Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models

600A
600AJ
S/N 0300177361 &
B300001393
to Present

ANSI ® AS/NZS 3121615

November 15, 2016
NOTE: This manual also applies to a machine with the following
Serial Number: 0300176207.
 FOREWORD

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.

3121615 – 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

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.
GROUND. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.
GROUND.

b – JLG Lift – 3121615

 FOREWORD

For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- Compliance Information
• Product Safety Publica-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions • Questions Regarding Special
THIS PRODUCT.
Product Applications
• Current Owner Updates
• Questions Regarding Prod-
• Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF
RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE
CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE Hagerstown, MD 21742
JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY USA
OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-
or Your Local JLG Office
SONAL PROPERTY OR THE JLG PRODUCT.
(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

3121615 – JLG Lift – c

FOREWORD

REVISION LOG

Original Issue - November 6, 2013

Revised - January 1, 2014
Revised - July 4, 2014
Revised - October 1, 2014
Revised - January 5, 2015
Revised - January 7, 2016
Revised - June 13, 2016
Revised - November 15, 2016

d – JLG Lift – 3121615

 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.3 LIMIT SWITCH FUNCTIONAL CHECK. . . . . . . . . . . . . . . . . . . 2-7
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . 3-10
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-18
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11 SECTION - 4 - MACHINE OPERATION
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, 4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
AND INSPECTION Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-5
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-8
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

3121615 – JLG Lift – i

TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.16 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-22
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-22
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-10 Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-22
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.17 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 SECTION - 5 - EMERGENCY PROCEDURES
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-11 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-12 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-12 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.8 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER . . . . . . . 4-13 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1
Level Override Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) 5.4 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 (CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-17
4.13 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . . . . . . . . . . 4-17
4.14 TOWING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.15 AUXILIARY POWER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Activating from the Platform Control Station . . . . . . 4-21
Activating from the Ground Control Station . . . . . . . 4-21

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 TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR SECTION - 7 - INSPECTION AND REPAIR LOG
MAINTENANCE
6.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Tires. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
6.5 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 6-30
6.6 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 6-31
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 6-32
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-33

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TABLE OF CONTENTS

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

This Page Left Blank Intentionally.

iv – JLG Lift – 3121615

 LIST OF FIGURES

FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

2-1. Basic Nomenclature - 600A . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 4-9. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
2-2. Basic Nomenclature - 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 4-10. 600A & 600AJ Decal Installation - Sheet 1 of 4 . . . . . . . . 4-25
2-3. Daily Walk-Around Inspection Diagram - 4-11. 600A & 600AJ Decal Installation - Sheet 2 of 4 . . . . . . . . 4-26
Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 4-12. 600A & 600AJ Decal Installation - Sheet 3 of 4 . . . . . . . . 4-27
2-4. Daily Walk-Around Inspection Diagram - 4-13. 600A & 600AJ Decal Installation - Sheet 4 of 4 . . . . . . . . 4-28
Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
2-5. Daily Walk-Around Inspection Diagram - GM 3.0L . . . . 2-14 6-2. Engine Operating Temperature Specifications -
2-6. Daily Walk-Around Inspection Points - Sheet 1 of 2 . . . 2-15 Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
2-7. Daily Walk-Around Inspection Points - Sheet 2 of 2 . . . 2-16 6-3. Engine Operating Temperature Specifications -
3-1. Ground Control Station - 600AJ. . . . . . . . . . . . . . . . . . . . . . . 3-3 Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
3-2. Ground Control Station - 600AJ with Machine Safety 6-4. Engine Operating Temperature Specifications -
System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-4 GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
3-3. Ground Control Station - 600A . . . . . . . . . . . . . . . . . . . . . . . 3-5 6-5. Engine Operating Temperature Specifications -
3-4. Ground Control Station - 600A with Machine Safety GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
System Override (MSSO) (CE Only) . . . . . . . . . . . . . . . . . 3-6 6-6. Operator Maintenance & Lubrication Diagram -
3-5. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . 3-11 Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
3-6. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14 6-7. Operator Maintenance & Lubrication Diagram -
3-7. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-19 Deutz TD2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
4-1. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-2 6-8. Operator Maintenance & Lubrication Diagram -
4-2. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-3 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
4-3. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 6-9. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 6-23
4-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 6-10. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
4-5. Boom Upright Positioning - Sheet 1 of 2 . . . . . . . . . . . . . 4-14
4-6. Boom Upright Positioning - Sheet 2 of 2 . . . . . . . . . . . . . 4-15
4-7. Towbar Connecting Points . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4-8. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

3121615 – JLG Lift – v

 LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE

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vi – JLG Lift – 3121615

 LIST OF TABLES

TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-16
4-2 600A Decal Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-3 600AJ Decal Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-5 Deutz TD 2.9 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-6 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-8 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-10 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-11 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-13 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-14 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-15 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6-16 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
6-17 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-29
7-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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 LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE

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viii – JLG Lift – 3121615

 SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL
This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL
safe machine usage and maintenance. It is mandatory that a daily COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR
routine is established based on the content of this manual to pro- DEATH.
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
1.2 PRE-OPERATION
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate. Operator Training and Knowledge
The owner/user/operator/lessor/lessee of the machine must not • The Operation and Safety Manual must be read and under-
accept operating responsibility until this manual has been read, stood in its entirety before operating the machine. For clarifi-
training is accomplished, and operation of the machine has been cation, questions, or additional information regarding any
completed under the supervision of an experienced and quali- portions of this manual, contact JLG Industries, Inc.
fied operator.
This section contains the responsibilities of the owner, user, oper-
ator, lessor, and lessee concerning safety, training, inspection,
maintenance, application, and operation. If there are any ques-
tions with regard to safety, training, inspection, maintenance,
application, and operation, please contact JLG Industries, Inc.
(“JLG”).

3121615 – JLG Lift – 1-1

 SECTION 1 - SAFETY PRECAUTIONS

• An operator must not accept operating responsibilities until Workplace Inspection

adequate training has been given by competent and autho-
rized persons. • Precautions to avoid all hazards in the work area must be
taken by the user before and during operation of the machine.
• Allow only those authorized and qualified personnel to oper-
ate the machine who have demonstrated that they under- • Do not operate or raise the platform from a position on trucks,
stand the safe and proper operation and maintenance of the trailers, railway cars, floating vessels, scaffolds or other equip-
unit. ment unless the application is approved in writing by JLG.
• Read, understand, and obey all DANGERS, WARNINGS, CAU- • Before operation, check work area for overhead hazards such
TIONS, and operating instructions on the machine and in this as electric lines, bridge cranes, and other potential overhead
manual. obstructions.
• Ensure that the machine is to be used in a manner which is • Check operating surfaces for holes, bumps, drop-offs, obstruc-
within the scope of its intended application as determined by tions, debris, concealed holes, and other potential hazards.
JLG. • Check the work area for hazardous locations. Do not operate
• All operating personnel must be familiar with the emergency the machine in hazardous environments unless approved for
controls and emergency operation of the machine as specified that purpose by JLG.
in this manual. • Ensure that the ground conditions are adequate to support
• Read, understand, and obey all applicable employer, local, and the maximum tire load indicated on the tire load decals
governmental regulations as they pertain to your utilization located on the chassis adjacent to each wheel. Do not travel
and application of the machine. on unsupported surfaces.

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 SECTION 1 - SAFETY PRECAUTIONS

Machine Inspection 1.3 OPERATION

• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
General
been performed. • Machine operation requires your full attention. Bring the
• Do not operate this machine until it has been serviced and machine to a full stop before using any device, i.e. cell phones,
maintained according to the maintenance and inspection two-way radios, etc. that will distract your attention from
requirements as specified in the machine’s Service and Main- safely operating the machine.
tenance Manual. • Do not use the machine for any purpose other than position-
• Ensure all safety devices are operating properly. Modification ing personnel, their tools, and equipment.
of these devices is a safety violation. • Before operation, the user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE occurs, shut down the machine. Remove the unit from service
ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER. and notify the proper authorities.
• Do not operate any machine on which the safety or instruction • Do not remove, modify, or disable any safety devices.
placards or decals are missing or illegible.
• Never slam a control switch or lever through neutral to an
• Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop
Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con-
• Avoid accumulation of debris on platform floor. Keep mud, oil, trols with slow and even pressure.
grease, and other slippery substances from footwear and plat- • Do not allow personnel to tamper with or operate the
form floor. machine from the ground with personnel in the platform,
except in an emergency.

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 SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature,
approved by JLG. ambient air temperature, and boom and platform position.
• When two or more persons are in the platform, the operator
shall be responsible for all machine operations.
Trip and Fall Hazards
• Always ensure that power tools are properly stowed and never • During operation, occupants in the platform must wear a full
left hanging by their cord from the platform work area. body harness with a lanyard attached to an authorized lanyard
anchorage point. Attach only one (1) lanyard per lanyard
• When driving, always position boom over rear axle in line with anchorage point.
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 or pull-
ing except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating • Enter and exit only through gate area. Use extreme caution
machine. Do not wear loose fitting clothing or long hair unre- when entering or leaving platform. Ensure that the platform
strained which may become caught or entangled in equip- assembly is fully lowered. Face the machine when entering or
ment. leaving the platform. Always maintain “three point contact”
• Persons under the influence of drugs or alcohol or who are with the machine, using two hands and one foot or two feet
subject to seizures, dizziness or loss of physical control must and one hand at all times during entry and exit.
not operate this machine.
• Hydraulic cylinders are subject to thermal expansion and con-
traction. This may result in changes to the boom and/or plat-
form position while the machine is stationary. Factors
affecting thermal movement can include the length of time

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 SECTION 1 - SAFETY PRECAUTIONS

• Before operating the machine, make sure all gates are closed Electrocution Hazards
and fastened in their proper position.
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.

• Keep both feet firmly positioned on the platform floor at all

times. Never position ladders, boxes, steps, planks, or similar
items on unit to provide additional reach for any purpose.
• Keep oil, mud, and slippery substances cleaned from footwear
and the platform floor.

3121615 – JLG Lift – 1-5

 SECTION 1 - SAFETY PRECAUTIONS

Table 1-1. Minimum Approach Distances (M.A.D.)

Voltage Range MINIMUM APPROACH DISTANCE

(Phase to Phase) in Feet (Meters)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
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 ener-
gized (exposed or insulated) parts according to the Minimum • Maintain a clearance of at least 10 ft. (3m) between any part of
Approach Distance (MAD) as shown in Table 1-1. the machine and its occupants, their tools, and their equip-
• Allow for machine movement and electrical line swaying. ment from any electrical line or apparatus carrying up to
50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.

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 SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating Tipping Hazards

barriers are installed to prevent contact, and the barriers are
rated for the voltage of the line being guarded. These barriers • The user must be familiar with the surface before driving. Do
shall not be part of (or attached to) the machine. The mini- not exceed the allowable sideslope and grade while driving.
mum approach distance shall be reduced to a distance within
the designed working dimensions of the insulating barrier.
This determination shall be made by a qualified person in
accordance with the employer, local, or governmental require-
ments for work practices near energized equipment.

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).

ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-
ERWISE.

• Do not elevate platform or drive with platform elevated while

on or near a sloping, uneven, or soft surface. Ensure machine is
positioned on a firm, level and smooth surface before elevat-
ing platform or driving with the platform in the elevated posi-
tion.
• Before driving on floors, bridges, trucks, and other surfaces,
check allowable capacity of the surfaces.

