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Operation and Safety Manual

1. 1 1 Platform Rotate 6 rs aa 5 2 Platform Leveling Override 5 D 06 E Ga 4 22 4 Power Emergency Stop 4 E 12 5 EngineStart Auxiliary Power 3 8 or B Engine Start Auxiliary Power Function Enable 6 Tower Telescope R 11 7 Hourmeter ii 8 Platform Ground Select Switch 9 Swing 5 10 10 Tower Lift 11 Main Boom Lift 6 12 Main Boom Telescope 7 9 8 Figure 3 1 Ground Control Station 3121204 JLG Lift 3 3 SECTION 3 MACHINE CONTROLS AND INDICATORS 5 Engine Start Auxiliary Power Switch or Engine Start Auxiliary Power Switch Function Enable To use auxiliary power the switch must be held h DOWN for duration of auxiliary pump use Aux To start the engine the switch must be held UP until the engine starts power can only be used if the engine is not run ning If equipped the enable switch must be held DOWN to enable all boom controls when the engine is running 6 Tower Telescope This switch provides raising and lowering of the tower boom This function works only when the tower boom is fully elevated lift up A WARNING TO AVOID UPSET AND SERIOUS INJURY DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE 3 4 NOTE NOTE JLG Lift Hourmeter Registers
2. 6 42 JLG Lift 3121204 SECTION 7 INSPECTION AND REPAIR LOG Machine Serial Number SECTION 7 INSPECTION AND REPAIR 106 Table 7 1 Inspection and Repair Log Date Comments 3121204 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 JLG Lift 3121204 amp Ajmou 5 2 noA OU SseJppy UUNI Jo auoyd j L 55 49UMQ elas 5191 uo aq jou pinoys sun pasea 310N LZ Gt4 LO L XeJ 1699 987 21 euoudajat vsn 29 12 IN eze d 7222 seujsnpu jueunjedeg Ayigereg Ajsjes 1 yueyL MOJ89q se jueunjedog 5 Ajyayes 19npoud 991 pejejduioo 5 5 Jo diusieuwo 0 uorneunojuri p
3. WITH 1 AND 6 14 NO OPERATION BELOW THIS AMBIENT TEMPERATURE Figure 6 2 Engine Operating Temperature Specifications Deutz Sheet 1 of 2 JLG Lift 120 49 NO OPERATION ABOVE THIS AMBIENT TEMPERATURE 11044332 100 38 90 F 32 C 80 F 27 C sl fel m fm m fe 70 21 ENGINE 2 E i E 60 F 16 C SPECIFICATIONS 2 at su ie 10 6 E 2 40 4 30 1 ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE I TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A a AN 10F 12 C FULLY CHARGED BATTERY ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER TM RECOMMENDED FLUIDS A FULLY CHARGED BATTERY GRADE pie THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER WE 4 _y Yo 20 F 29 C PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR KEROSENE Pa GLOW PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER ADDED 40 F 40 C AMBIENT AIR TEMPERATURE 2 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 180 F 82 C 82 OR ABOVE
4. 1 Drive Speed 5 Power EmergencyStop 9 Drive Steer 13 Tower Lift 2 Steer Select 6 Aux Power 10 Telescope 14 Platform Rotate 3 Platform Leveling Override 7 Fuel Select 11 Jib 15 Function Speed 4 Horn 8 Lights 12 TowerTelescope 16 MainLift Swing Figure 3 4 Platform Control Console 3 10 JLG Lift SECTION 3 MACHINE CONTROLS AND INDICATORS 3121204 felene Platform Leveling Override 7 mou Power Emergency Stop 9 Drive Steer 13 Tower Lift 17 Drive Orientation Override 10 Telescope 14 Platform Rotate 18 Soft Touch Override 11 Jib 15 Function Speed 19 Soft Touch Indicator 12 Tower Telescope 16 Main Lift Swing Figure 3 5 Platform Control Console w Drive Orientation JLG Lift 3 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 6 Auxiliary Power Energizes the electrically operated hydraulic pump when actuated Switch must be held ON for duration of auxiliary pump use The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail The auxiliary pump will operate tower boom lift tower telescope main boom lift main telescope and swing Fuel Select Dual Fuel Engine Only If Equipped Gasoline or liquid
5. JLG Lift For adjustments see Service Manual Limit Switch Adjust ments Check elevation limit switch as follows Main Boom Angle Limit Switch a Lift boom up to 5 degrees above horizontal Limit switch should activate at this point b Lift main boom down until limit switch resets This should be 4 degrees to 9 degrees below horizontal Angle indicator should be placed between the main boom pivot pin and the main boom lift cylinder attach point on the base boom On machines not equipped with ADE the main boom angle limit switch activation may be checked 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION by using test light in terminal 24 in the main terminal box Tower angle switch must be reset before main boom angle switch can be activated Tower Boom Angle Limit Switch a Place machine on level surface b Using the bottom of the upright and the ground as a reference lift the tower boom 40 to 42 101 6 to 106 6 cm from the stowed position The tower boom angle limit switch should activate at this point Lower the tower boom 25 to 30 63 5 to 76 2 cm from where the switch activated This switch should reset at this point NOTE machines not equipped with the tower boom angle limit switch activation may be checked by using a test light in terminal 43 on the main terminal box NOTE Step 8 is only applicable for 600A ANSI market machine
6. TEME IF EITHER OR BOTH CONDITIONS AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS TEMPERATURE THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE 120754826 NO OPERATION ABOVE THIS PROLONGED OPERATION IN NOTE 110 F 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES de OF 100 F 38 C OR ABOVE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES 100 F 38 0 CONSISTANTLY WITHIN SHOWN LIMITS 800070 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 80 F 27 C 5 70 F 21 C i E gt 60 16 50 F 10 C 2 2 HYDRAULIC SUMMER GRADE WINTER GRADE SPECIFICATIONS FUEL FEL 40 F 4 C 15 F c 30 F 1 C 8 432 0 20 F 7 C 23 5 EX 10 F 12 C oF 1890 DO NOT START UP HYDRAULIC SYSTEM ES WITHOUT HEATING AIDS WITH MOBILE 424 g 14 10 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE g o o Ire 920 2976 DO NOT START UP HYDRAULIC SYSTEM ES Tar vim 30 F 34 C WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE E 4 40 F 40 C NO OPERATION BELOW THIS 5 AMBIENT TEMPERATURE 48 25 22 30 0 10 20 30 40 50 60 OF ADDED KEROSENE 4150548 D Figure 6 3 Engine Operating Temperature Specifications Deutz Sheet 2 of 2 3121204 JLG Lift 6 15 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE
7. Figure 2 1 Machine Nomenclature 600AJ 3121204 JLG Lift 2 9 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Platform Platform Control Box Rotator Fly Boom Base Boom Main Boom Assembly Telescope Cylinder Inside Upright Fly Boom BaseBoom LowerLift Cylinder Ground Control Box Steer Wheels Frame Drive Wheels Swing Bearing Turntable Tower Telescope Cylinder Inside Boom Assembly Upright Level Cylinder Main Lift Cylinder 16 Slave Level Cylinder Footswitch ootswitc ge 7 Figure 2 2 Machine Nomenclature 600A ONO 2 10 JLG Lift 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 22 23 24 25 26 27 14 15 16 17 18 19 20 27 32 33 34 35 36 37 Figure 2 3 Daily Walk Around Inspection Diagram 3121204 JLG Lift 2 11 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION General Begin the Walk Around Inspection at Item 1 as noted on the diagram Continue to the right counterclockwise viewed from top checking each item in sequence for the conditions listed in the Walk Around Inspection Check list A WARNING TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING WALK AROUND INSPECTION NOTICE DO NOT OVERLOOK VISUA
8. 44 45 46 47 48 49 50 51 52 3121204 JLG Lift 4 33 SECTION 4 MACHINE OPERATION Table 4 2 600A Decal Legend S N 0300140401 to Present 4 34 Item ANSI psi CE Spanish Portuguese Japanese Australian 4 Eaka 0273891 10 0273893 9 0273895 6 0273899 10 0273901 9 0273903 11 1001114388 1 1001116840 3 1001116841 3 53 54 55 56 57 58 59 60 62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 1706941 1706941 65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862 67 1705351 1705429 1705910 1705905 1705426 1705430 1001116863 68 1001112551 Lift 3121204 SECTION 4 MACHINE OPERATION 3121204 Table 4 3 600AJ Decal Legend Prior to S N 0300140401 Item 4 ANSI Spanish Portuguese Japanese Australian 0273892 10 0273894 9 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 17
9. Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain Z 34 93 772 4700 34 93 771 1762 A JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 www jlg com
10. Remove all load and allow engine to operate 3 5 min utes at LOW setting to permit reduction of engine inter nal temperatures At Ground Controls turn KEY SELECT switch to center OFF Position POWER EMERGENCY STOP switch down to OFF Remove key Cover Platform Control console to protect instruction placards warning decals and operating controls from hostile environment 3121204 SECTION 4 MACHINE OPERATION 2 JO 1 19945 1 woog p p 4 UPIM 124949 eseqieeuM eseqieeuM s uonounj 5 190 5 WOOS INALSAS 9NIHOLIMS 4 11 JLG Lift 3121204 SECTION 4 MACHINE OPERATION 2 10 2 1995 1 woog 5 4 UPIM Ie49 0 PIM 340259131 27 W eseqjeeuw 3240953131 UW 1 ANIHOVW 3O ASN ONINNILNOD 380338 3291IA
11. Spanish Portuguese Japanese Australian d 1 0273891 10 0273893 9 0273895 6 0273899 10 0273901 9 0273903 11 1001114388 1 1001116840 3 1001116841 3 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 5 1701509 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 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 1705084 1705084 15 1705514 1705514 1705514 1705514 1705514 16 3121204 JLG Lift 4 31 SECTION 4 MACHINE OPERATION Table 4 2 600A Decal Legend S N 0300140401 to Present Item ANSI Spanish Portuguese Japanese Australian impie d 0273891 10 0273893 9 0273895 6 0273899 10 0273901 9 0273903 11 1001114388 1 1001116840 3 1001116841 3 17 3251243 3251243 3251243 3251243 18 19 1001117034 20 1001117035 21 1704006 1704007 1705901 22 1703953 1703942 1703941 1705903 1703944 1001116845 1703943 23 24 1702868 1704000 1704001 1705967 1706968 1001116846 25 1703797 1703924 1705921 1703923 1705895 1703926 1705921
12. 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 3121204 180 82 C EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F HYD OIL TANK TEMP 120 49 C 110 43 100 38 C 90 32 C 80 27 70 21 60 16 50 F 10 40 F 49 30 pero 20 F 7 C 10 F 12 0 F 18 C 10 F 23 C O 82 C OR ABOVE I EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC EITHER OR BOTH CONDITIONS L COOLER CONSULT JLG SERVICE MOBIL 424 10W 30 MOBIL DTE 13 NO OPERATION ABOVE THIS AMBIENT TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE HYDRAULIC SPECIFICATIONS EXXON UNIVIS HVI 26 DO NOT START UP HYDRAULIC SYSTEM HYDRAULIC OIL BELOW THIS TEMPERAT WITHOUT HEATING AIDS WITH MOBILE 424 URE 20 29 C 30 34 C C DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER V HYDRAULIC OIL BELOW THIS TEMPERATURE 40 F 40 C NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 4150548 D Figure 6 5 Engine O
13. 68 1001112551 JLG Lift 3121204 SECTION 4 MACHINE OPERATION Table 4 4 600AJ Decal Legend S N 0300140401 to Present Item ANSI 2 Spanish Portuguese Japanese Australian meis d 0273892 10 0273894 9 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 1001116842 3 1001116843 3 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 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 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 1705084 1705084 15 1705514 1705514 1705514 16 17 3251243 3251243 3251243 3251243 3251243 3121204 JLG Lift 4 39 SECTION 4 MACHINE OPERATION Table 4 4 600AJ Decal Legend S N 0300140401 to Present Item ANSI pn CE Spanish Portuguese Japanese Australian singe 4 dur hod 0273892 10 0273894 9 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 1001116842 3 1001
14. MG An Oshkosh Corporation Company Operation and Safety Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models 600A 600AJ ANSI CC 6 3121204 August 25 2010 Identification All 600A and 600AJ machines from S N 64249 incorporate ADE The following machine serial numbers prior to S N 64249 also utilize ADE 63908 63912 63932 63936 63938 63954 63959 and 63963 A Machine that incorporates ADE Advanced Design Elec tronics can be outwardly identi fied by the analyzer connection at the base of the platform con trol box as shown by the arrow FOREWORD 3121204 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 reserves the right to make specification changes without prior notification Contact JLG Industries Inc for updated information JLG Lift a 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 DANGER INDICATES IMMINENTLY HAZARDOUS SITUATI
15. 20 8 24 4 Strong Gale Light structure damage 1 10 Lift 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is necessary that it be operated and maintained only by trained personnel 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 Operator Training Operator training must cover 1 Use and limitations of the controls in the platform and at the ground emergency controls and safety systems 2 Control labels instructions and warnings on the machine 3 Rules 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 mal function JLG Lift 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles depressions holes drop offs 7 Means to avoid the hazards of unprotected electrical conductors 8 Specific job requirements or machine application Training Supervision Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to
16. 68 F 102 cSt on a yearly basis for viscosity at 40 C 1045 16091 at 100 212 10 Viscosity Index 220 JLG Lift 6 11 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Critical Stability Weights DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF FERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES COUNTERWEIGHT ENGINE amp PLATFORM DO NOT MOD IFY UNIT IN ANY WAY TO AFFECT STABILITY Table 6 19 Critical Stability Weights 600AJ 600A LB KG LB KG Tire and Wheel Ballasted Only Size 14 17 5 165 75 165 75 Engine Ford 460 209 460 209 Deutz 534 242 534 242 Continental 558 253 558 253 Counterweight Weight 6200 2812 5700 2586 Platform 6ft 1 83M 205 93 205 93 8ft 2 44 M 230 105 230 105 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 SERIAL NUMBER SERIAL NUMBER PLATE STAMPED ON FRAME Figure 6 1 Serial Number Locations 6 12 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE This page left blank intentionally 3121204 JLG Lift 6 13 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE
