Operation and Safety Manual

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

Model
600AJ
PVC 2001

ANSI ® AS/NZS 31215030

September 30, 2020 - Rev C
 WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
 FOREWORD

FOREWORD

The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var-
ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
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.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related documentation.

31215030 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 POTENTIONALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK- RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE
GROUND. PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES A POTENTIALLY HA ZARDOUS 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 31215030
 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 OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-
or Your Local JLG Office
ERTY 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

31215030 c
FOREWORD

REVISION LOG

Original Issue A - September 24, 2019

Revised B - June 5, 2020
Revised C - September 30, 2020

d 31215030
 TABLE OF CONTENTS

SECTION - 1 - SAFETY PRECAUTIONS 2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . . . . . . . . . . 2-6

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.4 BASIC NOMENCLATURE - 600AJ . . . . . . . . . . . . . . . . . . . . . . 2-9
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2.5 DAILY WALK-AROUND INSPECTION DIAGRAM . . . . . . . 2-10
Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1 Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Deutz TD2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ford DF 2.5L MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10 3.3 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11 600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 600AJ with Machine Safety System Override (MSSO)
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 (If Equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 3.4 GROUND CONTROL INDICATOR PANEL . . . . . . . . . . . . . . . 3-8
3.5 PLATFORM CONTROL CONSOLE . . . . . . . . . . . . . . . . . . . . 3-12
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, 3.6 PLATFORM CONTROL INDICATOR PANEL . . . . . . . . . . . . 3-16
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 SECTION - 4 - MACHINE OPERATION
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2 Platform Load Sensing System (LSS). . . . . . . . . . . . . . . . 4-1
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
SkyGuard® Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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TABLE OF CONTENTS

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Air Shutoff Valve (ASOV) (If Equipped). . . . . . . . . . . . . . 4-6 SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-7 4.12 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
4.4 DIESEL PARTICULATE FILTER (IF EQUIPPED) . . . . . . . . . . . 4-8 4.13 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-26
Standstill Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.14 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . . . . . . . . . . 4-26
Maintenance Standstill Cleaning Initiation Methods. . 4-10 4.15 TOWING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28
Canceling Maintenance Standstill . . . . . . . . . . . . . . . . . . . 4-10 4.16 AUXILIARY POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
Unsuccessful Cleaning Event . . . . . . . . . . . . . . . . . . . . . . . . 4-11 Activating from the Platform Control Station . . . . . . 4-29
DPF Filter Replacement due to Ash Load. . . . . . . . . . . . . 4-11 Activating from the Ground Control Station . . . . . . . 4-30
4.5 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16 4.17 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-30
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-17 Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-31
Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-31
4.6 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 4.18 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31
4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-18 SECTION - 5 - EMERGENCY PROCEDURES
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-20 Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-20 Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-20 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . . . . . . . . . . 5-2
4.9 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER . . . . . . . 4-21 5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
Level Override Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
4.10 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24 SECTION - 6 - ACCESSORIES
4.11 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
6.1 FALL ARREST PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24

ii 31215030
 TABLE OF CONTENTS

6.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.7 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Capacity Specifications (Australia Only). . . . . . . . . . . . . 6-4 6.8 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 6-13
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4 6.9 SKYSENSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . 6-16
6.3 SKYCUTTER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5 SkySense Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 Override Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 SkySense Coverage Areas . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR
6.4 SKYGLAZIER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 MAINTENANCE
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 7.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 7.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
6.5 SKYPOWER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
6.6 SKYWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 7.3 OPERATOR MAINTENANCE AND LUBRICATION
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Welding Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Deutz TD 2.9, 2.2L Stage V . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Ford DF 2.5L, MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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TABLE OF CONTENTS

7.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

7.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
7.6 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 7-29
7.7 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 7-30
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-30
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
7.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-32
7.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-32

SECTION - 8 - INSPECTION AND REPAIR LOG

iv 31215030
 LIST OF FIGURES

4-1. ASOV Reset (Closed to Open Position) . . . . . . . . . . . . . . . . 4-6

4-2. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-3. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-4. Boom Upright Positioning - Sheet 1 of 2 . . . . . . . . . . . . . 4-22
4-5. Boom Upright Positioning - Sheet 2 of 2 . . . . . . . . . . . . . 4-23
4-6. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
4-7. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
4-8. 600AJ Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . 4-33
4-9. 600AJ Decal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . . 4-34
4-10. 600AJ Decal Installation - Sheet 3 of 4 . . . . . . . . . . . . . . . 4-35
4-11. 600AJ Decal Installation - Sheet 4 of 4 . . . . . . . . . . . . . . . 4-36
6-1. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . 6-15
7-1. Engine Operating Temperature Specifications -
Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-2. Engine Operating Temperature Specifications -
Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7.3. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
7-4. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

31215030 v
 LIST OF FIGURES

vi 31215030
 LIST OF TABLES

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 600AJ Decal Legend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
6-1 Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Options/Accessories Relationship Table. . . . . . . . . . . . . . . 6-2
7-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Deutz TD 2.9L Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6 Deutz TD 2.9L Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 Ford DF 2.5L, MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-8 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-12 Mobil EAL H 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Mobil EAL 46 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-15 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-16 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-17 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-18
7-18 Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .7-19
7-19 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-29
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

31215030 vii
 LIST OF TABLES

viii 31215030
 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 • Read, understand, and study the Operation and Safety Manual
accept operating responsibility until this manual has been read, in its entirety before operating the machine. For clarification,
training is accomplished, and operation of the machine has been questions, or additional information regarding any portions of
completed under the supervision of an experienced and quali- 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”).

31215030 1-1
 SECTION 1 - SAFETY PRECAUTIONS

• Only personnel who have received proper training regarding Workplace Inspection
the inspection, application and operation of MEWPs (including
recognition and avoiding hazards associated with their opera- • Precautions to avoid all hazards in the work area must be
tion) shall be authorized to operate a MEWP. taken by the user before and during operation of the machine.
• Only properly trained personnel who have received unit-spe- • Do not operate or raise the platform from a position on trucks,
cific familiarization shall operate a MEWP. The user shall deter- trailers, railway cars, floating vessels, scaffolds or other equip-
mine if personnel are qualified to operate the MEWP prior to ment unless the application is approved in writing by JLG.
operation. • Before operation, check work area for overhead hazards such
• Read, understand, and obey all DANGERS, WARNINGS, CAU- as electric lines, bridge cranes, and other potential overhead
TIONS, and operating instructions on the machine and in this obstructions.
manual. • Check operating surfaces for holes, bumps, drop-offs, obstruc-
• Ensure that the machine is to be used in a manner which is tions, debris, concealed holes, and other potential hazards.
within the scope of its intended application as determined by • Check the work area for hazardous locations. Do not operate
JLG. the machine in hazardous environments unless approved for
• All operating personnel must have a thorough understanding that purpose by JLG.
of the intended purpose and function of the MEWP controls, • Ensure that the ground conditions are adequate to support
including platform, ground and emergency descent controls. the maximum tire load indicated on the tire load decals
• Read, understand, and obey all applicable employer, local, and located on the chassis adjacent to each wheel. Do not travel
governmental regulations as they pertain to your utilization on unsupported surfaces.
and application of the machine.

1-2 31215030
 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 A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT- occurs, shut down the machine. Remove the unit from service
TEN 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.

31215030 1-3
 SECTION 1 - SAFETY PRECAUTIONS

• Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con-
approved by JLG. traction. This may result in changes to the platform position
while the machine is stationary. Factors affecting thermal
• When two or more persons are in the platform, the operator
movement can include the length of time the machine will
shall be responsible for all machine operations.
remain stationary, hydraulic oil temperature, ambient air tem-
• Always ensure that power tools are properly stowed and never perature, and platform position.
left hanging by their cord from the platform work area.
• When driving, always position boom over rear axle in line with Trip and Fall Hazards
the direction of travel. Remember, if boom is over the front • Prior to operation, ensure all gates are closed and fastened in
axle, steer and drive functions will be reversed. their proper position.
• Do not assist a stuck or disabled machine by pushing or pull- • During operation, occupants in the platform must wear a full
ing except by pulling at the chassis tie-down lugs. body harness with a lanyard attached to an authorized lanyard
• Fully lower platform and shut off all power before leaving anchorage point. Attach only one (1) lanyard per lanyard
machine. anchorage point.

• Remove all rings, watches, and jewelry when operating

machine. Do not wear loose fitting clothing or long hair unre-
strained which may become caught or entangled in equip-
ment.
• Persons under the influence of drugs or alcohol or who are
subject to seizures, dizziness or loss of physical control must
not operate this machine.

1-4 31215030
 SECTION 1 - SAFETY PRECAUTIONS

• Enter and exit only through gate area. Use extreme caution Electrocution Hazards
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the platform when entering or • This machine is not insulated and does not provide protection
leaving the platform. Always maintain “three point contact” from contact or proximity to electrical current.
with the machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.

• It is not recommended to use the machine during lightning. To

prevent injury or machine damage if lightning occurs during
operation, lower the boom and shut down the machine in a
safe and secure location.

• 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.

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 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.

1-6 31215030
 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 • Ensure that the ground conditions are adequate to support
shall not be part of (or attached to) the machine. The mini- the maximum tire load indicated on the tire load decals
mum approach distance shall be reduced to a distance within located on the chassis adjacent to each wheel. Do not travel
the designed working dimensions of the insulating barrier. on unsupported surfaces.
This determination shall be made by a qualified person with • The user must be familiar with the operating surface before
respect to electrical transmission and distribution in accor- driving. Do not exceed the allowable sideslope and grade
dance with the employer, local, or governmental requirements while driving.
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 smooth, firm surface within the limits of the
maximum operating slope before elevating platform or driv-
ing with the platform in the elevated position.

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 SECTION 1 - SAFETY PRECAUTIONS

• Before driving on floors, bridges, trucks, and other surfaces, • Wind speed can be significantly greater at height than at
check allowable capacity of the surfaces. ground level.
• Never exceed the maximum platform capacity as specified on • Wind speed can change rapidly. Always consider approaching
the platform. Keep all loads within the confines of the plat- weather events, the time required to lower the platform, and
form, unless authorized by JLG. methods to monitor current and potential wind conditions.
• Keep the chassis of the machine a minimum of 2 ft. (0.6m) • Do not cover or increase surface area of the platform or the
from holes, bumps, drop-offs, obstructions, debris, concealed load. Do not carry large surface area items in the platform
holes, and other potential hazards at the ground level. when operating outdoors. The addition of such items
increases the exposed wind area of the machine. Increased
• Do not push or pull any object with the boom.
areas exposed to wind will decrease stability.
• Never attempt to use the machine as a crane. Do not tie-off
• Do not increase the platform size with unauthorized modifica-
machine to any adjacent structure. Never attach wire, cable, or
tions or attachments.
any similar items to platform.
• Do not operate the machine when wind conditions, including
gusts, may exceed specifications shown in Table 1-2, Beaufort
Scale. Factors affecting wind speed are; platform elevation,
surrounding structures, local weather events, and approach-
ing storms.

1-8 31215030
 SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS

EXCEED SPECIFICATIONS SHOWN IN SECTION 7.2 OR AS SHOWN
ON THE CAPACITY PLACARD ON THE PLATFORM BILLBOARD.

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.

31215030 1-9
 SECTION 1 - SAFETY PRECAUTIONS

Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from
machine during all 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,
• Watch for obstructions around machine and overhead when visibility, slope, location of personnel, and other factors.
driving. Check clearances above, on sides, and bottom of plat-
• Be aware of stopping distances in all drive speeds. When driv-
form during all operations.
ing in high speed, reduce drive 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.
• Ensure that operators of other overhead and floor level
machines are aware of the MEWP’s presence. Disconnect
power to overhead cranes.
• Do not operate over ground personnel. Warn personnel not to
• During operation, keep all body parts inside platform railing. work, stand, or walk under a raised boom or platform. Position
barricades on floor if necessary.
• Use the boom functions, not the drive function, to position the
platform close to obstacles.
• Always post a lookout when driving in areas where vision is
obstructed.

1-10 31215030
 SECTION 1 - SAFETY PRECAUTIONS

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

31215030 1-11
 SECTION 1 - SAFETY PRECAUTIONS

• DO NOT use your hand to check for • Do not replace items critical to stability, such as batteries or
leaks. Use a piece of cardboard or paper solid tires, with items of different weight or specification. Do
to search for leaks. Wear gloves to help not modify the MEWP in any way to affect stability.
protect hands from spraying fluid.
• Refer to the Service and Maintenance Manual for the weights
of critical stability items.

• Use only replacement parts or components that are approved

MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT-
by JLG. To be considered approved, replacement parts or com- TEN PERMISSION FROM THE MANUFACTURER.
ponents must be identical or 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.
• Do not use machine as a ground for welding.
• When performing welding or metal cutting operations, pre-
cautions must be taken to protect the chassis from direct
exposure to weld and metal cutting spatter.
• Do not refuel the machine with the engine running.
• Use only approved non-flammable cleaning solvents.

1-12 31215030
 SECTION 1 - SAFETY PRECAUTIONS

Battery Hazards
• Always disconnect batteries when servicing electrical compo-
nents or when performing welding on the machine.
• Do not allow smoking, open flame, or sparks near battery
during charging or servicing.
• Do not contact tools or other metal objects across the battery
terminals.
• Always wear hand, eye, and face protection when servicing
batteries. Ensure that battery acid does not come in contact
with skin or clothing.

BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND

CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH
CLEAN WATER AND SEEK MEDICAL ATTENTION.
• Charge batteries only in a well ventilated area.
• Avoid overfilling the battery fluid level. Add distilled water to
batteries only after the batteries are fully charged.

31215030 1-13
 SECTION 1 - SAFETY PRECAUTIONS

1-14 31215030
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING 7. The safest means to operate the machine where overhead
obstructions, other moving equipment, and obstacles,
The Mobile Elevating Work Platform (MEWP) is a personnel han- depressions, holes, and drop-offs exist.
dling device; so it is necessary that it be operated and maintained
8. Means to avoid the hazards of unprotected electrical con-
only by trained personnel.
ductors.
Operator Training 9. Selection of the appropriate MEWP and available options for
the work to be performed considering specific job require-
Operator training must cover:
ments, with involvement from the MEWP owner, user, and/
1. Reading and understanding the Operation and Safety Man- or supervisor.
ual.
10. The responsibility of the operator to ensure all platform
2. Thorough understanding of the intended purpose and func- occupants have a basic level of knowledge to work safely on
tion of the MEWP controls, including platform, ground, and the MEWP, and to inform them of applicable regulations,
emergency descent controls. standards, and safety rules.