3121615 – JLG Lift – 1-7

 SECTION 1 - SAFETY PRECAUTIONS

• Never exceed the maximum work load as specified on the • Do not operate the machine when wind conditions, including
platform. Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind
unless authorized by JLG. speed are; platform elevation, surrounding structures, local
weather events, and approaching storms. Refer to Table 1-2,
• Keep the chassis of the machine a minimum of 2 ft. (0.6m)
Beaufort scale (For Reference Only) or use other means to
from holes, bumps, drop-offs, obstructions, debris, concealed
monitor wind conditions.
holes, and other potential hazards at the ground level.
• Wind speed can be significantly greater at height than at
• Do not push or pull any object with the boom.
ground level.
• Never attempt to use the machine as a crane. Do not tie-off
• Wind speed can change rapidly. Always consider approaching
machine to any adjacent structure. Never attach wire, cable, or
weather events, the time required to lower the platform, and
any similar items to platform.
methods to monitor current and potential wind conditions.
• If boom assembly or platform is in a position that one or more
• Do not increase surface area of the platform or the load.
wheels are off the ground, all persons must be removed before
Increased areas exposed to wind will decrease stability.
attempting to stabilize the machine. Use cranes, forklift trucks,
or other appropriate equipment to stabilize machine. • Do not increase the platform size with unauthorized modifica-
tions or attachments.

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 SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/
S).

Table 1-2. Beaufort Scale (For Reference Only)

Beaufort Wind Speed

Description Land Conditions
Number mph m/s
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air 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. Flags waving near horizontal. Umbrella use
becomes difficult.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.

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 SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all driving and swing operations.
• Approved head gear must be worn by all operating and
• Under all travel conditions, the operator must limit travel
ground personnel.
speed according to conditions of ground surface, congestion,
• Check work area for clearances overhead, on sides, and bot- visibility, slope, location of personnel, and other factors which
tom of platform when lifting or lowering platform, and driving. may cause collision or injury to personnel.
• Be aware of stopping distances in all drive speeds. When driv-
ing in high speed, switch to low speed before stopping. Travel
grades in low speed only.
• Do not use high speed drive in restricted or close quarters or
when driving in reverse.
• Exercise extreme caution at all times to prevent obstacles from
striking or interfering with operating controls and persons in
the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s presence. Dis-
connect power to overhead cranes.
• During operation, keep all body parts inside platform railing.
• Warn personnel not to work, stand, or walk under a raised
• Use the boom functions, not the drive function, to position the boom or platform. Position barricades on floor if necessary.
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.

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 SECTION 1 - SAFETY PRECAUTIONS

1.4 TOWING, LIFTING, AND HAULING 1.5 MAINTENANCE

• Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must
hauling. be observed during maintenance of this machine. Additional pre-
cautions to be observed during machine maintenance are
• This machine should not be towed, except in the event of
inserted at the appropriate points in this manual and in the Ser-
emergency, malfunction, power failure, or loading/unloading.
vice and Maintenance Manual. It is of utmost importance that
Refer to the Emergency Procedures section of this manual for
maintenance personnel pay strict attention to these precautions
emergency towing procedures.
to avoid possible injury to personnel or damage to the machine
• Ensure boom is in the stowed position and the turntable or property. A maintenance program must be established by a
locked prior to towing, lifting or hauling. The platform must be qualified person and must be followed to ensure that the
completely empty of tools. machine is safe.
• When lifting machine, lift only at designated areas of the
machine. Lift the unit with equipment of adequate capacity. Maintenance Hazards
• Refer to the Machine Operation section of this manual for lift- • Shut off power to all controls and ensure that all moving parts
ing information. are secured from inadvertent motion prior to performing any
adjustments or repairs.
• Never work under an elevated platform until it has been fully
lowered to the full down position, if possible, or otherwise
supported and restrained from movement with appropriate
safety props, blocking, or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic hoses or fit-
tings while the machine is powered on or when the hydraulic
system is under pressure.
• Always relieve hydraulic pressure from all hydraulic circuits
before loosening or removing hydraulic components.

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 SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding.
board or paper to search for leaks. Wear gloves to help protect
• When performing welding or metal cutting operations, pre-
hands from spraying fluid.
cautions must be taken to protect the chassis from direct
exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Use only approved non-flammable cleaning solvents.
• Do not replace items critical to stability, such as batteries or
solid tires, with items of different weight or specification. Do
not modify unit in any way to affect stability.
• Refer to the Service and Maintenance Manual for the weights
of critical stability items.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE

• Ensure replacement parts or components are identical or ONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
equivalent to original parts or components.
• Never attempt to move heavy parts without the aid of a
mechanical device. Do not allow heavy objects to rest in an
unstable position. Ensure adequate support is provided when
raising components of the machine.

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 SECTION 1 - SAFETY PRECAUTIONS

Battery Hazards
• Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND
nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
• Do not allow smoking, open flame, or sparks near battery dur- CLEAN WATER AND SEEK MEDICAL ATTENTION.
ing charging or servicing. • Charge batteries only in a well ventilated area.
• Do not contact tools or other metal objects across the battery • Avoid overfilling the battery fluid level. Add distilled water to
terminals. batteries only after the batteries are fully charged.
• Always wear hand, eye, and face protection when servicing
batteries. Ensure that battery acid does not come in contact
with skin or clothing.

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 SECTION 1 - SAFETY PRECAUTIONS

NOTES:

1-14 – JLG Lift – 3121615

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
The aerial platform is a personnel handling device; so it is neces- depressions, holes, dropoffs.
sary that it be operated and maintained only by trained person-
7. Means to avoid the hazards of unprotected electrical con-
nel.
ductors.
Persons under the influence of drugs or alcohol or who are sub-
8. Specific job requirements or machine application.
ject to seizures, dizziness or loss of physical control must not
operate this machine.
Training Supervision
Operator Training Training must be done under the supervision of a qualified per-
son in an open area free of obstructions until the trainee has
Operator training must cover:
developed the ability to safely control and operate the machine.
1. Use and limitations of the controls in the platform and at the
ground, emergency controls and safety systems. Operator Responsibility
2. Control labels, instructions, and warnings on the machine. The operator must be instructed that he/she has the responsibil-
ity and authority to shut down the machine in case of a malfunc-
3. Rules of the employer and government regulations.
tion or other unsafe condition of either the machine or the job
4. Use of approved fall protection device. site.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential malfunc-
tion.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A
maintenance recommended by JLG Industries, Inc. Consult local PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL
regulations for further requirements for aerial work platforms. FOR THE SPECIFIC JLG PRODUCT MODEL.
The frequency of inspections and maintenance must be
increased as necessary when the machine is used in a harsh or
hostile environment, if the machine is used with increased fre-
quency, or if the machine is used in a severe manner.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1.Inspection and Maintenance Table

Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Before using each day; or User or Operator User or Operator Operator and Safety Manual
whenever there’s an Operator change.
Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
and applicable JLG inspection form
Frequent Inspection In service for 3 months or 150 hours, whichever comes first; Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
or and applicable JLG inspection form
Out of service for a period of more than 3 months; or
Purchased used.
Annual Machine Inspection Annually, no later than 13 months from the date of prior Owner, Dealer, or User Factory Trained Service and Maintenance Manual
inspection. Service Technician and applicable JLG inspection form
(Recommended)
Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual
Manual.
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

3121615 – JLG Lift – 2-3

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-3. thru Fig-

ure 2-7.
The Pre-Start Inspection should include each of the following:
6. Battery – Charge as required.
1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-
tery fluid) or foreign objects. Report any leakage to the 7. Fuel (Combustion Engine Powered Machines) – Add the
proper maintenance personnel. proper fuel as necessary.

2. Structure - Inspect the machine structure for dents, dam- 8. Engine Oil Supply - Ensure the engine oil level is at the Full
age, weld or parent metal cracks or other discrepancies. mark on the dipstick and the filler cap is secure.
9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
10. Accessories/Attachments - Reference the Operation and
Safety Manual of each attachment or accessory installed
upon the machine for specific inspection, operation, and
maintenance instructions.
Parent Metal Crack Weld Crack 11. Function Check – Once the “Walk-Around” Inspection is
complete, perform a functional check of all systems in an
3. Decals and Placards – Check all for cleanliness and legibil- area free of overhead and ground level obstructions. Refer to
ity. Make sure none of the decals and placards are missing. Section 4 for more specific instructions.
Make sure all illegible decals and placards are cleaned or
replaced.
4. Operators and Safety Manuals – Make sure a copy of the IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
Operator and Safety Manual, AEM Safety Manual (Domestic ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
only), and ANSI Manual of Responsibilities (Domestic only) is OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.
enclosed in the weather resistant storage container.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check 3. With the platform in the transport (stowed) position:

Perform the Function Check as follows: a. Drive the machine on a grade, not to exceed the rated
gradeability, and stop to ensure the brakes hold;
1. From the ground control panel with no load in the platform: b. Check the tilt sensor alarm to ensure proper operation.
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;
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;
c. Operate all functions and check all limiting and cut-out
switches;
d. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard Function Test NOTE: If the machine is equipped with both SkyGuard and Soft Touch,
functions will not reverse, only stop.
From the Platform Console:
NOTE: If equipped, ensure the blue beacon illuminates when SkyGuard
Test the SkyGuard feature by operating the telescope out func-
is activated.
tions and then activating the SkyGuard sensor. The telescope out
function will stop and the telescope in function will operate for a
Disengage the SkyGuard sensor, release controls, recycle the foot
short duration and the horn will sound until the SkyGuard sensor
switch, make sure normal operation is available.
and footswitch are disengaged.
If SkyGuard remains activated after function reversal or cutout,
depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the SkyGuard sensor is disen-
gaged.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 LIMIT SWITCH FUNCTIONAL CHECK 4. Swing turntable to LEFT and RIGHT a minimum of 45
degrees. Check for smooth motion.
5. Check the chassis out of level indicator located on the plat-
form control console by driving, with the machine in level
TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL
position, up a suitable ramp of at least 5° slope. Check the
SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-
out of level indicator, with the machine on the ramp. If the
GENCY STOP TO STOP THE MACHINE.
light does not illuminate, return the machine to a level sur-
face, shut down the machine, and contact a qualified techni-
NOTE: Perform checks from ground controls first, then from platform
cian before resuming operation.
controls.
NOTE: Steps 6 & 7 cover 600S ANSI market machines with dual capaci-
1. Operate machine from ground control. ties (500 & 1000 lb. [227 kg for ANSI markets and 230 kg for CE
and Australia markets & 454 kg for ANSI markets and 450 kg for
NOTE: For adjustments see Service Manual - Limit Switch Adjustments.
CE and Australia markets]).
2. Check elevation limit switch as follows:
6. Check capacity limit switch as follows:
a. Lift boom up to 2 degrees to 7 degrees above horizon-
tal. The switch should activate at this point. Boom Length Switch.
b. Lift boom down to 2.5 degrees to 7.5 degrees below a. Raise boom to horizontal (place angle indicator on base
horizontal. The switch should reset at this point. boom between boom pivot pin and lift cylinder attach
3. Raise main boom, extend and retract telescope. Check for pin).
delayed movement of fly section, indicating loose cables. b. Telescope boom out until 500 lb. (227 kg for ANSI mar-
kets and 230 kg for CE and Australia markets) light
comes on (may need to used auxiliary power to posi-
tion boom correctly).

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

c. Mark wear pad location on the fly and mid booms. d. Lift boom up until 1000 lb. (454 kg for ANSI markets and
d. Telescope boom out to full extension. 450 kg for CE and Australia markets) light comes on.
Boom angle should be 55 degrees to 64 degrees.
e. Measure from the mark on the fly boom to the wear
pad and measure from mark on the mid boom to the NOTE: If limit switch settings need to be changed, you will need to
wear pad. recheck that the 500 lb. (227 kg for ANSI markets and 230 kg for
f. Add These two numbers together (they should be CE and Australia markets) light comes on at 45 degrees to 50
approximately equal) they should measure 137" to 139" degrees when lifting down.
(348 to 353 cm).
7. Check capacity limit switch as follows:
Boom Angle Switch.
a. Telescope boom to full extension. Main Boom Length Switch.
b. Lift boom up until 1000 lb. (454 kg for ANSI markets and a. Lift main boom to approximately horizontal.
450 kg for CE and Australia markets) light comes on. b. Telescope boom out until 500 lb. (227 kg for ANSI mar-
c. Lift boom down using auxiliary power until 500 lb. (227 kets and 230 kg for CE and Australia markets) light
kg for ANSI markets and 230 kg for CE and Australia comes on (may need to used auxiliary power to posi-
markets) light comes on. Boom angle must be 45 tion boom correctly).
degrees to 50 degrees (place angle indicator on base c. Mark the wear pad location on the main fly boom.
boom between boom pivot pin and lift cylinder attach
d. Telescope the main boom to full extension.
pin).
e. Measure from the mark on the fly boom to the wear
pad. The dimension should be 125" to 127" (317.5 to
322.5 cm).