17. NO OPERATION ABOVE THI AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG SAE 5W 20 c SAE 5W 30 SAE 5W 40 ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 10W 30 5 10W 40 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 6 16 NO OPERATION BELOW THIS AMBIENT TEMPERATURE 120 F 49 C 110 F 43 C 100 F 38 C 90 F 3 2 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C gt 10 pel ai F 18 C 10 F 23 C 20 F 29 C 30 F 34 C 40 F 40 C Figure 6 4 Engine Operating Temperature Specifications Ford Sheet 1 of 2 JLG Lift
18. lever or controller for desired function and hold Release AUXILIARY POWER switch selected control switch lever or controller and footswitch Position POWER EMERGENCY STOP switch to OFF Activating from the Ground Control Station 1 JLG Lift Position PLATFORM GROUND SELECT KEY SWITCH to GROUND Position POWER EMERGENCY STOP switch to ON Position AUXILIARY POWER switch to ON and hold Operate appropriate control switch or controller for desired function and hold Release AUXILIARY POWER switch and appropriate control switch or controller Position POWER EMERGENCY STOP switch to OFF 3121204 SECTION 4 MACHINE OPERATION 4 14 DUAL FUEL SYSTEM GAS ENGINE ONLY The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas A CAUTION IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOWING THE ENGINE TO STOP EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 2 3121204 Start engine from Ground Control Station Open hand valve on LP gas supply tank by turning counterclockwise While engine is operating on GASOLINE under a no load condition place FUEL SELECT switch at Platform Control to LP position Changing From LP Gas to Gasoline 1 4 15 Level With engine operating on LP under a no load condition position FUEL SELECT switch at Platform Control Sta
19. 1704412 14 1705084 15 1705514 1705514 1705514 16 3121204 JLG Lift 4 27 SECTION 4 MACHINE OPERATION 4 28 Table 4 1 600A Decal Legend Prior to S N 0300140401 Item 4 ANSI pala CE Spanish Portuguese Japanese Australian 0273891 9 0273895 5 0273899 9 0273901 9 0273903 10 1001114388 1 0273893 9 17 3251243 3251243 3251243 3251243 18 19 20 21 1704006 1704007 1705901 22 1703953 1703942 1703941 1705903 1703944 23 24 1702868 1704000 1704001 1705967 25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 29 1703984 1705828 1703983 1705902 1703980 1705828 30 3251813 3251813 3251813 3251813 3251813 31 33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 34 1702631 1702631 1702631 1702631 1702631 1702631 Lift 3121204 SECTION 4 MACHINE OPERATION 3121204 Table 4 1 600A Decal Legend Prior to S N 0300140401 Item 4 ANSI 0273891 9 Canadian French 0273893 9 CE 0273895 5 Spanish 0273899 9 Portuguese 0273901 9 Japanese 0273903 10 Australian 1001114388 1 35 1702818 1702818 1702818 1702818 1702818 1702818 170281
20. 4 MACHINE OPERATION 3121204 Table 4 3 600AJ Decal Legend Prior to S N 0300140401 Item ANSI 0273892 10 Canadian French 0273894 9 CE 0273896 5 Spanish 0273900 10 Portuguese 0273902 9 Japanese 0273904 11 Australian 1001114389 1 36 1707013 1707046 1705978 1707049 1707052 1707054 1705978 37 1701645 1703996 1705978 1707056 1707057 1707059 1705978 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 JLG Lift 4 37 SECTION 4 MACHINE OPERATION 4 38 Table 4 3 600AJ Decal Legend Prior to S N 0300140401 Item ANSI pond CE Spanish Portuguese Japanese Australian 0273892 10 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 0273894 9 54 55 56 57 58 59 60 61 62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 67 1705351 1705429 1705910 1705905 1705426
21. 4 of 4 4 26 6 1 Serial Number Locations 6 12 6 2 Engine Operating Temperature Specifications Deutz 2 Sheet o 6 14 6 3 Engine Operating Temperature Specifications Deutz zSheet 2 0f 2 oleo uox REPE 6 15 6 4 Engine Operating Temperature Specifications Ford Sheet WO 2 oc cuca hon eC ERES 6 16 6 5 Engine Operating Temperature Specifications Ford Sheet 2 012 RD ue E ERES 6 17 6 6 Engine Operating Temperature Specifications Caterpillar Sheet 1 42 6 18 6 7 Engine Operating Temperature Specifications Caterpillar Sheet 2 042 6 19 6 8 Engine Operating Temperature Specifications GM Sheet 1 of2 soos o RS ue e 6 20 6 9 Engine Operating Temperature Specifications GM Sheet 2 012 xoc howe EA 6 21 6 10 Lubrication and Maintenance Point Location 6 22 6 11 Filter Lock 6 39 iv JLG Lift PAGE 3121204 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE LIST OF TABLES 6 15 Mobilfluid 424 6 10 1 4 Minimum Approach Distances M A D 1 5 6 16 Mobil DTE 13M Specs 6 10 1 2 Beaufort Scale For Reference Only 1 10 6 17 Univis 26 5 6 11 2 1 Inspection and Maintenance Table 2 3 6 18 Quintolubric 888 46 DC
22. 5 Hydraulic Return Filter e 268 Lube Point s Level Fill Plug Interval Change after first 50 hrs and every 6 months Capacity 17 oz 1 2 Full or 300 hrs thereafter or as indicated by Condition Indi Lube EPGL cator Interval Check level every 3 months or 150 hrs of oper ation change every 2 years or 1200 hours of operation 3121204 JLG Lift 6 25 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 Hydraulic Charge Filter 7 Hydraulic Tank FULL NORMAL OPERATING RANGE WITH BOOM IN STOWED POSITION tals ADD Interval Change after first 50 hrs and every 6 months Lube Point s Fill Cap or 300 hrs thereafter or as indicated by Condition Indi Capacity 31 gal 117 3 L Tank 37 2 gal 140 8 L cator System Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 6 26 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 8 Suction Strainers in tank 9 Oil Change w Filter Ford LRG423 Lube Point s Fill Cap Spin on Element Capacity 5 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 10 Oil Change w Filter Ford LRG425 REMOVE FILL CAP PLATE FROM TANK TO GAIN ACCESS TO STRAINERS Lube Point s 2 Interval Every 2 years or 1200 hours of operation remove and clean at time of hydraulic o
23. 82 C HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE 120 F 49 C NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 F 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES DOFO OF 100 38 C OR ABOVE 90 F 32 C 3 80 F 27 C 8 70 F 21 C 60 16 8 2 HYDRAULIC SO ROA SPECIFICATIONS 40 F 4 C S g 30 F 1 z 20 F 7 C 10 F 12 C F 1890 DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE 20 F 29 DO NOT START UP HYDRAULIC SYSTEM 30 34 WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THI bois AMBIENT TEMPERATURE 5 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTENTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL 4150548 D Figure 6 7 Engine Operating Temperature Specifications Caterpillar Sheet 2 of 2 3121204 JLG Lift 6 19 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE ON LPG UNAIDE
24. Consumption Continental TMD27 Diesel w Filter 7 0 quarts 6 65 L Low RPM 1 80 GPH 6 81 Iph Caterpillar 3044C Diesel w Filter 10 6 quarts 101 High RPM 2 30 GPH 8 71 Iph GM 4 5 qts 4 25 L w Filter Horsepower 66 5 3000 RPM Cooling System 16 Quarts 15 14 L Coolant 3 8 Gallons 3 61 Torque hubs should be one half full of lubricant 6 4 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 5 Ford LRG 423 Specifications Table 6 6 Ford LRG 425 Specifications Fuel Gasoline Fuel Gasoline Crankcase Capacity Crankcase Capacity 4 5 Quarts 4 25 L w Filter w Filter 5 00 Quarts 4 73L w o Filter 4 00 Quarts 3 791 Idle RPM 1000 Idle RPM 1000 Low RPM 1800 Low RPM 1800 High RPM 2800 High RPM 2800 Alternator 40 Amp Belt Drive Amps 12 VDC Battery 85 Amphour 550 Cold Cranking Amps 12 VDC Fuel Consumption Fuel Consumption Low RPM 3 45 GPH 13 06 Iph High RPM 4 60 GPH 17 41 Iph Horsepower 54 2400 RPM full load Cooling System 16 Quarts 15 14 L Low RPM 3 45 GPH 13 06 Iph High RPM 4 60 GPH 17 41 Iph Horsepower 54 2400 RPM full load Cooling System 16 Quarts 15 14 L Spark Plug AWSF 52 C Spark Plug Gap 0 044 in 1 117 mm Spark Plug AWSF 52 C Spark Plug Gap 0 044 in 1 117 mm 3121204 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENA
25. Displacement 20318 5 830 Stroke 3 6 in 91 44 mm Displacement 181 cu in 3 0 L 2966 cc Firing Order ieee Oil Capacity w filter 4 5 qts 4 25L Rotation viewed from flywheel Counterclockwise Minimum Oil Pressure Oil Capacity w filter 10 6 quarts 10 L atidle 6 psi 0 4 Bar 1000 rpm Cooling System Engine Only 5 8 quarts 5 5 L Hot 18 psi 1 2 Bar 2000 rpm Idle RPM 1000 Compression Ratio 9 2 1 Low RPM 1800 Firing Order 1 3 4 2 High RPM 3044C 2600 Max RPM 2800 High RPM 3 4 2500 Alternator 60 Amp belt drive Battery 930 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC 3121204 JLG Lift 6 7 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Tires Table 6 11 Tire Specifications Size 14x17 5 14x17 5 14x17 5 Load Range G G Ply Rating 14 14 N A Tire Pressure 90 PSI 6Bar Foam Filled Air Boss Load Capacity 11 800 Ib 5353 kg Static 6 8 Dimensional Data Table 6 12 Dimensional Data Machine Height Stowed 8ft 3 75 in 2 53 Machine Length Stowed 600A Over Drive Axle 26ft 5 in 8 05 m 600AJ Over Drive Axle 28 ft 11 4375 in 8 82 m Machine Width Standard 8 ft 2 44 m Narrow Chassis 7 ft 2 13 Wheelbase 8 ft 2 44 m Boom Elevation 600A 60 ft 5 3 8in 18 42 m 11in 0 28m Boom Elevation 600AJ 60ft 6 3 4 in 18 46 2ft 8 13 16 in 0 83 m JLG Lift 3
26. TEMPERATURE OIL COOLER CONSULT JLG SERVICE NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 F 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES 100 F 38 OF 100 F 38 C OR ABOVE 90 F 32 C 80 F 27 C 8 70 F 21 amp S ani 60 F 16 C a Q HYDRAULIC 50 F 10 C A SPECIFICATIONS 40 F 4 0 B B 30 F 1 C 2 20 F 7 C g d 10 F 12 0 F 18 C DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE 7207 o9 DO NOT START UP HYDRAULIC SYSTEM 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES 30 F 34 C WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS HYDRAULIC OIL BELOW THIS TEMPERATURE NO OPERATION BELOW THIS 2 ALL VALUES ARE ASSUMED TO BE AT SEALEVEL AMBIENT TEMPERATURE 4150548 D Figure 6 9 Engine Operating Temperature Specifications GM Sheet 2 of 2 3121204 JLG Lift 6 21 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 9 THRU 22 ENGINE LOCATED ON OPPOSITE SIDE OF MACHINE FROM VIEW SHOWN Figure 6 10 Lubrication and Maintenance Point Location 6 22 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 3 OPERATOR MAINTENANCE NOTE The following numbers correspond to those in Figure 6 10 Lubrication and Maintenance Point Location 1 Swing Bearing Table 6
27. WARM THE ENGINE TO OPERATING TEMPERA TURE BEFORE DRAINING THIS WILL ALLOW THE OILS TO FLOW FREELY FROM THE REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and bring to operating temperature With the engine running close the manual tank valve and run the engine out of fuel 3121204 JLG Lift 6 37 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 Remove the retainer clip for the LPG fuel temperature 6 7 PROPANE FUEL FILTER REPLACEMENT NOTE 6 38 sensor and remove the sensor from the regulator body 4 7 _ z m Have a small container ready to collect oil that will drain freely from the regulator at this point Once all of the oil has been drained reinstall the LPG fuel temperature sensor and reconnect the electrical connector Open the fuel tank manual valve Start the engine and verify all connections are secure Dispose of any drained oil per local regulations in a safe and proper fashion o oN PA F JLG Lift Removal 1 Relieve the propane fuel system pressure Refer to Pro pane Fuel System Pressure Relief Disconnect the negative battery cable Slowly loosen the Filter housing and remove it Pull the filter housing from the Electric lock off assembly Remove the filter from the housing Locate Filter magnet and remove it Remove and discard the housing seal If equipped remo
28. air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics Tire Damage For pneumatic tires JLG Industries Inc recommends that when any 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 recom mends that when any of the following are discovered measures must be taken to remove the JLG product from service immedi ately and arrangements must be made for replacement of the tire or tire assembly smooth even cut through the cord plies which exceeds 3 inches 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter 6 32 JLG Lift any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts Manual for the part number of the approved tire
29. not provide pro tection from contact or proximity to electrical current F Keep both feet firmly positioned on the platform floor at all W times Never use ladders boxes steps planks or similar items on platform to provide additional reach Never use the boom assembly to enter or leave the plat form JLG Lift 3121204 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Approach Distances M A D Voltage Range MINIMUM APPROACH DISTANCE Phase to Phase in Feet Meters Oto 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 Over 500 KV to 750 KV 35 11 Over 750 KV to 1000 KV 45 14 NOTE This requirement shall apply except where employer local or governmental regulations are more stringent Maintain distance from electrical lines apparatus or any energized exposed or insulated parts according to the Maintain a clearance of at least 10 ft 3m between any part Minimum Approach Distance MAD as shown in Table 1 of the machine and its occupants their tools and their 1 equipment from any electrical line or apparatus carrying up Allow for machine movement and electrical line swaying to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less 3121204 JLG Lift 1 5 SECTION 1 SAFETY PRECAUTIONS The minimum approach distance may be reduced if insulat Ti
