operation and safety manual...ansi ® operation and safety manual original instructions - keep this...

ANSI ®

Operation and Safety ManualOriginal Instructions - Keep this manual with the machine at all times.

Boom Lift ModelsE600E600JE600JPM600M600JM600JP

3121217March 9, 2016

FOREWORD

a

s.

rs, and lessees with the precautions and operatingtended purpose.

the right to make specification changes without

3121217 – JLG Lift –

FOREWORD

This manual is a very important tool! Keep it with the machine at all time

The purpose of this manual is to provide owners, users, operators, lessoprocedures essential for the safe and proper machine operation for its in

Due to continuous product improvements, JLG Industries, Inc. reservesprior notification. Contact JLG Industries, Inc. for updated information.

FOREWORD

b 3121217

SIGNAL WORDS

INDIRESUGROU

INDIRESUGROU

TIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULTRATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES.

AVE A YELLOW BACKGROUND.

ATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI-ETY OF PERSONNEL OR PROTECTION OF PROPERTY.

potential personal injury avoid possible injury or

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILLLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-ND.

CATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULDLT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-ND.

INDICATES A POTENIN MINOR OR MODETHIS DECAL WILL H

INDICATES INFORMRECTLY TO THE SAF

This is the Safety Alert Symbol. It is used to alert you to the hazards. Obey all safety messages that follow this symbol todeath

FOREWORD

c

ct:

uct Safety and Reliability DepartmentIndustries, Inc.4 Fountainhead Plaza

erstown, MD 21742

ur Local JLG Office addresses on inside of manual cover)

A:Free: 877-JLG-SAFE (877-554-7233)

de USA:

e: 240-420-2661 301-745-3713il: [email protected]

t Reporting

t Safety tions

Owner Updates

ns Regarding Prod-ty

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

3121217 – JLG Lift –

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLGINDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FORTHIS PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OFRECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THECURRENT OWNER RECORDS ARE UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHEREJLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURYOR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PER-SONAL PROPERTY OR THE JLG PRODUCT.

Conta

ProdJLG 1322HagUSA

or Yo(See

In USToll

Outsi

PhonFax: E-ma

For:• Acciden

• ProducPublica

• Current

• Questiouct Safe

FOREWORD

d 3121217

O

Re

Re

Re

Re

Re

Re

Re

Re

– JLG Lift –

REVISION LOG

riginal Issue - June 7, 2005

vised - July 21, 2006

vised - December 7, 2009

vised - March 2, 2010

vised - September 1, 2010

vised - April 26, 2012

vised - January 5, 2015

vised - October 27, 2015

vised - March 9, 2016

312 i

SEC PARAGRAPH, SUBJECT PAGE

TABLE OF CONTENTS

SEC

SECA

SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

- MACHINE CONTROLS AND INDICATORS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-14

- MACHINE OPERATION

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

MOTOR OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Power/Emergency Stop. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2Platform/Ground Select Switch . . . . . . . . . . . . . . . . . . . . 4-2

TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-5Traveling on a Grade. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Platform Level Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 4-7Platform Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

1217 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION -TION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Operator Training and Knowledge . . . . . . . . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-111.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11

Maintenance Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13

TION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, ND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

SECTION - 3

3.13.2

SECTION - 4

4.14.2

4.3

4.4

4.54.6

4.7

ii 3121217

TABLE OF CONTENTS

SECTIO AGRAPH, SUBJECT PAGE

4.8

4.94.1

4.14.14.14.1

4.14.1

SECTION

5.15.25.3

RGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-2UAL DESCENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2HINE SAFETY SYSTEM OVERRIDE (MSSO)ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

NERAL SPECIFICATIONS & OPERATOR E

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1RATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 6-1pacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4draulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

ajor Component Weights . . . . . . . . . . . . . . . . . . . . . . . . 6-6rial Number Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

RATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8ILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 6-12S & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13re Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13re Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13re Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13heel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14heel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14PLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-15

SPECTION AND REPAIR LOG

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PARRaising and Lowering the Upper Boom. . . . . . . . . . . . . 4-8

GENERATOR (OPTIONAL). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8Automatic Operating Mode. . . . . . . . . . . . . . . . . . . . . . . . 4-8Battery Only Operating Mode. . . . . . . . . . . . . . . . . . . . . . 4-9Manual (Charge) Operating Mode. . . . . . . . . . . . . . . . . . 4-9

FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . 4-90 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)

(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-91 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-102 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-103 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-114 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11

5 TOWING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-136 DRIVE HUB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

Disengaging for Towing . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14Engaging after Towing is Complete . . . . . . . . . . . . . . . 4-16

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-1Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-2

5.4 EME5.5 MAN5.6 MAC

(CE

SECTION - 6 - GEMAINTENANC

6.1 INTR6.2 OPE

CaTiHyMSe

6.3 OPE6.4 OSC6.5 TIRE

TiTiTiWW

6.6 SUP

SECTION - 7 - IN

312 iii

LIST OF FIGURES

FIG MBER - TITLE PAGEDecal Installation - Sheet 2 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-18Decal Installation - Sheet 3 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-19Decal Installation - Sheet 4 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-20Manual Descent Decal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6Operator Maintenance and Lubrication Diagram. . . . . . 6-7


URE NUMBER - TITLE PAGE FIGURE NU2-1. Basic Nomenclature - Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . 2-72-2. Basic Nomenclature - Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . 2-82-3. Basic Nomenclature - Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . 2-92-4. Daily Walk-Around Inspection - Sheet 1 of 4 . . . . . . . . . 2-102-5. Daily Walk-Around Inspection - Sheet 2 of 4 . . . . . . . . . 2-112-6. Daily Walk-Around Inspection - Sheet 3 of 4 . . . . . . . . . 2-122-7. Daily Walk-Around Inspection - Sheet 4 of 4 . . . . . . . . . 2-133-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23-2. Ground Control Station w/ Function Enable. . . . . . . . . . . 3-33-3. Ground Control Station w/ Machine Safety System