3. Control labels, instructions, and warnings on the machine. 11. The requirement for familiarization in addition to training.

4. Applicable regulations, standards, and safety rules. Training Supervision

5. Use of approved fall protection equipment.
Training must be delivered by a qualified person in an open area
6. Enough knowledge of the mechanical operation of the free of hazards until the trainee has demonstrated the ability to
machine to recognize a malfunction or potential malfunc- safely control and operate the machine.
tion.

31215030 2-1
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Operator Responsibility 2. Purpose and function of the machine controls and indicators
at the platform and ground control stations;
The operator must be instructed they have the responsibility and
authority to shut down the machine in case of a malfunction or 3. Purpose, location, and function of the emergency controls;
other unsafe condition of either the machine or the job site. 4. Operating characteristics and limitations;

Machine Familiarization 5. Features and devices;

6. Accessories and optional equipment.
NOTE: Responsibilities for familiarization may vary by region.

Only properly trained personnel who have received unit-specific

2.2 PREPARATION, INSPECTION, AND MAINTENANCE
familiarization shall operate a MEWP. The user shall determine if The following table covers machine inspections and mainte-
personnel are qualified to operate the MEWP prior to operation. nance required by JLG Industries, Inc. Consult local regulations for
The user shall ensure that after familiarization, the operator oper- further requirements for MEWPs. Frequency of inspections and
ates the MEWP for a sufficient period of time to achieve profi- maintenance must be increased as necessary when machine is
ciency. When authorized by the user, self-familiarization can be used in a harsh or hostile environment, if machine is used with
achieved, if authorized, by a properly trained operator reading, increased frequency, or if machine is used in a severe manner.
understanding and following the manufacturer’s operator’s man-
ual.
Prior to users authorization of an operator to use a specific model
of MEWP, the user shall ensure the operator is familiarized on the
following:
1. Location of the manual storage compartment and the
requirement to ensure the required manual(s) are present on
the MEWP;

2-2 31215030
 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.

IMPORTANT
JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR
THE SPECIFIC JLG PRODUCT MODEL.

31215030 2-3
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.3 BASIC NOMENCLATURE

15

14

1. Platform 5. Fly Boom 9. Front Drive/Steer Wheels 13. Jib Lift Cylinder
2. Platform Control Console 6. Base Boom 10. Ground Control Console 14. Foot Switch
3. Rotator 7. Upright 11. Rear Drive Wheels 15. SkyGuard
4. Jib 8. Tower Boom 12. Platform Leveling Cylinder

2-4 31215030
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Pre-Start Inspection 5. Walk-Around Inspection – Perform as instructed.

The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required.

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7. Fuel (Combustion Engine Powered Machines) – Add the
tery fluid) or foreign objects. Report any leakage to the proper fuel as necessary.
proper maintenance personnel. 8. Engine Oil Supply - Ensure the engine oil level is at the Full
2. Structure - Inspect the machine structure for dents, dam- mark on the dipstick and the filler cap is secure.
age, weld or parent metal cracks or other discrepancies. 9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydrau-
lic oil is added as required.
10. Accessories/Attachments - Refer to the Accessories section
in this manual or accessory installed upon the machine for
specific inspection, operation, and maintenance instruc-
tions.
11. Function Check – Once the Walk-Around Inspection is com-
Parent Metal Crack Weld Crack plete, perform a functional check of all systems in an area
free of overhead and ground level obstructions. Refer to Sec-
3. Decals and Placards – Check all for cleanliness and legibil- tion 4 for more specific instructions.
ity. Make sure none of the decals and placards are missing.
Make sure all illegible decals and placards are cleaned or 12. Platform Gate - Keep gate and surrounding area clean and
replaced. unobstructed. Verify the gate closes properly and is not bent
or damaged. Keep gate closed at all times except when
4. Operation and Safety Manuals – Make sure a copy of the entering/exiting the platform and loading/unloading mate-
Operation and Safety Manual, AEM Safety Manual (ANSI rials.
markets only), and ANSI Manual of Responsibilities (ANSI
markets only) is enclosed in the weather resistant storage
container.

31215030 2-5
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

13. Lanyard Attach Points - During operation, occupants in the

platform must wear a full body harness with a lanyard
attached to an authorized lanyard anchorage point. Attach
only one (1) lanyard per lanyard anchorage point.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-
ATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT
OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.

2-6 31215030
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.4 WALK-AROUND INSPECTION DIAGRAM

31215030 2-7
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

General 3. Platform Control Console - Switches and levers return to

neutral when activated and released, decals/placards secure
Begin the Walk-Around Inspection at Item 1, as noted on the dia- and legible, control markings legible.
gram. Continue checking each item in sequence for the condi-
tions listed in the following checklist. 4. Platform Rotator - See Inspection Note

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF. DO NOT OPERATE

MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

5. Jib Assembly and Jib Rotator (If Equipped) - See Inspec-

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THIS
tion Note.
AREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVE
MACHINE DAMAGE. 6. Boom Sections/Uprights/Turntable - See Inspection Note.
7. All Hydraulic Cylinders - No visible damage; pivot pins and
INSPECTION NOTE: On all components, make sure there are no
hydraulic hoses undamaged, not leaking.
loose or missing parts, that they are securely fastened, and no visible
damage, leaks or excessive wear exists in addition to any other crite- 8. Wheel/Tire Assemblies - Properly secured, no missing lug
ria mentioned. nuts. Inspect for worn tread, cuts, tears or other discrepan-
cies. Inspect wheels for damage and corrosion.
1. Platform Assembly and Gate - Footswitch works properly,
not modified, disabled or blocked. Gate latches and hinges 9. Drive Motor, Brake, and Hub - No evidence of leakage.
in working condition.
10. Tie Rod Ends and Steering Spindles - See Inspection Note.
2. SkyGuard - See Inspection Note.
11. Counterweight - See Inspection Note.

2-8 31215030
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

12. Ground Control Console - Switches and levers return to b. Ensure all functions stop when the function switch is
neutral when activated and released, decals/placards secure released.
and legible, control markings legible. c. Operate all functions and check all limiting and cut-out
13. Hood Assemblies - See Inspection Note. switches to ensure proper operation.
d. Check auxiliary power and ensure proper operation.
14. Manual Descent - See Inspection Note.
2. From the platform control console:
15. Swing Motor and Worm Gear - No evidence of damage.
a. Ensure that the control console is firmly secured in the
16. Turntable Bearing - Evidence of proper lubrication. No evi-
proper location;
dence of loose bolts or looseness between bearing and
machine. b. Check that all guards protecting the switches or locks
are in place;
17. Hydraulic Pump and Reservoir - See Inspection Note.
c. Ensure that all machine functions are disabled when
18. Battery - Batteries have proper electrolyte level; cables the Emergency Stop Button is pushed in.
tight; see Inspection Note. d. Ensure that all machine functions stop when the
19. Air Shutoff Valve (ASOV) (If Equipped) - See Inspection footswitch is released.
Note. e. Operate all functions and ensure proper operation.
20. Fuel Tank - See Inspection Note. 3. With the platform in the transport (stowed) position:
a. Drive the machine on a grade, not to exceed the rated
Function Check gradeability, and stop to ensure the brakes hold;
Perform the Function Check as follows: b. Check the tilt indicator is illuminated to ensure proper
operation.
1. From the ground control panel with no load in the platform:
a. Ensure that all machine functions are disabled when
the Emergency Stop Button is pushed in.

31215030 2-9
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

4. Swing the boom over either of the rear tires and ensure that
the Drive Orientation indicator illuminates and that the
Drive Orientation Override switch must be used for the drive
function to operate.
5. Place the machine in Transport Mode. Ensure machine is
positioned on a smooth, firm surface and drive machine
with tower boom down and fully retracted, elevate main
boom beyond 5° horizontal. Ensure drive speed is reduced
while operating.

2-10 31215030
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SkyGuard® Function Test 4. Disengage the SkyGuard sensor, release controls, then recy-
cle the footswitch. Ensure normal operation is available.
NOTE: Refer to Section 4.11 for additional information on SkyGuard
NOTE: On machines equipped with SkyLine, reattach magnetic end of
operation.
the cable to the bracket.
From the Platform Console in an area free from obstructions:
If SkyGuard remains activated after function reversal or cutout,
1. Operate the telescope out function. depress and hold the SkyGuard Override Switch to allow normal
use of machine functions until the sensor is disengaged.
2. Activate the SkyGuard sensor:
a. SkyGuard - Apply approximately 50 lb. (222 Nm) of
force to yellow bar.
b. SkyGuard SkyLine™ - Press cable to break magnetic
connection between the cable and right bracket.
c. SkyGuard SkyEye™ - Put arm or hand in path of sensor
beam.
3. Once the sensor has been activated, verify the following
conditions:
a. Telescope out function stops and telescope in function
operates for a short duration.
b. The horn sounds.
c. If equipped with SkyGuard beacon, the beacon illumi-
nates.

NOTE: If SkyGuard is enabled with the Soft Touch system, functions will
cut out instead of reversing.

31215030 2-11
 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-12 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL 3.2 CONTROLS AND INDICATORS
NOTE: The indicator panels use different shaped symbols to alert the
operator to different types of operational situations that could
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND arise. The meaning of those symbols are explained below.
OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH
GOOD SAFETY PRACTICES. Indicates a potentially hazardous situation, which if
not corrected, could result in serious injury or death.
This section provides the necessary information needed to This indicator will be red.
understand control functions.
Indicates an abnormal operating condition, which if
not corrected, may result in machine interruption or
damage. This indicator will be yellow.

Indicates important information regarding the operat-

ing condition, i.e. procedures essential for safe opera-
tion. This indicator will be green with the exception of
the capacity indicator which will be yellow.

31215030 3-1
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3.3 GROUND CONTROL STATION

600AJ without MSSO

1. Platform Rotate
2. Platform Leveling Override
3. Jib
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power
6. Tower Boom Telescope
7. Hourmeter
8. Platform/Ground Select
9. Swing
10. Tower Boom Lift
11. Main Boom Lift
12. Main Boom Telescope
13. Not Used
14. Air Shutoff Valve (ASOV) (If Equipped)

3-2 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

600AJ with MSSO

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

31215030 3-3
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

600AJ with MSSO and DPF

15
1
12
1. Platform Rotate
2. Platform Leveling Override
2
3. Jib 11
4. Power/Emergency Stop
5. Engine Start/Auxiliary Power
6. Tower Boom Telescope
7. Hourmeter
4 10
8. Platform/Ground Select
9. Swing
10. Tower Boom Lift 5
11. Main Boom Lift
12. Main Boom Telescope 6 QUAR TZ
11
11 00

13. Machine Safety System Override (MSSO)

H
HOOU
URR SS

!
14. Not Used 9
7
15. Diesel Particulate Filter (DPF)
1001180093 A

8
13

3-4 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

2. Platform Leveling Override

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR A three position switch allows the
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE operator to adjust the automatic self
OFF OR NEUTRAL POSITION WHEN RELEASED. leveling system. This switch is used to
adjust platform level in situations
NOTE: When machine is shut down the Platform/ such as ascending/descending a
Ground Select switch and Emergency Stop must grade.
be positioned to OFF.
3. Jib

Provides raising and lowering of the

jib.
1. Platform Rotate

Provides rotation of the platform.

NOTE: When Power/Emergency Stop switch is in the “On” position and

engine is not running, an alarm will sound, indicating Ignition is
“On”.

4. Power/Emergency Stop Switch

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR
A two-position red mushroom shaped switch
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
supplies power to Platform/Ground Select
switch when pulled out (on). When pushed in
(off ), power is shut off to the Platform/Ground Select switch.

31215030 3-5
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Tower Boom Telescope

ALWAYS POSITION EMERGENC Y STOP SWITCH TO THE ’OFF’ POSITION (PUSHED IN) This switch provides extending and
WHEN MACHINE IS NOT IN USE. retracting of the tower boom. This
function works only when the tower
NOTE: On machines with diesel engines, when Glow Plug Indicator is boom is fully elevated (lift up).
lighted (Yellow), wait until light goes out before cranking engine.

5. Engine Start/ Auxiliary Power Switch

To start the engine, the switch must be held TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT
"Up" until the engine starts. AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE.

To use auxiliary power, the switch must be 7. Hourmeter

held “Down” for duration of auxiliary pump
use. Registers the amount of time the
machine has been in use, with engine
running. By connecting into the oil
pressure circuit of the engine, only engine run hours are
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC-
recorded. The hourmeter registers up to 9,999.9 hours and
TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP
cannot be reset.
MOTOR.)
NOTE: When the Platform/Ground Select Switch is in the
center position, power is shut off to the controls at
both operating stations. Remove the key to pre-
vent the controls from being actuated.

3-6 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform/Ground Select Switch 10. Tower Boom Lift

The three position, key operated switch sup- This switch provides raising and low-
plies power to the platform control console ering of the tower boom. This func-
when positioned to Platform. With the switch tion works only when the tower
key turned to the Ground position only boom is fully retracted.
ground controls are operable.

NOTE: When the Platform/Ground Select Switch is in the center posi- 11. Main Boom Lift Control
tion, power is shut off to the controls at both operating stations.
Remove the key to prevent the controls from being actuated. Provides raising and lowering of the
main boom.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR

UNDER PLATFORM.
12. Main Boom Telescope Control
9. Swing Control
Provides extension and retraction of
the main boom.
Provides 360 degrees continuous
turntable rotation.

31215030 3-7
 SECTION 3 - MACHINE CONTROLS AND INDICATORS
13. Machine Safety System Override (MSSO)
(If Equipped)

Provides emergency override of function

controls that are locked out in the event of
Load Sense System activation.
14. Air Shutoff Valve (ASOV) (If Equipped)

The red LED ASOV light indicates when the

valve has been actuated.
15. Diesel Particulate Filter (DPF) (If Equipped)

This button initiates the standstill exhaust sys-

tem cleaning.