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Main Boom Angle Switch. d. Lift main boom down until 500 lb. (227 kg for ANSI mar-
kets and 230 kg for CE and Australia markets) light
a. Lift main boom to approximately horizontal.
comes on. The boom angle at this point should be 45
b. Telescope boom out until 500 lb. (227 kg for ANSI mar- degrees to 50 degrees.
kets and 230 kg for CE and Australia markets) light
comes on (may need to used auxiliary power to posi- NOTE: If limit switch settings need to be changed, you will need to
tion boom correctly). recheck that the 500 lb. (227 kg for ANSI markets and 230 kg for
CE and Australia markets) light comes on at 45 degrees to 50
c. Lift main boom up until 1000 lb. (454 kg for ANSI mar-
degrees when lifting down.
kets and 450 kg for CE and Australia markets) light
comes on. The boom angle at this point should be 55
degrees to 60 degrees.

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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1. Platform 5. Base Boom 9. Rear Drive Wheels

2. Platform Control Box 6. Upright 10. Footswitch
3. Rotator 7. Tower Boom 11. SkyGuard (If Equipped)
4. Fly Boom 8. Front Drive/Steer Wheels 12. Cross Rail

Figure 2-1. Basic Nomenclature - 600A

2-10 – JLG Lift – 3121615

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1. Platform 5. Fly Boom 9. Front Drive/Steer Wheels 13. Foot Switch

2. Platform Control Box 6. Base Boom 10. Rear Drive Wheels 14. SkyGuard (If Equipped)
3. Rotator 7. Upright 11. Platform Leveling Cylinder 15. Cross Rail
4. Jib 8. Tower Boom 12. Jib Lift Cylinder

Figure 2-2. Basic Nomenclature - 600AJ

3121615 – JLG Lift – 2-11

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-3. Daily Walk-Around Inspection Diagram - Deutz D2011L04

2-12 – JLG Lift – 3121615

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-4. Daily Walk-Around Inspection Diagram - Deutz TD2.9

3121615 – JLG Lift – 2-13

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-5. Daily Walk-Around Inspection Diagram - GM 3.0L

2-14 – JLG Lift – 3121615

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General 4. Jib (If Equipped) - See Inspection Note.

Begin the "Walk-Around Inspection" at Item 1, as noted on the

diagram. Continue checking each item in sequence for the con-
ditions listed in the following checklist.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF.

5. Power Track - See Inspection Note.
INSPECTION NOTE: On all components, make sure there are no 6. All Hydraulic Cylinders - See Inspection Note.
loose or missing parts, that they are securely fastened, and no visi-
ble damage, leaks or excessive wear exists in addition to any other 7. Drive Motor, Brake, and Hub - See Inspection Note.
criteria mentioned.
8. Wheel/Tire Assemblies - Properly secured, no missing lug
1. Platform Assembly and Gate - Footswitch works properly, nuts. Inspect for worn tread, cuts, tears or other discrepan-
not modified, disabled or blocked. Latch and hinges in cies. Inspect wheels for damage and corrosion.
working condition.
9. Tie Rod and Steering Linkage - See Inspection Note.
2. Platform & Ground Control Consoles - Switches and levers
10. Turntable Lock - Operable.
return to neutral, decals/placards secure and legible, con-
trol markings legible.
3. Rotator - See Inspection Note.

Figure 2-6. Daily Walk-Around Inspection Points - Sheet 1 of 2

3121615 – JLG Lift – 2-15

 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

11. Auxiliary Power Pump - See Inspection Note. 17. Battery - Proper electrolyte levels if adjustable; cables
tight, no visible damage or corrosion.
12. Swing Drive Motor and Brake - See Inspection Note.
18. Hydraulic Pump - See Inspection Note.
13. Main Control Valve - See Inspection Note.
19. Turntable - See Inspection Note.
14. Turntable Bearing - Evidence of proper lubrication. No evi-
dence of loose bolts or looseness between bearing and 20. Frame - See Inspection Note.
structure.
21. Main Boom Sections - See Inspection Note.
15. Fuel Tank - See Inspection Note.
22. SkyGuard (If Equipped)- See Inspection Note.
16. Hood Assemblies - See Inspection Note.
Figure 2-7. Daily Walk-Around Inspection Points - Sheet 2 of 2

2-16 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL NOTE: The indicator panels use different shaped symbols to alert the
operator to different types of operational situations that could
arise. The meaning of those symbols are explained below.
Indicates a potentially hazardous situation, which if
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.
OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH This indicator will be red.
GOOD SAFETY PRACTICES.
Indicates an abnormal operating condition, which if
This section provides the necessary information needed to
not corrected, may result in machine interruption or
understand control functions. damage. This indicator will be yellow.
3.2 CONTROLS AND INDICATORS
Indicates important information regarding the operat-
NOTE: All machines are equipped with control panels that use symbols ing condition, i.e. procedures essential for safe opera-
to indicate control functions. On ANSI machines refer to decal tion. This indicator will be green with the exception of
located on the control box guard in front of the control box or by the capacity indicator which will be green or yellow
the ground controls for these symbols and the corresponding depending upon platform position.
functions.

3121615 – JLG Lift – 3-1

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Station

(See Figure 3-1., Figure 3-2., Figure 3-3. and Figure 3-4.) ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR
NOTE: If equipped, the Function Enable switch must be FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
held down in order to operate Main Boom Tele-
scope, Tower Lift, Swing, Main Lift, Jib Lift, Plat- 2. Platform Leveling Override
form Level Override, and Platform Rotate functions.
A three position switch allows the
1. Platform Rotate operator to adjust the automatic self
leveling system. This switch is used to
Provides rotation of the platform. adjust platform level in situations
such as ascending/descending a
grade.
3. Jib (If Equipped)

This switch provides raising and low-

ering of the jib.

3-2 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform Rotate
2. Platform Leveling Override
3. Jib
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power/Function Enable
6. Boom Lift
7. Hourmeter
8. Platform/Ground Select Switch
9. Swing
10. Tower Lift
11. Main Boom Lift
12. Telescope

Figure 3-1. Ground Control Station - 600AJ

3121615 – JLG Lift – 3-3

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform Rotate
2. Platform Leveling Override
3. Jib
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power/Function Enable
6. Boom Lift
7. Hourmeter
8. Platform/Ground Select Switch
9. Swing
10. Tower Lift
11. Main Boom Lift
12. Telescope
13. Machine Safety System Override (MSSO)

Figure 3-2. Ground Control Station - 600AJ with Machine Safety System Override (MSSO) (CE Only)

3-4 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform Rotate
2. Platform Leveling Override
3. Not Used
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power/Function Enable
6. Tower Telescope
7. Hourmeter
8. Platform/Ground Select Switch
9. Swing
10. Tower Lift
11. Main Boom Lift
12. Main Boom Telescope

Figure 3-3. Ground Control Station - 600A

3121615 – JLG Lift – 3-5

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Platform Rotate
2. Platform Leveling Override
3. Not Used
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power/Function Enable
6. Tower Telescope
7. Hourmeter
8. Platform/Ground Select Switch
9. Swing
10. Tower Lift
11. Main Boom Lift
12. Main Boom Telescope
13. Machine Safety System Override (MSSO)

Figure 3-4. Ground Control Station - 600A with Machine Safety System Override (MSSO) (CE Only)

3-6 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When Power/Emergency Stop switch is in the “On” position and 5. Engine Start/ Auxiliary Power Switch /Function
engine is not running, an alarm will sound, indicating Ignition is Enable
“On”.
To start the engine, the switch must be held "Up" until the
engine starts.
To use auxiliary power, the switch must be
WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST
held “Down” for duration of auxiliary pump
BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.
use.
NOTE: On machines with diesel engines, when Glow Plug Indicator is When the engine is running, the switch must
lighted (Yellow), wait until light goes out before cranking engine. be held "Down" to enable all boom controls.

4. Power/Emergency Stop Switch

A two-position red mushroom shaped switch WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC-
supplies power to Platform/Ground Select TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
switch when pulled out (on). When pushed in MOTOR.)
(off ), power is shut off to the Platform/Ground Select switch.

3121615 – JLG Lift – 3-7

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Tower Telescope NOTE: When the Platform/Ground Select Switch is in the

center position, power is shut off to the controls at
This switch provides extending and both operating stations. Remove the key to pre-
retracting of the tower boom. This vent the controls from being actuated. The key is
function works only when the tower removable in the platform position on CE specifi-
boom is fully elevated (lift up). cation machines. The key must be available to
ground personnel in the event of an emergency.

8. Platform/Ground Select Switch

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT
AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE.
The three position, key operated switch sup-
plies power to the platform control console
7. Hourmeter
when positioned to Platform. With the switch
key turned to the Ground position only
Registers the amount of time the
ground controls are operable.
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.

3-8 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope, 10. Tower Lift
Tower Telescope, Platform Rotator and Auxiliary Power control
switches are spring-loaded and will automatically return to neu- This switch provides raising and low-
tral (off) when released. ering of the tower boom. This func-
tion works only when the tower
boom is fully retracted.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR

11. Main Boom Lift Control
UNDER PLATFORM.
Provides raising and lowering of the
main boom.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
OFF POSITION WHEN RELEASED.
12. Main Telescope Control
9. Swing Control
Provides extension and retraction of
Provides 360 degrees continuous the main boom.
turntable rotation.

3121615 – JLG Lift – 3-9

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

13. Machine Safety System Override (MSSO) (CE 4. Engine Oil Temperature Indicator (Deutz)
Only)
Indicates that the temperature of the engine
Provides emergency override of function oil, which also serves as engine coolant, is
controls that are locked out in the event of abnormally high and service is required.
Load Sense System activation.
5. System Distress Indicator
Ground Control Indicator Panel
The light indicates that the JLG Control System
(See Figure 3-5.) has detected an abnormal condition and a
Diagnostic Trouble Code has been set in the
1. No Alternator Output Indicator system memory. Refer to the Service Manual for instructions
concerning the trouble codes and trouble code retrieval.
Indicates a problem in the charging circuit,
and service is required. The system distress indicator light will illuminate for 2-3 sec-
onds when the key is positioned to the on position to act as
2. Engine Oil Pressure Indicator
a self test.
Indicates that engine oil pressure is below nor-
mal and service is required.
3. High Engine Coolant Temperature Indicator
(Liquid Cooled Engines)

Indicates that engine coolant temperature is

abnormally high and service is required.

3-10 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. No Alternator Output 5. System Distress

2. Low Engine Oil Pressure 6. Glow Plug Wait to Start
3. High Engine Coolant Temp. 7. Platform Overload
4. Engine Oil Temp. 8. Drive and Steer Disable

Figure 3-5. Ground Control Indicator Panel

3121615 – JLG Lift – 3-11

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Glow Plug/ Wait to Start Indicator Platform Station

Indicates the glow plugs are on. The glow (See Figure 3-6.)
plugs are automatically turned on with the
ignition circuit and remain on for approxi-
mately seven seconds. Start the engine only after the light
goes out. TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
7. Platform Overload Indicator. (If Equipped) OFF OR NEUTRAL POSITION WHEN RELEASED.
Indicates the platform has been overloaded. 1. Drive Speed/Torque Select
8. Drive and Steer Disable Indicator (If equipped)
The machine has a two position
Indicates the Drive and Steer Disable function switch - The forward position
has been activated. gives maximum drive speed. The
back position gives maximum
torque for rough terrain and
climbing grades.