Override (MSSO) (CE Only) - Prior to S/N 0300204368 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

3-3. Ground Control Station w/ Machine Safety System Override (MSSO) (CE Only) - S/N 0300204368 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

3-4. Platform Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-103-5. Platform Control Station - w/Drive Orientation . . . . . . . 3-113-6. Platform Control Indicator Panel. . . . . . . . . . . . . . . . . . . . . 3-143-7. Platform Control Indicator Panel

w/Drive Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-154-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-34-2. Position of Least Backward Stability . . . . . . . . . . . . . . . . . . 4-44-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64-4. Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74-5. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . . . . . . . . . 4-124-6. Decal Installation - Sheet 1 of 4 . . . . . . . . . . . . . . . . . . . . . . 4-17

4-7.4-8.4-9.5-1.6-1.6-2.

iv 3121217

LIST O

FIGURE ER - TITLE PAGE

lly.

– JLG Lift –

F FIGURES

NUMBER - TITLE PAGE FIGURE NUMB

This Page Left Blank Intentiona

312 v

LIST OF TABLES

TAB MBER - TITLE PAGE


LE NUMBER - TITLE PAGE TABLE NU1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-61-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-92-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-34-1 Skyguard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-104-2 Decal Legend - Prior to S/N 0300141450 . . . . . . . . . . . . .4-214-3 Decal Legend - S/N 0300141450 to Present . . . . . . . . . .4-256-1 Operating Specifications - Prior to S/N 0300141450 . . . 6-16-2 Operating Specifications - S/N 0300141450

to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-4 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46-5 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-6 Mobil DTE 11M Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-7 Component Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-66-8 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-86-9 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-157-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

vi 3121217

LIST O

TABLE N R - TITLE PAGE

lly.

– JLG Lift –

F TABLES

UMBER - TITLE PAGE TABLE NUMBE

This Page Left Blank Intentiona

SECTION 1 - SAFETY PRECAUTIONS

1-1

UTIONS

MPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR

-OPERATION

raining and Knowledge Operation and Safety Manual must be read and under-d in its entirety before operating the machine. For clarifi-

on, questions, or additional information regarding anytions of this manual, contact JLG Industries, Inc.

3121217 – JLG Lift –

SECTION 1. SAFETY PRECA

1.1 GENERALThis section outlines the necessary precautions for proper andsafe machine usage and maintenance. It is mandatory that a dailyroutine is established based on the content of this manual to pro-mote proper machine usage. A maintenance program, using theinformation provided in this manual and the Service and Mainte-nance Manual, must also be established by a qualified person andmust be followed to ensure that the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine must notaccept operating responsibility until this manual has been read,training is accomplished, and operation of the machine has beencompleted under the supervision of an experienced and quali-fied operator.

This section contains the responsibilities of the owner, user, oper-ator, lessor, and lessee concerning safety, training, inspection,maintenance, application, and operation. If there are any ques-tions with regard to safety, training, inspection, maintenance,application, and operation, please contact JLG Industries, Inc.(“JLG”).

FAILURE TO COCOULD RESULTDEATH.

1.2 PRE

Operator T• The

stoocatipor


1-2 3121217

pectionns to avoid all hazards in the work area must be

the user before and during operation of the machine.

perate or raise the platform from a position on trucks,ailway cars, floating vessels, scaffolds or other equip-less the application is approved in writing by JLG.

peration, check work area for overhead hazards suchic lines, bridge cranes, and other potential overheadions.

erating surfaces for holes, bumps, drop-offs, obstruc-bris, concealed holes, and other potential hazards.

e work area for hazardous locations. Do not operateine in hazardous environments unless approved forose by JLG.

hat the ground conditions are adequate to supportimum tire load indicated on the tire load decalsn the chassis adjacent to each wheel. Do not travelported surfaces.

– JLG Lift –

• An operator must not accept operating responsibilities untiladequate training has been given by competent and autho-rized persons.

• Allow only those authorized and qualified personnel to oper-ate the machine who have demonstrated that they under-stand the safe and proper operation and maintenance of theunit.

• Read, understand, and obey all DANGERS, WARNINGS, CAU-TIONS, and operating instructions on the machine and in thismanual.

• Ensure that the machine is to be used in a manner which iswithin the scope of its intended application as determined byJLG.

• All operating personnel must be familiar with the emergencycontrols and emergency operation of the machine as specifiedin this manual.

• Read, understand, and obey all applicable employer, local, andgovernmental regulations as they pertain to your utilizationand application of the machine.

Workplace Ins• Precautio

taken by

• Do not otrailers, rment un

• Before oas electrobstruct

• Check options, de

• Check ththe machthat purp

• Ensure tthe maxlocated oon unsup


1-3

RATION

hine operation requires your full attention. Bring thehine to a full stop before using any device, i.e. cell phones,-way radios, etc. that will distract your attention fromly operating the machine.

not use the machine for any purpose other than position-personnel, their tools, and equipment.

re operation, the user must be familiar with the machineabilities and operating characteristics of all functions.

er operate a malfunctioning machine. If a malfunctionrs, shut down the machine. Remove the unit from service

notify the proper authorities.

ot remove, modify, or disable any safety devices.

er slam a control switch or lever through neutral to anosite direction. Always return switch to neutral and stopre moving the switch to the next function. Operate con- with slow and even pressure.

not allow personnel to tamper with or operate thehine from the ground with personnel in the platform,pt in an emergency.

3121217 – JLG Lift –

Machine Inspection • Do not operate this machine until the inspections and func-

tional checks as specified in Section 2 of this manual havebeen performed.

• Do not operate this machine until it has been serviced andmaintained according to the maintenance and inspectionrequirements as specified in the machine’s Service and Main-tenance Manual.

• Ensure all safety devices are operating properly. Modificationof these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADEONLY WITH PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.