3-8 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3.4 GROUND CONTROL INDICATOR PANEL

1 2 3 4 5 6

10 9 8 7

1. Battery Charge 5. Capacity Zone Indicator 8. Platform Overload

2. Low Fuel (Ford DF 2.5L Only) 6. Glow Plug 9. Engine Error
3. System Distress 7. Generator 10. Emissions Temperature
4. Drive and Steer Disable

31215030 3-9
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Charge Indicator 5. Capacity Zone Indicator

Indicates a problem in the battery or charging Indicates the platform capacity zone for the
circuit, and service is required. current position of the platform. Restricted
capacities are permitted at restricted platform
2. Low Fuel Warning Indicator (Ford DF 2.5L Only)
positions (shorter boom lengths and higher
boom angles).
Indicates the fuel in the fuel tank is low.
NOTE: Refer to the capacity decals on the machine for
restricted and unrestricted platform capacities.
3. System Distress Indicator
6. Glow Plug Indicator
The light indicates that the JLG Control System
has detected an abnormal condition and a
Indicates the glow plugs are on. The glow
Diagnostic Trouble Code has been set in the
plugs are automatically turned on with the
system memory. Refer to the Service Manual for instructions
ignition circuit and remain on for approxi-
concerning the trouble codes and trouble code retrieval.
mately seven seconds. Start the engine only after the light
goes out.
The system distress indicator light will illuminate for 2-3 sec-
onds when the key is positioned to the ON position to act as 7. AC Generator Indicator
a self test.
Indicates the generator is in operation.
4. Drive and Steer Disable Indicator

Indicates the Drive and Steer Disable function 8. Platform Overload Indicator
has been activated.
Indicates the platform has been overloaded.

3-10 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

9. Engine Error Indicator

Indicates a fault with the engine and service is

required or is requesting a cleaning sequence.
10. Emissions Temperature Indicator

Indicator illuminates when exhaust tempera-

ture reaches 1022° F (550° C).

31215030 3-11
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3.5 PLATFORM CONTROL CONSOLE

1 2 3 4 5 6

1702676 D
1001107677 A

1702566 B 1702565 B

1702567 B

1702938 1705170 A

17 16 15 14 13 12 11 10 9 8 7

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

3-12 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Horn

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR A push-type Horn switch supplies electrical
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE power to an audible warning device when pressed.
OFF OR NEUTRAL POSITION WHEN RELEASED.
4. Power/Emergency Stop Switch

A two-position red mushroom shaped switch

furnishes power to Platform Controls when
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
pulled out (on). When pushed in (off ), power is
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
shut off to the platform functions.
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.
5. Start/Auxiliary Power
1. Drive Speed/Torque Select
When pushed forward, the switch energizes
The machine has a three position the starter motor to start the engine.
switch - The forward position
The Auxiliary Power control switch energizes
gives maximum drive speed. The
the electrically operated hydraulic pump.
back position gives maximum
(Switch must be held on for duration of auxil-
torque for rough terrain and
iary pump use.)
climbing grades. The center posi-
tion allows the machine to be driven as quietly as possible. The auxiliary pump functions to provide sufficient oil flow to
operate the basic machine functions should the main pump
2. Platform Leveling Override
or engine fail. The auxiliary pump will operate tower boom
lift, tower telescope, main boom lift, main telescope and
A three position switch allows the operator to
swing.
adjust the automatic self leveling system. This
switch is used to adjust platform level in situa-
tions such as ascending/descending a grade.

31215030 3-13
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Drive Orientation Override NOTE: To operate the Drive joystick, pull up on the lock-
ing ring below the handle.
When the boom is swung over the rear tires or
further in either direction, the Drive Orienta-
tion indicator will illuminate when the drive
function is selected. Push and release the switch, and within
3 seconds move the Drive/Steer control to activate drive or
steer. Before driving, locate the black/white orientation
arrows on both the chassis and the platform controls. Move NOTE: The Drive joystick is spring loaded and will automatically return
the drive controls in a direction matching the directional to neutral (off) position when released.
arrows for the intended direction of travel.
7. Drive/Steer
NOTE: Lift, Swing, and Drive control levers are spring-loaded and will
automatically return to neutral (off) position when released. Push forward to drive forward,
pull back to drive in reverse.
Steering is accomplished via a
thumb-activated rocker switch on
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR the end of the steer handle.
TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE
OFF OR NEUTRAL POSITION WHEN RELEASED.
8. Main Boom Telescope

Provides extension and retraction of the main

boom.
9. Lights (If Equipped)

This switch operates the accessory lights pack-

age if the machine is so equipped.

3-14 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: The ignition switch does not have to be on to operate the lights,
so care must be taken to avoid draining the battery if left unat- For machines equipped with both SkyGuard and SkySense:
tended. The master switch and/or the ignition switch at the
The switch operates like the SkyGuard
ground control will turn off power to all lights.
override switch as described above.
The switch also enables the functions
10. Jib Lift
cut out by the SkySense system to
operate again at creep speed, allowing the operator to move
Provides raising and lowering of the upright
the platform closer to the obstacle that caused the shut-
and lower booms.
down situation if desired.
12. Tower Telescope
11. Soft Touch/SkyGuard/SkySense Override Switch
For machines equipped with SkyGuard: This switch provides for extending and retract-
ing of the tower boom when positioned to in
The SkyGuard override switch enables
or out. Tower Telescope must be fully retracted
functions cut out by the Skyguard sys-
before operating Tower Lift. (Tower Telescope should not
tem to be operated again, allowing the
function when Tower Lift is not fully elevated “up”).
operator to resume use of machine
functions. 13. Tower Lift
For machines equipped with both SkyGuard and Soft Touch:
This switch provides for raising and lowering of
The switch operates like the SkyGuard the tower boom when positioned to “up” or
override switch as described above. “down”. Tower Lift must be fully elevated “up”
The switch also enables the functions before operating Tower Telescope. (Tower Lift should not
cut out by the Soft Touch system to function when Tower Telescope is extended).
operate again at creep speed, allowing the operator to move
the platform away from the obstacle that caused the shut-
down situation.

31215030 3-15
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

16. Function Speed Control

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT This control affects the speed of the Tele-
AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE. scope, Tower Lift, Tower Telescope, Jib Lift,
and Platform Rotate functions.
14. Soft Touch/SkyGuard/SkySense Indicator
NOTE: During platform rotation, a speed difference
Indicates the Soft Touch bumper is against an object or the may not be noticeable to the operator.
SkyGuard sensor has been activated. All controls are cut out
until the override button is pushed. For Soft Touch, controls Turning the knob all the way counterclockwise until it clicks
are then active in the Creep Mode or for SkyGuard, controls puts the machine into Creep Mode. Creep Mode puts the
will work normally. functions listed above, as well as the Drive/Steer and Main
Lift/Swing functions into the slowest speed setting.
If machine is equipped with SkySense, the switch will mute NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the
the SkySense speakers. locking ring below the handle
15. Platform Rotate
NOTE: The Main Boom Lift/Swing joystick is spring
Provides rotation of the platform. loaded and will automatically return to neutral
(off) position when released..

17. Main Lift/Swing Controller

DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEED
SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL. Provides main lift and swing. Push
forward to lift up, pull backward to
boom down. Move right to swing
right, move left to swing left.

3-16 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

3.6 PLATFORM CONTROL INDICATOR PANEL

1 2 3 4 5 6 7 8

!
!

14 13 12 11 10 9

1. Low Fuel (Ford DF 2.5L Only) 5. Tilt Alarm/Warning 9. Engine Emissions System Failure 13. Diesel Particulate Filter Indicator
2. System Distress 6. Creep 10. Generator 14. Emissions Temperature
3. Drive Orientation 7. Footswitch 11. Platform Overload
4. Capacity Zone Indicator 8. Glow Plug 12. Engine Error

31215030 3-17
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Low Fuel Warning Indicator (Ford DF 2.5L Only) 4. Capacity Zone Indicator

Indicates the fuel in the fuel tank is low. Indicates the maximum platform capacity
zone for the current position of the platform.
Restricted capacities are permitted at
2. System Distress Indicator
restricted platform positions (shorter boom
lengths and higher boom angles).
The light indicates that the JLG Control System
has detected an abnormal condition and a NOTE: Refer to the capacity decals on the machine for
Diagnostic Trouble Code has been set in the restricted and unrestricted platform capacities.
system memory. Refer to the Service Manual for instructions
concerning the trouble codes and trouble code retrieval. 5. Tilt Warning Light and Alarm
3. Drive Orientation Indicator
This red illuminator indicates that the chassis is
on a slope. If the boom is above horizontal and
When the boom is swung beyond the rear
the machine is on a slope, the tilt alarm warn-
drive tires or further in either direction, the
ing light will illuminate, an alarm will sound, available func-
Drive Orientation indicator will illuminate
tions are placed in CREEP speed, and drive is cut out in
when the drive function is selected. This is a signal for the
direction of travel. Drive in the opposite direction may be
operator to verify that the drive control is being operated in
allowed under certain conditions.
the proper direction (i.e. controls reversed situations).

Tilt Angle Market

5° China
4° ANSI/CE/AUS
3° ANSI (7ft Chassis)

3-18 31215030
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH
RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT BY BLOCKING OR ANY OTHER MEANS.
IT IS WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE BEFORE EXTENDING
BOOM OR RAISING BOOM ABOVE HORIZONTAL. 8. Glow Plug Indicator

6. Creep Speed Indicator Indicates the glow plugs are operating. After
turning on ignition, wait until light goes out
When the Function Speed Control is turned to before cranking engine.
the creep position, the indicator acts as a
9. Engine Emissions System Failure Indicator
reminder that all functions are set to the slow-
est speed.
Icon illuminates when there is a fault with the
7. Footswitch/Enable Indicator Emissions After Treatment system.
10. AC Generator Indicator
To operate any function, the footswitch must
be depressed and the function selected within
Indicates the generator is in operation.
seven seconds. The enable indicator shows
that the controls are enabled. If a function is not selected
within seven seconds, or if a seven second lapse between 11. Platform Overload Indicator
ending one function and beginning the next function, the
enable light will go out and the footswitch must be released Indicates the platform has been overloaded.
and depressed again to enable the controls.

Releasing the footswitch removes power from all controls

and applies the drive brakes.

31215030 3-19
 SECTION 3 - MACHINE CONTROLS AND INDICATORS

12. Engine Error Indicator

Indicates a fault with the engine and service is

required.
13. Diesel Particulate Filter (DPF) Indicator

Icon will illuminate when standstill exhaust

system cleaning is required.
14. Emissions Temperature Indicator

Icon illuminates when the engine emissions

control sensor reaches a high temperature.

3-20 31215030
 SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION 1. Machine is positioned on a smooth, firm surface within the
limits of the maximum operating slope.
This machine is a Mobile Elevating Work Platform (MEWP) used to
2. Load is within manufacturer’s rated capacity.
position personnel, along with their necessary tools and materi-
als at work locations. 3. All machine systems are functioning properly.
The primary operator control station is in the platform. From this 4. Machine is as originally equipped from JLG.
control station, the operator can drive and steer the machine in
both forward and reverse directions. The operator can raise or Platform Load Sensing System (LSS)
lower the main or tower boom or swing the boom to the left or
The Platform Load Sensing System provides the platform capac-
right. Standard boom swing is 360 degree continuous left and
ity to the control system.
right of the stowed position. The machine has a Ground Control
Station. Ground Controls operate all functions except drive and If the LSS system senses an overload condition, boom functions
steer. Except for performing inspections and the Function Check, will be disabled, the overload indicator is illuminated at both con-
the ground controls are to be used in an emergency to lower the trol stations, and the overload alarm will sound. Reduce the
platform to the ground should the operator in the platform be weight in the platform to not exceed the rated workload indi-
unable to do so. cated on the capacity decal, then the controls will work again.

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities
The boom can be raised above horizontal with or without any
load in platform, if:

31215030 4-1
 SECTION 4 - MACHINE OPERATION

Stability Position of Least Backward 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 “Position of Least Forward Stabil-
ity” on page 3, and its position of least BACKWARD stability is
shown in “Position of Least Backward Stability” on page 2.

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

THE MACHINE BEYOND THE LIMIT OF THE MAXIMUM OPERATING SLOPE.

4-2 31215030
 SECTION 4 - MACHINE OPERATION

Position of Least Forward Stability

31215030 4-3
 SECTION 4 - MACHINE OPERATION

4.3 ENGINE OPERATION Starting Procedure

NOTE: When operating a machine at high altitudes, a decrease in
machine performance may occur due to a decrease in air den-
sity. IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME.
SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MIN-
NOTE: When operating a machine at high ambient temperatures, a UTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE
decrease in machine performance and an increase in engine MANUAL.
coolant temperature may occur.
NOTE: Diesel engines only: After turning on ignition,
NOTE: Contact JLG Customer Service for operation under abnormal operator must wait until glow plug indicator light
conditions. goes out before cranking engine.
NOTE: Initial starting should always be performed
from the Ground Control station. 1. Turn key of Platform/Ground Select switch to
Ground.

2. Pull the Power/Emergency Stop switch to On.

3. Push the Engine Start switch until engine starts.

4-4 31215030
 SECTION 4 - MACHINE OPERATION

8. Push the Engine Start switch until engine starts.

ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING
ANY LOAD.
NOTE: Footswitch must be in released (up) position before starter will
4. After engine has had sufficient time to warm operate. If starter operates with footswitch in the depressed posi-
up, push in the Power/Emergency Stop switch tion, DO NOT OPERATE MACHINE.
and shut engine off.
Shutdown Procedure
5. Turn Platform/Ground Select switch to Plat-
form.
IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN, DETERMINE
THE CAUSE AND CORRECT IT BEFORE RESTARTING THE ENGINE.

6. From Ground Control Console, pull Power/ 1. Remove all load and allow engine to operate at low speed
Emergency Stop switch out. for 3-5 minutes; this allows further reduction of internal
engine temperature.
2. Push Power/Emergency Stop switch in.
7. From Platform, pull Power/Emergency Stop
switch out.