3-12 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Steer Select (If Equipped)

When equipped with four wheel steering, the ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
action of the steering system is operator THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
selectable. The center switch position gives FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
conventional front wheel steering with the rear wheels unaf-
fected. This is for normal driving at maximum speeds. The 3. Platform Leveling Override
forward position is for “crab” steering. When in this mode
both front and rear axles steer in the same direction, which A three position switch allows the operator to
allows the chassis to move sideways as it goes forward. This adjust the automatic self leveling system. This
can be used for positioning the machine in aisle ways or switch is used to adjust platform level in situa-
against buildings. The back switch position is for “coordi- tions such as ascending/descending a grade.
nated” steering. In this mode the front and rear axles steer in
4. Horn
the opposite directions to produce the tightest turning cir-
cle for maneuvering in confined areas.
A push-type Horn switch supplies electrical
power to an audible warning device when pressed.
To re-synchronize the front and rear axles, position the rear
drive wheels to the forward drive position by selecting
either crab or compound steer, then select front steer (cen-
ter switch position) to operate the normal steering function.

3121615 – JLG Lift – 3-13

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Drive Speed 6. Start/Aux. Power 11. Lights 16. Soft Touch/SkyGuard Indicator
2. Steer Select 7. Fuel Select 12. Jib 17. Platform Rotate
3. Platform Leveling Override 8. Drive Orientation Override 13. Soft Touch/SkyGuard Override 18. Function Speed
4. Horn 9. Drive/Steer 14. Tower Telescope 19. Main Lift/Swing
5. Power/Emergency Stop 10. Main Boom Telescope 15. Tower Lift
Figure 3-6. Platform Control Console

3-14 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Power/Emergency Stop Switch 7. Fuel Select (Dual Fuel Engine Only) (If
Equipped)
A two-position red mushroom shaped switch
furnishes power to Platform Controls when Gasoline or liquid propane fuel may be
pulled out (on). When pushed in (off ), power is selected by moving the switch to the appropriate position. It
shut off to the platform functions. is unnecessary to purge the fuel system before switching
fuels, so there is no waiting period when switching fuels
while the engine is running.
6. Start/Auxiliary Power
8. Drive Orientation Override
When pushed forward, the switch energizes
the starter motor to start the engine. When the boom is swung over the rear tires or
further in either direction, the Drive Orienta-
The Auxiliary Power control switch energizes
tion indicator will illuminate when the drive
the electrically operated hydraulic pump.
function is selected. Push and release the switch, and within
(Switch must be held on for duration of auxil-
3 seconds move the Drive/Steer control to activate drive or
iary pump use.)
steer. Before driving, locate the black/white orientation
The auxiliary pump functions to provide sufficient oil flow to arrows on both the chassis and the platform controls. Move
operate the basic machine functions should the main pump the drive controls in a direction matching the directional
or engine fail. The auxiliary pump will operate tower boom arrows.
lift, tower telescope, main boom lift, main telescope and
swing.

3121615 – JLG Lift – 3-15

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: Lift, Swing, and Drive control levers are spring-loaded and will 10. Main Boom Telescope
automatically return to neutral (off) position when released.
Provides extension and retraction of the main
boom.
11. Lights (If Equipped)
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
This switch operates control console panel
OFF OR NEUTRAL POSITION WHEN RELEASED.
lights and head lights if the machine is so
equipped. The ignition switch does not have to be on to
NOTE: To operate the Drive joystick, pull up on the lock-
operate the lights, so care must be taken to avoid draining
ing ring below the handle.
the battery if left unattended. The master switch and / or the
ignition switch at the ground control will turn off power to
all lights.
12. Jib (If Equipped)

Push forward to lift up, pull back to lift down.

NOTE: The Drive joystick is spring loaded and will automatically return Variable lift speed is using the Function Speed
to neutral (off) position when released. Control.

9. Drive/Steer 13. Soft Touch/SkyGuard Override Switch (If equipped)

Push forward to drive forward, The machine can be equipped with one of three options. It
pull back to drive in reverse. may have Soft Touch, SkyGuard, or both Soft Touch and Sky-
Steering is accomplished via a Guard.
thumb-activated rocker switch on
the end of the steer handle.

3-16 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

If equipped with Soft Touch, the switch

enables the functions that were cut out
by the Soft Touch system to operate TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT
again at creep speed, allowing the AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE.
operator to move the platform away from the obstacle that
caused the shutdown situation. 15. Tower Lift
If equipped with SkyGuard, the switch
This switch provides for raising and lowering of
enables functions cut out by the Sky-
the tower boom when positioned to “up” or
guard system to be operated again,
“down”. Tower Lift must be fully elevated “up”
allowing the operator to resume use of
before operating Tower Telescope. (Tower Lift should not
machine functions.
function when Tower Telescope is extended).
If equipped with both Soft Touch and
16. Soft Touch/SkyGuard Indicator (If Equipped)
SkyGuard, the switch operates like
described above and allows the opera-
Indicates the Soft Touch bumper is against an object or the
tor to override the system that has
SkyGuard sensor has been activated. All controls are cut out
experienced a cutout situation.
until the override button is pushed. For Soft Touch, controls
14. Tower Telescope are then active in the Creep Mode or for SkyGuard, controls
will work normally.
This switch provides for extending and retract-
17. Platform Rotate
ing of the tower boom when positioned to in
or out. Tower Telescope must be fully retracted
Provides rotation of the platform when posi-
before operating Tower Lift. (Tower Telescope should not
tioned to the right or left.
function when Tower Lift is not fully elevated “up”).

3121615 – JLG Lift – 3-17

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

swing right, move left to swing left. Moving the joystick acti-
vates switches to provide the functions selected.
DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEED
SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL. Platform Control Indicator Panel
18. Function Speed Control (See Figure 3-7., Platform Control Indicator Panel)

1. Tilt Alarm Warning Light and Alarm

This control affects the speed of telescope,
tower lift, and swing. Turning the knob all
This illuminator indicates that the chassis is on
the way counterclockwise until it clicks puts a slope. An alarm will also sound when the
drive, main lift, tower lift, and swing into chassis is on a slope and the boom is above
creep mode. horizontal. If lit when boom is raised or extended, retract
NOTE: To operate the Main Boom Lift/Swing joystick, and lower to below horizontal then reposition machine so
that it is level before continuing operation. If the boom is
pull up on the locking ring below the handle.
above horizontal and the machine is on a slope, the tilt
alarm warning light will illuminate and an alarm will sound
NOTE: The Main Boom Lift/Swing joystick is spring
and CREEP is automatically activated.
loaded and will automatically return to neutral
(off) position when released.

19. Main Lift/Swing Controller IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED,
RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT
Provides main lift and swing. Push IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.
forward to lift up, pull backward
NOTE: When the tilt sensor alarm is activated the Drive function will be
to boom down. Move right to
disabled if the boom is elevated above horizontal.

3-18 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Tilt 5. Glow Plug 8. AC Generator

2. Overload 6. Low Fuel 9. Drive Orientation
3. Capacity 7. System Distress 10. Creep
4. Enable
Figure 3-7. Platform Control Indicator Panel

3121615 – JLG Lift – 3-19

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Platform Overload (If equipped) 4. Footswitch/Enable Indicator

Indicates the platform has been overloaded. To operate any function, the footswitch must
be depressed and the function selected within
3. Capacity Indicator seven seconds. The enable indicator shows
that the controls are enabled. If a function is not selected
Indicates the maximum platform capacity for within seven seconds, or if a seven second lapse between
the current position of the platform. ending one function and beginning the next function, the
Restricted capacities are permitted at enable light will go out and the footswitch must be released
restricted platform positions (shorter boom and depressed again to enable the controls.
lengths and higher boom angles).

NOTE: Refer to the capacity decals on the machine for Releasing the footswitch removes power from all controls
restricted and unrestricted platform capacities. and applies the drive brakes.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH

BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY

OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

3-20 – JLG Lift – 3121615

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Glow Plug/Wait to Start Indicator 8. AC Generator (If Equipped)

Indicates the glow plugs are operating. After Indicates the generator is in operation.
turning on ignition, wait until light goes out
before cranking engine.
9. Drive Orientation Indicator
6. Low Fuel Indicator (Yellow)
When the boom is swung beyond the rear
Indicates the fuel tank is 1/8 full or less. When drive tires or further in either direction, the
the light first turns on, there are approximately Drive Orientation indicator will illuminate
four usable gallons of fuel remaining. when the drive function is selected. This is a signal for the
operator to verify that the drive control is being operated in
7. System Distress Indicator
the proper direction (i.e. controls reversed situations).
The light indicates that the JLG Control System 10. Creep Speed Indicator
has detected an abnormal condition and a
Diagnostic Trouble Code has been set in the When the Function Speed Control is turned to
system memory. Refer to the Service Manual for instructions the creep position, the indicator acts as a
concerning the trouble codes and trouble code retrieval. reminder that all functions are set to the slow-
est speed.

3121615 – JLG Lift – 3-21

 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-22 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION 4.2 OPERATING CHARACTERISTICS AND LIMITATIONS
This machine is a self-propelled hydraulic personnel lift equipped
with a work platform on the end of an elevating and rotating
Capacities
boom.
The boom can be raised above horizontal with or without any
The primary operator control station is in the platform. From this load in platform, if:
control station, the operator can drive and steer the machine in
both forward and reverse directions. The operator can raise or 1. Machine is positioned on a smooth, firm and level surface.
lower the main or tower boom or swing the boom to the left or 2. Load is within manufacturer’s rated capacity.
right. Standard boom swing is 360 degree continuous left and
right of the stowed position. The machine has a Ground Control 3. All machine systems are functioning properly.
Station which will override the Platform Control Station. Ground 4. Proper tire pressure.
Controls operate Boom Lift and Swing, and are to be used in an
emergency to lower the platform to the ground should the oper- 5. Machine is as originally equipped from JLG.
ator in the platform be unable to do so.

3121615 – JLG Lift – 4-1

 SECTION 4 - MACHINE OPERATION

Stability
Machine stability is based on two positions which are called FOR-
WARD and BACKWARD stability. The machines position of least
FORWARD stability is shown in Figure 4-2., Position of Least For-
ward Stability, and its position of least BACKWARD stability is
shown in Figure 4-1., Position of Least Backward Stability.

TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPERATE

THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

Figure 4-1. Position of Least Backward Stability

4-2 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Forward Stability

3121615 – JLG Lift – 4-3

 SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION 2. Pull the Power/Emergency Stop switch to On.

NOTE: Initial starting should always be performed

from the Ground Control station.
3. Push the Engine Start switch until engine starts.

Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING
ANY LOAD.

4. After engine has had sufficient time to warm

up, push in the Power/Emergency Stop switch
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME.
and shut engine off.
SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN-
UTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE 5. Turn Platform/Ground Select switch to Plat-
MANUAL. form.
NOTE: Diesel engines only: After turning on ignition,
operator must wait until glow plug indicator light
goes out before cranking engine.
6. From Platform, pull Power/Emergency Stop
switch out.
1. Turn key of Platform/Ground Select switch to
Ground.