• Do not operate any machine on which the safety or instructionplacards or decals are missing or illegible.

• Check the machine for modifications to original components.Ensure that any modifications have been approved by JLG.

• Avoid accumulation of debris on platform floor. Keep mud, oil,grease, and other slippery substances from footwear and plat-form floor.

1.3 OPE

General • Mac

mactwosafe

• Do ing

• Befocap

• Nevoccuand

• Do n

• Nevoppbefotrols

• Do macexce


1-4 3121217

c cylinders are subject to thermal expansion and con-This may result in changes to the boom and/or plat-sition while the machine is stationary. Factors thermal movement can include the length of timeine will remain stationary, hydraulic oil temperature,

air temperature, and boom and platform position.

azards peration, occupants in the platform must wear a fullness with a lanyard attached to an authorized lanyarde point. Attach only one (1) lanyard per lanyarde point.

d exit only through gate area. Use extreme cautiontering or leaving platform. Ensure that the platform is fully lowered. Face the machine when entering orhe platform. Always maintain “three point contact” machine, using two hands and one foot or two feethand at all times during entry and exit.

– JLG Lift –

• Do not carry materials directly on platform railing unlessapproved by JLG.

• When two or more persons are in the platform, the operatorshall be responsible for all machine operations.

• Always ensure that power tools are properly stowed and neverleft hanging by their cord from the platform work area.

• When driving, always position boom over rear axle in line withthe direction of travel. Remember, if boom is over the frontaxle, steer and drive functions will be reversed.

• Do not assist a stuck or disabled machine by pushing or pull-ing except by pulling at the chassis tie-down lugs.

• Fully lower platform and shut off all power before leavingmachine.

• Remove all rings, watches, and jewelry when operatingmachine. 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 aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

• Hydraulitraction. form poaffectingthe machambient

Trip and Fall H• During o

body haranchoraganchorag

• Enter anwhen enassemblyleaving twith theand one


1-5

ion Hazards machine is not insulated and does not provide protection contact or proximity to electrical current.

3121217 – JLG Lift –

• Before operating the machine, make sure all gates are closedand fastened in their proper position.

• Keep both feet firmly positioned on the platform floor at alltimes. Never position ladders, boxes, steps, planks, or similaritems on unit to provide additional reach for any purpose.

• Keep oil, mud, and slippery substances cleaned from footwearand the platform floor.

Electrocut• This

from


1-6 3121217

a clearance of at least 10 ft. (3m) between any part ofhine and its occupants, their tools, and their equip-m any electrical line or apparatus carrying up toolts. One foot additional clearance is required forditional 30,000 volts or less.

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

e Rangeto Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

50 KV 10 (3)

V to 200 KV 15 (5)

V to 350 KV 20 (6)

V to 500 KV 25 (8)

V to 750 KV 35 (11)

V to 1000 KV 45 (14)

requirement shall apply except whereloyer, local or governmental regulations are

re stringent.

– JLG Lift –

• Maintain distance from electrical lines, apparatus, or any ener-gized (exposed or insulated) parts according to the MinimumApproach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintainthe macment fro50,000 vevery ad

Table 1

Voltag(Phase

0 to

Over 50K

Over 200 K

Over 350 K

Over 500 K

Over 750 K

NOTE: Thisempmo


1-7

azards user must be familiar with the surface before driving. Doexceed the allowable sideslope and grade while driving.

not elevate platform or drive with platform elevated whiler near a sloping, uneven, or soft surface. Ensure machine is

itioned on a firm, level and smooth surface before elevat-platform or driving with the platform in the elevated posi-.

re driving on floors, bridges, trucks, and other surfaces,ck allowable capacity of the surfaces.

3121217 – JLG Lift –

• The minimum approach distance may be reduced if insulatingbarriers are installed to prevent contact, and the barriers arerated for the voltage of the line being guarded. These barriersshall not be part of (or attached to) the machine. The mini-mum approach distance shall be reduced to a distance withinthe designed working dimensions of the insulating barrier.This determination shall be made by a qualified person inaccordance with the employer, local, or governmental require-ments for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD).ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH-ERWISE.

Tipping H• The

not

• Do on oposing tion

• Befoche


1-8 3121217

perate the machine when wind conditions, includingay exceed 28 mph (12.5 m/s). Factors affecting winde; platform elevation, surrounding structures, localevents, and approaching storms. Refer to Table 1-2, scale (For Reference Only) or use other means towind conditions.

eed can be significantly greater at height than atevel.

ed can change rapidly. Always consider approachingevents, the time required to lower the platform, and to monitor current and potential wind conditions.

increase surface area of the platform or the load. areas exposed to wind will decrease stability.

crease the platform size with unauthorized modifica-ttachments.

– JLG Lift –

• Never exceed the maximum work load as specified on theplatform. Keep all loads within the confines of the platform,unless authorized by JLG.

• Keep the chassis of the machine a minimum of 2 ft. (0.6m)from holes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards at the ground level.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-offmachine to any adjacent structure. Never attach wire, cable, orany similar items to platform.

• If boom assembly or platform is in a position that one or morewheels are off the ground, all persons must be removed beforeattempting to stabilize the machine. Use cranes, forklift trucks,or other appropriate equipment to stabilize machine.

• Do not ogusts, mspeed arweather Beaufortmonitor

• Wind spground l

• Wind speweather methods

• Do not Increased

• Do not intions or a


1-9

nce Only)

Land Conditions

vertically

le in smoke

ed skin. Leaves rustle

twigs in constant motion

er raised. Small branches begin to move.

.

otion. Flags waving near horizontal. Umbrella use

ion. Effort needed to walk against the wind.

trees. Cars veer on road.

age.

