Sheet 1 of 4 ...

Page 92: ...SECTION 4 MACHINE OPERATION 4 26 JLG Lift 3121615 Figure 4 11 600A 600AJ Decal Installation Sheet 2 of 4 ...

Page 93: ...SECTION 4 MACHINE OPERATION 3121615 JLG Lift 4 27 3 4 5 12 12 12 12 12 13 66 66 24 25 29 37 37 42 39 43 47 58 55 54 52 58 55 51 53 63 22 67 Figure 4 12 600A 600AJ Decal Installation Sheet 3 of 4 ...

Page 94: ...SECTION 4 MACHINE OPERATION 4 28 JLG Lift 3121615 Figure 4 13 600A 600AJ Decal Installation Sheet 4 of 4 ...

Page 95: ...1509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1704412 1704412 1704412...

Page 96: ...951 28 1703805 1703936 1705961 1703935 1705897 1703938 1703937 1001116851 1703939 29 3252347 1703984 1705828 1703983 1705902 1703980 1001116852 1703982 1703981 30 3251813 3251813 31 32 33 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 34 1702631 1702631 1702631 1702631 35 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702819 Tab...

Page 97: ... 1001121809 1001122200 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 Table 4 2 600A Decal Legend Item ANSI 1001156889 B Canadian French 1001156985 B CE AUS 1001156987 B Spanish 1001156972 B Portuguese 1001156974 B Japanese 1001156976 B Chinese Simplified 1001156980 B Chinese Traditional 100115...

Page 98: ...1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1001116861 1001116862 1703987 67 1705351 1705429 1705910 1705905 1705426 1705430 1001116863 1705427 68 Table 4 2 600A Decal Legend Item ANSI 1001156889 B Canadian French 1001156985 B CE AUS 1001156987 B Spanish 1001156972 B Portuguese 1001156974 B Japanese 1001156976 B Chinese...

Page 99: ...509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 170...

Page 100: ...03936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851 1703939 29 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982 1703981 30 3251813 3251813 31 32 33 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 34 1702631 1702631 1702631 1702631 1702631 1702631 35 1702819 1702819 1702819 1702819 1702819 1702819 1702819 1...

Page 101: ...12 1001121810 1001121918 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 Table 4 3 600AJ Decal Legend Item ANSI 1001156890 B Canadian French 1001156986 B CE 1001156988 B Spanish 1001156973 B Portuguese 1001156975 B Japanese 1001156977 B Australian 1001156978 B Chinese Simplified 1001156982 B Chinese Tra...

Page 102: ...7 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862 1703987 67 1705351 1705429 1705910 1705905 1705426 1705430 1001116863 1705427 68 1001112551 Table 4 3 600AJ Decal Legend Item ANSI 1001156890 B Canadian French 1001156986 B CE 1001156988 B Spanish 1001156973 B Portuguese 1001156975 B Japanese 1001156977 B Austr...

Page 103: ...s of such an occurrence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CON TROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING COR RECTLY 5 3 EMERGENCY OPERATION Operator...

Page 104: ...an operator that is pinned trapped or unable to operate the machine and function controls are locked out from the platform due to a platform overload sit uation 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 Th...

Page 105: ...ded in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual Global Spec s n 0300177361 to Present 3121616 Illustrated Parts Manual Global Spec s n 0300177361 to Present 3121617 6 2 OPERATING SPECIFICATIONS Table 6 1 Operating Specifications MaximumWorkLoad Capacity ANSI Unrestricted Restricted 500lb 227kg 1000lb 454kg MaximumWorkLoad Capacity CE Australia ...

Page 106: ...ssis 21 640lbs 9 816kg 22 040lbs 9 997kg 23 900lbs 10 841kg GrossMachineWeight 600AJ Approximate 2WS 4WS NarrowChassis 22 240lbs 10 088kg 22 740lbs 10 315kg 24 000lbs 10 886kg Table 6 1 Operating Specifications Table 6 2 Dimensional Data MachineHeight Stowed 600A 600AJ 8ft 4in 2 54m 8ft 5in 2 57m MachineLength Stowed 600A 600AJ 26ft 5in 8 05m 29ft 8 80m MachineWidth bytiresize 355 55D 625 41 18LLx...

Page 107: ...eCrankcase DeutzD2011L04 DeutzTD2 9L GM 11quarts 10 5L 2 4Gallon 8 9L w Filter 4 5qts 4 25L w Filter Torquehubsshouldbeonehalffulloflubricant Table 6 4 Deutz D2011L04 Specifications Fuel Diesel OilCapacity CoolingSystem Crankcase TotalCapacity 5Quarts 4 5L 11Quarts 10 5L w Filter 16Quarts 15L IdleRPM 1000 LowRPM 1800 HighRPM 2500 Alternator 60Amp beltdrive Battery 950ColdCrankingAmps 205Minutes Re...