4-4 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

7. Push the Engine Start switch until engine starts. Fuel Reserve / Shut-Off System
NOTE: Reference the Service and Maintenance Manual along with a
qualified JLG Mechanic to verify your machine setup.
NOTE: Footswitch must be in released (up) position before starter will
operate. If starter operates with footswitch in the depressed posi-
The Fuel Shutoff System monitors the fuel in the tank and senses
tion, DO NOT OPERATE MACHINE.
when the fuel level is getting low. The JLG Control System auto-
matically shuts the engine down before the fuel tank is emptied
Shutdown Procedure unless the machine is set up for Engine Restart.
If fuel level reaches the Empty range, the Low Fuel
light will begin to flash once a second and there will
be approximately 60 minutes of engine run time
IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE
left. If the system is in this condition and automati-
THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.
cally shuts down the engine or if the operator man-
ually shuts down the engine before the 60 minute run time is
1. Remove all load and allow engine to operate at low speed
complete, the Low Fuel light will flash 10 times a second and the
for 3-5 minutes; this allows further reduction of internal
engine will react according to machine setup. Setup options are
engine temperature.
as follows:
2. Push Power/Emergency Stop switch in.
• Engine One Restart - When the engine shuts down, the
operator will be permitted to cycle power and restart the
engine once with approximately 2 minutes of run time.
3. Turn Platform/Ground Select switch to Off. After the 2 minute run time is complete or if the engine is
shut down by the operator prior to the completion of the 2
Refer to Engine Manufacturer’s manual for detailed minute run time, it cannot be restarted until fuel is added
information. to the tank.

3121615 – JLG Lift – 4-5

 SECTION 4 - MACHINE OPERATION

• Engine Restart - When the engine shuts down, the opera- 4.4 TRAVELING (DRIVING)
tor will be permitted to cycle power and restart the engine
for approximately 2 minutes of run time. After the 2 min- See Figure 4-3., Grade and Sideslope
utes of run time is complete, the operator may cycle power
and restart the engine for an additional 2 minutes of run NOTE: Refer to the Operating Specifications table for Gradeability and
time. The operator can repeat this process until there is no Sideslope ratings.
more fuel available.
All ratings for Gradeability and Sideslope are based upon the
machine’s boom being in the stowed position, fully lowered, and
retracted.
CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO
MORE FUEL IS AVAILABLE.
Traveling is limited by two factors:
• Engine Stop - When the engine shuts down, no restarts 1. Gradeability, which is the percent of grade of the incline the
will be permitted until fuel is added to the tank. machine can climb.
2. Sideslope, which is the angle of the slope the machine can
be driven across.

4-6 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Sideslope

3121615 – JLG Lift – 4-7

 SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND
1. At Platform Controls, pull out Emergency Stop
LEVEL SURFACE.
switch and activate footswitch.
TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON
GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.
2. Position Drive controller to FORWARD or
REVERSE as desired.
BE SURE THE TURNTABLE LOCK IS 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 This machine is equipped with a Drive Orientation Indicator. The
PLATFORM IS ELEVATED. yellow light on the platform control console indicates that the
boom is swung beyond the rear drive tires and the machine may
BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IF Drive/Steer in the opposite direction from the movement of the
BOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED. controls. If the indicator is illuminated, operate the Drive function
in the following manner:

4-8 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

1. Match the black and Traveling on a Grade

white direction arrows
on both platform con- When traveling a grade, maximum braking and traction are obtained
trol panel and the chas- with the boom stowed, in position over the rear (drive) axle, and in
sis to determine the line with the direction of travel. Drive the machine forward when
direction the machine climbing a grade, and in reverse when descending a grade. Do not
will travel. exceed the machine's maximum rated gradability.
2. Push and release the Drive Orientation Over-
ride switch. Within 3 seconds, slowly move the
Drive control toward the arrow matching the
intended direction of machine travel. The indi-
cator light will flash during the 3 second inter-
val until the drive function is selected.

Figure 4-4. Traveling on a Grade

IF THE BOOM IS OVER THE FRONT (STEER) AXLE, DIRECTION OF STEER AND DRIVE
MOVEMENT WILL BE OPPOSITE FROM THE MOVEMENT OF THE CONTROLS.

3121615 – JLG Lift – 4-9

 SECTION 4 - MACHINE OPERATION

4.5 STEERING 4.7 BOOM

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

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR TOG-
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR GLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY. NEUTRAL POSITION WHEN RELEASED.

To Level Up or Down - Position the Platform/Level IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED,
control switch Up or Down and hold until the plat- REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE
form is level. MACHINE.

Platform Rotation
To rotate the platform to the left or right, use the
Platform Rotate control switch to select the direc-
tion and hold until desired position is reached.

4-10 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Swinging the Boom Raising and Lowering the Tower Boom

To swing boom, use Swing control switch to select This machine has two controls for the tower boom (two toggle
Right or Left direction. switches), one controls tower lift, the other tower telescope. The
switching system will sequence its Lift and Telescope functions as
follows:
1. Sequence while raising the Tower Boom from the fully low-
WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO ered position.
CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.
a. The Tower Boom must be fully elevated “up”
NOTE: On CE Market machines, when boom functions are being oper- (approximately 13 degrees from vertical)
ated there is an interlock that prevents the use of Drive and Steer before the Tower Boom can be extended
functions. 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 ele-
vated “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.

3121615 – JLG Lift – 4-11

 SECTION 4 - MACHINE OPERATION

b. The Tower lift “down” will only operate when Raising and Lowering the Main Boom
the Tower Boom is fully retracted.
To raise or lower the Main Boom, position the Main
Boom Lift switch to Up or Down until the desired
height is reached.

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

4-12 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

4.8 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER To Operate:

1. Pull the red knob
Level Override Valve
2. Using the ground control raise the lower boom 6 feet.
A pull type control valve allows the operator to adjust the tower 3. Release the knob.
lift cylinder and the upright cylinder if the upright cylinder is not
4. Fully lower the boom.
fully retracted when boom is in the stowed position. This valve is
located in the engine compartment area. 5. Repeat if necessary.

3121615 – JLG Lift – 4-13

 SECTION 4 - MACHINE OPERATION

Figure 4-5. Boom Upright Positioning - Sheet 1 of 2

4-14 – JLG Lift – 3121615
 SECTION 4 - MACHINE OPERATION

Figure 4-6. Boom Upright Positioning - Sheet 2 of 2

3121615 – JLG Lift – 4-15
 SECTION 4 - MACHINE OPERATION

4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE 4.10 SKYGUARD OPERATION

ONLY) Skyguard is used to provide enhanced control panel protection.
When the SkyGuard sensor is activated, functions that were in
The Machine Safety System Override (MSSO) is
use at the time of actuation will reverse or cutout. The table
used to override function controls for Emergency
below outlines these functions.
Platform Retrieval only. Refer to Section 5.5,
Machine Safety System Override (MSSO)(CE Only)
for operating procedures.
Table 4-1. Skyguard Function Table

Drive Drive
Main Main Forward Reverse Tower Tower
Main Platform Platform Jib
Tele Tele Swing DOS DOS Lift Lift
Lift DOS DOS Level Rotate Lift
In Out Not Not Up Down
Enabled Enabled
Enabled Enabled
R C R R R C* R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* Disregard when boom is in line and driving forward with or without steering and no other function active
Note: When Soft Touch is enabled with SkyGuard all functions are cut out only.

4-16 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

4.11 SHUT DOWN AND PARK 4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)
1. Drive machine to a protected area.
2. Assure boom is fully retracted and lowered over rear (Drive) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-
axle; all access panels and doors closed and secured. PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.
3. Remove all load and allow engine to operate 3-5 minutes at
idle to permit reduction of engine internal temperatures. Refer to Section 6.5, Oscillating Axle Lockout Test (If Equipped) for
procedure.
4. At Ground Controls, turn Key Select switch to (center) Off
Position, Power/Emergency Stop switch (down) to Off. 4.13 STEER/TOW SELECTOR (IF EQUIPPED)
Remove key.
5. Cover Platform Control console to protect instruction plac-
ards, warning decals and operating controls from hostile
DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COMPLETE TOW PACK-
environment
AGE FROM MANUFACTURER.

A push-pull type selector valve located adjacent to the steer cyl-

inder 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.

3121615 – JLG Lift – 4-17

 SECTION 4 - MACHINE OPERATION

4.14 TOWING (IF EQUIPPED) Prior to towing the machine, complete the following:

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING
VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT
1. Retract, lower and position boom over rear drive wheels in
PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR
line with direction of travel; lock turntable.
DEATH.
2. Connect tow bar to front of frame with attach pins, and tow
MAXIMUM TOWING SPEED 8 M.P.H. (13 K.M.H.) bar to towing vehicle.

MAXIMUM TOWING GRADE 25%.

4-18 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

STEER SELECT
VALVE

Figure 4-7. Towbar Connecting Points

3121615 – JLG Lift – 4-19

 SECTION 4 - MACHINE OPERATION

3. Disconnect drive hubs by inverting disconnect cap.Refer to

Figure 4-8., Drive Disconnect Hub.
4. Actuate steer/tow selector valve for towing; pull valve knob
OUT to float position. (This opens the steer circuit to reser-
voir, allowing the steer cylinder rod free travel.) The machine
is now in the towing mode.
After towing the machine, complete the following:
1. Actuate steer/tow selector valve for steering; push valve
knob IN to the actuated position.
2. Reconnect drive hubs by inverting disconnect cap.
3. Disconnect tow bar from steering hitch and from towing
vehicle. The machine is now in the driving mode.

Figure 4-8. Drive Disconnect Hub

4-20 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

4.15 AUXILIARY POWER 4. Position Auxiliary Power switch to On and

hold.

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC-
5. Operate appropriate control switch, lever or controller for
TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXIL-
desired function and hold.
IARY PUMP MOTOR.)
6. Release Auxiliary Power switch, selected control switch, lever
A toggle type auxiliary power control switch is located on the or controller, and footswitch.
platform control station and another is located on the ground
control station. Operation of either switch turns on the electri- 7. Position Power/Emergency Stop switch to Off.
cally driven auxiliary hydraulic pump. This should be used in case
of failure of the main power plant. The auxiliary pump will oper-
ate boom lift, telescope and swing. To activate auxiliary power:
Activating from the Ground Control Station
Activating from the Platform Control Station
1. Position Platform/Ground Select Key Switch to
1. Position Platform/Ground Select Key Switch to Ground.
Platform.
2. Position Power/Emergency Stop switch to On.

2. Position Power/Emergency Stop switch to On.

3. Position Auxiliary Power switch to On and
hold.
3. Depress and hold footswitch.

3121615 – JLG Lift – 4-21

 SECTION 4 - MACHINE OPERATION

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

6. Position Power/Emergency Stop switch to Off.

4.16 DUAL FUEL SYSTEM (GAS ENGINE ONLY) 2. Open hand valve on LP gas supply tank by turning counter-
clockwise.
The dual fuel system enables the standard gasoline engine to run
on either gasoline or LP gas. 3. While engine is operating on Gasoline under a no-
load condition, place Fuel Select switch at Platform
Control to LP position.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOW- Changing From LP Gas to Gasoline
ING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING
INSTRUCTIONS MUST BE FOLLOWED. 1. With engine operating on LP under a no-load con-
dition, position Fuel Select switch at Platform Con-
trol Station to Gasoline position.
2. Close hand valve on LP gas supply tank by turning
clockwise.

4-22 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

4.17 TIE DOWN AND LIFTING NOTE: Lifting eyes are provided at the front and rear in the frame slab.
Each of the four chains or slings used for lifting machine must be
adjusted individually so machine remains level when elevated.
When transporting machine, boom must be in the stowed mode
with turntable lock pin engaged and machine securely tied down
to truck or trailer deck. Four tie down eyes are provided in the
frame slab, one at each corner of the machine.
SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES
If it becomes necessary to lift the machine using an overhead or OR HAULING MACHINE ON TRUCK/TRAILER.
mobile crane, it is very important that the lifting devices are
attached only to the designated lifting eyes, and that the turnta-
ble lock pin is engaged (See Figure 4-9., Lifting Chart).