30. steering push valve E zi v knob IN to the actuated position N E gaged 2 Reconnect drive hubs by inverting disconnect cap ps B 3 Disconnect tow bar from steering hitch and from towing vehicle The machine is now in the driving mode DISCONNECT __ REVERSED DRIVE gt HUB Drive Hub Disconnected Figure 4 8 Drive Disconnect Hub 4 16 JLG Lift 3121204 SECTION 4 MACHINE OPERATION 4 12 AUXILIARY POWER NON ADE EQUIPPED MACHINES A CAUTION WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE 12 VOLT AUXILIARY PUMP MOTOR A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electri cally driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump will operate boom lift telescope and swing To activate auxil iary power Activat 1 3121204 ing from the Platform Control Station Position PLATFORM GROUND SELECT KEY SWITCH to PLATFORM Position POWER EMERGENCY STOP switch to ON Depress and hold footswitch Operate appropriate control switch lever or controller for desired function and hold 5 7 Position AUXILIARY POWER switch to ON and hold Release AUXILIARY POWER switch se
31. the Service and Maintenance Manual Be sure the footswitch and all other safety devices are operating properly Modification of these devices is a safety violation A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU FACTURER Do not operate any machine on which safety or instruction placards or decals are missing or illegible Avoid any buildup of debris on the platform floor Keep mud oil grease and other slippery substances from foot wear and platform floor 3121204 SECTION 1 SAFETY PRECAUTIONS 1 3 OPERATION General 3121204 Do not use the machine for any purpose other than posi tioning personnel their tools and equipment Never operate a machine that is not working properly If a malfunctions occurs shut down the machine Never slam a control switch or lever through neutral to an opposite direction Always return switch to neutral and stop before moving the switch to the next function Oper ate controls with slow and even pressure Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform except in an emergency Do not carry materials directly on platform railing Contact JLG for approved material handling accessories When two or more persons are in the platform the opera tor shall be responsible for all machine operations Always ensure that power tools are pro
32. tion to GASOLINE position Close hand valve on LP gas supply tank by turning clockwise RE SYNCHRONIZE THE LOWER LIFT CYLINDER Override Valve A pull type control valve allows the operator to adjust the tower lift cylinder and the upright cylinder if the upright cylin der is not fully retracted when boom is in the stowed posi tion This valve is located in the engine compartment area To Operate 1 JLG Lift Pull the red knob Using the ground control raise the lower boom 6 feet Release the knob Fully lower the boom Repeat if necessary 4 19 SECTION 4 MACHINE OPERATION 4 16 TIE DOWN AND LIFTING NOTE 4 20 When transporting machine boom must be in the stowed mode with turntable lock pin engaged and machine securely tied down to truck or trailer deck Four tie down eyes are pro vided in the frame slab one at each corner of the machine See Figure 4 9 Machine Tie Down Lifting eyes are provided at the front and rear in the frame slab Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING If it becomes necessary to lift the machine using an over LONG DISTANCES OR HAULING MACHINE ON TRUCK TRAILER head or mobile crane it is very important that the lifting devices are attached only to the designated lifting eyes and that the turn
33. 01509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 14 1705084 15 1705514 16 17 3251243 3251243 3251243 3251243 3251243 JLG Lift 4 35 SECTION 4 MACHINE OPERATION 4 36 Table 4 3 600AJ Decal Legend Prior to S N 0300140401 Item ANSI Spanish Portuguese Japanese Australian 0273892 10 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 0273894 9 18 19 20 21 1704006 1704007 1705901 22 1703953 1703942 1703941 1705903 1703944 23 24 1702868 1704000 1704001 1705967 25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 29 1703984 1705828 1703983 1705902 1703980 1705828 30 3251813 3251813 3251813 3251813 3251813 31 32 33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 35 1702819 1702819 1702819 1702819 1702819 1702819 1702819 JLG Lift 3121204 SECTION
34. 0300080000 to 3121201 Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Illustrated Parts Manual ANSI Spec Prior to s n 0300068000 3120719 Illustrated Parts Manual Euro Spec Prior to s n 0300068000 3120841 Illustrated Parts Manual ANSI Spec s n 0300068000 to s n 0300087000 3121177 Illustrated Parts Manual Euro Spec s n 0300068000 to s n 0300087000 3121855 Illustrated Parts Manual Global Spec s n 0300087000 to 3121206 3121204 JLG Lift 6 1 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 2 OPERATING SPECIFICATIONS Table 6 1 Operating Specifications Prior to S N 0300140401 Maximum Work Load Capacity Unrestricted Restricted 500 lb 230 kg 1000 Ib 450 kg Maximum Travel Grade Gradeability 2WD 30 4WD 4596 Maximum Travel Grade Side Slope 5 Turning Radius outside 2WS AWS 17 ft 8in 5 38 11 ft 8in 3 56 Turning Radius outside narrow chassis 2WS 16 ft 5 03 4WS 11 ft 2 in 3 4m Turning Radius inside 2WS 11 ft 5in 3 48 4WS 5ft 1 68 m Turning Radius inside narrow chassis 2WS 4WS 12 ft 2in 3 71 5 ft 7in
35. 1 7m Maximum Tire Load 11 500 Ibs 5227 kg 6 2 Table 6 1 Operating Specifications Prior to S N 0300140401 Ground Bearing Pressure 600A 77 psi 5 4 kg cm 600AJ 75 psi 5 3 kg cm 600A narrow chassis 94 psi 6 6 kg cm 600AJ narrow chassis 94 psi 6 6 kg cm Maximum Drive Speed A Models 2WD 3 6 MPH 5 80 Km hr 4WD 4 MPH 6 44 Gross Machine Weight Approximate 600A 600AJ 600A narrow chassis 6004 narrow chassis 21 500 Ibs 9 752 kg 22 200 Ibs 10 025 kg 23 900 Ibs 10 841 kg 24 000 Ibs 10 886 kg JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 2 Operating Specifications a S N 0300140401 to Table 6 2 Operating Specifications S N 0300140401 to Present Maximum Work Load Capacity ANSI Unrestricted Restricted 50010 227 kg 1000 Ib 454 kg Maximum Work Load Capacity CE amp Australia Unrestricted Restricted 500 Ib 230 kg 100010 450 kg Maximum Travel Grade Gradeability Present Maximum Tire Load 11 500 Ibs 5216 kg Ground Bearing Pressure 600A 77 psi 5 4 kg cm 600AJ 75 psi 5 3 kg cm 600A narrow chassis 94 psi 6 6 kg cm 600AJ narrow chassis 94 psi 6 6 kg cm Maximum Drive Speed A Models 2WD 3 6 MPH 5 80 Km hr 4WD 4 MPH 6 44 2WD 30 4WD 4596 Maximum Travel Grade Side Slope 5 Turning Rad
36. 1001116847 1703925 26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 1001116848 1001116849 27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 1001116850 1703949 28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851 29 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982 30 3251813 3251813 3251813 3251813 3251813 3251813 3251813 31 32 33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 4 32 JLG Lift 3121204 SECTION 4 MACHINE OPERATION Table 4 2 600A Decal Legend S N 0300140401 to Present Item ANSI 0273891 10 Canadian French 0273893 9 CE 0273895 6 Spanish 0273899 10 Portuguese 0273901 9 Japanese 0273903 11 Australian 1001114388 1 Chinese Simplified 1001116840 3 Chinese Traditional 1001116841 3 35 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818 36 1001121813 1001121815 1705978 1001121817 1001121819 1001121820 1705978 1001121824 1001121822 37 1001121800 1001121802 1705978 1001121804 1001121806 1001121807 1705978 1001121811 1001121809 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 41 42 43
37. 116843 3 18 19 1001117034 20 1001117035 21 1704006 1704007 1705901 22 1703953 1703942 1703941 1705903 1703944 1001116845 1703943 23 24 1702868 1704000 1704001 1705967 1706968 1001116846 25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 1001116847 1703925 26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 1001116848 1001116849 27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 1001116850 1703949 28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851 29 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982 30 3251813 3251813 3251813 3251813 3251813 3251813 3251813 31 32 33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 35 1702819 1702819 1702819 1702819 1702819 1702819 1702819 1702818 1702818 4 40 JLG Lift 3121204 SECTION 4 MACHINE OPERATION Table 4 4 600AJ Decal Legend S N 0300140401 to Present Item ANSI 0273892 10 Canadian French 0273894 9 CE 0273896 5 Spanish 0273900 10 Portuguese 0273902 9 Japanese 0273904 11 Australian 1001114389 1 Chinese Simplified 1001116842 3 Chinese Traditional 1001116843 3 36 1001121814 1001121816 1705978 1001121818 1001121655 1001121821 1705978 1001121825 1001121823 37 1001121801 1001121803 1705978 1001121805 1001121656 1001121808 1705
38. 121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Torque Requirements Table 6 13 Torque Requirements Hydraulic Oil Table 6 14 Hydraulic Oil Specifications 3121204 JLG Lift Description Torque Value Dry yoga HYDRAULIC SYSTEM OPERATING SAE VISCOSITY wale TEMPERATURE RANGE GRADE Bearing To Chassis See Note 50 600 0 to 180 F 18 C to 83 10W Bearing To Turntable See Note 50 600 UN dud 50 F to 2109 2 10 C to 210 C 20W 20 Wire Rope 15 ft Ibs 20 Nm 150 NOTE oils must have anti wear qualities at least to Wheel Lugs See SECIONO 199 Service Classification GL 3 and sufficient chemical stabil Engine Mounting Bolts 165 ft Ibs 231 Nm A R ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an Engine Manifold Mounting Bolts 30 ft Ibs 42 Nm A R SAE viscosity index of 152 Check swing bearing bolts for security after first 50 hours of operation and NOTE When temperatures remain below 20 F 7 C JLG every 600 hours thereafter See Swing Bearing in Section 3 Industries recommends the use of Mobil DTE 13M SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Aside from JLG recommendations it is not advisable to mix oils of different brands or types as they may not contain the same requi
39. 20 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F 177 C Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classifica tion GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 cpi 5 2 Grease Fittings EO Engine crankcase 01 Gas API SF SH SG class MIL L 2104 Ec MEG Diesel API CC CD class MIL L 2104B MIL L 2104C NOTICE LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON DITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD INGLY Interval Every 3 months or 150 hrs of operation Comments Remote Access 3121204 JLG Lift 6 23 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 2 Wheel Bearings 3 Swing Drive Hub gt Lube Point s Repack Lube Point s Level Fill Plug Capacity A R Capacity 17 oz 1 2 Full Lube MPG Lube EPGL Interval Every 2 years or 1200 hours of operation Interval Check level every 3 months or 150 hrs of oper ation change every 2 years or 1200 hours of operation 6 24 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 4 Wheel Drive Hub
40. 8 36 1707014 1707046 1705978 1707048 1707051 1707053 1705978 37 1704096 1704099 1705978 1704098 1706380 1704102 1705978 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 JLG Lift 4 29 SECTION 4 MACHINE OPERATION 4 30 Table 4 1 600A Decal Legend Prior to S N 0300140401 Item ANSI Portuguese Japanese Australian 0273891 9 0273895 5 0273899 9 0273901 9 0273903 10 1001114388 1 0273893 9 53 54 55 56 57 58 59 60 61 62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 67 1705351 1705429 1705910 1705905 1705426 68 1001112551 Lift 3121204 SECTION 4 MACHINE OPERATION Table 4 2 600A Decal Legend S N 0300140401 to Present Item 4 ANSI
41. 978 1001121812 1001121810 38 39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 40 1706948 1706948 1706948 1706948 1706948 41 42 43 44 45 46 47 48 49 50 51 52 53 3121204 JLG Lift 4 41 SECTION 4 MACHINE OPERATION Table 4 4 600AJ Decal Legend S N 0300140401 to Present 4 42 Item ANSI 5 Spanish Portuguese Japanese Australian Seed 4 0273892 10 0273894 9 0273896 5 0273900 10 0273902 9 0273904 11 1001114389 1 1001116842 3 1001116843 3 54 55 56 57 58 59 60 61 62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584 63 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493 64 1706941 1706941 1706941 1706941 1706941 1706941 1706941 65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862 67 1705351 1705429 1705910 1705905 1705426 1705430 1001116863 68 1001112551 JLG Lift 3121204 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of s
42. APACITY 5 GlowPlug 9 NotUsed Overload 6 Low Fuel 10 Creep Capacity 7 Engine Malfunction 11 Drive Orientation Figure 3 7 Platform Control Indicator Panel w Drive Orientation JLG Lift 3 17 SECTION 3 MACHINE CONTROLS AND INDICATORS 4 Enable Indicator Footswitch 5 To operate any function the footswitch must be depressed and the function selected within seven sec onds The enable indicator shows that the controls are enabled If a function is not selected within seven sec onds 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 Releasing the footswitch removes power from all con 7 trols and applies the drive brakes A WARNING TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS A WARNING FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 6 3 MM OF TRAVEL TOP OR BOTTOM 3 18 JLG Lift Glow Plug Indicator When illuminated the glow plugs are operating After turning on ignition wait until light goes out before crank ing engine Low Fuel Indicator Yellow Indicates the fuel tank is 1 8 full or less When the light first turns on there are approximately four usable gal lons of fuel remaining Engine Malfunction Indicator On all mach
43. Battery Proper electrolyte levels cables tight no visi ble damage or corrosion Engine Oil Supply Full mark on dipstick filler cap secure Muffler and Exhaust System See Note Hydraulic Pump See Note Engine Tray Pivot See Note 38 39 40 41 42 43 44 Hydraulic Swivel See Note LP Gas Tank If Equipped See Note Flow Valves See Note Tower Boom Upright Wear pads secure All cylinders rod end shafts and barrel end shafts properly secured Upright in vertical position If Tower Boom does not rest on stop with machine in the stowed position this indicates upright is out of plumb Frame See Note Main Boom Sections Wear pads secure All cylinders rod end shafts and barrel end shafts properly secured Platform Pivot Pin See Note Figure 2 6 Daily Walk Around Inspection Points Sheet 3 of 3 JLG Lift 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS SECTION 3 MACHINE CONTROLS AND INDICATORS 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 3 1 GENERAL THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES This section provides the necessary information needed to understand control functions 3 2 CONTROLS AND