3121217 – JLG Lift –

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

Table 1-2. Beaufort Scale (For Refere

Beaufort Number

Wind SpeedDescription

mph m/s

0 0 0-0.2 Calm Calm. Smoke rises

1 1-3 0.3-1.5 Light air Wind motion visib

2 4-7 1.6-3.3 Light breeze Wind felt on expos

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller

4 13-18 5.5-7.9 Moderate breeze Dust and loose pap

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway

6 25-31 10.8-13.8 Strong breeze Large branches in mbecomes difficult.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in mot

8 39-46 17.2-20.7 Fresh Gale Twigs broken from

9 47-54 20.8-24.4 Strong Gale Light structure dam


1-1 3121217

Cru n-operating personnel at least 6 ft. (1.8m) away from during all driving and swing operations.

ll travel conditions, the operator must limit travelcording to conditions of ground surface, congestion, slope, location of personnel, and other factors whichse collision or injury to personnel.

of stopping distances in all drive speeds. When driv-h speed, switch to low speed before stopping. Travel low speed only.

se high speed drive in restricted or close quarters orving in reverse.

extreme caution at all times to prevent obstacles fromr interfering with operating controls and persons in

orm.

that operators of other overhead and floor levels are aware of the aerial work platform’s presence. Dis-power to overhead cranes.

rsonnel not to work, stand, or walk under a raised platform. Position barricades on floor if necessary.

0 – JLG Lift –

shing and Collision Hazards• Approved head gear must be worn by all operating and

ground personnel.

• Check work area for clearances overhead, on sides, and bot-tom of platform when lifting or lowering platform, and driving.

• During operation, keep all body parts inside platform railing.

• Use the boom functions, not the drive function, to position theplatform close to obstacles.

• Always post a lookout when driving in areas where vision isobstructed.

• Keep nomachine

• Under aspeed acvisibility,may cau

• Be awareing in higgrades in

• Do not uwhen dri

• Exercise striking othe platf

• Be sure machineconnect

• Warn peboom or


1-11

INTENANCEb-section contains general safety precautions which musterved during maintenance of this machine. Additional pre-ns to be observed during machine maintenance ared at the appropriate points in this manual and in the Ser-d Maintenance Manual. It is of utmost importance thatnance personnel pay strict attention to these precautionsd possible injury to personnel or damage to the machineerty. A maintenance program must be established by a

ied person and must be followed to ensure that thee is safe.

nce Hazardst off power to all controls and ensure that all moving partssecured from inadvertent motion prior to performing anystments or repairs.

er work under an elevated platform until it has been fullyered to the full down position, if possible, or otherwiseported and restrained from movement with appropriatety props, blocking, or overhead supports.

NOT attempt to repair or tighten any hydraulic hoses or fit-s while the machine is powered on or when the hydraulicem is under pressure.

ays relieve hydraulic pressure from all hydraulic circuitsre loosening or removing hydraulic components.

3121217 – JLG Lift –

1.4 TOWING, LIFTING, AND HAULING• Never allow personnel in platform while towing, lifting, or

hauling.

• This machine should not be towed, except in the event ofemergency, malfunction, power failure, or loading/unloading.Refer to the Emergency Procedures section of this manual foremergency towing procedures.

• Ensure boom is in the stowed position and the turntablelocked prior to towing, lifting or hauling. The platform must becompletely empty of tools.

• When lifting machine, lift only at designated areas of themachine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lift-ing information.

1.5 MAThis sube obscautioinsertevice anmainteto avoior propqualifmachin

Maintena• Shu

are adju

• Nevlowsupsafe

• DO tingsyst

• Alwbefo


1-1 3121217

se machine as a ground for welding.

rforming welding or metal cutting operations, pre- must be taken to protect the chassis from direct to weld and metal cutting spatter.

fuel the machine with the engine running.

approved non-flammable cleaning solvents.

eplace items critical to stability, such as batteries ors, with items of different weight or specification. Doify unit in any way to affect stability.

the Service and Maintenance Manual for the weightsl stability items.

LTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADERITTEN PERMISSION FROM THE MANUFACTURER.

2 – JLG Lift –

• DO NOT use your hand to check for leaks. Use a piece of card-board or paper to search for leaks. Wear gloves to help protecthands from spraying fluid.

• Ensure replacement parts or components are identical orequivalent to original parts or components.

• Never attempt to move heavy parts without the aid of amechanical device. Do not allow heavy objects to rest in anunstable position. Ensure adequate support is provided whenraising components of the machine.

• Do not u

• When pecautionsexposure

• Do not re

• Use only

• Do not rsolid tirenot mod

• Refer to of critica

MODIFICATION OR AONLY WITH PRIOR W


1-13

ID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH AND SEEK MEDICAL ATTENTION.

rge batteries only in a well ventilated area.

id overfilling the battery fluid level. Add distilled water toeries only after the batteries are fully charged.

3121217 – JLG Lift –

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 dur-ing charging or servicing.

• Do not contact tools or other metal objects across the batteryterminals.

• Always wear hand, eye, and face protection when servicingbatteries. Ensure that battery acid does not come in contactwith skin or clothing.

BATTERY FLUCLOTHING ATCLEAN WATER

• Cha

• Avobatt


1-1 3121217
4 – JLG Lift –
NOTES:

S, MACHINE PREPARATION, AND INSPECTION

2-1

REPARATION, AND INSPECTION

e safest means to operate the machine where overhead structions, other moving equipment, and obstacles, pressions, holes, dropoffs.

eans to avoid the hazards of unprotected electrical con-ctors.

ecific job requirements or machine application.

upervisiong must be done under the supervision of a qualified per- an open area free of obstructions until the trainee hasped the ability to safely control and operate the machine.

esponsibilityerator must be instructed that he/she has the responsibil- authority to shut down the machine in case of a malfunc- other unsafe condition of either the machine or the job

SECTION 2 - USER RESPONSIBILITIE

3121217 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE P

2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it is neces-sary that it be operated and maintained only by trained person-nel.

Persons under the influence of drugs or alcohol or who are sub-ject to seizures, dizziness or loss of physical control must notoperate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential malfunc-tion.