3. Turn Platform/Ground Select switch to Off.

NOTE: Refer to Engine Manufacturer’s manual for

detailed information.

31215030 4-5
 SECTION 4 - MACHINE OPERATION

Air Shutoff Valve (ASOV) (If Equipped)

DO NOT USE ASOV AS AN ALTERNATIVE TO SHUTTING DOWN MACHINE PROPERLY.
Air Shutoff Valve (ASOV ) is an overspeed protection device
mounted to the engine’s air intake system. When the valve is
actuated, it obstructs airflow intake and stops the engine. Weekly
tests are recommended to ensure the valve remains in good
working condition.
1. Start the engine, running at idle.
2. Open the red switch guard on ASOV test switch, then acti-
vate toggle to test mode.

NOTE: Test switch is located under hood to the left of

the ground control panel (look for test decal). ASOV
3. At the ground control panel, select any TEST
1001227964A
function and activate until valve actuates
at test RPM of 1500. Once valve actuates,
engine will stop.
4. Turn ignition to OFF.
5. Visually inspect valve to ensure it appears in good condition.
6. Reset valve by rotating valve handle to the Open position.

NOTE: The handle cannot be turned unless the machine is off. Ensure
Figure 4-1. ASOV Reset (Closed to Open Position)
the ignition is moved to the OFF position.

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 SECTION 4 - MACHINE OPERATION

Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera-
tor will be permitted to cycle power and restart the engine
for approximately 2 minutes of run time. After the 2 min-
NOTE: Reference the Service and Maintenance Manual along with a
utes of run time is complete, the operator may cycle power
qualified JLG Mechanic to verify your machine setup.
and restart the engine for an additional 2 minutes of run
time. The operator can repeat this process until there is no
The Fuel Shutoff System monitors the fuel in the tank and senses
more fuel available.
when the fuel level is getting low. The JLG Control System auto-
matically shuts the engine down before the fuel tank is emptied
unless the machine is set up for Engine Restart.
CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO
If fuel level reaches the Empty range, the Low Fuel
MORE FUEL IS AVAILABLE.
light will begin to flash once a second and there will
be approximately 60 minutes of engine run time
• Engine Stop - When the engine shuts down, no restarts
left. If the system is in this condition and automati-
will be permitted until fuel is added to the tank.
cally shuts down the engine or if the operator man-
ually shuts down the engine before the 60 minute run time is
complete, the Low Fuel light will flash 10 times a second and the
engine will react according to machine setup. Setup options are
as follows:
• 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.
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
minute run time, it cannot be restarted until fuel is added
to the tank.

31215030 4-7
 SECTION 4 - MACHINE OPERATION

4.4 DIESEL PARTICULATE FILTER (IF EQUIPPED) Standstill Cleaning

Diesel Particulate Filter (DPF) is an emissions control system used The following conditions must be met to perform Standstill
in diesel engines and requires operator interaction to make sure Cleaning.
proper operation of the system.
• Machine must be stationary
For peak operation, the DPF system must be cleaned using one of • Boom in the stowed position
two methods, Standstill Cleaning and Maintenance Standstill
Cleaning. Standstill Cleaning is any cleaning requested by the • No personnel in platform
engine outside of the regular maintenance window (for example, • Engine must be idling
if the system detects excessive soot in the DPF canister). Mainte-
nance Standstill Cleaning is cleaning requested by the engine on • Coolant temperature must be above 104° F (40° C)
the regular maintenance interval. • Machine in Ground Station mode
NOTE: The system will reset the maintenance interval back to zero 1. The Diesel Particulate Filter (DPF) Indicator on
hours after Standstill or Maintenance Standstill Cleaning events the Platform Control Panel will flash when stand-
are performed. still cleaning is required.

2. Move the machine to an suitable area free of flammables

and personnel that could be exposed to hot exhaust.

4-8 31215030
 SECTION 4 - MACHINE OPERATION

3. Launch the cleaning process by pressing the DPF button on

the Ground Console for 3 seconds. The Indicator Gauge will
display the following screen.

4. The Main Cleaning process will begin and last for approxi-
mately 30 to 60 minutes. The following screen will show that
the process has begun and includes a status bar that indi-
cates the progress of the cleaning process.

31215030 4-9
 SECTION 4 - MACHINE OPERATION

5. After the cleaning process is complete, the engine will run Canceling Maintenance Standstill
for approximately 5 minutes to allow the engine and
Exhaust After Treatment (EAT) to cool down. The Indicator Maintenance Standstill Cleaning will be stopped immediately if:
Gauge will display the "Regen Complete" screen as shown • The Platform/Ground Select switch is switched from
and the Emissions Temperature indicator will no longer be Ground to Platform mode
illuminated.
• Any function switch is enabled to perform a boom func-
tion
• The Engine is powered down
If Maintenance Standstill Cleaning is interrupted, it must be re-
initiated and the Indicator Gauge will display the "Regen Failed"
screen as shown.

Maintenance Standstill Cleaning Initiation Methods

Maintenance Standstill Cleaning can be started by one of two
methods, by using the Analyzer or the DPF button on the Ground
Console. All the same conditions as outlined under Standstill
Cleaning must be met.

4-10 31215030
 SECTION 4 - MACHINE OPERATION

Unsuccessful Cleaning Event DPF Filter Replacement due to Ash Load

If there is an unsuccessful cleaning event, the DPF icon will show The DPF collects non-burnable particulates which cannot be
on the display gauge. Possible causes of an Unsuccessful Clean- removed by the Standstill Cleaning process. Build up of the ash
ing Event are: load requires filter maintenance and/or exchange.
• Engine is not warmed up DPF filter maintenance or exchange requirement is indicated by
the DPF Exchange icon shown on the display gauge.
• DEF tank is frozen
.
• Machine functions operated during cleaning event in
progress
• Other engine faults are active DP F F ilter E xchange

The Gauge will display "Regen Failed" screen as shown. If the

cleaning event has failed, the process must be repeated.
.

31215030 4-11
 SECTION 4 - MACHINE OPERATION

Table 4-1. Ash Load DPF Filter Replacement

DPF Filter Engine Error

Ash Load Derate
Exchange Indicator Indicator
Normal Operation <100% -- -- None

Filter Exchange Required ≥100% DPF Filter E xchange

-- None

Blinking

Warning Level ≥105% DPF Filter E xchange

-- None

Blinking Continuous
Machine placed in Creep and DTC active.
Warning Level ≥110% DPF Filter E xchange
Contact Deutz Dealer

4-12 31215030
 SECTION 4 - MACHINE OPERATION

Machine Hours Emissions

Standstill Cleaning Engine Error
Since Last DPF Indicator Temperature Derate Comments
Levels Indicator
Cleaning Indicator*
0-500 Between 500 and 650 hours,
Normal
0 -- -- None cleaning cycle can be initiated
Operation 500-650 with JLG analyzer.

Standstill
1 650-750 -- None
Required Engine coolant temperature
must be >40° C and machine
Continuous must be in ground station
Warning Machine placed in Creep mode.
2 750-775
Level and DTC active

Blinking Idle Lock. Boom Func-

Shut Off
3 >775 tions Locked Out and
Level
trapped in Transport.
Contact Deutz Dealer
DPF Regeneration Blinking
Idle Lock. Boom Func-
Filter NOT POSSIBLE
4 tions Locked Out and
Exchange DPF Filter exchange
trapped in Transport.
required
*Emissions Temperature indicator continuously ON during Standstill Cleaning

31215030 4-13
 SECTION 4 - MACHINE OPERATION

Emissions
Soot Load/ DPF Cleaning Engine Error
Soot Levels DPF Indicator Temperature Derate Comments
Time Initiation Methods Indicator
Indicator*

Normal Opera-
<99% -- -- None
tion

Will remain in Stand-

100% to 109% Switch in JLG Machine
Standstill still mode for 100 hours
or or -- None
Required or until the soot load
100 Hours JLG Analyzer
reaches 109%
Continuous Will remain in Warning
109% to 125% Switch in JLG Machine
Machine placed in Creep level (Derate) for 25
Warning Level or or
and DTC active hours or until the soot
25 Hours JLG Analyzer
load reaches 125%
Blinking Idle Lock. Boom Functions
Shut Off Level 125% to 161% DPF Cleaning Not Possible Locked Out and Trapped in
Transport
Contact Deutz Dealer
Blinking Idle Lock. Boom Functions
Filter Exchange >161% DPF Cleaning Not Possible Locked Out and Trapped in
Transport
*Emissions Temperature indicator continuously ON during Standstill Cleaning

4-14 31215030
 SECTION 4 - MACHINE OPERATION

Figure 4-2. Grade and Sideslope

31215030 4-15
 SECTION 4 - MACHINE OPERATION

4.5 TRAVELING (DRIVING)

See Figure 4-2., Grade and Sideslope DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM SUR-
FACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE.
NOTE: Refer to the Operating Specifications table for Gradeability and
Sideslope ratings. TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER, DO NOT DRIVE MACHINE ON
GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION
All ratings for Gradeability and Sideslope are based upon the OF THIS MANUAL.
machine’s boom being in the stowed position, fully lowered, and
retracted. BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED TRAVELING.

Traveling is limited by two factors: DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES FOR CHINA AND 4 DEGREES
FOR ANSI/CE/AUS MARKETS.
1. Gradeability, which is the percent of grade of the incline the
machine can climb.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE
2. Sideslope, which is the angle of the slope the machine can PLATFORM IS ELEVATED.
be driven across.
BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE
CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC-
TION MATCHING THE DIRECTIONAL ARROWS FOR THE INTENDED DIRECTION OF
TRAVEL.

4-16 31215030
 SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse 2. Push and release the Drive Orientation Over-
ride switch. Within 3 seconds, slowly move the
Drive control toward the arrow matching the
1. At Platform Controls, pull out Emergency Stop
intended direction of machine travel. The indi-
switch and activate footswitch.
cator light will flash during the 3 second inter-
val until the drive function is selected.

2. Position Drive controller to FORWARD

or REVERSE as desired.

This machine is equipped with a Drive Ori-

entation Indicator. The yellow light on the platform control con-
sole indicates that the boom is swung beyond the rear drive tires
and the machine may Drive/Steer in the opposite direction from
the movement of the controls. If the indicator is illuminated,
operate the Drive function in the following manner:
1. Match the black and white direction
arrows on both platform control panel
and the chassis to determine the
direction the machine will travel.

31215030 4-17
 SECTION 4 - MACHINE OPERATION

Traveling on a Grade 4.6 STEERING

When traveling a grade, maximum braking and traction are obtained Position thumb switch on Drive/Steer controller to
with the boom stowed, in position over the rear (drive) axle, and in Right for steering right, or to Left for steering left.
line with the direction of travel. Drive the machine forward when
climbing a grade, and in reverse when descending a grade. Do not 4.7 PLATFORM
exceed the machine's maximum rated gradability.
Platform Level Adjustment

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF
THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR
FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

To Level Up or Down - Position the Platform/Level

control switch Up or Down and hold until the plat-
form is level.

Platform Rotation
Figure 4-3. Traveling on a Grade To rotate the platform to the left or right, use the
Platform Rotate control switch to select the direc-
tion and hold until the platform is level.

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

4-18 31215030
 SECTION 4 - MACHINE OPERATION

4.8 BOOM
TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL
SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER-
A RED TILT WARNING LIGHT IS LOCATED ON THE CONTROL CONSOLE WHICH LIGHTS WHEN GENCY STOP SWITCH TO STOP THE MACHINE.
THE CHASSIS IS ON AN EXCESSIVE SLOPE. DO NOT SWING OR RAISE BOOM ABOVE HORI-
ZONTAL WHEN INDICATOR IS LIT. Swinging the Boom
DO NOT DEPEND ON THE TILT WARNING LIGHT AS A LEVEL INDICATOR FOR THE CHASSIS.
To swing boom, use Swing control switch to select
THE TILT WARNING LIGHT INDICATES CHASSIS IS ON AN EXCESSIVE SLOPE (5 DEGREES OR
Right or Left direction.
GREATER). CHASSIS MUST BE LEVEL BEFORE SWINGING OR RAISING BOOM ABOVE HORI-
ZONTAL OR DRIVING WITH THE BOOM ELEVATED.

TO AVOID TIP OVER IF RED TILT WARNING LIGHT LIGHTS WHEN THE BOOM IS RAISED
ABOVE HORIZONTAL, LOWER PLATFORM TO GROUND LEVEL. THEN REPOSITION MACHINE WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO
SO THAT CHASSIS IS LEVEL BEFORE RAISING BOOM. CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, NOTE: On CE Market machines, when boom functions are being oper-
REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE ated there is an interlock that prevents the use of Drive and Steer
MACHINE. functions.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR

TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE
‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

31215030 4-19
 SECTION 4 - MACHINE OPERATION

Raising and Lowering the Tower Boom b. The Tower lift “down” will only operate when
the Tower Boom is fully retracted.
This machine has two controls for the tower boom (two toggle
switches), one controls tower lift, the other tower telescope. The
switching system will sequence its Lift and Telescope functions as
follows:
TO AVOID TIPPING MACHINE IF TOWER BOOM SWITCHING MALFUNCTIONS:
1. Sequence while raising the Tower Boom from the fully low-
ered position.
— LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELESCOPE FUNC-
a. The Tower Boom must be fully elevated “up” TIONS.
(approximately 13 degrees from vertical)
before the Tower Boom can be extended — HAVE CONDITION CORRECTED BY A QUALIFIED JLG SERVICE TECHNICIAN BEFORE
from the fully retracted position. CONTINUING USE OF MACHINE.
b. The Tower Telescope “out” or “in” will only
be operable when the Tower Boom is fully Raising and Lowering the Main Boom
elevated “up”.
To raise or lower the Main Boom, position the Main
Boom Lift switch to Up or Down until the desired
2. Sequence while lowering the Tower Boom from the fully ele- height is reached.
vated “up” position.
a. Operate Tower Telescope “in” until Tower
Boom is fully retracted. (Tower must not lift
Telescoping the Main Boom
“down until tower boom is full retracted.
To extend or retract the main boom, use the Main
Telescope Control Switch to select In or Out move-
ment.