44. D AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG 120 49 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 60 F 16 50 10 30 F 1C ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY E JSAE 10W 30 4 A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 6 20 SAE 5W 30L NO OPERATION BELOW THIS AMBIENT TEMPERATURE 20F 7C bus F 18 C 10 F 23 C 20 F 29 C C s 30 F 34 C 40 40 Figure 6 8 Engine Operating Temperature Specifications GM Sheet 1 of 2 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE HYDRAULIC OIL TANK TEMPERATURES OF 180 F 180 F 82 C 82 OR ABOVE HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS EXTENDED DRIVING WITH AMBIENT AIR THE ADDITION OF A HYDRAULIC
45. D FROM THE END OF THE VALVE BEFORE NORMAL OPERATION OF THE MACHINE CAN RESUME When this operation has been completed turn 1 2 and 4 counterclockwise 3 turns Turn 3 clockwise until tight To lower the upper boom THE LOWER BOOM MUST BE COMPLETELY LOWERED BEFORE STARTING THIS OPERATION IN ORDER TO MAINTAIN STABILITY OF THE MACHINE Turn knob 1 and 2 clockwise until tight Pump the hand pump until tight When this opera tion has been completed turn 1 and 2 counterclock wise 3 turns When the manual descent operation has been com pleted knob 1 2 and 4 should be open counter clockwise 3 turns Knob should be closed clockwise 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 1 INTRODUCTION Other Publications Available Service and Maintenance Manual ANSI Spec This ee loner ihe manual provides additional necessary Prior to s n 0300080000 3120718 information to the operator for proper operation and mainte nance of this machine Service and Maintenance Manual Euro Spec The maintenance portion of this section is intended as infor Prior to s n 0300080000 3120841 mation to assist the machine operator to perform daily main Service and Maintenance Manual Global Spec tenance tasks only and does not replace the more thorough s n
46. FF POSITION WHEN RELEASED 10 Tower Lift This switch provides raising and lowering of the tower boom This function works only when the tower boom is fully retracted telescope in 3121204 JLG Lift 3 5 SECTION 3 MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel See Figure 3 2 Ground Control Indicator Panel 1 Battery Charging 7 GlowPlug 2 Engine Oil Pressure 8 Platform Overload 3 Engine Water Temp 9 Hyd Filter Bypass 4 Engine Oil Temp 10 Transmission Filter By Pass 5 Engine Malfunction Indicator 11 Engine Air Filter By Pass 6 Low Fuel Figure 3 2 Ground Control Indicator Panel 3 6 Lift Battery Charging Indicator Indicates a problem in the battery or charging circuit and service is required Engine Oil Pressure Indicator Indicates that engine oil pressure is below normal and service is required Engine Coolant Temperature Ford and Continental Indicator Indicates that engine coolant temperature is abnormally high and service is required Engine Oil Temperature Indicator Deutz Indicates the temperature of the engine oil which also serves as engine coolant is abnormally high and ser vice is required 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS 5 Engine Malfunction Indicator Ford Engines S N 48907 to S N 64249 refer to ADE System Identifica tion page at the front of the book Indicates that the Engine Control Modu
47. H 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 and tow bar to towing vehicle 4 13 SECTION 4 MACHINE OPERATION A WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES TOWING VEHICLE MUST BE ABLE TO 4 STEER SELECT CONTROL MACHINE AT ALL TIMES ON a VALVE HIGHWAY TOWING NOT PERMITTED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH Figure 4 6 Towbar Connecting Points Prior to S N 81836 4 14 JLG Lift 3121204 SECTION 4 MACHINE OPERATION A WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH Figure 4 7 Towbar Connecting Points S N 81836 to Present 3121204 JLG Lift 4 15 SECTION 4 MACHINE OPERATION 3 Disconnect drive hubs by inverting disconnect cap 4 Actuate steer tow selector valve for towing pull valve knob OUT to float position This opens the steer circuit to reservoir allowing the steer cylinder rod free travel The machine is now in the towing mode DISCONNECT CAP After towing the machine complete the following E P 1 Actuate steer tow selector valve for
48. H3S 591 QqaialLd35 V Q31938HO9D 3AVH SNOILONNA 340253131 14 NIYIN VIA OL IWHOA31V ld SHNDIO SIHL H3AO GIOAV OL 7 3121204 JLG Lift 4 12 SECTION 4 MACHINE OPERATION 4 9 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED Refer to Section 6 5 Oscillating Axle Lockout Test If Equipped for procedure 4 10 STEER TOW SELECTOR IF EQUIPPED See Figure 4 6 A WARNING DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COM PLETE TOW PACKAGE FROM MANUFACTURER A push pull type selector valve located adjacent to the steer cylinder and linkage regulates oil flow in the steer circuit for steering and towing When steering the unit the valve knob is pushed IN When towing the unit the valve knob is pulled OUT to the float position 3121204 JLG Lift 4 11 TOWING IF EQUIPPED RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOL LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH MAXIMUM TOWING SPEED 10 M PH 16 K M H MAXIMUM TOWING GRADE 25 Prior to towing the machine complete the following A CAUTION DO NOT TOW MACHINE WIT
49. INDICATORS NOTE All machines are equipped with control panels that use symbols to indicate control functions On ANSI machines refer to decal located on the control box guard in front of the control box or by the ground controls for these sym bols and the corresponding functions o A Ss 3121204 JLG Lift Indicates a potentially hazardous situation which if not corrected could result in serious injury or death This indicator will be red Indicates an abnormal operating condition which if not corrected may result in machine interruption or damage This indicator will be yel low Indicates important information regarding the operating condition i e procedures essential for safe operation This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position 3 1 SECTION 3 MACHINE CONTROLS AND INDICATORS Ground Controls See Figure 3 1 Ground Control Station NOTE If equipped the Function Enable switch must be held down in order to operate Main Boom Telescope Tower Lift Swing Main Lift Jib Lift Platform Level Override and Platform Rotate func tions 1 Platform Rotate A three position switch permits rotation of the platform A WARNING 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 RESU
50. ION 3 MACHINE CONTROLS AND INDICATORS 12 EFI System Test Button Ford Engines S N 48907 to S N 64249 refer to ADE System Identification page at the front of the book By pushing and holding the system test button on the side of the ground control box the Diagnostic Trouble Codes will be displayed on the Malfunction Indicator Light Refer to the Service Manual for instructions con cerning the trouble codes and trouble code retrieval ENGINE MALFUNCTION INDICATOR LIGHT TEST BUTTON D Figure 3 3 Malfunction Indicator Light and Test Button 3 8 JLG Lift 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control See Figure 3 4 and Figure 3 5 1 3121204 Drive Speed Torque Select The machine has a two position switch The forward position produces maximum speed and torque by giv ing speed when the drive controller is moved The back ward position allows the machine to be driven with the engine at mid speed Steer Select If Equipped When equipped with four wheel steering the action of the steering system is operator selectable The center Switch position gives conventional front wheel steering with the rear wheels unaffected This is for normal driv ing at maximum speeds The forward position is for crab st
51. L INSPECTION OF CHASSIS UNDERSIDE CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE NOTE each item make sure there are no loose or missing parts that they are securely fastened and that no visible damage exists in addition to any other criteria men tioned 10 11 Platform Assembly Platform Assembly and Gate Footswitch works properly not modified disabled or blocked Latch stop and hinges in working condition Platform Control Console Switches and levers return to neutral and are properly secured decals placards secure and legible control marking legible Rotator See Note Rotator Motion Control Valve See Note Articulating Jib Boom See Note Dual Capacity Limit Switch Arm free to move and free from dirt and grease Power Track See Note Steer Cylinder Assembly See Note Spindle Evidence of proper lubrication See Note Drive Motor and Brake See Note Drive Hub See Note Figure 2 4 Daily Walk Around Inspection Points Sheet 1 of 3 2 12 JLG Lift 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 12 13 14 15 16 17 18 19 20 21 3121204 Wheel Tire Assembly No loose or missing lug nuts Inspect for worn tread cuts tears or other discrepan cies Inspect wheels for damage and corrosion Tie Rod and Steering Linkage 4 Wheel Steer Tie rod
52. LT IN DEATH OR SERIOUS INJURY 2 Platform Leveling Override A three position switch allows the operator to compen sate for any difference in the automatic self leveling sys tem 3 2 JLG Lift 3 Jib If Equipped This switch provides raising and lowering of the jib NOTE When Power Emergency Stop switch is in the ON posi tion and engine is not running an alarm will sound indi cating Ignition is ON A CAUTION WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY NOTE machines with diesel engines when Glow Plug Indi cator is lighted Yellow wait until light goes out before cranking engine 4 Power Emergency Stop Switch Pull out ON OFF POWER EMERGENCY STOP SWITCH to turn on engine ignition and power to the electrical system Push in to shut off engine and remove power from the controls The Ground Control Emergency Stop Switch must be pulled out to operate the machine from either Ground Control or Platform Control This allows the machine to be shut down in emergency situations by those untrained in the operation of the lift but who rec ognize the Emergency Stop Switch The keyed Master Switch can also be used for the same purpose 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS
53. MACHINE OPERATION MAIN BOOM FULLY RETRACTED LEVEL SURFACE DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE OR IF TOWER BOOM UPRIGHT IS PLACED BEYOND THIS POSITION 1 5 e 76 20 MACHINE WILL OVER IN THIS UPRIGHT Figure 4 2 Position of Least Backward Stability 3121204 4 4 TRAVELING DRIVING DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE BE SURE THE TURNTABLE LOCK I ENGAGED BEFORE ANY EXTENDED TRAVELING DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED BEFORE DRIVING MAKE SURE BOOM 15 POSITIONED OVER REAR DRIVE AXLE IF IS OVER FRONT WHEELS STEER AND DRIVE CONTROLS WILL BE REVERSED JLG Lift 4 5 SECTION 4 MACHINE OPERATION Traveling Forward and Reverse 4 6 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 platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer in the oppos
54. N DUE EM 6 11 4 1 600A Decal Legend Prior to S N 0300140401 4 27 6 19 Critical Stability Weights IA A CERCA TRE NOE 6 12 4 2 600 Decal Legend S N 0300140401 to Present4 31 6 20 Lubrication 6 23 4 3 600 Decal Legend Prior to S N 0300140401 4 35 6 21 Wheel Torque Chart fee e e ee eee 6 35 4 4 600AJ Decal Legend S N 0300140401 7 1 Inspection and Repair Log 7 1 to Present eO Ree peces 4 39 6 1 Operating Specifications Prior to S N 0300140401 6 2 6 2 Operating Specifications S N 0300140401 to PreSeNtir ici Pee peas 6 3 6 3 6 4 6 4 Continental TMD27 Specifications 6 4 6 5 Ford LRG 423 Specifications 6 5 6 6 Ford LRG 425 6 5 6 7 Deutz F4M1011F F4M2011 Specifications 6 6 6 8 Deutz D2011L04 Specifications 6 6 6 9 Caterpillar 3044 3 4 6 7 6 10 GM D ees edes a 6 7 6 11 Tire Specifications 6 8 6 12 Dimensional 6 8 6 13 Torque 6 9 6 14 Hydraulic Oil 5 6 9 3121204 JLG Lift TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE This page left blank intentional
55. NCE Table 6 7 Deutz FAM1011F F4M2011 Specifications Table 6 8 Deutz 02011104 Specifications Fuel Diesel Oil Capacity Cooling System 5 Quarts 4 51 Crankcase w Filter 11 Quarts 10 51 Total Capacity 16 Quarts 151 Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 60 Amp belt drive Battery 950 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC Fuel Consumption Fuel Diesel Oil Capacity Cooling System 5 Quarts 4 5 L Crankcase 11 Quarts 10 5 L w Filter Total Capacity 16 Quarts 151 Idle RPM 1000 Low RPM 1800 High RPM 2500 Alternator 60 Amp belt drive Battery 950 Cold Cranking Amps 205 Minutes Reserve Capacity 12 VDC Low RPM 1 90 7 19 Iph High RPM 2 50 GPH 9 46 Iph Horsepower 65 Fuel Consumption 6 6 Low RPM 1 90 7 19 Iph High RPM 2 50 GPH 9 46 Iph Horsepower 49 3121204 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 9 Caterpillar 3044C 3 4 Table 6 10 GM 3 0L Type Four Stroke Cycle Fuel Gasoline or Gasoline LP Gas Cylinders 4in line Vo of Cylinders 4 Bore 3 70 inch 94 mm BHP Stroke 4 72 inch 120 mm Gasoline 83hp 3000 rpm Aspiration turbocharged fd Tp 3000 rpm Bore 4 0 in 101 6 mm Compression ratio 19 1
56. NG pe xi ing A Rams dont 4 6 PLATFORM he dee ei aA 4 6 Platform Level Adjustment 4 6 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE Platform 4 6 4 16 TIE DOWN AND 4 20 4 7 BOOM REA CER na 4 8 Swinging the 4 8 SECTION 5 EMERGENCY PROCEDURES Raising and Lowering the Tower Boom 4 9 54 GENERALE 5 1 Raising and Lowering the Main Boom 4 10 5 2 INCIDENT 5 1 Telescoping the Main 4 10 5 8 EMERGENCY 5 1 4 8 5 4 10 Operator Unable to Control Machine 5 1 49 OSCILLATING AXLE LOCKOUT TEST Platform or Boom Caught Overhead 5 2 IF EQUIPPED 214 5 4 EMERGENCY TOWING PROCEDURES 5 2 4 10 STEER TOW SELECTOR IF EQUIPPED 4 13 5 5 MANUAL DESCENT MACHINES PRIOR TO S N 4 11 TOWING IF 4 13 UE 5 2 4 12 AUXILIARY NON EQUIPPED MA RS 4 17 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR Activating from the Platform Control Station 4 17 MAINTENANCE Activating from the Ground Control Station 4 17 61 INTRODUCTION 6 1 AtS PO