6. Thobde

7. Mdu

8. Sp

Training STraininson indevelo

Operator RThe opity andtion orsite.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121217

2.2. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A

UCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL PRODUCT MODEL.

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCEThe following table covers the periodic machine inspections andmaintenance recommended by JLG Industries, Inc. Consult localregulations for further requirements for aerial work platforms.The frequency of inspections and maintenance must beincreased as necessary when the machine is used in a harsh orhostile environment, if the machine is used with increased fre-quency, or if the machine is used in a severe manner.

JLG INDUSTRIES, INCPERSON WHO HAS SFOR THE SPECIFIC JLG


2-3

nce Table

rybility

Service Qualification Reference

User or Operator Operator and Safety Manual

User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

User Qualified JLG Mechanic Service and Maintenance Manual and applicable JLG inspection form

User Factory Trained Service Technician (Recommended)

Service and Maintenance Manual and applicable JLG inspection form

User Qualified JLG Mechanic Service and Maintenance Manual

ual to perform inspections.


3121217 – JLG Lift –

Table 2-1.Inspection and Maintena

Type Frequency PrimaResponsi

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Operator

Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery. Owner, Dealer, or

Frequent Inspection In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

Owner, Dealer, or

Annual Machine Inspection Annually, no later than 13 months from the date of prior inspection.

Owner, Dealer, or

Preventative Maintenance At intervals as specified in the Service and Maintenance Manual.

Owner, Dealer, or

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Man


2-4 3121217

Pre y – Charge as required.

ombustion Engine Powered Machines) – Add the fuel as necessary.

ulic Oil – Check the hydraulic oil level. Ensure hydrau- added as required.

on Check – Once the “Walk-Around” Inspection is te, perform a functional check of all systems in an e of overhead and ground level obstructions. Refer to 4 for more specific instructions.

ES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDI-PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOTNE UNTIL IT IS DECLARED SAFE FOR OPERATION.

– JLG Lift –

-Start InspectionThe Pre-Start Inspection should include each of the following:

1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat-tery fluid) or foreign objects. Report any leakage to the proper maintenance personnel.

2. Decals and Placards – Check all for cleanliness and legibil-ity. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

3. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container.

4. “Walk-Around” Inspection – Refer to Figure 2-4., Figure 2-5., and Figure 2-7.

5. Batter

6. Fuel (Cproper

7. Hydralic oil is

8. Functicomplearea freSection

IF THE MACHINE DOATELY! REPORT THE OPERATE THE MACHI


2-5

om the platform control console:

. Ensure that the control console is firmly secured in theproper location;

. Check that all guards protecting the switches or locksare in place;

. Operate all functions and check all limiting and cut-outswitches;

. Ensure that all machine functions are disabled whenthe Emergency Stop Button is pushed in.

. With machine in the transport (stowed) position, driveon a grade (not to exceed the rated gradeability) andstop to ensure the brakes hold;

. With machine in the transport (stowed) position, checkthe tilt sensor indicator light to ensure proper opera-tion.


3121217 – JLG Lift –

Function CheckPerform the Function Check as follows:

1. From the ground control panel with no load in the platform:

a. Check that all guards protecting the switches or locksare in place.

b. Operate all functions and check all limiting and cut-outswitches.

c. Check auxiliary power (or manual descent).

d. Ensure that all machine functions are disabled whenthe Emergency Stop Button is activated.

2. Fr

a

b

c

d

e

f


2-6 3121217

Sky achine is equipped with both SkyGuard and Soft Touch,s will not reverse, only stop.

ed, ensure the blue beacon illuminates when SkyGuardted.

the SkyGuard sensor, release controls, recycle the foote sure normal operation is available.

remains activated after function reversal or cutout, hold the SkyGuard Override Switch to allow normal

hine functions until the SkyGuard sensor is disen-

– JLG Lift –

Guard Function Test From the Platform Console:

Test the SkyGuard feature by operating the telescope out func-tions and then activating the SkyGuard sensor. The telescope outfunction will stop and the telescope in function will operate for ashort duration and the horn will sound until the SkyGuard sensorand footswitch are disengaged.

NOTE: If the mfunction

NOTE: If equippis activa

Disengage switch, mak

If SkyGuarddepress anduse of macgaged.


2-7

et 1 of 3

1. Battery Pack2. Fuel Tank3. Hydraulic Tank4. Main Terminal Box5. Swing Drive6. Turntable Lock7. Frame8. Turntable9. Battery Charger10. Generator Control Module (M Models)


3121217 – JLG Lift –

10

1

2

3

45

6

9

8

7

Figure 2-1. Basic Nomenclature - She


2-8 3121217

of 3

1. Frame2. Main Valve3. Generator Start Battery (M Models)4. Generator (M Models)5. Battery Pack6. Ground Control7. Turntable

– JLG Lift –

5

64

3

2

1

7

Figure 2-2. Basic Nomenclature - Sheet 2


2-9

Figu

re 2

-3. B

asic

Nom

encl

atur

e - S

heet

3 o

f 3

1. P

latfo

rm2.

Rot

ator

3. B

oom

4. L

ift Cy

linde

r5.

Upr

ight

6. To

wer B

oom

7. To

wer L

ift8.

Boo

m Li

nk9.

Mas

ter C

ylind

er10

. Slav

e Cyli

nder

11. J

ib12

. Plat

form

Cont

rol B

ox13

. Sky

Guar

d (If E

quip

ped)

14. C

ross

Rail (

If Equ

ipped

)


3121217 – JLG Lift –


2-1 3121217

Sheet 1 of 4

0 – JLG Lift –

Figure 2-4. Daily Walk-Around Inspection -


2-11

latform & Ground Control Console - Switches and control vers; placards secure and legible; control lever and

witches return to neutral; control lever lock functions roperly; emergency stop switch functions properly; con-

rol markings legible.

otator - See Note.

ll Hydraulic Cylinders - No visible damage; Pivot pins and ydraulic hoses undamaged, not leaking.

oom - Pivot pins secure; Upright in vertical position. See ote.

rive Axle and Motor - See Note

heel/Tire Assembly - No loose or missing lug nuts, roper inflation (pneumatic). Inspect for worn tread, cuts,

ears, or other discrepancies. Inspect wheels for damage nd corrosion

rame (top and underside) - See Note.