Page 108: ... 1200 50rpm HighRPM 2600 50rpm Alternator 95Amp FuelConsumption 0 65GPH 2 48lph Table 6 6 GM 3 0L Fuel GasolineorGasoline LPGas No ofCylinders 4 BHP Gasoline LP 83hp 3000rpm 75hp 3000rpm Bore 4 0in 101 6mm Stroke 3 6in 91 44mm Displacement 181cu in 3 0L 2966cc OilCapacityw filter 4 5qts 4 25L MinimumOilPressure atidle Hot 6psi 0 4Bar 1000rpm 18psi 1 2Bar 2000rpm CompressionRatio 9 2 1 FiringOrder ...

Page 109: ...ds or types as they may not contain the same required additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired contact JLG Industries for proper recommendations Table 6 7 Tire Specifications Size IN355 55D 625 IN355 55D625 14x17 5 LoadRange G G PlyRating 14 14 N A TirePressure 90PSI 6Bar Foam Filled Air Boss LoadCapacity 11 700lb 5307kg Static Size 41 ...

Page 110: ...5 PourPoint Max 46 F 43 C FlashPoint Min 442 F 228 C Viscosity Brookfield cPat 18 C 2700 at40 C 55cSt at100 C 9 3cSt ViscosityIndex 152 Table 6 10 Mobil DTE 13M Specs ISOViscosityGrade 32 SpecificGravity 0 877 PourPoint Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at100 C 6 6cSt at100 F 169SUS at210 F 48SUS cpat 20 F 6 200 ViscosityIndex 140 ...

Page 111: ...Flash Point 500 F 260 C Operating Temp 0 to 180 F 17 to 162 C Weight 7 64 lb per gal 0 9 kg per liter Viscosity at40 C 45cSt at100 C 8 0cSt ViscosityIndex 153 Table 6 12 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscos...

Page 112: ...220 C OperatingTemp 0to180 F 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 37cSt at100 C 8 4cSt ViscosityIndex 213 NOTE Must be stored above 32 F 14 C Table 6 14 Quintolubric 888 46 Density 0 91 15 C 59 F PourPoint 20 C 4 F FlashPoint 275 C 527 F FirePoint 325 C 617 F AutoignitionTemperature 450 C 842 F Viscosity at0 C 32 F 360cSt at20 C 68 F 102cSt at40 C 104 F 46cSt at100 C 212 F...

Page 113: ...TFORM DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY Table 6 15 Critical Stability Weights LB KG TireandWheel standardPneumatic 355 55D345 235 107 TireandWheel standardFoam Filled 355 55D345 440 200 Engine DeutzD2011 1222 554 DeutzTD2 9L 1250 567 GM 1070 486 Counterweight 600A 5400 2449 600AJ 6100 2767 NarrowFrame 8050 3651 600Aw SoftTouch 6100 2767 Platform 30x48 151 68 30x60 165 75 36x72 199 ...

Page 114: ... JLG Lift 3121615 Serial Number Locations A serial number plate is affixed to the left rear side of the frame If the serial number plate is damaged or missing the machine serial number is stamped on the left side of the frame Figure 6 1 Serial Number Locations ...

Page 115: ...THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY AMBIENT AIR TEMPERATURE SUMMER GRADE FUEL WINTER GRADE FUEL WINTER GRADE FUEL WITH KEROSENE ADDED NO OPERATION BELOW THIS AMBIENT TEMPER...

Page 116: ...80 F 82 C OR ABOVE NO OPERATION BELOW THIS AMBIENT TEMPERATURE MOBIL 424 10W 30 HYDRAULIC SPECIFICATIONS NO OPERATION ABOVE THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE EXXON UNIVIS HVI 26 MOBIL DTE 13 NOT...

Page 117: ...OPERATING TEMPERATURE ON LPG ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 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 IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER EN...

Page 118: ...THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE EXXON UNIVIS HVI 26 MOBIL DTE 13 NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTENTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVE...

Page 119: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121615 JLG Lift 6 15 Figure 6 6 Operator Maintenance Lubrication Diagram Deutz D2011L04 ...

Page 120: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 16 JLG Lift 3121615 Figure 6 7 Operator Maintenance Lubrication Diagram Deutz TD2 9 ...

Page 121: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121615 JLG Lift 6 17 Figure 6 8 Operator Maintenance Lubrication Diagram GM 3 0L ...