57. NSIBILITIES MACHINE PREPA RATION AND INSPECTION 21 PERSONNEL TRAINING 2 1 Operator 0 2 1 Training 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function 2 5 3121204 SECTION PARAGRAPH SUBJECT PAGE 2 3 LIMIT SWITCH FUNCTIONAL CHECK 2 5 Gerieralis ire eie emet aes 2 12 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERALE aeta 3 1 3 2 CONTROLS AND INDICATORS 3 1 Ground 3 2 Ground Control Indicator Panel 3 6 Platform Control 3 9 Platform Control Indicator Panel 3 15 SECTION 4 MACHINE OPERATION 4 1 4 2 4 8 4 4 4 5 JLG Lift 4 1 OPERATING CHARACTERISTICS AND LIMITATIONS 4 1 Capacities 4 1 Stability ben eee bras 4 2 ENGINE 4 2 Starting Procedure 4 2 Shutdown Procedure 4 3 TRAVELING 4 5 Traveling Forward and Reverse 4 6 STEERI
58. ON IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE A RED BACKGROUND A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND b JLG Lift CAUTION INDICATES 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 3121204 FOREWORD A WARNING THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE TINS CONTACT JLG INDUSTRIES INC OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT NOTICE JLG INDUSTRIES INC SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE CONTACT JLG INDUSTRIES INC TO ENSURE THAT THE CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE NOTICE JLG INDUSTRIES INC MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT 3121204 For Accident Reporting Standards and Regulations Product Safety Publica Compliance Information tions Questions Regarding Spe Current Owner Updates cial Product Applications Questions Regarding Prod Quesiione
59. Regarding uct Modifications Product Safety Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 or Your Local JLG Office See addresses on inside of manual cover In USA Toll Free 877 JLG SAFE 877 554 7233 Outside USA Phone 240 420 2661 Fax 301 745 3713 E mail ProductSafety JLG com JLG Lift FOREWORD REVISION LOG Original Issue April 1 2005 Revised October 6 2005 Revised February 27 2006 Revised May 8 2006 Revised February 22 2008 Revised January 1 2009 Revised September 17 2009 Revised November 25 2009 Revised July 22 2010 Revised August 25 2010 JLG Lift 3121204 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION 1 SAFETY PRECAUTIONS 1 41 GENERAL n ERES endis Rhe og n Ad 1 1 12 1 Operator Training and Knowledge 1 1 Workplace 1 2 Machine Inspection 1 2 1 3 OPERATION erm eR EDI 1 3 General eset teas as 1 3 Trip Fall 1 3 Electrocution Hazards 1 4 Tipping 1 6 Crushing and Collision Hazards 1 7 1 4 TOWING LIFTING AND HAULING 1 8 1 5 ADDITIONAL HAZARDS SAFETY 1 9 SECTION 2 USER RESPO
60. TION AND INSPECTION WARNING TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE 00 FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE Check hydraulic boom sequence cam valves Raise extend retract and lower tower boom Check for smooth and proper operation NOTE Perform checks from ground controls first then from plat 2 6 form controls Operate machine from ground control Move TOWER TELESCOPE to out position Tower should not telescope with TOWER BOOM less than fully elevated up Must be approximately 13 degrees from vertical to move TOWER TELESCOPE out Move TOWER BOOM to up position and hold until the TOWER BOOM is completely elevated Move TOWER TELESCOPE to out position and hold until the TOWER BOOM is fully extended With TOWER BOOM completely extended place TOWER LIFT in down position Tower boom should not LIFT down unless the TOWER BOOM is fully retracted 6 Place TOWER TELESCOPE to in position and fully retract the TOWER BOOM Place TOWER BOOM to down and fully lower the TOWER BOOM Upright in vertical position If Tower Boom does not rest on stop with machine in the stowed position this indicates upright is out of plumb See Section 4 Boom Synchro nizing Procedure in Service Manual A WARNING TO AVOID TIPPING OVER DO NOT USE MACHINE IF TOWER BOOM SWITCHING IS OUT OF SEQUENCE NOTE 7
61. TION 1 SAFETY PRECAUTIONS 1 5 ADDITIONAL HAZARDS SAFETY Do not refuel the machine with the engine running Do not use machine as a ground for welding Battery fluid is highly corrosive Avoid contact with skin and clothing at all times When performing welding or metal cutting operations Charge batteries only in a well ventilated area precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter 3121204 JLG Lift 1 9 SECTION 1 SAFETY PRECAUTIONS NOTICE DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH 12 5 M S Table 1 2 Beaufort Scale For Reference Only 1 Description Land Conditions 0 0 0 0 2 Calm Calm Smoke rises vertically 1 1 3 0 3 1 5 Lightair Wind motion visible in smoke 2 4 7 1 6 3 3 Light breeze Wind felt on exposed skin Leaves rustle 3 8 12 3 4 5 4 Gentle breeze Leaves and smaller twigs in constant motion 4 13 18 5 5 7 9 Moderate breeze Dust and loose paper raised Small branches begin to move 5 19 24 8 0 10 7 Fresh breeze Smaller trees sway 6 25 31 10 8 13 8 Strong breeze Large branches in motion Whistling heard in overhead wires Umbrella use becomes difficult 7 32 38 13 9 17 1 NearGale Moderate Gale Whole trees in motion Effort needed to walk againstthe wind 8 39 46 17 2 20 7 Fresh Gale Twigs broken from trees Cars veer on road 9 47 54
62. WER ADREQUIPPED aaa 62 OPERATING SPEGIFIGATIONS 62 Activating from the Platform Control Station 4 18 Activating from the Ground Control Station 4 18 T eee hte yee ae 6 8 4 14 DUAL FUEL SYSTEM GAS ENGINE ONLY 4 19 Dimensional Data 6 8 Changing From Gasoline to LP 4 19 Torque Re Due A qa criam aT ee ee a 6 9 Changing From LP Gas to Gasoline 4 19 H e oi VOX DS RD MEE 6 9 4 15 RE SYNCHRONIZE THE LOWER LIFT CYLINDER4 19 Stability Weights 6 12 FIS Serial Number Locations 6 12 ii JLG Lift 3121204 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT 6 3 OPERATOR MAINTENANCE 6 4 TIRES amp WHEELS Tire Replacement Wheel Replacement Wheel Installation OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED DRAINING OIL BUILD UP FROM THE PROPANE REG ULATOR PRIOR TO S N 0300132529 PROPANE FUEL FILTER REPLACEMENT PROPANE FUEL SYSTEM PRESSURE RELIEF 6 40 SUPPLEMENTAL INFORMATION SECTION 7 INSPECTION AND REPAIR LOG SECTION PARAGRAPH SUBJECT PAGE LIST OF FIGURES 2 1 Machine Nomenclature 600 2 9 2 2 Machine Nomenclature 600 2 10 2 8 Daily Walk Around Inspection Diagram 2 11 2 4 Daily Walk Around Inspection Points Sheet 1 08 ea D eruere 2 12 2 5 Daily Walk Around Inspection Points Sheet Of 3 525 pde ha oec d N 2 13 2 6 Daily W
63. Y PRECAUTIONS Read understand and obey all DANGERS WARNINGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by JLG All operating personnel must be familiar with the emer controls and emergency operation of the machine as specified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all haz ards in the work area prior to machine operation Do not operate or raise the platform while on trucks trail ers railway cars floating vessels scaffolds or other equip ment unless approved in writing by JLG Do not operate the machine in hazardous environments unless approved for that purpose by JLG Besure that the ground conditions are able to support the maximum load shown on the decals located on the machine JLG Lift This machine can be operated in temperatures of 0 F to 104 F 20 C to 40 C Consult JLG for operation out side this range Machine Inspection Before machine operation perform inspections and func tional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in
64. ability WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels The proper procedure for attaching wheels is as follows 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 3121204 JLG Lift 6 33 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 2 Tighten nuts in the following sequence 9 LUG PATTERN 8 LUG PATTERN 3 The tightening of the nuts should be done in stages Fol lowing the recommended sequence tighten nuts per wheel torque chart 6 34 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 21 Wheel Torque Chart TORQUE SEQUENCE 1stStage 2nd Stage 3rd Stage 40 ft Ibs 95 ft Ibs 170 ft Ibs 55 Nm 130 Nm 230 Nm 6 5 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM 4 Wheel nuts should be torqued before first road use and OPERATION IS SUSPECTED 3121204 after each wheel removal Check and torq
65. alk Around Inspection Points Sheet SiO Gc ssec cb b RES 2 14 3 1 Ground Control 3 3 3 2 Ground Control Indicator Panel 3 6 3 8 Malfunction Indicator Light and Test Button 3 8 3 4 Platform Control 3 10 3 5 Platform Control Console w Drive Orientation 3 11 3 6 Platform Control Indicator Panel 3 16 3 7 Platform Control Indicator Panel w Drive 3 17 4 1 Position of Least Forward Stability 4 4 4 2 Position of Least Backward Stability 4 5 4 3 Grade 4 7 4 4 Upright Positioning Sheet 1 2 4 11 4 5 Boom Upright Positioning Sheet 2 of2 4 12 4 6 Towbar Connecting Points Prior to S N 81836 4 14 4 7 Towbar Connecting Points S N 81836 to TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT Present ee Exo EE Lope de ies 4 15 4 8 Drive Disconnect 4 16 4 9 Machine Tie 4 21 4 10 Lifting 4 22 4 11 600A amp 600AJ Decal Installation Sheet 1 of 4 4 23 4 12 600A amp 600AJ Decal Installation Sheet 2 of 4 4 24 4 13 600A amp 600AJ Decal Installation Sheet 3 of 4 4 25 4 14 600A amp 600AJ Decal Installation Sheet
66. ant to monitor the CHASSIS OUT OF LEVEL indicator light on the platform control console manually activate the indicator light by com pressing any one of the three tilt indicator mounting springs If the light does not illuminate shut down machine and contact a qualified service technician before continuing operation JLG Lift NOTE Step 12 is applicable for machines with an internal tilt sen Sor 12 Check the chassis out of level indicator located on the platform 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 surface shut down the machine and contact a qualified technician before resuming operation 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Platform Platform Control Box Rotator Articulating Jib Fly Boom Base Boom Main Boom Assembly Telescope Cylinder Inside Upright Hy Boom BaseBoom LowerLift Cylinder Ground Control Box Steer Wheels Frame Drive Wheels Swing Bearing Turntable Tower Telescope Cylinder Inside Boom Assembly Upright Level Cylinder Main Lift Cylinder Slave Level Cylinder Articulating Fly Lift Cylinder Footswitch
67. arra Road Port Macquarie N S W 2444 Australia c 461265811111 61265810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England fc 44 0 161 654 1000 44 0 161 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France f 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany fc 49 0 421 69 350 20 49 0 421 69 350 45 A 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 39029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 65 6591 9030 JLG Polska UI Krolewska 00 060 Warsawa Poland 48 0 914 320 245 48 0 914 358 200 A JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 44 0 141 773 1907
68. ated posi Approved head gear must be worn by all operating and tion unless the machine is on firm level and smooth sur ground personnel faces Check work area for clearances overhead on sides and Keep the chassis of the machine at least 2 ft 0 6m from bottom of platform when lifting or lowering platform and holes bumps drop offs obstructions debris concealed driving holes and other potential hazards on the floor surface Do not push or pull any object with the boom Never attempt to use the machine as a crane Do not tie off machine to any adjacent structure Do not operate the machine when wind conditions exceed 28 mph 12 5 m s Refer to Table 1 2 Beaufort Scale For Reference Only Do not increase the surface area of the platform or the load Increase of the area exposed to the wind will decrease stability Do not increase the platform size with unauthorized deck or attachments During operation keep all body parts inside platform rail ing 3121204 JLG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS Use the boom functions not the drive function to position the platform close to obstacles Always post a lookout when driving in areas where vision is obstructed Keep non operating personnel at least 6 ft 1 8m away from machine during all driving and swing operations Limit travel speed according to conditions of ground sur face congestion visibility slope
69. c Check auxiliary power or manual descent d Ensure that all machine functions 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 Operate all functions and check all limiting and cut out switches d Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in 3 With the platform in the transport stowed position 3121204 JLG Lift a Drive the machine on a grade not to exceed the rated gradeability and stop to ensure the brakes hold b Check the tilt sensor alarm to ensure proper opera tion 2 3 LIMIT SWITCH FUNCTIONAL CHECK TO AVOID MACHINE UPSET DO NOT USE MACHINE IF TOWER BOOM SWITCHING IS OUT OF SEQUENCE IF THE TOWER BOOM LIFTS DOWN WITH THE TOWER BOOM TELE SCOPED OUT SHUT DOWN MACHINE AND CONTACT A CERTIFIED JLG TECHNICIAN IF THE TOWER TELESCOPES WITH THE TOWER BOOM LESS THAN FULLY ELEVATED UP SHUT DOWN MACHINE AND CONTACT QUALIFIED JLG TECHNICIAN TO AVOID UPSET IF TOWER SWITCHING MALFUNCTIONS LOWER THE PLATFORM TO GROUND VIA MAIN BOOM LIFT AND TELESCOPE FUNCTIONS HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH NICIAN BEFORE CONTINUING USE OF MACHINE 2 5 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARA
70. d Sideslope JLG Lift 4 7 SECTION 4 MACHINE OPERATION 47 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 RAISING BOOM TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE MENT DOES NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE 00 FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE 4 8 JLG Lift Swinging the Boom To swing boom use SWING control switch to select RIGHT or LEFT direction NOTICE WHEN SWINGING THE MAKE SURE THERE IS AMPLE ROOM FOR THE TO CLEAR SURROUNDING WALLS PARTITIONS AND EQUIP MENT NOTE When boom functions are being operated there an inter lock prevents the use of DRIVE and STEER functions 3121204 SECTION 4 MACHINE OPERATION Raising and Lowering the Tower Boom This machine will have two controls for the tower boom two toggle switches one controls tower lift the other tower tele scope The switching system will sequence its LIFT and TELESCOPE functions as follows 1 Sequence while RAISING the TOWER BOOM from the fully lowered position a The TOWER BOOM must be fu
71. eering When in this mode both front and rear axles steer in the same direction which allows the chas sis to move sideways as it goes forward This can be used for positioning the machine in aisle ways or against buildings The back switch position is for coordinated steering In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas To re synchronize the front and rear axles position the rear drive wheels to the forward drive position by select ing either crab or compound steer then select front steer center switch position to operate the normal steering function A WARNING 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 3 Platform Leveling Override This switch allows the operator to adjust the level of the platform 4 Horn Supplies electrical power to the horn when pressed 5 Power Emergency Stop An ON OFF POWER EMERGENCY STOP switch and a separate ENGINE START AUXILIARY POWER toggle switch on the platform console supply electrical power to the starter solenoid when the ignition switch is placed in the ON position and the ENGINE START switch is push forward JLG Lift 3 9 SECTION 3 MACHINE CONTROLS AND INDICATORS
72. ejepdn 597r uio siu esn eseajd 51 uormeoinou 9J9uM 59522 ui SIY sesn pue 19npoud 10 HTP 51 jo diusieuwo 1uaJuno YUM dee juej0duii 1 4 sunoejnq esodand ay 104 no OUM pJnOM s1y Aq onpoud jo Jeseuound LON 1nq umo nof j 49UMQ 1 OL Kueduio uone1od102 usoxuso dIHSH3NMO 30 H33SNVHL The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm 1702961 PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 El 717 485 6417 JLG Worldwide Locations 3121204 JLG Industries Australia P O Box 5119 11 Bolw
73. end studs locked Turntable Lock Operable Auxiliary Power Pump See Note Control Valve Tank Compartment See Note Turntable Bearing and Pinion No evidence of loose bolts or looseness between bearing and structure Hydraulic Oil Medium Pressure Filter Housing Hous ing secure Hydraulic Oil Return Filter Housing Housing secure Manual Descent See Note LP Gas Tank If Equipped See Note 22 23 24 25 26 27 28 Hydraulic Oil Supply Recommended oil level sight gauge Check level with cold oil systems shut down machine in stowed position Cap in place and secure Hydraulic Oil Breather Element in place not clogged no sign of overflow Ground Controls Switches operable decals secure and legible Fuel Supply Fuel filler cap secure Tank See Note Swing Drive Motor and Brake See Note Door and Latches Hood door and latches in working condition Oscillating Cam Valve If Equipped See Note Figure 2 5 Daily Walk Around Inspection Points Sheet 2 of 3 JLG Lift 2 13 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 14 29 30 31 32 33 34 35 36 37 Oscillating Axle Cylinder If Equipped See Note Dual Capacity and Horizontal Cutout Limit Switch No damage to the switch arm free to move and free from dirt and grease Oscillating Axle If Equipped See Note Engine Air Filter Element clean
74. f the platform or boom becomes jammed or snagged in overhead structures or equipment rescue platform occu pants prior to freeing the machine 54 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited unless properly equipped However provisions for moving the machine have been incorporated For specific procedures refer to Section 4 5 5 MANUAL DESCENT MACHINES PRIOR TO S N 70975 The manual descent valves are used in the event of total power failure to retract and lower the boom using gravity The manual descent valves are located on the right side of the turntable in tank compartment Look for the instruction decal located on the right side of turntable below control valve The procedure is as follows 1 To retract the lower boom telescope function turn knob 4 1 and knob 4 clockwise until tight Pump the hand pump until tight When this operation has been com pleted turn 1 and 4 counterclockwise 3 turns 5 2 JLG Lift To retract the lower boom turn knob 1 2 and 4 clockwise until tight Turn knob 3 counterclockwise 3 turns Locate a knurled head screw attached to a wire cable on the right side of the main valve bank assembly Thread this into the end of the coil assembly that it is attached to Pump the hand pump until the lower boom is completely lowered When this operation is complete remove the knurled head screw from the end of the valve coil THE KNURLED HEAD SCREW MUST BE REMOVE
75. gure 4 12 600A amp 600AJ Decal Installation Sheet 2 of 4 4 24 JLG Lift 3121204 SECTION 4 MACHINE OPERATION ALTERNATE LOCATION 12 Figure 4 13 600A amp 600AJ Decal Installation Sheet 3 of 4 3121204 JLG Lift 4 25 SECTION 4 MACHINE OPERATION Figure 4 14 600A amp 600AJ Decal Installation Sheet 4 of 4 4 26 JLG Lift 3121204 SECTION 4 MACHINE OPERATION Table 4 1 600A Decal Legend Prior to S N 0300140401 Canadian Item ANSI French CE Spanish Portuguese Japanese Australian 0273891 9 0273895 5 0273899 9 0273901 9 0273903 10 1001114388 1 0273893 9 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 7 8 9 n us 10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 13 1704412 1704412 1704412 1704412 1704412 1704412
76. h the ENGINE START switch until engine starts A CAUTION ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 3121204 SECTION 4 MACHINE OPERATION 2 After engine has had sufficient time to warm up shut Shutdown Procedure engine off Turn SELECT switch to PLATFORM A CAUTION 4 From Platform pull POWER EMERGENCY STOP switch IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN out then push the ENGINE START switch until engine DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE starts ENGINE NOTE Footswitch must be in released up position before 1 starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE Remove all load and allow engine to operate at low speed for 3 5 minutes this allows further reduction of internal engine temperature 2 Push POWER EMERGENCY STOP switch in 3 MASTER switch to Off Refer to Engine Manufacturer s manual for detailed informa tion 3121204 JLG Lift 4 3 SECTION 4 MACHINE OPERATION MAIN BOOM LEVEL AND FULLY EXTENDED xy MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE 13 DEGREES FROM VERTICAL TOWER BOOM FULLY ELEVATED AND FULLY RETRACTED LEVEL SURFACE Figure 4 1 Position of Least Forward Stability 4 4 JLG Lift 3121204 SECTION 4
77. icator 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 selected This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct 3 19 SECTION 3 MACHINE CONTROLS AND INDICATORS LS NOTES 3 20 JLG Lift 3121204 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION 4 2 OPERATING CHARACTERISTICS AND This machine is a self propelled hydraulic lift equipped with a LIMITATIONS work platform on the end of an elevating articulating and 22 rotating boom Capacities The primary operator control station is in the platform From this control station the operator can drive and steer the machine in both forward and reverse directions The opera tor can raise or lower the upper or lower boom or swing the 1 Machine is positioned on a smooth firm and level sur boom to the left or right Standard boom swing is 360 con face tinuous 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 plat form to the ground should the operator in the platform be unable to do so The Grou
78. il change Lube Point s Fill Cap Spin on Element Capacity 4 5 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 3121204 JLG Lift 6 27 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 28 11 12 Oil Change w Filter De Oil Change w Filter Continental 13 Lube Point s Fill Cap Spin on Element Capacity 6 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual utz 4 lt Lube Point s Fill Cap Spin on Element Capacity 11 Quarts Crankcase 5 Quarts Cooler Lube EO Interval Every Year or 1200 hours of operation Comments Check oil level fill oil to max marking on the dipstick Check level daily Change in accordance with engine manual JLG Lift Oil Change w Filter Caterpillar Lube Point s Fill Cap Spin on Element Capacity 10 6 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 15 FuelFilter Ford 7 e Lube Point s Fill Cap Spin on Element Lube Point s Replaceable Element JLG P N 7027965 Interval Every Year or 1200 hours of operation Capacity 4 5 qt 4 25 L w filter Lube EO 16 FuelFilte
79. ines prior to S N 48907 and machines with a Deutz engine prior to S N 64249 the light turns on and an alarm sounds when machine s power system requires immediate service Any of the following condi tions will turn on light and alarm low engine oil pres sure high engine coolant temperature clogged engine air filter low alternator output clogged hydraulic oil return filter or clogged charge pump filter On machines with Ford engines from S N 48907 and machines with Deutz engines after S N 64249 the light indicates that the Engine Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory Refer to the Service Manual for instructions concerning the trouble codes and trou 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS ble code retrieval 9 The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test 8 AC Generator Green 10 Indicates the generator is in operation 11 3121204 JLG Lift Soft Touch Indicator If Equipped Indicates the Soft Touch bumper is against an object controls are cut out until the override button is pushed at which time controls are active in the Creep mode Creep Speed Indicator When the Function Speed Control is turned to the creep position the indicator acts as a reminder that all func tions are set to the slowest speed Drive Orientation Ind
80. ing of the tower boom TOWER TELESCOPE must be fuly RETRACTED before operating TOWER LIFT TOWER TELESCOPE should not function when TOWER LIFT is not fully elevated UP 13 Tower Lift This three position switch provides for raising and lower ing of the tower boom TOWER LIFT must be fully ele vated UP before operating TOWER TELESCOPE TOWER LIFT should not function when TOWER TELE SCOPE is extended NOTE MAIN LIFT SWING and DRIVE control levers are spring loaded and will automatically return to neutral OFF posi tion when released A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED A WARNING TO AVOID TIPPING OVER AND SERIOUS INJURY DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER PRESCRIBED IN 12 AND 13 ABOVE Lift 3 13 SECTION 3 MACHINE CONTROLS AND INDICATORS 14 Platform Rotate This switch allows the operator to rotate the basket to the left or right A CAUTION DO NOT OPERATE MACHINE IF DRIVE SPEED TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORI ZONTAL 15 16 3 14 Function Speed Control Controls the speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed To adjust to creep turn knob fully CCW until it clicks Main Lift Swing Con
81. ite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both plat form control panel and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direction of machine travel The indicator light will flash during the 3 second interval until the drive function is selected 4 5 STEERING Position thumb switch on Drive Steer controller to RIGHT for steering right or to LEFT for steering left 4 6 PLATFORM Platform Level Adjustment To Level Up or Down Position the Platform Level control switch Up or Down and hold until the platform is level A WARNING 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 Platform Rotation To rotate the platform to the left or right use the Platform Rotate control switch to select the direction and hold until desired position is reached JLG Lift 3121204 SECTION 4 MACHINE OPERATION DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLACARD DO NOT DRIVE ON SIDESLOPES EXCEEDING 5 8 7596 3121204 Figure 4 3 Grade an
82. ius outside 2WS AWS 17 ft 8in 5 38 11 ft 8in 3 56 Turning Radius outside narrow chassis 2WS 16 ft 5 03 Gross Machine Weight Approximate 600A 600AJ 600A narrow chassis 6004 narrow chassis 21 500 bs 9 752 kg 22 200 Ibs 10 025 kg 23 900 Ibs 10 841 kg 24 000 Ibs 10 886 kg 4WS 11 ft 2in 3 4m Turning Radius inside 2WS 11 ft 5in 3 48 AWS 5 ft 1 68 Turning Radius inside narrow chassis 2WS 4WS 12ft 2in 3 71 5 ft 7in 1 7m 3121204 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Capacities Engine Data Table 6 3 Capacities Table 6 4 Continental TMD27 Specifications Fuel Tank 30 U S Gallons 113 61 Fuel Diesel Hydraulic Oil Tank 30 6 Gallons 115 8 L with 1096 air Oil Capacity space w Filter 7 00 Quarts 6 65 w o Filter 6 00 Quarts 5 7 Hydraulic System Including Tank 36 72 Gallons 1391 Low RPM 1800 Torque Hub Drive 17 ounces 0 50 L High RPM 2800 Engine Crankcase Ford LRG 425 Gas w Filter 4 5 quarts 4 251 Alternator 63 Amps Belt Drive Ford LRG 423 Gas w Filter 5 0 quarts 4 73 L Batter Amph Id Cranki DeutzF4M1011F Diesel w Filter 11 quarts 10 5L ee Nes Deutz FAM201 1F Diesel w Filter 11 quarts 10 5L Deutz D2011L04 11 quarts 10 5L Fuel
83. l for cleanliness and legibility Make sure none of the decals and placards are missing Make sure all illegible decals and placards are cleaned or replaced Operators and Safety Manuals Make sure a copy of the Operator and Safety Manual EMI Safety Manual Domestic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 3 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines Add the proper fuel as necessary 8 Hydraulic Oil Check the hydraulic oil level Ensure hydraulic oil is added as required 9 Function Check Once the Walk Around Inspection is complete perform a functional check of all systems in an area free of overhead and ground level obstructions Refer to Section 4 for more specific instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDIATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION JLG Lift 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Function Check Perform the Function Check as follows 1 From the ground control panel with no load in the plat form a Check that all guards protecting the switches or locks are in place b Operate all functions and check all limiting and cut out switches