- Sheet 2 of 4


3121217 – JLG Lift –

GENERAL

Begin your Walk-Around Inspection at item 1, as noted on thediagram. Continue to your right (counterclockwise viewed fromthe top) checking each item in sequence for the conditionslisted in the following checklist.

TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DURING “WALK-AROUND INSPECTION”.

DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. CHECKING THISAREA MAY RESULT IN DISCOVERY OF CONDITIONS WHICH COULD CAUSE EXTENSIVEMACHINE DAMAGE.

NOTE: On each item, make sure there are no loose or missing parts,that they are securely fastened and that no visible damageexists in addition to any other criteria mentioned.

1. Platform Assembly - Platform mounting pins secure. Foot-switch in good working order; not modified, disabled or blocked.

2. Plespt

3. R

4. Ah

5. BN

6. D

7. Wpta

8. F

Figure 2-5. Daily Walk-Around Inspection


2-1 3121217

ing and Latches - See Note

ulic Pump and Reservoir - Recommended hydraulic evel on dipstick (system shut down, boom in stowed

ion). Breather cap/dipstick secure and working.

al Descent Valve - See Note

ol Valve - No unsupported or damaged wires or .

rator Start Battery - See Note

e Oil Supply - Full mark on dipstick; filler cap and fil-cure.

ry Compartment Right Side - See Note

terweight - See Note

Switches - Switches operable.

d Ends and Steering Spindles - Tie rod end stubs d.

f 4

2 – JLG Lift –

9. Boom Limit Switch - Switch operable; 10. Cowl

11. Hydrafluid lposit

12. Manu

13. Contrhoses

14. Gene

15. Enginter se

16. Batte

17. Coun

18. Limit

19. Tie Rolocke

Figure 2-6. Daily Walk-Around Inspection - Sheet 3 o


2-13

attery Compartment - See Note

el Supply - Fuel filler cap secure; Tank - Decals secure d legible.

ydraulic Oil Filter Housing - See Note

attery Charger - See Note

rntable Bearing - Evidence of proper lubrication. No ose bolts or looseness between bearing and structure.

ing Motor - Evidence of proper lubrication.

latform Pivot Pins - See Note

latform Gate - Latch and Hinges in working condition.

yGuard (If Equipped) - See Inspection Note.

- Sheet 4 of 4


3121217 – JLG Lift –

20. Oscillating Axle and Lockout Valve (If Equipped) - Check the lockout valve plunger in the depressed position. Swing the turntable until the axle lockout bracket passes the plunger and make sure the plunger is fully extended as shown below

21. B

22. Fuan

23. H

24. B

25. Tulo

26. Sw

27. P

28. P

29. Sk

Figure 2-7. Daily Walk-Around Inspection


2-1 3121217
4 – JLG Lift –
NOTES:

N 3 - MACHINE CONTROLS AND INDICATORS

3-1

ND INDICATORS

ntrol Station3-1., Figure 3-2., and Figure 3-3.

TE FROM GROUND CONTROL STATION WITH PERSONNEL IN THE PLAT-N AN EMERGENCY.

ANY PRE-OPERATIONAL CHECK AND INSPECTIONS FROM GROUNDOSSIBLE.

en machine is shut down the Platform/Ground Select switch Emergency Stop must be positioned to OFF.

quipped, the Function Enable switch must be held down iner to operate Telescope, Lift, Swing, Jib Lift, Platform Level

erride, and Platform Rotate functions.

wer/Emergency Stop

two-position red mushroom shaped switch furnishes wer to Platform/Ground Select switch when pulled out

n). When pushed in (off ), power is shut off to the Platform/ound Select switch.

SECTIO

3121217 – JLG Lift –

SECTION 3. MACHINE CONTROLS A

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION ANDOPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITHGOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: The optional generator engine will automatically shut downunder the following conditions:

Batteries Fully ChargedHigh Oil TemperatureLow Oil PressureEngine OverspeedOvervoltage

NOTE: The optional generator engine will not start if the batteries arefully charged or if the Generator Enable switch on the platformconsole is not in the on position.

Ground CoSee Figure

DO NOT OPERAFORM EXCEPT I

PERFORM AS MCONTROLS AS P

NOTE: Whand

NOTE: If eordOv

1. Po

A po(oGr

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121217

Power/Emergency Stop Platform/Ground Select Platform RotatePlatform Leveling OverrideMain LiftTelescopeSwingBattery Indicator and HourmeterGenerator Enabled Indicator

. Generator/Engine Start

. Jib Boom

. Jib Rotate

. Platform Overload

– JLG Lift –

1.2.3.4.5.6.7.8.9.10111213

Figure 3-1. Ground Control Station


3-3

1. Power/Emergency Stop 2. Platform/Ground Select 3. Platform Rotate4. Platform Leveling Override5. Main Lift6. Telescope7. Swing8. Battery Indicator and Hourmeter9. Generator Enabled Indicator10. Generator/Engine Start11. Jib Boom 12. Jib Rotate13. Platform Overload14. Function Enable

ction Enable

SECTIO

3121217 – JLG Lift –

Figure 3-2. Ground Control Station w/ Fun


3-4 3121217

Power/Emergency Stop Platform/Ground Select Platform RotatePlatform Leveling OverrideMain LiftTelescopeSwingNot UsedGenerator Enabled Indicator

. Generator/Engine Start

. Jib Boom

. Jib Rotate

. Platform Overload

. Function Enable

. Indicator Gauge

. Charger Status

. Machine Safety System Override (MSSO)