3121615 – JLG Lift – 4-23

 SECTION 4 - MACHINE OPERATION

Figure 4-9. Lifting Chart

4-24 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Aus 22
68
26 36 28 27
36
64 44
10 33
11 22
61

7
16
17 10
49 35 39 11
48

43 6

62 21 34

Figure 4-10. 600A & 600AJ Decal Installation - Sheet 1 of 4

3121615 – JLG Lift – 4-25

 SECTION 4 - MACHINE OPERATION

Figure 4-11. 600A & 600AJ Decal Installation - Sheet 2 of 4

4-26 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

13
63
12
66
12 3
4
66

12

47

22 67
12
51
55 52
12 58 54
55
24 58

29
5
37 53 25
43 37

42 39

Figure 4-12. 600A & 600AJ Decal Installation - Sheet 3 of 4

3121615 – JLG Lift – 4-27

 SECTION 4 - MACHINE OPERATION

Figure 4-13. 600A & 600AJ Decal Installation - Sheet 4 of 4

4-28 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Table 4-2. 600A Decal Legend

Canadian Chinese Chinese

Item # ANSI CE/AUS Spanish Portuguese Japanese Korean
French Simplified Traditional
1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B
1001156985-B 1001156980-B 1001156979-B
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 1705514 1705514
16 -- -- -- -- -- -- -- -- --
17 3251243 3251243 -- 3251243 3251243 3251243 3251243 3251243 3251243

3121615 – JLG Lift – 4-29

 SECTION 4 - MACHINE OPERATION

Table 4-2. 600A Decal Legend

Canadian Chinese Chinese

Item # ANSI CE/AUS Spanish Portuguese Japanese Korean
French Simplified Traditional
1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B
1001156985-B 1001156980-B 1001156979-B
18 -- -- -- -- -- -- -- -- --
19 -- -- -- -- -- -- -- -- --
20 -- -- -- -- -- -- -- -- --
21 -- -- -- 1704007 1705901 -- -- --
22 1703953 1703942 -- 1703941 1705903 1703944 1001116845 1703943 1703945
23 -- -- -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- 1706968 1001116846 1705969
25 1703797 1703924 1705921 1703923 1705895 1703926 1001116847 1703925 1703927
26 1705336 1705347 1705822 1705917 1705896 1705344 1001116848 1001116849 1705345
27 1703804 1703948 1701518 1703947 1705898 1703950 1001116850 1703949 1703951
28 1703805 1703936 1705961 1703935 1705897 1703938 1703937 1001116851 1703939
29 3252347 1703984 1705828 1703983 1705902 1703980 1001116852 1703982 1703981
30 3251813 3251813 -- -- -- -- -- -- --
31 -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- --
33 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891
34 -- 1702631 -- -- -- -- 1702631 1702631 1702631
35 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702819

4-30 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Table 4-2. 600A Decal Legend

Canadian Chinese Chinese

Item # ANSI CE/AUS Spanish Portuguese Japanese Korean
French Simplified Traditional
1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B
1001156985-B 1001156980-B 1001156979-B
36 1001121813 1001121815 1705978 1001121817 1001121819 1001121820 1001121824 1001121822 1001122201
37 1001121800 1001121802 1705978 1001121804 1001121806 1001121807 1001121811 1001121809 1001122200
38 -- -- -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1706948 1706948 -- -- 1706948 1706948 -- -- --
41 -- -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- --
53 -- -- -- -- -- -- -- -- --

3121615 – JLG Lift – 4-31

 SECTION 4 - MACHINE OPERATION

Table 4-2. 600A Decal Legend

Canadian Chinese Chinese

Item # ANSI CE/AUS Spanish Portuguese Japanese Korean
French Simplified Traditional
1001156889-B 1001156987-B 1001156972-B 1001156974-B 1001156976-B 1001156983-B
1001156985-B 1001156980-B 1001156979-B
54 -- -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- -- --
61 -- -- -- -- -- -- -- -- --
62 1001131269 1001131269 -- -- -- 1700584 1700584 -- --
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 1001108493 1001108493 1001108493
64 1706941 1706941 -- 1706941 1706941 1706941 1706941 1706941 1706941
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1001116861 1001116862 1703987
67 1705351 1705429 -- 1705910 1705905 1705426 1705430 1001116863 1705427
68 -- -- -- -- -- -- -- -- --

4-32 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Table 4-3. 600AJ Decal Legend

Canadian Chinese Chinese

Item # ANSI CE Spanish Portuguese Japanese Australian Korean
French Simplified Traditional
1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B
1001156986-B 1001156982-B 1001156981-B
1 -- -- -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 -- -- -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- -- -- --
10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
14 -- -- -- -- -- -- 1705084 1705084 1705084 1705084
15 -- 1705514 -- -- -- -- 1705514 1705514 1705514 1705514
16 -- -- -- -- -- -- -- -- -- --
17 3251243 3251243 3251243 3251243 3251243 3251243 -- -- -- 3251243

3121615 – JLG Lift – 4-33

 SECTION 4 - MACHINE OPERATION

Table 4-3. 600AJ Decal Legend

Canadian Chinese Chinese

Item # ANSI CE Spanish Portuguese Japanese Australian Korean
French Simplified Traditional
1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B
1001156986-B 1001156982-B 1001156981-B
18 -- -- -- -- -- -- -- -- -- --
19 -- -- -- -- -- -- -- -- 1001117034 --
20 -- -- -- -- -- -- -- -- 1001117035 --
21 -- -- -- -- -- -- -- -- -- --
22 1703953 1703942 -- 1703941 1705903 1703944 -- 1001116845 1703943 1703945
23 -- -- -- -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- -- 1706968 1001116846 1705969
25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 1001116847 1703925 1703927
26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 1001116848 1001116849 1705345
27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 1001116850 1703949 1703951
28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851 1703939
29 -- 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982 1703981
30 3251813 3251813 -- -- -- -- -- -- -- --
31 -- -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- -- --
33 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891
34 -- -- 1702631 -- -- 1702631 1702631 1702631 1702631 1702631
35 1702819 1702819 1702819 1702819 1702819 1702819 1702819 1702818 1702818 1702819

4-34 – JLG Lift – 3121615

 SECTION 4 - MACHINE OPERATION

Table 4-3. 600AJ Decal Legend

Canadian Chinese Chinese

Item # ANSI CE Spanish Portuguese Japanese Australian Korean
French Simplified Traditional
1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B
1001156986-B 1001156982-B 1001156981-B
36 1001121814 1001121816 1705978 1001121818 1001121655 1001121821 1705978 1001121825 1001121823 1001121921
37 1001121801 1001121803 1705978 1001121805 1001121656 1001121808 1705978 1001121812 1001121810 1001121918
38 -- -- -- -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 -- 1706948 -- -- 1706948 -- -- -- -- --
41 -- -- -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- -- --
53 -- -- -- -- -- -- -- -- -- --

3121615 – JLG Lift – 4-35

 SECTION 4 - MACHINE OPERATION

Table 4-3. 600AJ Decal Legend

Canadian Chinese Chinese

Item # ANSI CE Spanish Portuguese Japanese Australian Korean
French Simplified Traditional
1001156890-B 1001156988-B 1001156973-B 1001156975-B 1001156977-B 1001156978-B 1001156984-B
1001156986-B 1001156982-B 1001156981-B
54 -- -- -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- -- -- --
61 -- -- -- -- -- -- -- -- -- --
62 1001131269 1001131269 -- 1702573 -- -- -- -- -- 1001131269
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 -- 1001108493 1001108493 1001108493
64 1706941 1706941 -- 1706941 1706941 1706941 -- 1706941 1706941 1706941
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862 1703987
67 1705351 1705429 -- 1705910 1705905 1705426 -- 1705430 1001116863 1705427
68 -- -- -- -- -- -- 1001112551 -- -- --

4-36 – JLG Lift – 3121615

 SECTION 5 - EMERGENCY PROCEDURES

SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL
This section explains the steps to be taken in case of an emer- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL
gency situation while operating. FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-
TROLS. DO NOT LIFT ABOVE 3 M (10 FT.) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS
5.2 INCIDENT NOTIFICATION BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-
JLG Industries, Inc. must be notified immediately of any incident RECTLY.
involving a JLG product. Even if no injury or property damage is
evident, the factory should be contacted by telephone and pro- 5.3 EMERGENCY OPERATION
vided with all necessary details.
In USA:
Operator Unable to Control Machine
JLG Phone: 877-JLG-SAFE (554-7233) IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
(8am till 4:45pm EST) OPERATE OR CONTROL MACHINE:
1. Other personnel should operate the machine from ground
Outside USA:
controls only as required.
240-420-2661
2. Other qualified personnel on the platform may use the plat-
E-mail: form controls. DO NOT CONTINUE OPERATION IF CONTROLS
DO NOT FUNCTION PROPERLY.
ProductSafety@JLG.com
3. Cranes, forklift trucks or other equipment can be used to
Failure to notify the manufacturer of an incident involving a JLG
remove platform occupants and stabilize motion of the
Industries product within 48 hours of such an occurrence may
machine.
void any warranty consideration on that particular machine.

3121615 – JLG Lift – 5-1

 SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE
If the platform or boom becomes jammed or snagged in over- ONLY)
head structures or equipment, rescue platform occupants prior to
freeing the machine. The Machine Safety System Override (MSSO) is
only to be used to retrieve an operator that is
5.4 EMERGENCY TOWING PROCEDURES pinned, trapped, or unable to operate the
machine and function controls are locked out
Towing this machine is prohibited, unless properly equipped. from the platform due to a platform overload sit-
However, provisions for moving the machine have been incorpo- uation.
rated. For specific procedures, refer to Section 4.
NOTE: If the MSSO functionality is used, the fault indicator will flash
and a fault code is set in the JLG Control System which must be
reset by a qualified JLG Service Technician.

NOTE: No functional checks of the MSSO system are necessary. The JLG
Control system will set a Diagnostic Trouble Code if the control
switch is faulty.

To operate the MSSO:

1. From the ground control console, place the Platform/
Ground Select switch in the Ground position.
2. Pull out the Power/Emergency Stop control.
3. Start the engine.
4. Press and hold the MSSO switch and the control switch for
the desired function.

5-2 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION 6.2 OPERATING SPECIFICATIONS
This section of the manual provides additional necessary infor- Table 6-1. Operating Specifications
mation to the operator for proper operation and maintenance of
this machine. Maximum Work Load (Capacity) - ANSI
Unrestricted: 500 lb (227 kg)
The maintenance portion of this section is intended as informa-
Restricted: 1000 lb (454 kg)
tion to assist the machine operator to perform daily maintenance
tasks only, and does not replace the more thorough Preventive Maximum Work Load (Capacity) - CE &
Maintenance and Inspection Schedule included in the Service Australia
and Maintenance Manual. Unrestricted: 500 lb (230 kg)
Maximum Travel Grade (Gradeability)
Other Publications Available: 2WD 30%
Service and Maintenance Manual - Global Spec 4WD 45%
(s/n 0300177361 to Present)....................................................3121616 Maximum Travel Grade (Side Slope) 5°
Illustrated Parts Manual - Global Spec Turning Radius - (outside)
(s/n 0300177361 to Present)....................................................3121617 2WS 17 ft. 8 in. (5.38 m)
4WS 11 ft. 8 in. (3.56 m)
Turning Radius - (outside) narrow chassis
2WS 16 ft. 6 in. (5.03 m)
4WS 11 ft. 2 in. (3.4 m)
Turning Radius - (inside)
2WS 11 ft. 5 in. (3.48 m)
4WS 5 ft. 6 in. (1.68 m)

3121615 – JLG Lift – 6-1

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-1. Operating Specifications Dimensional Data