84. le has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test Low Fuel Level Indicator Indicates that the fuel level is 1 8 full or less When the light first turns on there are approximately four usable gallons of fuel remaining Glow Plug Indicator Diesel Indicates glow plugs are on The glow plugs are auto matically turned on with the ignition circuit and remain on for approximately about seven seconds Start the engine only after the light goes out JLG Lift 8 10 11 Platform Overload If equipped Indicates the platform has been overloaded Hydraulic Oil Filter Indicator Prior to S N 84829 Indicates the return oil filter is too restrictive and needs to be replaced Transmission Pump Oil Filter Indicator Prior to S N 84829 Indicates that charge pump filter is too restrictive and needs to be replaced This indicator has an integral tem perature sensor 70 degrees so that false signals are not generated when the hydraulic oil is below normal operating temperature Engine Air Filter Indicator Prior to S N 84829 Indicates that the air filter is too restrictive and needs to be replaced SECT
85. lease or rental delivery Owner Dealer or User Qualified JLG Service and Maintenance See Note Mechanic Manual and applicable JLG inspection form Frequent Inspection In service for months or 150 hours whichever Owner Dealer orUser Qualified JLG Service and Maintenance comes first Mechanic Manual and applicable JLG or inspection form Out of service for a period of more than 3 months or Purchased used Annual Machine Annually no later than 13 months fromthe date Owner Dealer or User Factory Qualified Service and Maintenance Inspection of prior inspection Service Technician Manual and applicable JLG inspection form Preventative Atintervals as specified in the Service and Main Owner Dealer or User Qualified JLG Service and Maintenance Maintenance tenance Manual Mechanic Manual NOTE Inspection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 3121204 Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Pre Start Inspection The Pre Start Inspection should include each of the follow ing 1 3 2 4 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel Structure Inspect the machine structure for dents damage weld or parent metal cracks or other discrep ancies Weld Crack Decals and Placards Check al
86. lected control switch lever or controller and footswitch Position POWER EMERGENCY STOP switch to OFF Activating from the Ground Control Station 1 Lift Position PLATFORM GROUND SELECT KEY SWITCH to GROUND Position POWER EMERGENCY STOP switch to ON Operate appropriate control switch or controller for desired function and hold Position AUXILIARY POWER switch to ON and hold Release AUXILIARY POWER switch and appropriate control switch or controller Position POWER EMERGENCY STOP switch to OFF SECTION 4 MACHINE OPERATION 4 13 AUXILIARY POWER ADE EQUIPPED MACHINES A CAUTION WHEN OPERATING ON AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE 12 VOLT AUXILIARY PUMP MOTOR A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electri cally driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump will operate boom lift telescope and swing To activate auxil iary power Activating from the Platform Control Station 1 4 18 Position PLATFORM GROUND SELECT KEY SWITCH to PLATFORM Position POWER EMERGENCY STOP switch to ON Depress and hold footswitch Position AUXILIARY POWER switch to ON and hold 7 Operate appropriate control switch
87. lly elevated approximately 13 degrees from vertical before the TOWER BOOM can be extended from the fully retracted position b The TOWER TELESCOPE out or in will only be operable when the TOWER BOOM is fully elevated up 2 Sequence while LOWERING the TOWER BOOM from the fully elevated up position a Operate TOWER TELESCOPE in until TOWER BOOM is fully retracted TOWER must not lift down until boom is telescoped in or up fully b The TOWER lift down will only operate when the TOWER BOOM is fully retracted 3121204 JLG Lift A WARNING TO AVOID TILTING MACHINE IF TOWER BOOM SWITCHING MALFUNC TIONS LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELE SCOPE FUNCTIONS HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH NICIAN BEFORE CONTINUING USE OF MACHINE SECTION 4 MACHINE OPERATION Raising and Lowering the Main Boom 4 8 SHUT DOWN AND PARK To raise and lower Main Boom position MAIN LIFT control switch or controller to UP OR DOWN and hold until desired 2 height is reached Telescoping the Main Boom To extend or retract Main Boom position MAIN TELESCOPE control switch to IN or OUT and hold until platform reaches desired position 4 4 10 JLG Lift Drive machine to a protected area Assure main boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured
88. location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stop ping Travel grades in low speed only Do not use high speed drive in restricted or close quarters or when driving in reverse Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and per sons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised boom or platform Position barricades on floor if neces sary JLG Lift 1 4 TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to the Emergency Procedures section of this manual for emergency towing procedures Ensure boom is in the stowed position and the turntable locked prior to towing lifting or hauling The platform must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift the unit with equipment of adequate capac ity Refer to the Machine Operation section of this manual for lifting information 3121204 SEC
89. lope and the boom is above horizontal If lit when boom is raised or extended retract and lower to below hori zontal then reposition machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated A WARNING IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL 3121204 JLG Lift 2 Platform Overload If equipped Indicates the platform has been overloaded Capacity Indicator Indicates the maximum platform capacity for the current position of the platform Restricted capacities are permit ted at restricted platform positions shorter boom lengths and higher boom angles NOTE Refer to the capacity decals on the machine for restricted and unrestricted platform capacities 3 15 SECTION 3 MACHINE CONTROLS AND INDICATORS 1 Tilt 5 Glow Plug 9 SoftTouch 2 Overload 6 Low Fuel 10 Creep 3 Capacity 7 Engine Malfunction 4 Enable 8 AC Generator Figure 3 6 Platform Control Indicator Panel 3 16 JLG Lift 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS 3121204 1 Tilt 2 3 4 Enable 8 AC Generator UNRESTRICTED CAPACITY RESTRICTED C
90. ly vi JLG Lift 3121204 SECTION 1 SAFETY PRECAUTIONS 1 1 SECTION 1 SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and safe machine operation and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A maintenance program using the information provided in this manual and the Service and Maintenance Manual must also be estab lished by a qualified person and followed to ensure the machine is safe to operate The owner user operator lessor lessee of the machine should not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc ULG A WARNING FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROPERTY DAM AGE PERSONAL INJURY OR DEATH 3121204 JLG Lift 1 2 PRE OPERATION Operator Training and Knowledge Read and understand this manual before operating the machine Do not operate this machine until complete training is per formed by authorized persons Only authorized and qualified personnel can operate the machine 1 1 SECTION 1 SAFET
91. n switch OFF 7 Install the filter up to the bottom of the electric lock off A CAUTION niter Nm RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS 9 Open manual shut off valve Start the vehicle and leak TEM ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS check the propane fuel system at each serviced fitting CONNECTING ANY FUEL LINE Refer to Propane Fuel System Leak Test 6 40 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 9 SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006 42 EC and is only applicable to CE machines For electric powered machines the equivalent continuous A Weighted sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound 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 subjected does not exceed 2 5 m s The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s 3121204 JLG Lift 6 41 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE ex NOTES
92. nd Control is also to be used in Pre Start Inspection The boom can be raised above horizontal with or without any load in platform if Load is within manufacturer s rated capacity All machine systems are functioning properly Proper tire pressure gro 0 Machine is as originally equipped from JLG 3121204 JLG Lift 4 1 SECTION 4 MACHINE OPERATION Stability Machine stability is based on two positions which are called FORWARD and BACKWARD stability The machines position of least BACKWARD stability is shown in Figure 4 2 Position of Least Backward Stability and its position of least FOR WARD stability is shown in Figure 4 1 Position of Least For ward Stability A WARNING TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPERATE THE MACHINE ON AN OUT OF LEVEL SURFACE 4 2 JLG Lift 4 3 ENGINE OPERATION NOTE Initial starting should always be performed from the Ground Control station Starting Procedure A CAUTION IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED TIME SHOULD ENGINE FAIL TO START AGAIN ALLOW STARTER TO COOL OFF FOR 2 3 MINUTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE 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 SELECT switch to GROUND Position POWER EMERGENCY STOP switch to ON then pus
93. perating Temperature Specifications Ford Sheet 2 of 2 JLG Lift 6 17 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY SAE 0W 30 SAE 0W 40 SAE 5W 30 SAE 5W 40 SAE 10W 30 AND THE AID OF A COMPLETE JLG HYDRAULIC OIL TANK HEATER ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND SAE 15W 40 lL SAE 0W 20 L3 lt 1 NO OPERATION BELOW THIS AMBIENT TEMPERATURE 10 F 23 C 20 F 29 C 30 F 34C 40 F 40 C 120 F 49C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16C 50 F 10C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C OF 18 C Figure 6 6 Engine Operating Temperature Specifications Caterpillar Sheet 1 of 2 6 18 JLG Lift AMBIENT A TEMPERATU 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE EXTENDED DRIV HYDRAULIC OIL T ERATURES ec Oh OVE ING WITH ANK F 1809 1809
94. perly stowed and never left hanging by their cord from the platform work area Supplies or tools which extend outside the platform are prohibited unless approved by JLG When driving always position boom over rear axle in line with the direction of travel Remember if boom is over the front axle steer and drive functions will be reversed Do not assist a stuck or disabled machine by pushing pulling or by using boom functions Only pull the unit from the tie down lugs on the chassis Do not place boom or platform against any structure to steady the platform or to support the structure Stow boom and shut off all power before leaving machine Trip and Fall Hazards During operation occupants in the platform must wear a full body harness with a lanyard attached to an authorized lan yard anchorage point Attach only one 1 lanyard per lan yard anchorage point JLG Lift SECTION 1 SAFETY PRECAUTIONS Before operating the machine make sure all gates are Use extreme caution when entering or leaving platform closed and fastened in their proper position Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform closer to the ground for entry exit Face the machine maintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Electrocution Hazards This machine is not insulated and does
95. pping Hazards ing barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These The user must be familiar with the surface before driving barriers shall not be part of or attached to the machine The Do not exceed the allowable sideslope and grade while minimum approach distance shall be reduced to a distance driving within the designed working dimensions of the insulating e barrier This determination shall be made by a qualified per son in accordance with the employer local or governmental requirements for work practices near energized equipment E DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE 1 6 JLG Lift 3121204 SECTION 1 SAFETY PRECAUTIONS Do not elevate platform or drive with platform elevated f boom assembly or platform is in a position that one or while on a sloping uneven or soft surface more wheels are off the ground all persons must be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distribute loads evenly on platform floor Crushing and Collision Hazards Do not raise the platform or drive from an elev
96. propane fuel may be selected by mov ing the switch to the appropriate position It is unneces sary to purge the fuel system before switching fuels so there is no waiting period when switching fuels while the engine is running NOTE JLG Lift 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 the battery if left unattended The master switch and or the ignition switch at the ground control will turn off power to all lights Drive Steer The DRIVE joystick provides for driving either forward or backward The controller is ramped to allow variable drive speed Steering is controlled by a thumb operated switch on top of the joystick When boom is positioned above horizontal and any of the following switches DRIVE SPEED TORQUE SELECT or FUNCTION SPEED are positioned to HIGH high function speeds are automatically cut out and the machine contin ues to operate at a lower speed 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS 10 3121204 Main Telescope Control This control allows extension and retraction of the main boom Jib If Equipped Push forward to lift up pull back to lift down Variable lift speed is using the Function Speed Control Tower Telescope This three position switch provides for extending and retract