SO) (CE Only) - Prior to S/N 0300202137

– JLG Lift –

1704428 B

+- +-

2

1

10

9

5

11

4

3

12

13

14

15

16

6

7

17

1.2.3.4.5.6.7.8.9.1011121314151617

Figure 3-3. Ground Control Station w/ Machine Safety System Override (MS


3-5

1. Power/Emergency Stop 2. Platform/Ground Select 3. Platform Rotate4. Platform Leveling Override5. Main Lift6. Telescope7. Swing8. Not Used9. Generator Enabled Indicator10. Generator/Engine Start11. Jib Boom 12. Jib Rotate13. Platform Overload14. Function Enable15. Indicator Gauge16. Not Used17. Machine Safety System Override (MSSO)

MSSO) (CE Only) - S/N 0300202137 to Present

SECTIO

3121217 – JLG Lift –

1001196785 B2

1

10

9

5

114

3

12

13

14

15

17

6

7

Figure 3-3. Ground Control Station w/ Machine Safety System Override (


3-6 3121217

NOT

ORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OFORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR SO COULD RESULT IN DEATH OR SERIOUS INJURY.

m Leveling Override

e position switch allows the operator to adjust theatic self leveling system. This switch is used to adjustm level in situations such as ascending/descending a

Lift

s for raising and lowering of the Boom.

pe

s for extension and retraction of the Boom.

itch provides 400 degrees non-continuous turntable n. To activate SWING, position switch to LEFT or

– JLG Lift –

2. Platform/Ground Select

A three position, key operated switch supplies power to the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground controls are operable.

E: With PLATFORM/GROUND SELECT switch in the center position,power is shut off to controls at both operating stations.

3. Rotate

A three position switch permits rotation of the platform.

ONLY USE THE PLATFTHE PLATFORM. INCFALL. FAILURE TO DO

4. Platfor

A threautomplatforgrade.

5. Boom

Provide

6. Telesco

Provide

7. Swing

This swrotatioRIGHT.


3-7

ticulating Jib Boom (If Equipped)

is switch provides raising and lowering of the jib.

Rotate (If Equipped)

three position switch permits rotation of the jib and plat-rm.

atform Overload (If Equipped)

dicates the platform has been overloaded.

nction Enable (If Equipped)

equipped, the enable switch must be held "DOWN" toable all boom controls when the engine is running.

SECTIO

3121217 – JLG Lift –

8. Battery Indicator and Hourmeter

An hourmeter is installed in the upper portion of the Ground Control Box. The hourmeter registers up to 9,999.9 hours and cannot be reset.

9. Generator Enabled Indicator

The generator enabled indicator lights to signify the genera-tor is enabled and may start at any time as the batteries require. If the indicator flashes, it signifies an abnormal con-dition for the generator engine (high oil temperature or low oil pressure) or, on all electric machines, an electrical system fault.

NOTE: Refer to the Service Manual for the generator fault codes.

10. Generator/Engine Start Button (if equipped)

The generator/engine start push-button switch allows the generator to be started manually to top-off the battery charge. The generator will start automatically when the bat-teries reach a low-charge level.

11. Ar

Th

12. Jib

A fo

13. Pl

In

14. Fu

If en


3-8 3121217

rol Station

Platform Control Station)

Emergency Stop

-position red mushroom shaped switch furnishesto PLATFORM Controls when pulled out (on). When in (off ), power is shut off to the platform functions.

about 2 seconds of pulling the switch out, thee will perform a diagnostic check of the various elec-

ircuits, and if everything is OK, the platform alarm willnce. During this time the lights on the indicator panelo blink once as a bulb check.

NJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS ORONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE

SITION WHEN RELEASED.

– JLG Lift –

15. Indicator Gauge

Registers the amount of time the machine has been in use,with functions operating. In the event of a fault, the hourme-ter also displays the three digit fault code. Refer to the Ser-vice Manual for a listing of fault codes. Additionally, there is asmall, red indicator light that will blink when there is a faulton the machine to draw operator attention to the display.

16. Charger Status

The Charger Status LEDs give a visual indicator of the statusof the battery charger. The red LED indicates ChargingAbnormal. The yellow LED indicates charging in progress.The green LED indicates charging is complete.

17. Machine Safety System Override (MSSO) (CEOnly)

Provides emergency override of functioncontrols that are locked out in the event ofLoad Sense System activation.

Platform Cont

(See Figure 3-4.,

1. Power/

A twopower pushed

Withinmachintrical cbeep owill als

TO AVOID SERIOUS ITOGGLE SWITCHES COFF OR NEUTRAL PO


3-9

lescope Control

is switch allows extension and retraction of the main om.

ticulating Jib (If Equipped)

is switch controls the raising and lowering of the jib (up or wn).

Rotate (If Equipped)

three position switch permits rotation of the jib and plat-rm (left or right).

atform Rotate

is switch controls the rotation of the basket (left or right).

SECTIO

3121217 – JLG Lift –

2. Generator Enable Control (if equipped)

This switch allows the operator to prevent the generator engine from starting to charge the batteries when using the machine indoors.

3. Lights (If Equipped)

This switch operates accessory light packages if the machine is so equipped.

4. Drive/Steer

The DRIVE joystick provides for driving either forward or backward. The controller is ‘ramped’ to allow variable drive speed.

Steering is controlled by a thumb operated switch on top of the joystick.