Turning Radius - (inside) narrow chassis
2WS 12 ft. 2 in. (3.71 m) Table 6-2. Dimensional Data
4WS 5 ft. 7 in. (1.7 m)
Machine Height (Stowed)
Maximum Tire Load: 11,700 lbs. (5307 kg) 600A 8 ft. 4 in. (2.54 m)
Ground Bearing Pressure 600AJ 8 ft. 5 in. (2.57 m)
600A 77 psi (5.5kg/cm2)
Machine Length (Stowed)
600AJ 77 psi (5.5 kg/cm2) 600A 26ft. 5 in. (8.05 m)
600A - narrow chassis 94 psi (6.6 kg/cm2) 600AJ 29 ft. (8.80 m)
600AJ - narrow chassis 94 psi (6.6 kg/cm2)
Machine Width (by tire size)
Maximum Drive Speed 4.25 MPH (6.84 Km/hr.) 355/55D-625 98 in. (2.49 m)
Gross Machine Weight --600A (Approximate) 41/18LLx22.5X625 (turf) 100 in. (2.54 m)
2WS 21,640 lbs. (9,816 kg)
4WS 22,040 lbs. (9,997 kg) Wheelbase 8 ft. 2 in. (2.49m)
Narrow Chassis 23,900 lbs. (10,841 kg)
Ground Clearance 11.7 in. (0.29 m)
Gross Machine Weight --600AJ (Approximate)
2WS 22,240 lbs. (10,088 kg) Platform Height
4WS 22,740 lbs. (10,315 kg) 600A 60 ft. 5 in. (18.42 m)
Narrow Chassis 24,000 lbs. (10,886 kg) 600AJ 60 ft. 7 in. (18.47 m)

Horizontal Reach
600A 39 ft. 7 in. (12.07 m)
600AJ 39 ft. 9 in. (12.10 m)

Tail Swing 0 in. (0 m)

6-2 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Capacities Engine Data

Table 6-3. Capacities
Table 6-4. Deutz D2011L04 Specifications
Fuel Tank 30 Gallons (113.6 L) Fuel Diesel
Hydraulic Oil Tank 30.6 Gallons (115.8 L) Oil Capacity
Cooling System 5 Quarts (4.5 L)
Hydraulic System (Including Tank) 40 Gallons (151.4 L) Crankcase 11 Quarts (10.5 L) w/Filter
Total Capacity 16 Quarts (15 L)
Torque Hub, Drive* 20 ounces (0.6 L)
Idle RPM 1000
Engine Crankcase Low RPM 1800
Deutz D2011L04 11 quarts (10.5 L) High RPM 2500
Deutz TD 2.9L 2.4 Gallon (8.9 L) w/Filter
Alternator 60 Amp, belt drive
GM 4.5 qts. (4.25 L) w/Filter
Battery 950 Cold Cranking Amps, 205 Minutes
*Torque hubs should be one half full of lubricant. Reserve Capacity, 12 VDC
Fuel Consumption 0.65 GPH (2.46 lph)
Horsepower 49

3121615 – JLG Lift – 6-3

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-5. Deutz TD 2.9 Specifications Table 6-6. GM 3.0L

Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline or Gasoline/LP Gas
Output 67 hp (50 kW) No. of Cylinders 4
Torque 173 ft.lbs. (234 Nm) @ 1800rpm BHP
Oil Capacity (Crankcase) 2.4 Gallon (8.9 L) w/Filter Gasoline 83 hp @ 3000 rpm
LP 75 hp @ 3000 rpm
Cooling System 3.3 Gallon (12.5 L)
Bore 4.0 in. (101.6 mm)
Low RPM 1200 ±50 rpm
Stroke 3.6 in. (91.44 mm)
High RPM 2600±50 rpm
Displacement 181 cu.in. (3.0 L, 2966 cc)
Alternator 95 Amp
Oil Capacity w/filter 4.5 qts. (4.25 L)
Fuel Consumption 0.65 GPH (2.48 lph)
Minimum Oil Pressure
at idle 6 psi (0.4 Bar) @ 1000 rpm
Hot 18 psi (1.2 Bar) @ 2000 rpm
Compression Ratio 9.2:1
Firing Order 1-3-4-2
Max. RPM 2800
Fuel Consumption
Gas 1.27 gph (4.81 lph)
LP 7.25 Lb./h (3.29 Kg/h)

6-4 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tires Hydraulic Oil

Table 6-7. Tire Specifications Table 6-8. Hydraulic Oil

Size IN355/55D 625 IN355/55D 625 14 x 17.5 HYDRAULIC SYSTEM OPERATING

SAE VISCOSITY GRADE
Load Range G G * TEMPERATURE RANGE
Ply Rating 14 14 N/A +0° to +180° F (-18° C to +83° C) 10W
Tire Pressure 90 PSI (6 Bar) Foam-Filled Air-Boss +0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30
* Load Capacity - 11,700 lb. (5307 kg) - Static +50° F to +210° F (+10° C to +210° C) 20W-20

NOTE: Hydraulic oils must have anti-wear qualities at least to API Ser-
Size 41/18LLx22.5 36x12-20FA vice Classification GL-3, and sufficient chemical stability for
mobile hydraulic system service. JLG Industries recommends
Load Range* G **
Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of
Ply Rating -- N/A 152.
Tire Pressure 70 PSI (5 Bar) Solid-Boss
* Load Capacity - 15,500 lb. (5443 kg) - Static NOTE: When temperatures remain below 20° F (-7 degrees C), JLG
** Load Capacity - 11,800 lb. (4404 kg) - Static Industries recommends the use of Mobil DTE 13M.

Aside from JLG recommendations, it is not advisable to mix oils of

different brands or types, as they may not contain the same
required additives or be of comparable viscosities. If use of
hydraulic oil other than Mobilfluid 424 is desired, contact JLG
Industries for proper recommendations.

3121615 – JLG Lift – 6-5

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-9. Mobilfluid 424 Specs Table 6-10. Mobil DTE 13M Specs

SAE Grade 10W30 ISO Viscosity Grade #32

Gravity, API 29.0 Specific Gravity 0.877
Density, Lb/Gal. 60°F 7.35 Pour Point, Max -40°F (-40°C)
Pour Point, Max -46°F (-43°C) Flash Point, Min. 330°F (166°C)
Flash Point, Min. 442°F (228°C) Viscosity
Viscosity at 40° C 33cSt
Brookfield, cP at -18°C 2700 at 100° C 6.6 cSt
at 40° C 55 cSt at 100° F 169 SUS
at 100° C 9.3 cSt at 210° F 48 SUS
Viscosity Index 152 cp at -20° F 6,200
Viscosity Index 140

6-6 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-11. Mobil EAL H 46 Specs Table 6-12. Exxon Univis HVI 26 Specs

Type Synthetic Biodegradable Specific Gravity 32.1

ISO Viscosity Grade 46 Pour Point -76°F (-60°C)
Flash Point 217°F (103°C)
Specific Gravity .910
Viscosity
Pour Point -44°F (-42°C)
at 40° C 25.8 cSt
Flash Point 500°F (260°C)
at 100° C 9.3 cSt
Operating Temp. 0 to 180°F (-17 to 162°C) Viscosity Index 376
7.64 lb. per gal. NOTE: Mobil/Exxon recommends that this oil be checked on a
Weight
(0.9 kg per liter) yearly basis for viscosity.
Viscosity
at 40° C 45 cSt
at 100° C 8.0 cSt
Viscosity Index 153

3121615 – JLG Lift – 6-7

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 6-13. Mobil EAL 224H Specs Table 6-14. Quintolubric 888-46

Type Synthetic Biodegradable Density 0.91 @ 15°C (59°F)

ISO Viscosity Grade 32/46 Pour Point <-20°C (<-4°F)
Specific Gravity .922 Flash Point 275°C (527°F)
Pour Point, Max -25°F (-32°C) Fire Point 325°C (617°F)
Flash Point, Min. 428°F (220°C)
Autoignition Temperature 450°C (842°F)
Operating Temp. 0 to 180°F (-17 to 162°C)
Viscosity
Weight 7.64 lb. per gal.
(0.9 kg per liter) at 0° C (32°F) 360 cSt
Viscosity at 20° C (68°F) 102 cSt
at 40° C 37 cSt at 40° C (104°F) 46 cSt
at 100° C 8.4 cSt at 100° C (212°F) 10 cSt
Viscosity Index 213 Viscosity Index 220
NOTE: Must be stored above 32°F (14°C)

6-8 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Critical Stability Weights Table 6-15. Critical Stability Weights

Platform 30x48 151 68

30x60 165 75
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT
OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTERWEIGHT, 36x72 199 90
ENGINE & PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO AFFECT STABILITY.
36x96 230 105
Table 6-15. Critical Stability Weights

LB. KG.

Tire and Wheel (standard Pneumatic) 355/55D345 235 107

Tire and Wheel (standard Foam-Filled) 355/55D345 440 200

Engine Deutz D2011 1222 554

Deutz TD2.9L 1250 567

GM 1070 486

Counterweight 600A 5400 2449

600AJ 6100 2767

Narrow Frame 8050 3651

600A w/Soft Touch 6100 2767

3121615 – JLG Lift – 6-9

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Serial Number Locations

A serial number plate is affixed to the left rear side of the frame. If
the serial number plate is damaged or missing, the machine serial
number is stamped on the left side of the frame.

Figure 6-1. Serial Number Locations

6-10 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

AMBIENT AIR
TEMPERATURE

120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30°F(-1°C)
WINTER 20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
ADDED
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2

3121615 – JLG Lift – 6-11

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
100° F (38° C) MOBIL 424 10W-30
CONSISTANTLY WITHIN SHOWN LIMITS
90° F (32° C)
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
80° F (27° C)

EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
HYDRAULIC SUMMER-GRADE WINTER-GRADE
50° F (10° C) FUEL
MOBIL DTE 13

SPECIFICATIONS FUEL
40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
+14 -10

AMBIENT TEMPERATURE
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE -13 -25

-22 -30
0 10 20 30 40 50 60

% OF ADDED KEROSENE 4150548-E

Figure 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2

6-12 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

AMBIENT AIR
TEMPERATURE

120 F(49 C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)

ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE

Figure 6-4. Engine Operating Temperature Specifications - GM - Sheet 1 of 2

3121615 – JLG Lift – 6-13

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180°F
(82° C) OR ABOVE.
180° F(82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30

90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13

SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
DO NOT START UP HYDRAULIC SYSTEM
0° F (-18° C)
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE:
-20° F (-29° C)
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
-40° F (-40° C)
NO OPERATION BELOW THIS 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
AMBIENT TEMPERATURE

4150548-E
Figure 6-5. Engine Operating Temperature Specifications - GM - Sheet 2 of 2

6-14 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-6. Operator Maintenance & Lubrication Diagram - Deutz D2011L04

3121615 – JLG Lift – 6-15

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-7. Operator Maintenance & Lubrication Diagram - Deutz TD2.9

6-16 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Figure 6-8. Operator Maintenance & Lubrication Diagram - GM 3.0L

3121615 – JLG Lift – 6-17

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.3 OPERATOR MAINTENANCE 1. Swing Bearing

NOTE: The following numbers correspond to those in Figure 6-6., Oper-

ator Maintenance & Lubrication Diagram - Deutz D2011L04.

Table 6-16. Lubrication Specifications

KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel-
lent water resistance and adhesive qualities, and being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classification GL-5 or MIL-
Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD Lube Point(s) - 1 Grease Fittings
class, MIL-L-2104B/MIL-L-2104C. Capacity - A/R
Lube - MPG
Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access. Apply grease and rotate in 90
degree intervals until bearing is completely lubricated.
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL
CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED
TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE
INCREASED ACCORDINGLY.

6-18 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Wheel Bearings (If equipped) 3. Swing Drive Hub

Lube Point(s) - Repack Lube Point(s) - Level/Fill Plug

Capacity - A/R Capacity - 43 oz. (1.3 L)
Lube - MPG Lube - 90w80 Gear Oil
Interval - Every 2 years or 1200 hours of operation Interval - Check level every 3 months or 150 hrs of operation;
change every 2 years or 1200 hours of operation

3121615 – JLG Lift – 6-19

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Wheel Drive Hub 5. Hydraulic Return Filter

Lube Point(s) - Level/Fill Plug

Capacity - 20 oz. (0.6 L)
Lube - EPGL
Interval - Check level every 3 months or 150 hrs of operation;
change every 2 years or 1200 hours of operation

Interval - Change after first 50 hrs. and every 6 months or

300 hrs. thereafter or as indicated by Condition Indicator.