97. r Continental Interval 3 Months or 150 hours of operation Lube Point s Replaceable Element Comments Check level daily Change in accordance Interval Every Year or 600 hours of operation with engine manual 3121204 JLG Lift 6 29 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 17 FuelFilter Deutz 20 AirFilter Lube Point s Replaceable Element Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as Interval Every Year or 600 hours of operation indicated by the condition indicator 18 Fuel Filter Caterpillar Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 19 Fuel Filter Gasoline GM Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation 6 30 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 21 Electronic Pressure Regulator LP only 22 Fuel Filter Propane GM Engine Interval 3 Months or 150 hours of operation Interval 3 Months or 150 hours of operation Comments Drain oil build up Refer to Section 6 6 Comments Replace filter Refer to Section 6 7 Propane DRAINING OIL BUILD UP FROM THE PROPANE REG Fuel Filter Replacement ULATOR Prior to S N 0300132529 3121204 JLG Lift 6 31 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 4 TIRES amp WHEELS Tire Inflation The
98. red additives or be of comparable viscosities If use of hydraulic oil other than Mobilfluid 424 is desired con tact JLG Industries for proper recommendations Table 6 15 Mobilfluid 424 Specs Table 6 16 Mobil DTE 13M Specs 150 Viscosity Grade 32 Specific Gravity 0 877 Pour Point Max 40 F 40 C Flash Point Min 330 F 166 C Viscosity at 40 C 33cSt at 100 C 6 6 cSt at 100 F 169 SUS at210 F 48 SUS cp at 20 F 6 200 Viscosity Index 140 SAE Grade 10W30 Gravity API 29 0 Density Lb Gal 60 F 7 35 46 43 Flash Point Min 442 F 228 Viscosity Brookfield cP at 18 C 2700 at 40 C 55 cSt at 100 C 9 3 cSt Viscosity Index 152 6 10 JLG Lift 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 17 Exxon Univis HVI 26 Specs Table 6 18 Quintolubric 888 46 3121204 Specific Gravity 32 1 Density 0 91 15 C 59 F 76 F 60 C Pour Point lt 20 C lt 4 F Flash Point 217 F 103 C Flash Point 275 C 527 F Viscosity Fire Point 325 C 617 F at 40 C 25 8 cSt Autoignition Temperature 450 C 842 F at 100 C 9 3 cSt Viscosity Viscosity Index 376 at0 C 32 F 360 cSt NOTE Mobil Exxon recommends that this oil be checked at 20 C
99. s 8 Check capacity limit switch as follows Main Boom Length Switch a Lift main boom to approximately horizontal 3121204 JLG Lift b Telescope boom out until 500 Ib 227 kg light comes on may need to used auxiliary power to position boom correctly Mark the wear pad location on the main fly boom Telescope the main boom to full extension Measure from the mark on the fly boom to the wear pad The dimension should be 125 to 127 317 5 to 322 6 cm Main Boom Angle Switch a b Lift main boom to approximately horizontal Telescope boom out until 500 Ib 227 kg light comes on may need to used auxiliary power to position boom correctly Lift main boom up until 1000 Ib 454 kg light comes on The boom angle at this point should be 55 degrees to 60 degrees Lift main boom down until 500 Ib 227 kg light comes on The boom angle at this point should be 45 degrees to 50 degrees If limit switch settings need to be changed you will need to recheck that the 500 227 kg light comes on at 45 degrees to 50 degrees when lifting down SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 9 10 NOTE 11 2 8 Raise extend retract and lower main boom Check for smooth operation Swing turntable to LEFT and RIGHT a minimum of 45 degrees Check for smooth motion Step 11 is only applicable for machines with an external tilt sensor With the aid of an assist
100. s for a particular machine model If not using a JLG approved replace ment tire we recommend that replacement tires have the follow ing characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast filled tire assembly with a pneu matic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recommended 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE by JLG Due to size variations between tire brands both tires Wheel Installation on the same axle should be the same It is extremely important to apply and maintain proper wheel Wheel Replacement mounting torque The rims installed on each product model have been designed A WARNING uid 2 WHEEL NUTS MUST BE INSTALLED AND MAINTAINED THE PROPER 22222 E Du ai Poe ete without vite TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI Oe Or SIR Kanore en BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE factory recommendations may result in an unsafe condition TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE regarding st
101. safely control and operate the machine Operator Responsibility The operator must be instructed that he she has the respon sibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site 2 1 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND 2 2 MAINTENANCE The following table covers the periodic machine inspections and maintenance recommended by JLG Industries Inc Consult local regulations for further requirements for aerial work platforms The frequency of inspections and mainte nance must be increased as necessary when the machine is used in a harsh or hostile environment if the machine is used with increased frequency or if the machine is used in a severe manner NOTICE JLG INDUSTRIES INC RECOGNIZES A FACTORY QUALIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL JLG Lift 3121204 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Table 2 1 Inspection and Maintenance Table Primary Service Frequency Responsibility Qualification Reference Pre Start Inspection Before using each day or User or Operator User or Operator Operator and Safety Manual whenever there s an Operator change Pre Delivery Inspection Before each sale
102. table lock pin is engaged See Figure 4 10 Lift ing Chart JLG Lift 3121204 SECTION 4 MACHINE OPERATION When transporting machine over rough terrain or long distance the boom needs to be chocked and strapped whenever the base boom is unable to rest on its pad This prevents the boom from Bouncing up and down preventing possible damage while transporting Figure 4 9 Machine Tie Down 3121204 JLG Lift 4 21 SECTION 4 MACHINE OPERATION A Dimension MODEL Steer Axle To Center Of Gravity 42 1066 8 mm 42 1066 8 mm 39 990 6 mm 39 990 6 mm LIFT HERE CENTER GRAVITY ROTATION Figure 4 10 Lifting Chart 4 22 JLG Lift 3121204 SECTION 4 MACHINE OPERATION BOTH SIDES OF gg 45 22 FRAME REAR 36 26 36 28 27 DEL VIEW C C 62 21 34 Figure 4 11 600A amp 600AJ Decal Installation Sheet 1 of 4 3121204 JLG Lift 4 23 SECTION 4 MACHINE OPERATION ree 23 wsipE OF ENGINE e TRAY 35 5 59 600 59 600 Fi
103. the amount of time the machine has been in use with engine running By connecting into the oil pressure circuit of the engine only engine run hours are recorded The hourmeter registers up to 9 999 9 hours and cannot be reset Platform Ground Select Switch A three position center off key activated PLATFORM GROUND SELECT switch supplies power to the plat form control console when positioned to PLATFORM With the switch in GROUND position power is shut off to the platform control console and only the controls on the ground control panel are operable With the Platform Ground Select Switch in the center posi tion power is shut off to controls at both operating sta tions Swing Control Provides 360 degrees continuous turntable rotation Main Lift Tower Lift Swing Platform Level Main Tele scope Tower Telescope Platform Rotator and Auxiliary Power control switches are spring loaded and will auto matically return to neutral off when released 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS A WARNING 11 Main Lift Control WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL Provides raising and lowering of the main boom AROUND OR UNDER PLATFORM 12 Main Telescope Control A WARNING Provides extension and retraction of the boom when TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON peiigoneg soll TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE O
104. trol lever to Reverse and drive machine off of block and ramp Have an assistant check to see that right front wheel remains locked in position off of ground 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 activate Drive to release cylinders If lockout cylinders do not function properly have quali fied personnel correct the malfunction prior to any fur ther operation 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 6 DRAINING OIL BUILD UP FROM THE 4 Pushin the Emergency Switch once the engine stops PROPANE REGULATOR PRIOR TO S N 5 Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR 0300132529 i _ During the course of normal operation oils may build inside the primary and secondary chambers of the propane pres sure regulator These oils may be a result of poor fuel quality contamination of the fuel supply chain or regional variation in the make up of the fuel If the build up of the oil is signifi cant this can effect the operation of the fuel control system Refer to Section 6 3 Operator Maintenance for maintenance intervals More frequent draining may be required if the fuel supply has been contaminated NOTICE FOR BEST RESULTS
105. troller An infinitely proportional dual axis joystick is provided for main lift and swing Push forward to lift up pull back ward to lift down Move right to swing right move left to swing left 17 18 19 JLG Lift Drive Orientation Override When the boom is swung over the rear tires or further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driv ing locate the black white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction Soft Touch Override Switch If equipped This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shutdown situation Soft Touch Indicator If Equipped Indicates the Soft Touch bumper is against an object All controls are cut out until the override button is pushed at which time controls are active in the Creep Mode 3121204 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel See Figure 3 6 and Figure 3 7 1 Tilt Alarm Warning Light and Alarm This orange illuminator indicates that the chassis is on a slope An alarm will also sound when the chassis is on a s
106. uch an occur This section explains the steps to be taken in case of an rence may void any warranty consideration on that particular emergency situation while operating machine 5 2 INCIDENT NOTIFICATION NOTICE JLG Industries Inc must be notified immediately of any inci FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE dent involving a JLG product Even if no injury or property TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS damage is evident the factory should be contacted by tele THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 10 FT 3 phone and provided with all necessary details M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF In USA REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY JLG Phone 877 JLG SAFE 554 7233 Bam till 4 45pm EST 5 3 EMERGENCY OPERATION Outside USA Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR E mail UNABLE TO OPERATE OR CONTROL MACHINE 1 Other personnel should operate the machine from P tSafet LG rogueaga ground controls only as required 2 Other qualified personnel on the platform may use the platform controls DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION PROPERLY 3121204 JLG Lift 5 1 SECTION 5 EMERGENCY PROCEDURES 3 Cranes forklift trucks or other equipment can be used to 2 remove platform occupants and stabilize motion of the machine Platform or Boom Caught Overhead I
107. ue every 3 months or 150 hours of operation NOTE Ensure boom is fully retracted lowered and centered between drive wheels prior to beginning lockout cylinder test 1 Place a 6 inches 15 2 cm high block with ascension ramp in front of left front wheel 2 From platform control station start engine 3 Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block JLG Lift 6 35 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 4 6 36 Carefully activate Swing control lever and position boom over right side of machine With boom over right side of machine place Drive con trol lever to Reverse and drive machine off of block and ramp Have an assistant check to see that left front wheel remains locked in position off of ground 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 Place the 6 inches 15 2 cm high block with ascension ramp in front of right front wheel Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block 10 11 12 13 JLG Lift With boom over left side of machine place Drive con
108. ve and discard the retaining bolt seal Remove and discard mounting plate to lock off O ring seal 3121204 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 1 ElectricLockOffSolenoid 6 Seal 10 Filter 2 Mounting Plate 7 Electrical Connector 11 Fuellnlet 3 Housing Seal 8 Fuel Outlet 12 Retaining Bolt 4 Filter Magnet 9 O ring 13 Ring 5 Filter Housing Figure 6 11 Filter Lock Assembly 3121204 JLG Lift 6 39 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Installation 6 8 PROPANE FUEL SYSTEM PRESSURE RELIEF BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 BEFORE INSTALLING NEW SEAL PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRESSURE WHERE 1 Install the mounting plate to lock off O ring seal APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COM 2 lfequipped install the retaining bolt seal PONENTS 3 Install the housing seal To relieve propane fuel system pressure 4 Drop the magnet into the bottom of the filter housing 1 Close the manual shut off valve on the propane fuel 5 5 Install the filter into the housing 6 If equipped install the retaining bolt into the filter hous R vehicle OTI engine stalls ing 3 Turn the ignitio

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