4-20 31215030
 SECTION 4 - MACHINE OPERATION

4.9 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.

31215030 4-21
4-22
SECTION 4 - MACHINE OPERATION

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

31215030
31215030

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

4-23
SECTION 4 - MACHINE OPERATION
 SECTION 4 - MACHINE OPERATION

4.10 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) SkyGuard

(IF EQUIPPED)
The Machine Safety System Override (MSSO) is
used to override function controls for Emergency
Platform Retrieval only. Refer to Section 5.5,
Machine Safety System Override (MSSO) (If
Equipped) for operating procedures.

4.11 SKYGUARD OPERATION

SkyGuard provides enhanced control panel protection. When the 0"$

SkyGuard sensor is activated, functions in use at the time of actu- Approximately 50 lb (222 Nm) of force is applied to yellow bar.
ation will reverse or cutout. The SkyGuard Function Table pro-
vides more details on these functions. SkyGuard - SkyLine
During activation, the horn will sound and the SkyGuard beacon
(if equipped) will illuminate until sensor and footswitch are disen-
gaged.
If the SkyGuard sensor remains activated after function reversal
or cutout, depress and hold the SkyGuard Override Switch to
allow normal functions until the sensor is disengaged.
Consult the following illustrations to determine which type of
SkyGuard the machine has and how it is activated. Regardless of
type, SkyGuard function according to the SkyGuard Function 0"%
Table does not change.
Cable is pressed, breaking the magnetic connection between the
cable and right bracket.

4-24 31215030
 SECTION 4 - MACHINE OPERATION

SkyGuard - SkyEye

0"$
0"$
Reattach magnetic end of cable to bracket if it becomes discon-
Operator passes through path of sensor beam.
nected.

SkyGuard Function Table

Tower Boom
Drive Drive Tower Tower Tower Boom Boom Boom Basket Basket
Steer Swing Lift Lift Jib Lift
Forward Reverse Lift Up Tele Out Tele In Lift Up Tele Out Tele In Level Rotate
Down Down
R*/C ** R C R R C C C R R R C C C C
R = Indicates Reversal is Activated
C = Indicates Cutout is Activated
* DOS (Drive Orientation System) Enabled
* * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active
Note: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing.

31215030 4-25
 SECTION 4 - MACHINE OPERATION

4.12 SHUT DOWN AND PARK 4.13 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)
The preferred procedures to shut down and park the machine are
as follows:
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-
1. Drive machine to a reasonably well protected area. PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.
2. Ensure boom is fully retracted and lowered over rear axle.
Refer to Section 7.6, Oscillating Axle Lockout Test (If Equipped) for
3. Shut down Emergency Stop at Platform Controls. procedure.
4. Shut down Emergency Stop at Ground Controls. Position
Platform/Ground Select switch to center OFF (center posi- 4.14 STEER/TOW SELECTOR (IF EQUIPPED)
tion).
5. If necessary, cover Platform Controls to protect instruction
placards, warning decals, and operating controls from hos- DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COMPLETE TOW PACK-
tile 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
IF PARKING A MEWP WITH THE BOOM ELEVATED IN AN EFFORT TO CONSERVE SPACE,
and towing. When steering the unit the valve knob is pushed IN.
BOOMS MAY BE ELEVATED, BUT SHALL NOT BE EXTENDED. IT IS THE OPERATOR’S
When towing the unit the valve knob is pulled OUT to the float
RESPONSIBILITY TO ENSURE ALL SAFETY PRECAUTIONS IN SECTION 1 OF THIS MAN-
position.
UAL ARE FOLLOWED FOR EACH UNIQUE SITUATION.

4-26 31215030
 SECTION 4 - MACHINE OPERATION

Towbar Connecting Points

STEER SELECT
VALVE

31215030 4-27
 SECTION 4 - MACHINE OPERATION

4.15 TOWING (IF EQUIPPED) After towing the machine, complete the following:
1. Actuate steer/tow selector valve for steering; push valve
RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOW-
knob IN to the actuated position.
ING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY
TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE 2. Reconnect drive hubs by inverting disconnect cap.
SERIOUS INJURY OR DEATH.
3. Disconnect tow bar from steering hitch and from towing
MAXIMUM TOWING SPEED 8 MPH (13 KM/H) vehicle. The machine is now in the driving mode.

MAXIMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

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

1. Retract, lower and position boom over rear drive wheels in

line with direction of travel; lock turntable.
2. Connect tow bar to front of frame with attach pins, and tow
bar to towing vehicle.
3. Disconnect drive hubs by inverting disconnect cap. Refer to
Figure 4-6., Drive Disconnect Hub.
4. Actuate steer/tow selector valve for towing; pull valve knob
OUT to float position. (This opens the steer circuit to reser-
voir, allowing the steer cylinder rod free travel.) The machine
is now in the towing mode.

4-28 31215030
 SECTION 4 - MACHINE OPERATION

4.16 AUXILIARY POWER

WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNC-
TION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE 12-VOLT AUXIL-
IARY PUMP MOTOR.)

A toggle type auxiliary power control switch is located on the

platform control station and another is located on the ground
control station. Operation of either switch turns on the electri-
cally driven auxiliary hydraulic pump. This should be used in case
of failure of the main power plant. The auxiliary pump will oper-
ate tower boom lift, tower telescope, main boom lift, main tele-
scope and swing. To activate auxiliary power:

Activating from the Platform Control Station

1. Position Platform/Ground Select Key Switch to
Platform.

2. Position Power/Emergency Stop switch to On.

Figure 4-6. Drive Disconnect Hub

31215030 4-29
 SECTION 4 - MACHINE OPERATION

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

hold.
4. Position Auxiliary Power switch to On and
hold. 4. Operate appropriate control switch or control-
ler for desired function and hold.
5. Operate appropriate control switch, lever or controller for 5. Release Auxiliary Power switch, and appropriate control
desired function and hold. switch or controller.
6. Release Auxiliary Power switch, selected control switch, lever 6. Position Power/Emergency Stop switch to Off.
or controller, and footswitch.
7. Position Power/Emergency Stop switch to Off.

4.17 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Activating from the Ground Control Station The dual fuel system enables the standard gasoline engine to run
on either gasoline or LP gas.
1. Position Platform/Ground Select Key Switch to
Ground.
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT ALLOW-
ING THE ENGINE TO STOP. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING
2. Position Power/Emergency Stop switch to On. INSTRUCTIONS MUST BE FOLLOWED.

4-30 31215030
 SECTION 4 - MACHINE OPERATION

Changing From Gasoline to LP Gas 4.18 TIE DOWN AND LIFTING

1. Start engine from Ground Control Sta- When transporting machine, boom must be in the stowed mode
tion. 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.
If it becomes necessary to lift the machine using an overhead or
mobile crane, it is very important that the lifting devices are
attached only to the designated lifting eyes, and that the turnta-
2. Open hand valve on LP gas supply tank by turning counter- ble lock pin is engaged (See Figure 4-7., Lifting Chart).
clockwise.
NOTE: Lifting eyes are provided at the front and rear in the frame slab.
3. While engine is operating on Gasoline under a no- Each of the four chains or slings used for lifting machine must be
load condition, place Fuel Select switch at Platform adjusted individually so machine remains level when elevated.
Control to LP position.

Changing From LP Gas to Gasoline

SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES
1. With engine operating on LP under a no-load con- OR HAULING MACHINE ON TRUCK/TRAILER.
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.

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 SECTION 4 - MACHINE OPERATION

Figure 4-7. Lifting Chart

4-32 31215030
 SECTION 4 - MACHINE OPERATION

68 41
203 37 204 68
36 205 206
203
64 44 204
104 301 206 206
105
61

110 104
48 35 39 105
49

103
43 70 62 34 73

Figure 4-8. 600AJ Decal Installation - Sheet 1 of 4

31215030 4-33
 SECTION 4 - MACHINE OPERATION

41
108 206
30 204 72
35
205
204
206 201
61

61

43
40 103
57 253 48 49

Figure 4-9. 600AJ Decal Installation - Sheet 2 of 4

4-34 31215030
 SECTION 4 - MACHINE OPERATION

Figure 4-10. 600AJ Decal Installation - Sheet 3 of 4

31215030 4-35
 SECTION 4 - MACHINE OPERATION

205 204

65

207

104
105 45
46
301

103
205 204

Figure 4-11. 600AJ Decal Installation - Sheet 4 of 4

4-36 31215030
 SECTION 4 - MACHINE OPERATION

Table 4-2. 600AJ Decal Legend

Eng/ Chinese Chinese

Item # ANSI Eng/French CE Eng/Spanish Japanese Australian Korean
Portuguese Simplified Traditional
1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B
1001243640-B 1001243648-B 1001243647-B
29 3252347 -- 1705828 -- -- -- -- -- -- --
30 3251813 3251813 -- 3251813 3251813 3251813 3251813 3251813 3251813 3251813
34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
35 1702819 1702819 1702819 1702818 1702819 1702819 1702819 1702819 1702819 1702819
36 1001253921 1001253923 1705978 1001253931 1001253937 1001253933 -- 1001253935 1001253927 1001253925
37 1001253920 1001253922 1705978 1001253930 1001253936 1001253932 1705978 1001253934 1001253926 1001253924
39 1704885 1704885 -- 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1001253997 1001253997 1001253993 1001253997 1001253997 -- 1001253994 1001253997 1001253997 1001253997
41 1001159323 1001159323 1001159323 1001159323 1001159323 1001159323 1001159323 1001159323 1001159323 1001159323
42 1701435 1701435 1701435 1701435 1701435 1701435 1701435 1701435 1701435 1701435
43 1702773 1702773 1702773 1702773 1702773 1702773 1702773 1702773 1702773 1702773
44 1702860 1702860 -- 1702860 1702860 1702860 1702860 1702860 1702860 1702860
45 3250872 3250872 1706957 -- -- -- -- -- -- --
46 1705090 1705820 1706960 -- -- -- -- -- -- --
47 1701505 -- -- -- -- -- -- 1701505 1701505 --
48 1701542 1701542 -- 1701542 1701542 -- 1701542 1701542 1701542 1701542
49 1700818 1704271 -- 1702720 1702720 -- 1700818 -- -- --

31215030 4-37
 SECTION 4 - MACHINE OPERATION

Table 4-2. 600AJ Decal Legend

Eng/ Chinese Chinese

Item # ANSI Eng/French CE Eng/Spanish Japanese Australian Korean
Portuguese Simplified Traditional
1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B
1001243640-B 1001243648-B 1001243647-B
50 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011 0100011
51 0641406 0641406 0641406 0641406 0641406 0641406 0641406 0641406 0641406 0641406
53 0860520 0860520 0860520 0860520 0860520 0860520 0860520 0860520 0860520 0860520
55 3311405 3311405 3311405 3311405 3311405 3311405 3311405 3311405 3311405 3311405
57 3820001 3820001 3820001 3820001 3820001 3820001 3820001 3820001 3820001 3820001
58 4751400 4751400 4751400 4751400 4751400 4751400 4751400 4751400 4751400 4751400
60 1001184618 1001184618 -- 1001184618 1001184618 1001184618 1001184618 1001184618 1001184618 1001184618
61 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051
62 1001131269 1001131269 -- -- -- -- -- -- -- --
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 1001112551 1705430 1001116863 1705427
68 1001197408 1001197408 -- 1001197408 1001197408 1001197408 1001197408 1001197408 1001197408 1001197408
69 1001180861 1001200120 -- 1001200126 -- -- -- -- -- --
70 1001223055 1001223971 1001143852 1001224049 1001224052 1001224053 -- 1001224051 1001224050 1001224048
71 -- -- 1702788 -- -- -- -- -- -- --
72 1001229007 1001229007 1001229007 1001229007 1001229007 1001229007 1001229007 1001229007 1001229007 1001229007
73 1001223453 1001223453 -- -- -- -- -- -- -- --

4-38 31215030
 SECTION 4 - MACHINE OPERATION

Table 4-2. 600AJ Decal Legend

Eng/ Chinese Chinese

Item # ANSI Eng/French CE Eng/Spanish Japanese Australian Korean
Portuguese Simplified Traditional
1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B
1001243640-B 1001243648-B 1001243647-B
74 1001231801 -- -- -- -- -- -- -- --
100 2902303 2902303 -- 2902303 2902303 2902303 2902303 2902303 2902303 2902303
101
102 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
103 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
104 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
105 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
106 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
107 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
108 -- -- 1705084 -- -- -- 1705084 -- -- --
109
110 3251243 3251243 -- 3251243 3251243 3251243 3251243 3251243 3251243 3251243
200 2902307 2902322 -- 2902311 2902312 2902308 2902329 1001116844 2902309 2902310
201 1702868 1704000 -- 1704001 1705967 -- -- 1705968 1001116846 1705969
202 1703797 1703924 -- 1703923 1705895 1703926 1705921 1001116847 1703925 1703927
203 1705336 1705347 -- 1705917 1705896 1705344 1705822 1001116848 1001116849 1705345
204 1703804 1703948 -- 1703947 1705898 1703950 1701518 1001116850 1703949 1703951
205 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851 1703939

31215030 4-39
 SECTION 4 - MACHINE OPERATION

Table 4-2. 600AJ Decal Legend

Eng/ Chinese Chinese

Item # ANSI Eng/French CE Eng/Spanish Japanese Australian Korean
Portuguese Simplified Traditional
1001243539-B 1001243634-B 1001156988-H 1001243637-B 1001243642-B 1001244329-B 1001244191-B
1001243640-B 1001243648-B 1001243647-B
206 1703953 1703942 1701518 1703941 1705903 1703944 -- 1001116845 1703943 1703945
207 -- -- -- -- -- -- -- -- -- --
208 -- -- -- -- -- -- -- -- -- --
209 -- 1703984 -- 1703983 1705902 1703980 1705828 1001116852 1703982 1703981
300 1001156892 1001156892 1001156892 1001156892 1001156892 1001156892 1001156892 1001156892 1001156892 1001156892
301 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891 1001156891

4-40 31215030
 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.
• USA: 877-JLG-SAFE (554-7233)
Operator Unable to Control Machine
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TO
• EUROPE: (32) 0 89 84 82 20
OPERATE OR CONTROL MACHINE:
• AUSTRALIA: (61) 2 65 811111
1. Other personnel should operate the machine from ground
• E-mail: ProductSafety@JLG.com controls only as required.
Failure to notify the manufacturer of an incident involving a JLG 2. Other qualified personnel on the platform may use the plat-
Industries product within 48 hours of such an occurrence may form controls. DO NOT CONTINUE OPERATION IF CONTROLS
void any warranty consideration on that particular machine. DO NOT FUNCTION PROPERLY.
3. Cranes, forklift trucks or other equipment can be used to
remove platform occupants and stabilize motion of the
machine.