6-20 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6. Hydraulic Charge Filter 7. Hydraulic Tank

NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION

Interval - Change after first 50 hrs. and every 6 months or Lube Point(s) - Fill Cap
300 hrs. thereafter or as indicated by Condition Indicator. Capacity - 30.6 gal. (115.8 L) Tank; 40 gal. (151.4 L) System
Lube - HO
Interval - Check Level daily; Change every 2 years or 1200
hours of operation.

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 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

8. A. Oil Change w/Filter - Deutz 2011 B. Oil Change w/Filter - Deutz TD2.9

Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Capacity - 9.6 Quarts (9.0 L)
Lube - EO Lube - EO
Interval - Every Year or 1200 hours of operation Interval - Every Year or 600 hours of operation
Comments - Check level daily/Change in accordance with Comments - Check level daily/Change in accordance with
engine manual. Refer to Figure 6-9., Deutz 2011 Engine Dip- engine manual.
stick.

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 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

MINIMUM OIL MINIMUM LEVEL OIL

LEVEL HOT
MAXIMUM LEVEL OIL
HOT

MAXIMUM OIL MINIMUM LEVEL OIL

LEVEL COLD MAXIMUM LEVEL OIL
COLD

NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down.

Figure 6-9. Deutz 2011 Engine Dipstick

3121615 – JLG Lift – 6-23

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

9. Oil Change w/Filter - GM 10. A. Fuel Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element

Capacity - 4.5 qt. (4.25 L) w/filter On Engine:
Lube - EO Lube Point(s) - Replaceable Element
Interval - 3 Months or 150 hours of operation Interval - Change in accordance with engine manual
Comments - Check level daily/Change in accordance with
engine manual.

6-24 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

B. Fuel Filter - Deutz TD2.9 (On Turntable) C. Fuel Filter - Deutz TD2.9 (On Engine)

Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Change in accordance with engine manual Interval - Change in accordance with engine manual
11. Fuel Filter (Gasoline) - GM
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation

3121615 – JLG Lift – 6-25

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

12. A. Air Filter (Deutz 2011 and GM) B. Air Filter (Deutz TD 2.9)

Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every 6 months or 300 hours of operation or as Interval - Every 6 months or 300 hours of operation or as
indicated by the condition indicator indicated by the condition indicator

6-26 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

13. Fuel Filter (Propane) - GM Engine 6.4 TIRES & WHEELS

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

Tire Damage
For pneumatic tires, JLG Industries, Inc. 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
Interval - 3 Months or 150 hours of operation of the tire or tire assembly.
Comments - Replace filter. Refer to Section 6.6, Propane Fuel
Filter Replacement For polyurethane foam filled tires, JLG Industries, Inc. recommends
that when any of the following are discovered, measures must be
taken to remove the JLG product from service immediately and
arrangements must be made for replacement of the tire or tire
assembly.

• a 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

3121615 – JLG Lift – 6-27

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

• any damage to the bead area cords of the tire Wheel Replacement
If a tire is damaged but is within the above noted criteria, the tire
The rims installed on each product model have been designed for
must be inspected on a daily basis to insure the damage has not
stability requirements which consist of track width, tire pressure, and
propagated beyond the allowable criteria.
load capacity. Size changes such as rim width, center piece location,
larger or smaller diameter, etc., without written factory recommen-
Tire Replacement dations, may result in an unsafe condition regarding stability.
JLG recommends a replacement tire be the same size, ply and brand
as originally installed on the machine. Please refer to the JLG Parts
Wheel Installation
Manual for the part number of the approved tires for a particular It is extremely important to apply and maintain proper wheel
machine model. If not using a JLG approved replacement tire, we mounting torque.
recommend that replacement tires have the following characteris-
tics:

• Equal or greater ply/load rating and size of original WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO
PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION
• Tire tread contact width equal or greater than original
OF WHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE
• Wheel diameter, width, and offset dimensions equal to the ANGLE OF THE WHEEL.
original
• Approved for the application by the tire manufacturer 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
(including inflation pressure and maximum tire load)
not have a torque wrench, tighten the fasteners with a lug wrench,
Unless specifically approved by JLG Industries Inc. do not replace a then immediately have a service garage or dealer tighten the lug
foam filled or ballast filled tire assembly with a pneumatic tire. When nuts to the proper torque. Over-tightening will result in breaking the
selecting and installing a replacement tire, ensure that all tires are studs or permanently deforming the mounting stud holes in the
inflated to the pressure recommended by JLG. Due to size variations wheels. The proper procedure for attaching wheels is as follows:
between tire brands, both tires on the same axle should be the same.

6-28 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

1. Start all nuts by hand to prevent cross threading. DO NOT Table 6-17. Wheel Torque Chart
use a lubricant on threads or nuts.
TORQUE SEQUENCE
2. Tighten nuts in the following sequence:
1st Stage 2nd Stage 3rd Stage
40 ft. lbs. 95 ft. lbs. 170 ft. lbs.
(55 Nm) (130 Nm) (230 Nm)

4. Wheel nuts should be torqued after first 50 hours of opera-

tion and after each wheel removal. Check torque every 3
months or 150 hours of operation.

3. The tightening of the nuts should be done in stages. Follow-

ing the recommended sequence, tighten nuts per wheel
torque chart.

3121615 – JLG Lift – 6-29

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.5 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) boom reaches center, stowed position, lockout cylinders
should release and allow wheel to rest on ground, it may be
necessary to activate Drive to release cylinders.

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- 8. Place the 6 inches (15.2 cm) high block with ascension ramp
PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. in front of right front wheel.
9. Place Drive control lever to Forward and carefully drive
NOTE: Ensure boom is fully retracted, lowered, and centered between machine up ascension ramp until right front wheel is on top
drive wheels prior to beginning lockout cylinder test. of block.

1. Place a 6 inches (15.2 cm) high block with ascension ramp in 10. With boom over left side of machine, place Drive control
front of left front wheel. lever to Reverse and drive machine off of block and ramp.

2. From platform control station, start engine 11. Have an assistant check to see that right front wheel remains
locked in position off of ground.
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front 12. Carefully activate Swing control lever and return boom to
wheel is on top of block. stowed position (centered between drive wheels). When
boom reaches center, stowed position, lockout cylinders
4. Carefully activate Swing control lever and position boom should release and allow wheel to rest on ground, it may be
over right side of machine. necessary activate Drive to release cylinders.
5. With boom over right side of machine, place Drive control 13. If lockout cylinders do not function properly, have qualified
lever to Reverse and drive machine off of block and ramp. personnel correct the malfunction prior to any further oper-
6. Have an assistant check to see that left front wheel remains ation.
locked in position off of ground.
7. Carefully activate Swing control lever and return boom to
stowed position (centered between drive wheels). When

6-30 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.6 PROPANE FUEL FILTER REPLACEMENT

Removal
1. Relieve the propane fuel system pressure. Refer to Propane
Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing and remove it.
4. Pull the filter housing from the Electric lock off assembly.
5. Remove the filter from the housing.
6. Locate Filter magnet and remove it.
7. Remove and discard the housing seal.
1. Electric Lock Off Solenoid 6. Fuel Outlet
2. Housing Seal 7. O-ring
3. Filter Magnet 8. Filter
4. Filter Housing 9. Fuel Inlet
5. Electrical Connector 10. Ring
Figure 6-10. Filter Lock Assembly

3121615 – JLG Lift – 6-31

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Installation 6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO
NEW SEAL MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL
SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL
1. Install the housing seal. SYSTEM COMPONENTS.
2. Drop the magnet into the bottom of the filter housing.
To relieve propane fuel system pressure:
3. Install the filter into the housing.
1. Close the manual shut-off valve on the propane fuel tank.
4. Install the filter up to the bottom of the electric lock off.
2. Start and run the vehicle until the engine stalls.
5. Tighten the filter bowl retainer to 106 in lbs (12 Nm).
3. Turn the ignition switch OFF.
6. Open manual shut-off valve. Start the vehicle and leak check
the propane fuel system at each serviced fitting. Refer to
Propane Fuel System Leak Test.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE
WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.

6-32 – JLG Lift – 3121615

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.8 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 sub-
jected does not exceed 2,5 m/s2. The highest root mean square
value of weighted acceleration to which the whole body is sub-
jected does not exceed 0,5 m/s2.

3121615 – JLG Lift – 6-33

 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

NOTES:

6-34 – JLG Lift – 3121615

 SECTION 7 - INSPECTION AND REPAIR LOG

SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 7-1. Inspection and Repair Log

Date Comments

3121615 – JLG Lift – 7-1

 SECTION 7 - INSPECTION AND REPAIR LOG

Table 7-1. Inspection and Repair Log

Date Comments

7-2 – JLG Lift – 3121615

 JLG Industries, Inc. (717) 485-5161 (Corporate)
1 JLG Drive (800) 544-5438 (Service)
McConnellsburg PA. 17233-9533 (717) 485-6417
USA
www.jlg.com

JLG Worldwide Locations

JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin) Equipment
358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Technology LTD
Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi Shanghai Branch
NSW 2143 3630 Maasmechelen Indiaatuba-SP 13347-404 No 465 Xiao Nan Road
Sydney 2143 Belgium Brasil Feng Xian District
Australia +32 (0) 89 84 82 26 +55 (19) 3936 7664 (Parts) Shanghai 201204
+6 (12) 87186300 Email: emeaservice@jlg.com China
+55(19)3936 9049 (Service)
+6 (12) 65813058 Email: comercialpecas@jlg.com +86 (21) 800 819 0050
Email: techservicesaus@jlg.com Email: servicos@jlg.com

JLG Industries Dubai JLG France SAS JLG Deutschland GmbH JLG Equipment Services Ltd.
Jafza View Z.I. Guillaume Mon Amy Max Planck Str. 21 Rm 1107 Landmark North
PO Box 262728, LB 19 30204 Fauillet 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue
20th Floor, Office 05 47400 Tonniens Germany Sheung Shui N. T.
Jebel Ali, Dubai France +49 (0) 421 69350-0 Hong Kong
+971 (0) 4 884 1131 +33 (0) 553 84 85 86 +49 (0) 421 69350-45 +(852) 2639 5783
+971 (0) 4 884 7683 +33 (0) 553 84 85 74 Email:german-parts@jlg.com +(852) 2639 5797
Email: emeaservice@jlg.com Email: pieces@jlg.com

JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & Services JLG Industries
Via Po. 22 Polaris Avenue 63 2B Fisher Cresent Vahutinskoe shosse 24b.
20010 Pregnana Milanese (MI) 2132 JH Hoofdorf Mt Wellington 1060 Khimki
Italy The Netherlands Auckland, New Zealand Moscow Region 141400
+39 (0) 2 9359 5210 +31 (0) 23 565 5665 +6 (12) 87186300 Russia Federation
+39 (0) 2 9359 5211 Email: emeaservice@jlg.com +6 (12) 65813058 +7 (499) 922 06 99
Email: ricambi@jlg.com Email:techservicesaus@jlg.com +7 (499) 922 06 99

Oshkosh-JLG Singapore Technology JLG Iberica S.L. JLG Sverige AB JLG Industries (UK) Ltd.
Equipment Pte Ltd. Trapadella, 2 Enkopingsvagen 150 Bentley House
35 Tuas Avenue 2 Pol. Ind. Castellbisbal Sur 176 27 Jarfalla Bentley Avenue
Jurong Industrial Estate 08755 Castellbisbal Barcelona Sweden Middleton, Greater Manchester
Singapore 639454 Spain +46 (0) 8 506 595 00 M24 2GP
+65 6591 9030 +34 (0) 93 772 47 00 United Kingdom
+46 (0) 8 506 595 27
+65 6591 9045 +34 (0) 93 771 1762 +44 (0) 161 654 1000
Email: nordicsupport@jlg.com
Email: SEA@jlg.com Email:parts_iberica@jlg.com +44 (0) 161 654 1003
Email: ukparts@jlg.com