Page 122: ...t s 1 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access Apply grease and rotate in 90 degree intervals until bearing is completely lubricated Table 6 16 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excel lentwaterresistanceandadhesivequalities andbeingofextremepressuretype Tim...

Page 123: ... equipped Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 3 Swing Drive Hub Lube Point s Level Fill Plug Capacity 43 oz 1 3 L Lube 90w80 Gear Oil Interval Check level every 3 months or 150 hrs of operation change every 2 years or 1200 hours of operation ...

Page 124: ...oint 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 5 Hydraulic Return Filter Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator ...

Page 125: ...after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indicator 7 Hydraulic Tank Lube Point s Fill Cap Capacity 30 6 gal 115 8 L Tank 40 gal 151 4 L System Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation NORMALOPERATING RANGEWITHBOOM INSTOWEDPOSITION ...

Page 126: ...ler Lube EO Interval Every Year or 1200 hours of operation Comments Check level daily Change in accordance with engine manual Refer to Figure 6 9 Deutz 2011 Engine Dip stick B Oil Change w Filter Deutz TD2 9 Lube Point s Fill Cap Spin on Element Capacity 9 6 Quarts 9 0 L Lube EO Interval Every Year or 600 hours of operation Comments Check level daily Change in accordance with engine manual ...

Page 127: ...E 3121615 JLG Lift 6 23 Figure 6 9 Deutz 2011 Engine Dipstick MAXIMUMOIL LEVEL NOTE Hotoilchecksshouldbemadeaperiodof5minutesaftertheenginehasbeenshutdown MINIMUMLEVELOIL HOT MAXIMUMLEVELOIL HOT MINIMUMLEVELOIL COLD MAXIMUMLEVELOIL COLD MINIMUMOIL LEVEL ...

Page 128: ...Lube Point s Fill Cap Spin on Element Capacity 4 5 qt 4 25 L w filter Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 10 A Fuel Filter Deutz On Engine Lube Point s Replaceable Element Interval Change in accordance with engine manual ...

Page 129: ...ble Lube Point s Replaceable Element Interval Change in accordance with engine manual C Fuel Filter Deutz TD2 9 On Engine Lube Point s Replaceable Element Interval Change in accordance with engine manual 11 Fuel Filter Gasoline GM Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation ...

Page 130: ...eutz 2011 and GM Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator B Air Filter Deutz TD 2 9 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator ...

Page 131: ...ny cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures must be taken to remove the JLG product from service immediately Arrangements must be made for replacement of the tire or tire assembly For polyurethane foam filled tires JLG Industries Inc recommends that when any of the following are discovered measures must be taken to remove the JLG product from ser...

Page 132: ...cement tire ensure that all tires are inflated to the pressure recommended by JLG Due to size variations between tire brands both tires on the same axle should be the same Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width tire pressure and load capacity Size changes such as rim width center piece location larger or...

Page 133: ... sequence 3 The tightening of the nuts should be done in stages Follow ing the recommended sequence tighten nuts per wheel torque chart 4 Wheel nuts should be torqued after first 50 hours of opera tion and after each wheel removal Check torque every 3 months or 150 hours of operation Table 6 17 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2ndStage 3rdStage 40ft lbs 55Nm 95ft lbs 130Nm 170ft lbs 230...

Page 134: ... position off of ground 7 Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When 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 Place the 6 inches 15 2 cm high block with ascension ramp in front of right front wheel 9 Place Drive...

Page 135: ...e negative battery cable 3 Slowly loosen the Filter housing and remove it 4 Pull the filter housing from the Electric lock off assembly 5 Remove the filter from the housing 6 Locate Filter magnet and remove it 7 Remove and discard the housing seal 1 ElectricLockOffSolenoid 2 HousingSeal 3 FilterMagnet 4 FilterHousing 5 ElectricalConnector 6 FuelOutlet 7 O ring 8 Filter 9 FuelInlet 10 Ring Figure 6...

Page 136: ...k the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test 6 7 PROPANE FUEL SYSTEM PRESSURE RELIEF THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRESSURE WHERE APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS To relieve propane fuel system pressure 1 ...

Page 137: ...essure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is sub jected does no...

Page 138: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 34 JLG Lift 3121615 NOTES ...

Page 139: ...SECTION 7 INSPECTION AND REPAIR LOG 3121615 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerialNumber_______________________________________ Table 7 1 Inspection and Repair Log Date Comments ...

Page 140: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121615 Table 7 1 Inspection and Repair Log Date Comments ...

Page 141: ......

Page 142: ... 27721 Ritterhude Ihlpohl Germany 49 0 421 69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 63...

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