31215030 5-1
 SECTION 5 - EMERGENCY PROCEDURES

Platform or Boom Caught Overhead 5.4 EMERGENCY TOWING PROCEDURES

If the platform or boom becomes jammed or snagged in over- Towing this machine is prohibited, unless properly equipped.
head structures or equipment, do the following: However, provisions for moving the machine have been incorpo-
rated. For specific procedures, refer to Section 4.
1. Shut off the machine.
2. Rescue all people in the platform before freeing the
machine. Personnel must be out of the platform before
operating any controls on the machine.
3. Use cranes, forklifts, or other equipment to stabilize motion
of the machine to prevent a tip over as required.
4. From the ground controls, use the Auxiliary Power System (if
equipped) to carefully free the platform or boom from the
object.
5. Once clear, restart the machine and return the platform to a
safe position.
6. Inspect the machine for damage. If the machine is damaged
or does not operate properly, turn off the machine immedi-
ately. Report the problem to the proper maintenance per-
sonnel. Do not operate the machine until it is declared safe
for operation.

5-2 31215030
 SECTION 5 - EMERGENCY PROCEDURES

5.5 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(IF EQUIPPED)
The Machine Safety System Override (MSSO) is
only to be used to retrieve an operator that is
pinned, trapped, or unable to operate the
machine and function controls are locked out
from the platform due to a platform overload sit-
uation.

NOTE: If the MSSO functionality is used, the fault indicator is set with a
fault code 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.

31215030 5-3
 SECTION 5 - EMERGENCY PROCEDURES

5-4 31215030
 SECTION 6 - ACCESSORIES

SECTION 6. ACCESSORIES

Table 6-1. Available Accessories

Market
Accessory ANSI
ANSI CSA CE AUS Japan China
(USA Only)
Fall Arrest Platform (36" x 72")     
Fall Arrest Platform (36" x 96")    
Pipe Racks   
SkyCutter™     
SkyGlazier™     
SkyPower - 7.5 kW      
Generator - 4 kW       
SkyWelder™     
Soft Touch     
SkySense       
Bolt-On External Fall Arrest (36" x 72")     
Bolt-On External Fall Arrest (36" x 96")     

31215030 6-1
 SECTION 6 - ACCESSORIES

Table 6-2. Options/Accessories Relationship Table

COMPATIBLE WITH
ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2)
(Note 1)
Platform MMR**, Platform MTR*, SkyGlazier™, SkyCutter™,
Pipe Racks SkyPower™
Soft Touch SkyWelder™,
4’Platform, Pipe Racks, Platform
SkyCutter™ SkyPower™ SkyWelder™ SkyGlazier™
MTR*, Soft Touch
4’Platform, Pipe Racks, Platform
SkyGlazier™ SkyPower™ SkyCutter™, SkyWelder™
MTR*, Soft Touch
SkyCutter™, SkyGlazier™,
SkyPower™
SkyWelder™
4’Platform, Pipe Racks, Platform
SkyWelder™ SkyPower™ SkyCutter™ SkyGlazier™
MTR*, Soft Touch
Pipe Racks, SkySense, SkyCutter™,
Soft Touch SkyPower™
SkyGlazier™, SkyWelder™
Pipe Racks, Sof t Touch, SkyCutter™,
SkySense SkyPower™ SkyGlazier™, SkyWelder™, Plat-
form MMR**, Platform MTR*
Note 1: Any non-"Sky" accessory not listed under "INCOMPATIBLE WITH" is assumed to be compatible.
4150459 M
Note 2: Can be used on same unit but not simultaneously.
* Platform MTR = Platform Mesh to Top Rail; ** Platform MMR = Platform Mesh to Mid Rail

6-2 31215030
 SECTION 6 - ACCESSORIES

6.1 FALL ARREST PLATFORM 6.2 PIPE RACKS

NOTE: See the JLG External Fall Arrest System manual (PN 3128935) for
more detailed information.

The external fall arrest system is designed to provide a lanyard

attach point while allowing the operator to access areas outside
the platform. Exit/enter the platform through the gate area only.
The system is designed for use by one person.
Personnel must use fall protection at all times. A full body harness
is required with lanyard not to exceed 6 ft (1.8 m) in length, that
limits the maximum arrest force to 900 lb (408 kg) for the trans-
fastener type and 1350 lb (612 kg) for the shuttle type fall arrest
system.

Safety Precautions

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM. USE
CAUTION WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.

Pipe Racks provide a way to store pipe or conduit inside the plat-
form in order to prevent rail damage and optimize platform util-
ity. This accessory consists of two racks with adjustable straps to
secure the load in place.

31215030 6-3
 SECTION 6 - ACCESSORIES

Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform.
• Do not exit platform over rails or stand on rails.
Max. Platform Capacity
Max. Capacity in Racks • Do not drive machine without material secured
(With Max. Weight in Racks)
80 kg 184 kg • Return racks to the stowed position when not in use.
Max. Length of Material in Racks: 6.0 m • Use this option only on approved models.
Min. Length of Material in Racks: 2.4 m
Preparation and Inspection
Safety Precautions • Ensure racks are secured to the platform rails.
• Replace torn or frayed tie-down straps.

REDUCE PLATFORM CAPACITY BY 100 LB (45.5 KG) WHEN INSTALLED.

Operation
1. To prepare racks for loading, remove locking pins, rotate
each rack 90 degrees from stowed to working position, then
secure with locking pins.
WEIGHT IN RACKS PLUS WEIGHT IN PLATFORM MUST NOT EXCEED RATED CAPACITY.
2. Loosen and remove tie-down straps. Place material on racks
with weight evenly distributed between both racks.
3. Route the tie-down straps at each end across loaded mate-
THE MAXIMUM LOAD IN THE RACKS IS 180 LB (80 KG) EVENLY DISTRIBUTED rial and tighten.
BETWEEN THE TWO RACKS.
4. To remove material, loosen and remove tie-down straps,
then carefully remove material from racks.

THE MAXIMUM LENGTH OF MATERIAL IN RACKS IS 20 FT (6.1 M). NOTE: Reinstall tie-down straps across any remaining material before
continuing machine operations.

6-4 31215030
 SECTION 6 - ACCESSORIES

6.3 SKYCUTTER™ Safety Precautions

DO NOT OVERLOAD PLATFORM.

DE-RATE THE PLATFORM BY 70 LB (32 KG) WHEN ACCESSORY IS IN THE PLATFORM.

• Check for cracked welds and damage to plasma supports.

• Check for secure installation of cutter and bracket.
• Ensure no personnel are beneath platform.
• Do not exit platform over rails or stand on rails.
• Use this option only on approved models.
• Keep lanyard attached at all times.
• Use correct cutting settings.
• Do not use electrical cords without ground.
• Do not use electrical tools in water.
SkyCutter™ is capable of cutting up to a thickness of 3/8" metal. It
can produce 27 A at 92 VDC at 35% duty cycle or 14 A at 92 VDC • Do not cut platform, or ground through the platform.
at 60% duty cycle. It receives power from the SkyPower™ system. • Wear proper cutting apparel.
• Do not drive machine while connected to external air/gas
sources.

31215030 6-5
 SECTION 6 - ACCESSORIES

Accessory Ratings
Amperes Input @
Plasma Gas Flow/ Rated Cutting
Spec. Rated Output Rated Output, 60 kVa/kW Plasma Gas Max. OCV
Pressure Capacity @ 10 IPM
Hz, 1-Phase
120 Volts ±10% 27 A @ 91 VDC @ 20% 28.8 max; 3.4 kVa
(20 A) Duty Cycle 0.30 * 3.2 kW
4.5 cfm
Air or Nitrogen Only
120 Volts ±10% 20 A @ 88 VDC @ 35% 20.6 max; 2.5 kVa (129 L/Min) 3/8 in
@ 90 - 120 psi 400 VDC
(15 A) Duty Cycle 0.30 * 2.3 kW @ 60 psi (10 mm)
(621 - 827 kPa)
(414 kPa)
240 Volts ±10% 27 A @ 91 VDC @ 35% 13.9 max; 3.3 kVa
(27 A) Duty Cycle 0.13 * 3.0 kW
* While idling.

Generator Output Preparation and Inspection

Engine Speed of 1800 rpm +/- 10%. • Connect ground clamp to metal being cut.
ANSI Specifications: • Ensure there is a good ground connection.

• 3-phase: 240 V, 60 Hz, 7.5 kW Operation

• 1-phase: 240 V/120 V, 60 Hz, 6 kW
Start the engine, turn on the generator, then turn on the plasma
cutter.
See the Miller Plasma Cutter Owner’s Manual (PN 3128420) for
more information.

6-6 31215030
 SECTION 6 - ACCESSORIES

6.4 SKYGLAZIER™ Capacity Specifications

Max. Platform Capacity
Capacity Zone * Max. Tray Capacity
(With Max. Weight in Tray)

500 lb 150 lb 250 lb

(227 kg) (68 kg) (113 kg)
550 lb 150 lb 250 lb
(250 kg) (68 kg) (113 kg)
600 lb 150 lb 250 lb
(272 kg) (68 kg) (113 kg)
750 lb 150 lb 440 lb
(340 kg) (68 kg) (200 kg)
1000 lb 250 lb 500 lb
(454 kg) (113 kg) (227 kg)
* Refer to the capacity decals installed on the machine for capac-
ity zone information.

Required Platform Type: Side-Entry

Max. Dimensions of Panel: 32 sq ft (3 sq m)

SkyGlazier™ allows glaziers to position panels efficiently. The gla-
zier package consists of a tray that attaches the bottom of the
platform. The panel rests on the tray and against top-rail of the
platform, which is padded to prevent damage. SkyGlazier™
includes a strap to secure the panel to the platform rail.

31215030 6-7
 SECTION 6 - ACCESSORIES

Safety Precautions Preparation and Inspection

• Check for cracked welds and damage to tray.
• Ensure tray is properly secured to platform.
ENSURE PANEL IS SECURED WITH STRAP.
• Ensure strap is not torn or frayed.

Operation
DO NOT OVERLOAD TRAY OR PLATFORM. TOTAL MACHINE CAPACITY IS REDUCED
1. Load SkyGlazier™ tray with panel.
WHEN TRAY IS INSTALLED.
2. Route the adjustable strap around the panel and tighten
until secure.
3. Position panel to its desired location.
WITH SKYGLAZIER™ INSTALLED, THE ORIGINAL PLATFORM CAPACITY RATINGS ARE
REDUCED AS SPECIFIED IN THE SPECIFICATIONS TABLE ABOVE. DO NOT EXCEED THE
NEW PLATFORM CAPACITY RATING. REFER TO CAPACITY DECAL LOCATED ON TRAY.

AN INCREASE OF THE AREA EXPOSED TO THE WIND WILL DECREASE STABILITY. LIMIT
PANEL AREA TO 32 SQ FT (3 SQ M).

• Ensure no personnel are beneath platform.

• Do not exit platform over rails or stand on rails.
• Remove tray when not in use.
• Use this option only on approved models.

6-8 31215030
 SECTION 6 - ACCESSORIES

6.5 SKYPOWER™ 7.5 KW AND GENERATOR 4 KW All power regulation components are located in a watertight box
connected by cable to the generator. The generator supplies
power when running at the specified speed with the power
switch on (switch is located on platform). A two-pole, 20 A (4 kW)
or a three-pole, 30 A (7.5 kW) circuit breaker protects the genera-
tor from overload.

Output
SkyPower 7.5 kW Specifications:
• 3-phase: 240 V, 60 Hz, 7.5 kW (Peak: 8.5 kW)
• 1-phase: 240 V/120 V, 60 Hz, 6 kW (Peak: 6.0 kW)
Generator 4 kW Specifications:
• 3-phase: 240 V, 7.5 kW, 18.3 A, 1.0-pf
• 1-phase: 240 V/120 V, 60 Hz, 4 kW
• 1-phase: 230 V/115 V, 50 Hz, 4 kW

Accessory Ratings
• 3000 rpm (50 Hz)
• 3600 rpm (60 Hz)

The SkyPower™ and generator systems supply AC power to the

platform through an AC receptacle to run tools, lights, cutting,
and welding equipment.

31215030 6-9
 SECTION 6 - ACCESSORIES

Safety Precautions 6.6 SKYWELDER™

DO NOT OVERLOAD PLATFORM.

• Ensure no personnel are beneath platform.

• This factory-installed option is available only on specified
models.
• Keep lanyard attached at all times.
• Do not use electrical tools in water.
• Use correct voltage for tool being used.
• Do not overload circuit.

Preparation and Inspection

• Ensure generator is secure.
• Check condition of belt and wiring.

Operation
Start the engine, then turn on the generator. SkyWelder™ is capable of TIG and Stick welding, producing 200
Amps at 100% duty cycle or 250 Amps at 50% duty cycle. This
See the Miller Generator Technical Manual (PN 3121677) for more accessory receives power from the SkyPower™ system.
information.

6-10 31215030
 SECTION 6 - ACCESSORIES

Accessory Ratings
Welding Amps Input At Rated Load Output (50/60 Hz)
Maximum Open
Welding Mode Input Power Rated Output Amperage
Circuit Voltage 230 V 460 V 575 V kVa kW
Range
280 Amp at 31.2 V,
32 17 13 15.7 10
35% Duty Cycle
3- phase 5-250 A 79 VDC
200 Amp at 28 V,
20 11 8 10.3 6.4
Stick (SMAW) 100% Duty Cycle
TIG (GTAW) 200 Amp at 28 V,
35 ------ ------ 9.8 6.5
50% Duty Cycle
1 -phase 5-200 A 79 VDC
150 Amp at 28 V,
34 ------ ------ 6.9 4.4
100% Duty Cycle

Generator Output Welding Accessories

Engine Speed of 1800 rpm +/- 10%. • 12 ft welding leads with clamp and stinger (stored in the
platform)
ANSI Specifications:
• Fire extinguisher
• 3-phase: 240 V, 60 Hz, 7.5 kW
• 1-phase: 240 V/120 V, 60 Hz, 6 kW

31215030 6-11
 SECTION 6 - ACCESSORIES

Safety Precautions • Use correct rod size and current settings.

• Do not use electrical cords without ground.
• Do not use electrical tools in water.
DO NOT OVERLOAD PLATFORM.
• Do not weld to the platform.
• Do not ground through the platform.
• Do not use a high frequency arc starter with TIG welder.
DE-RATE THE PLATFORM BY 70 LB (32 KG) WHEN WELDER IS IN THE PLATFORM.
Preparation and Inspection
• Check for cracked welds and damage to welder supports.
• Connect ground clamp to metal being welded.
• Check for proper and secure installation of welder and
bracket. • Ensure there is a good ground connection and observe
proper polarity.
• Ensure no personnel are beneath platform.
• Do not exit platform over rails or stand on rails. Operation
• Use this option only on approved models. Start the engine, turn on the generator, then turn on the welder.
• Keep lanyard attached at all times. See the Miller Welder Owner’s Manual (PN 3128957) for more
• Ensure correct polarity of leads. information.
• Wear proper welding apparel.

6-12 31215030
 SECTION 6 - ACCESSORIES

6.7 SOFT TOUCH 6.8 BOLT-ON EXTERNAL FALL ARREST

A padding kit is mounted to the platform rails and to a frame sus- The bolt-on external fall arrest system is designed to provide a lan-
pended below the platform. Limit switches deactivate platform yard attach point while allowing the operator to access areas outside
functions when the padded framework contacts an adjacent the platform. Exit/Enter the platform through the gate area only. The
structure. A button on the platform console allows override of the system is designed for use by one person.
system.
Personnel must use fall protection at all times. A full body harness is
required with lanyard not to exceed 6 ft. (1.8 M) in length, that limits
OVERRIDE BUTTON
OVERRIDE INDICATOR LIGHT the maximum arrest force to 900 lb (408 kg).
RAIL BUMPER
External Fall Arrest System capacity is 310 lb (140 kg) - one (1) person
maximum.

Do not move platform during use of the external fall arrest system.

DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM. BE

CAREFUL WHEN ENTERING/EXITING THE PLATFORM AT ELEVATION.
LIMIT
SWITCH

IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE

DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY
LIMIT
SWITCH INSPECTED BEFORE RETURNING TO SERVICE. REFER TO THE SERVICE MANUAL FOR
SUSPENDED FRAME AND RAIL BUMPER REMOVAL AND INSTALLATION PROCEDURES.

31215030 6-13
 SECTION 6 - ACCESSORIES

Bolt-On External Fall Arrest Cable Tension

THE EXTERNAL FALL ARREST SYSTEM REQUIRES AN ANNUAL INSPECTION AND CERTI- GAP SHOWING:
FICATION. THE ANNUAL INSPECTION AND CERTIFICATION MUST BE PERFORMED BY A INCORRECT
QUALIFIED PERSON OTHER THAN THE USER.

Inspection Before Use

The external fall arrest system must be inspected before each use of
the machine. Replace components if there are any signs of wear or
damage. NO GAP: CORRECT

Before each use, perform a visual inspection of the following compo-

nents:
• Cable: Inspect cable for proper tension, broken strands, kinks, or
any signs of corrosion.
• Fittings & Brackets: Ensure all fittings are tight and there are no
signs of fractures. Inspect brackets for any damage.
• Attachment Ring: No cracks or signs of wear are acceptable. Any
signs of corrosion requires replacement.
• Attaching Hardware: Inspect all attaching hardware to ensure
there are no missing components and hardware is properly tight-
ened.
• Platform Rails: No visible damage is acceptable.

6-14 31215030
 SECTION 6 - ACCESSORIES

Bolt-On External Fall Arrest System

7
1,2,3,4

1. Belleville Washer
5 2. Washer
3. Hex Nut
4. Jam Nut
6 5. LH Bracket
6. Attachment Ring
7. Cable
8. RH Bracket
9. Decal

31215030 6-15
 SECTION 6 - ACCESSORIES

6.9 SKYSENSE Preparation and Inspection

Pre-Operation Inspection:
1. Inspect each of the SkySense tubes for dents, cracks, or other
SKYSENSE IS NOT INTENDED TO REPLACE OR REDUCE THE NEED FOR THE OPERATOR
damage.
TO BE AWARE OF THE ENVIRONMENT AROUND THE MACHINE. HAZARDS THAT WILL
CAUSE SERIOUS INJURY OR DEATH MAY NOT BE PREVENTED OR REDUCED BY SKY- 2. Inspect each SkySense sensor for any damage to the hous-
SENSE. THE OPERATOR MUST ALWAYS LOOK IN THE DIRECTION OF TRAVEL, AVOID ing or sensor.
POWER LINES, AVOID OBSTACLES THAT COULD STRIKE THE MACHINE OR PERSONS IN
To test the SkySense system:
THE PLATFORM, AND FOLLOW ALL INSTRUCTIONS, DECALS, AND OTHER WARNINGS
PROVIDED WITH THIS MACHINE. 1. In an area free of obstructions, ensure the machine is on a
smooth, firm surface within the limits of the maximum oper-
THE OPERATOR MUST NOT RELY ON SKYSENSE AS A SUBSTITUTE FOR FOLLOWING THE ating slope.
INSTRUCTIONS AND WARNINGS CONTAINED IN THE MANUALS AND PLACARDS PRO-
VIDED WITH THIS MACHINE. 2. From the platform control console, elevate the boom until
the bottom of the platform is at least 6 feet off the ground.
SKYSENSE IS INTENDED TO ASSIST THE OPERATOR. SKYSENSE MAY NOT DETECT CER- 3. Continue to elevate the platform.
TAIN OBJECTS DEPENDING ON SHAPE, TYPE OF MATERIAL, OR ORIENTATION OF THE
OBJECT TO THE SENSORS. IT IS THE OPERATOR’S RESPONSIBILITY TO BE AWARE OF 4. While elevating, hold your hand 6 inches to 12 inches above
THEIR SURROUNDINGS AT ALL TIMES. one of the upward facing sensors. The machine should stop,
and the LED corresponding to that sensor (left LED for left
sensor bar; right LED for right sensor bar; both LEDs for cen-
ter sensor bar or overhead sensor) should be red.
DE-RATE THE PLATFORM BY 10 LB (4.5 KG) PER BAR WHEN INSTALLED ON THE PLAT- 5. Recycle the footswitch and press the override button on the
FORM (20 LB (9 KG) OR 30 LB (14 KG) TOTAL). platform control console.

NOTE: SkySense is not active when operating the machine from the
ground controls.

6-16 31215030
 SECTION 6 - ACCESSORIES

6. Ensure the area below the platform is clear of obstructions Operation

and lower the platform. The machine should slow down,
(SkySense Status LED will blink yellow with increasing fre- SkySense slows a machine’s function to creep speed when it is a
quency) and stop, (SkySense Status LED will be illuminated certain distance away from an object, known as the "warning
solid red) when the bottom of the platform is approximately zone." If the machine continues to approach the object and
12 inches from the ground. The alarm should sound if it is moves into the "stop zone," SkySense stops all machine functions.
not muted (refer to SkySense Alarm).
For proportional functions activated by the joystick, the size of
7. Recycle the footswitch and press the override button on the the warning zone varies based on the amount of joystick activa-
platform control console. tion. The stop zone always activates at the same distance from
the object regardless of the joystick’s position.
8. Continue to lower the platform. The machine should move
in the elevated drive speed mode (SkySense Status LED will If the function has reached the warning zone, normal drive speed
remain red). will resume when a function is activated in the opposite direc-
tion. If the machine has reached the SkySense stop zone, release
NOTE: The SkySense system will not stop machine operation while in the function and recycle the footswitch to activate a function in
Creep. the opposite direction.
SkySense is active during the following functions:
• Lift Up/Down (including jib functions)
• Platform Rotate (including jib rotate)
• Telescope Out
• Swing
• Reverse Drive

31215030 6-17
 SECTION 6 - ACCESSORIES

NOTE: During active DOS (Drive Orientation System), SkySense is active

when driving in both forward and reverse directions.
1 2
There are two LED indicators on the platform control box that sig-
nal SkySense activity.
• No LED: Normal operation.
• LED Flashing Yellow: Machine is in SkySense warning
zone and will reduce function speed to creep. Flash fre-
quency correlates to proximity of object.
• LED Red: Machine is in SkySense stop zone and all
machine functions will cease.
LED Flashing Red: SkySense sensor is obstructed or damaged.
Obstructions must be removed and proper function verified. Damaged
sensors must be replaced.

4 3

1. LED Indicator Light

2. LED Indicator Light
3. Override Button
4. Mute Speaker Switch

SkySense Platform Panel Indicators

6-18 31215030
 SECTION 6 - ACCESSORIES

SkySense Alarm Override Button

Activation of SkySense is signaled by an audible alarm and the The yellow override button allows operators to bypass normal
LEDs on the platform console that indicate SkySense activity SkySense operation in order to move closer to an object in the
when reaching the warning or stop zones. stop zone.
In the warning zone, the audible alarm will pulse and increase in When the operator overrides the SkySense via the override but-
frequency as the machine moves closer to the object. In the stop ton to get closer to a work surface, the machine will maintain
zone, the alarm will sound a continuous tone. creep speed and flash the appropriate indicator color based on
location in either the warning or stop zones.
Additionally, when the machine is in the stop zone, the platform
control panel audible alarm will sound. The system may be reset NOTE: Override is only required to be engaged if the operator desires to
by recycling the footswitch. move the platform closer to an object that is in or entering the
stop zone.
The audible SkySense alarms can be muted by a switch on the
platform control console, although LEDs will continue to light.
SKYGUARD OPERATION IS AFFECTED WHEN SKYSENSE IS INSTALLED ON A
The platform control panel alarm will sound when the machine
MACHINE. IF SKYSENSE ACTIVATION OCCURS PRIOR TO SKYGUARD ACTIVA-
enters the SkySense stop zone even when muted.
TION, SKYGUARD WILL ONLY CUT OUT FUNCTIONS IF ACTIVATED. IF SKY-
GUARD ACTIVATION OCCURS PRIOR TO SKYSENSE ACTIVATION, SKYGUARD
WILL FUNCTION NORMALLY.

31215030 6-19
 SECTION 6 - ACCESSORIES

SkySense Coverage Areas

Level 2 (3 - Bar)

Level 1 (2 - Bar)
NOTE: Sensor Cones shown are approximations for reference only.

6-20 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.1 INTRODUCTION 7.2 OPERATING SPECIFICATIONS
This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications
mation to the operator for proper operation and maintenance of
this machine. Maximum Work Load (Capacity) - ANSI
Unrestricted: 500 lb (227 kg)
The maintenance portion of this section is intended as informa-
tion to assist the machine operator to perform daily maintenance Maximum Work Load (Capacity) - CE &
tasks only, and does not replace the more thorough Preventive Australia
Maintenance and Inspection Schedule included in the Service Unrestricted: 500 lb (230 kg)
and Maintenance Manual. Maximum Operating Slope ANSI/CE/AUS - 4°
China - 5°
Other Publications Available: 7ft Chassis - ANSI - 3°
Service and Maintenance Manual .......................................... 31215031 7ft Chassis - China - 5°

Illustrated Parts Manual ............................................................. 31215032 Maximum Travel Grade, Stowed Position
(Gradeability)
2WD 30%
4WD 45%
Maximum Travel Grade, Stowed Position ANSI/CE/AUS - 4°
(Side Slope) China - 5°
7ft Chassis - ANSI/AUS - 3°
7ft Chassis - China - 5°
Turning Radius - (outside)
2WS 17 ft. 8 in. (5.38 m)
4WS 11 ft. 8 in. (3.56 m)

31215030 7-1
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-1. Operating Specifications Dimensional Data

Turning Radius - (outside) 7ft chassis
2WS 16 ft. 6 in. (5.03 m) Table 7-2. Dimensional Data
4WS 11 ft. 2 in. (3.4 m)
Machine Height (Stowed)
Turning Radius - (inside) 600AJ 8 ft. 5 in. (2.57 m)
2WS 11 ft. 5 in. (3.48 m)
4WS 5 ft. 6 in. (1.68 m) Machine Length (Stowed)
Turning Radius - (inside) 7ft chassis 600AJ 29 ft. (8.80 m)
2WS 12 ft. 2 in. (3.71 m)
Machine Width (by tire size)
4WS 5 ft. 7 in. (1.7 m)
355/55D-625 98 in. (2.49 m)
Maximum Tire Load: 12,500 lb (5670 kg) 41/18LLx22.5X625 (turf) 100 in. (2.54 m)
Ground Bearing Pressure
Wheelbase 8 ft. 2 in. (2.49m)
600AJ 77 psi (5.5 kg/cm2)
7ft chassis 94 psi (6.6 kg/cm2) Ground Clearance 11.7 in. (0.29 m)
Maximum Drive Speed 4.25 MPH (6.84 Km/hr.) Platform Height
Gross Machine Weight --600AJ (Approximate) 600AJ 60 ft. 7 in. (18.47 m)
2WS 22,240 lb (10,088 kg)
4WS 22,740 lb (10,315 kg) Horizontal Reach
7ft Chassis 24,000 lb (10,886 kg) 600AJ 39 ft. 9 in. (12.10 m)

Ambient (Operating) Temperature See Figures 7-1 through 7-4 Tail Swing 0 in. (0 m)

7-2 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Capacities Engine Data

Table 7-3. Capacities
Table 7-4. Deutz D2011L04 Specifications
Fuel Tank 30 Gallons (113.6 L) Fuel Diesel
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
*Torque hubs should be one half full of lubricant. Battery 950 Cold Cranking Amps, 205 Minutes
Reserve Capacity, 12 VDC
Fuel Consumption 0.65 GPH (2.46 lph)
Horsepower 49

31215030 7-3
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-5. Deutz TD 2.9L Specifications Table 7-7. Ford DF 2.5L, MSG 425

Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline/LP Gas
Output 67 hp (50 kW) Oil Capacity 7 qt (6.6L)
Torque 173 ft.lbs. (234 Nm) @ 1800rpm Coolant Capacity 0.63 Gallon (2.4L)
Oil Capacity (Crankcase) 2.4 Gallon (8.9 L) w/Filter Low RPM 1000±50 RPM
Cooling System 3.3 Gallon (12.5 L) High RPM 3200 ±5 0 RPM
Low RPM 1200 ±50 rpm Alternator 150 Amp
High RPM 2600±50 rpm Starter 64.4 Amp@3574 RPM
Alternator 95 Amp Fan Ratio 1:3
Fuel Consumption 0.65 GPH (2.48 lph) Fuel Consumption
Gas 1 GPH (3.79 LPH)
Table 7-6. Deutz 2.2L Stage V Specifications LP 5.34 lb/h (2.42 Kg/h)
Fuel Ultra Low Sulfur Diesel (15 ppm) Max Output (Power)
Output 49 hp (36.5 kW) Gasoline 84HP@3200
LP 80HP@3200
Torque 173 ft.lbs. (234 Nm) @ 1800rpm
Max Output (Torque)
Oil Capacity (Crankcase) 2.11 Gallon (8 L) w/Filter
Gasoline 142 ft.lb (192 Nm)@2400 RPM
Cooling System 3.31 Gallon (8.75 L) LP 145 ft. lb (197 Nm)@2400 RPM
Low RPM 1200 ±50 rpm
High RPM 2600±50 rpm
Alternator 95 Amp
Fuel Consumption 0.69 GPH (2.63 lph)

7-4 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tires Hydraulic Oil

Table 7-8. Tire Specifications Table 7-9. Hydraulic Oil
Size IN355/55D 625 36x14-20FA HYDRAULIC SYSTEM OPERATING
SAE VISCOSITY GRADE
Load Range G * TEMPERATURE RANGE
Ply Rating 14 N/A +0° to +180° F (-18° C to +83° C) 10W
Tire Pressure Foam-Filled Solid-Boss +0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30
* Load Capacity - 11,800 lb. (4404 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-
vice Classification GL-3, and sufficient chemical stability for
mobile hydraulic system service. JLG Industries recommends
standard UTTO which has an SAE viscosity index of 152.

NOTE: When temperatures remain below 20° F (-7 degrees C), JLG
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 standard UTTO is desired, contact JLG
Industries for proper recommendations.

31215030 7-5
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-10. Mobilfluid 424 Specs Table 7-11. Mobil DTE 10 Excel 32 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

7-6 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-12. Mobil EAL H 46 Specs Table 7-13. Mobil EAL 46 Specs

Type Synthetic Biodegradable Type Synthetic Biodegradable

ISO Viscosity Grade 46 ISO Viscosity Grade 46
Density at 15° C .874 Density at 15° C .93
Pour Point -49°F (-45°C) Pour Point -27°F (-33°C)
Flash Point 500°F (260°C) Flash Point 568°F (298°C)
Operating Temp. -20 to 200°F (-29 to 93°C) Operating Temp. -20 to 200°F (-29 to 93°C)
7.64 lb/gal 7.64 lb/gal
Weight Weight
(0.9 kg/L) (0.9 kg/L)
Viscosity Viscosity
at 40° C 48.8 cSt at 40° C 43.3 cSt
at 100° C 7.8 cSt at 100° C 7.7 cSt
Viscosity Index 145 Viscosity Index 149

31215030 7-7
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-14. Exxon Univis HVI 26 Specs Table 7-15. Mobil EAL 224H Specs
Specific Gravity 32.1 Type Synthetic Biodegradable
Pour Point -76°F (-60°C) ISO Viscosity Grade 32/46
Flash Point 217°F (103°C) Specific Gravity .922
Viscosity Pour Point, Max -25°F (-32°C)
at 40° C 25.8 cSt Flash Point, Min. 428°F (220°C)
at 100° C 9.3 cSt Operating Temp. 0 to 180°F (-17 to 162°C)
Viscosity Index 376 Weight 7.64 lb. per gal.
NOTE: Mobil/Exxon recommends that this oil be checked on a (0.9 kg per liter)
yearly basis for viscosity. Viscosity
at 40° C 37 cSt
at 100° C 8.4 cSt
Viscosity Index 213
NOTE: Must be stored above 32°F (14°C)

7-8 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Table 7-16. Quintolubric 888-46

Density 0.92 g/cm3

Pour Point <-30°C (<-22°F)
Flash Point 300°C (572°F)
Fire Point 360°C (680°F)
Autoignition Temperature >450°C (842°F)
Viscosity
at 0° C (32°F) 320 cSt
at 20° C (68°F) 109 cSt
at 40° C (104°F) 47.5 cSt
at 100° C (212°F) 9.5 cSt
Viscosity Index 190

31215030 7-9
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Serial Number Locations

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

7-10 31215030
 SECTION 7 - 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 7-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2

31215030 7-11
 SECTION 7 - 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 AREFORAMBIENTTEMPERATURES
100° F (38° C) CONSISTANTLYWITHINSHOWNLIMITS

MOBIL 424 10W-30

90° F (32° C)
2) ALL VALUES AREASSUMEDTOBEAT SEA LEVEL.
80° F (27° C)

EXXON UNIVIS HVI 26

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

SPECIFICATIONS FUEL 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

AMBIENT TEMPERATURE
WITHOUT HEATING AIDS WITH MOBILE 424 + 14 -10
-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

%OFADDEDKEROSENE 4150548-E

Figure 7-2. Hydraulic Operating Temperature Specifications - Deutz - Sheet 2 of 2

7-12 31215030
 SECTION 7 - 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 7-3. Hydraulic System Operating Temperature Specifications - Sheet 1 of 2

31215030 7-13
 SECTION 7 - 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

Figure 7-4. Hydraulic System Operating Temperature Specifications - Sheet 2 of 2 4150548-E

7-14 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.3 OPERATOR MAINTENANCE AND LUBRICATION DIAGRAM

DEUTZ D2011L04

31215030 7-15
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Deutz TD 2.9L, 2.2L Stage V

7-16 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Ford DF 2.5L, MSG 425

2,4 4
1

3 11 7 5

13 6
9
12

2,4 4

31215030 7-17
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.4 OPERATOR MAINTENANCE 1. Swing Bearing

NOTE: The following numbers correspond to those in Figure 7.3, Opera-

tor Maintenance and Lubrication Diagram Deutz D2011L04.

Table 7-17. 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. standard UTTO.
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.

7-18 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

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

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

31215030 7-19
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

4. Wheel Drive Hub 5. Hydraulic Return Filter

Lube Point(s) - Level/Fill Plug

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

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

300 hrs. thereafter or as indicated by Condition Indicator.

7-20 31215030
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6. Hydraulic Charge Filter 7. Hydraulic Tank

NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION

Interval - Change after first 50 hrs. and every 6 months or Lube Point(s) - Fill Cap
300 hrs. 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.

31215030 7-21
 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 11 Quarts Crankcase; 5 Quarts Cooler Capacity - 9.6 Quarts (9.0 L)
Lube - EO Lube - EO
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 7-5., Deutz 2011 Engine Dip- engine manual.
stick.

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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 7-5. Deutz 2011 Engine Dipstick

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

9. Oil Change w/Filter - Ford 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.

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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) - Ford
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation

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12. A. Air Filter (Deutz 2011 and Ford) 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

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

13. Fuel Filter (Propane) - Ford Engine • 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
• any damage to the bead area cords of the tire

If a tire is damaged but is within the above noted criteria, the tire
must be inspected on a daily basis to insure the damage has not
propagated beyond the allowable criteria.

Interval - 3 Months or 150 hours of operation

Comments - Replace filter. Refer to Section 7.7, Propane Fuel
Filter Replacement

7.5 TIRES & WHEELS

Tire Damage
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.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

Tire Replacement smaller diameter, etc., without written factory recommendations,

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
• Tire tread contact width equal or greater than original PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION
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
(including inflation pressure and maximum tire load) coming loose. Use a torque wrench to tighten the fasteners. If you do
not have a torque wrench, tighten the fasteners with a lug wrench,
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.
1. Start all nuts by hand to prevent cross threading. DO NOT
Wheel Replacement use a lubricant on threads or nuts.

The rims installed on each product model have been designed for
stability requirements which consist of track width and load capacity.
Size changes such as rim width, center piece location, larger or

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

2. Tighten nuts in the following sequence: Table 7-18. Wheel Torque Chart

TORQUE SEQUENCE
1st Stage 2nd Stage 3rd Stage
40 ft. lbs. 95 ft. lbs. 170 ft. lbs.
(55 Nm) (130 Nm) (230 Nm)

7.6 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-
PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and centered between

3. The tightening of the nuts should be done in stages. Follow- drive wheels prior to beginning lockout cylinder test.
ing the recommended sequence, tighten nuts per wheel
torque chart. 1. Place a 6 in (15.2 cm) high block with ascension ramp in front
of left front wheel.
4. Wheel nuts should be torqued after first 50 hours of opera- 2. From platform control station, start engine
tion and after each wheel removal. Check torque every 3
months or 150 hours of operation. 3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front
wheel is on top of block.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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-
ation.
6. Have an assistant check to see that left front wheel remains
locked in position off of ground.
7.7 PROPANE FUEL FILTER REPLACEMENT
7. Carefully activate Swing control lever and return boom to
stowed position (centered between drive wheels). When Removal
boom reaches center, stowed position, lockout cylinders
should release and allow wheel to rest on ground, it may be 1. Relieve the propane fuel system pressure. Refer to Propane
necessary to activate Drive to release cylinders. Fuel System Pressure Relief.
8. Place the 6 in (15.2 cm) high block with ascension ramp in 2. Disconnect the negative battery cable.
front of right front wheel.
3. Slowly loosen the Filter housing and remove it.
9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on top 4. Pull the filter housing from the Electric lock off assembly.
of block. 5. Remove the filter from the housing.
10. With boom over left side of machine, place Drive control 6. Locate Filter magnet and remove it.
lever to Reverse and drive machine off of block and ramp.
7. Remove and discard the housing seal.
11. Have an assistant check to see that right front wheel remains
locked in position off of ground.
12. Carefully activate Swing control lever and return boom to
stowed position (centered between drive wheels). When
boom reaches center, stowed position, lockout cylinders

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Installation

BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING
NEW SEAL

1. Install the housing seal.

2. Drop the magnet into the bottom of the filter housing.
3. Install the filter into the housing.
4. Install the filter up to the bottom of the electric lock off.
5. Tighten the filter bowl retainer to 106 in lb (12 Nm).
6. Open manual shut-off valve. Start the vehicle and leak check
1. Electric Lock Off Solenoid 6. Fuel Outlet the propane fuel system at each serviced fitting. Refer to
2. Housing Seal 7. O-ring Propane Fuel System Leak Test.
3. Filter Magnet 8. Filter
4. Filter Housing 9. Fuel Inlet
5. Electrical Connector 10. Ring
Figure 7-6. Filter Lock Assembly

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

7.8 PROPANE FUEL SYSTEM PRESSURE RELIEF 7.9 SUPPLEMENTAL INFORMATION ONLY APPLICABLE
TO CE MACHINES
The following information is provided in accordance with the
THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO
requirements of the European Machinery Directive 2006/42/EC.
MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL
SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL The A-Weighted emission sound pressure level at the work plat-
SYSTEM COMPONENTS. form is less than 70dB(A).
The guaranteed Sound Power Level (LWA) per European Directive
To relieve propane fuel system pressure:
2000/14/EC (Noise Emission in the Environment by Equipment
1. Close the manual shut-off valve on the propane fuel tank. for Use Outdoors) based on test methods in accordance with
Annex III, Part B, Method 1 and 0 of the directive, is 104 dB (A).
2. Start and run the vehicle until the engine stalls.
The vibration total value to which the hand-arm system is sub-
3. Turn the ignition switch OFF.
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.
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE
WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE.

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EC Declaration of Conformity Machine Type: Mobile Elevating Work Platform

Manufacturer: Model Type: 600AJ

JLG Industries, Inc. Notified Body: Kuiper Certificering b.v.
EC-Number: 2842
Address:
Address: Van Slingelandtstraat 75, 7331 NM
1 JLG Drive Apeldoorn, The Netherlands
1McConnellsburg, PA 17233 USA
Certificate Number: KCEC4412
Reference Standards: • EN 55011:2009/A1:2010
Technical File: • EN 61000-6-2:2005
JLG EMEA B.V. • EN 60204-1:2018
Polaris avenue 63, • EN 280:2013+ A1:2015
2132 JH Hoofddorp • EN ISO 12100:2010
The Netherlands
JLG Industries Inc. hereby declares that the above mentioned
machine conforms with the requirements of:
Contact / Position:
• 2006/42/EC - Machinery Directive
Director of Engineering
• 2014/30/EU - EMC Directive
Europe
• 2014/53/EU - RED Directive (If fitted with optional equipment)
• 2000/14/EC - Outdoor Noise Directive
Date / Place:
NOTE: This declaration conforms with the requirements of annex II-A of
Hoofddorp, Netherlands
the council directive 2006/42/EC. Any modification to the above
described machine violates the validity of this declaration.

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 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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 SECTION 8 - INSPECTION AND REPAIR LOG

SECTION 8. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________

Table 8-1. Inspection and Repair Log

Date Comments

31215030 8-1
 SECTION 8 - INSPECTION AND REPAIR LOG

Table 8-1. Inspection and Repair Log

Date Comments

8-2 31215030
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233-9533 USA
(717) 485-5161 (Corporate)
(877) 554-5438 (Customer Support)
(717) 485-6417

Visit our website for JLG Worldwide Locations

www.jlg.com