5. Te

Thbo

6. Ar

Thdo

7. Jib

A fo

8. Pl

Th


3-1 3121217

11. Posi Track 12. Platform Leveling Override13. Horn

0 – JLG Lift –

1. Power/Emergency Stop 2. Generator Enable 3. Lights4. Drive/Steer

5. Telescope6. Articulating Jib Boom7. Jib Rotate

8. Platform Rotate9. Function Speed10. Main Lift/Swing

Figure 3-4. Platform Control Station


3-11

Override

13. Horn14. Drive Orientation Override15. Soft Touch/SkyGuard Override16. Soft Touch/SkyGuard Indicator

e Orientation

SECTIO

3121217 – JLG Lift –

1. Power/Emergency Stop 2. Generator Enable 3. Lights4. Drive/Steer

5. Telescope6. Articulating Jib Boom7. Jib Rotate8. Platform Rotate

9. Function Speed10. Main Lift/Swing11. Posi Track 12. Platform Leveling

Figure 3-5. Platform Control Station - w/Driv


3-1 3121217

NOT

ack Control

ing the Posi-Track switch distributes available power between the two drive wheels for improved traction. ntrol system may also engage the posi-track function atically when more traction is required.

onal 4 Wheel Assist will also engage with the Posi-Track

ORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OFORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR SO COULD RESULT IN DEATH OR SERIOUS INJURY.

m Leveling Override

e position switch allows the operator to adjust theatic self leveling system. This switch is used to adjustm level in situations such as ascending/descending a

2 – JLG Lift –

9. Function Speed Control

Controls the speed of Boom and Swing Functions. Rotate CCW for slower speed and CW for faster speed. To adjust to creep, turn knob fully CCW until it clicks.

10. Main Lift/Swing

The dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lower. Move right to swing right, move left to swing left. Proportional control of these functions can be attained by using the Function Speed control.

E: Main lift and swing functions may be selected at the same time.Maximum speed is reduced when both functions are selected.

11. Posi-Tr

ActivatevenlyThe coautom

NOTE: The optiControl.

ONLY USE THE PLATFTHE PLATFORM. INCFALL. FAILURE TO DO

12. Platfor

A threautomplatforgrade.


3-13

equipped with SkyGuard, the switchables functions cut out by the Sky-ard system to be operated again,

lowing the operator to resume use ofachine functions.

equipped with both Soft Touch andyGuard, the switch operates likescribed above and allows the opera-r to override the system that hasperienced a cutout situation.

ft Touch/SkyGuard Indicator (If Equipped)

dicates the Soft Touch bumper is against an object or theyGuard sensor has been activated. All controls are cut outtil the override button is pushed. For Soft Touch, controls

e then active in the Creep Mode or for SkyGuard, controlsill work normally.

SECTIO

3121217 – JLG Lift –

13. Horn

If pressed, this switch supplies power to the horn.

14. Drive Orientation Override

When the boom is swung over the rear tires or further ineither direction, the Drive Orientation indicator will illumi-nate when the drive function is selected. Push and releasethe switch, and within 3 seconds move the Drive/Steer con-trol to activate drive or steer. Before driving, locate the black/white orientation arrows on both the chassis and the plat-form controls and match the control direction arrow to theintended chassis direction.

15. Soft Touch/SkyGuard Override Switch (If equipped)

The machine can be equipped with one of three options. Itmay have Soft Touch, SkyGuard, or both Soft Touch and Sky-Guard.

If equipped with Soft Touch, the switchenables the functions that were cut outby the Soft Touch system to operateagain at creep speed, allowing theoperator to move the platform away from the obstacle thatcaused the shutdown situation.

If engualm

If Skdetoex

16. So

InSkunarw


3-1 3121217

Pla

(S

NOT

Warning indicatoristress k

5. Footswitch/Enable Indicator6. Low Battery Indicator7. Creep Indicator8-11. Not Used

3-6. Platform Control Indicator Panel

4 – JLG Lift –

tform Control Indicator Panel

ee Figure 3-6., Platform Control Indicator Panel)

E: The platform control indicator panel uses different shaped sym-bols to alert the operator to different types of operational situa-tions that could arise. The meaning of those symbols areexplained below.

Indicates a potentially hazardous situation, which ifnot corrected, could result in serious injury or death.This indicator will be red.

Indicates an abnormal operating condition, which ifnot corrected, may result in machine interruption ordamage. 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 ofthe capacity indicator which will be green or yellowdepending upon platform position.

1. Tilt Alarm2. Overload3. System D4. Posi Trac

Figure


3-15

lt Alarm Warning Light and Alarm

is orange illuminator indicates that the chassis is on ape. An alarm will also sound when the chassis is on ape and the boom is above horizontal. If lit when boom is

ised or extended, retract and lower to below horizontalen reposition machine so that it is level before continuingeration. If the boom is above horizontal and the machine

on a slope, the tilt alarm warning light will illuminate and alarm will sound and CREEP is automatically activated.

NG LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED,LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THATORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

atform Overload (If Equipped)

dicates the platform has been overloaded.

SECTIO

3121217 – JLG Lift –

1. Ti

Thsloslorathopis an

IF TILT WARNIRETRACT AND IT IS LEVEL BEF

2. Pl

In

1704239 E

+-

1001110226A

+-

7 9 6

1 543 82

1. Tilt2. Platform Overload3. System Distress4. Posi-Track5. Enable

6. Low Battery7. Creep8. Drive Orientation Override9. Soft Touch Indicator

Figure 3-7. Platform Control Indicator Panel w/Drive Orientation


3-1 3121217

e enable light will go out and the footswitch must be d and depressed again to enable the controls.

ng the footswitch removes power from all controls plies the drive brakes.

JURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH OTHER MEANS.

BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLYST 1/4" OF TRAVEL, TOP OR BOTTOM.

ttery Light

ht indicates when battery voltage is below 45 volts shes below 40 volts. The machine will shut down 33 volts.

Speed Indicator

he Function Speed Control is turned to the creep n, the indicator acts as a reminder that all functions to the slowest speed.

6 – JLG Lift –

3. System Distress Light

The system distress light indicates an abnormal condition for machine control system.

The three likely causes of a system fault are:

a. The seven second enable time has been allowed tolapse or a function was selected before pushing downthe footswitch.

b. The maximum power limit has been reached and themachine is not moving. This condition is the same asstalling the engine by asking it to provide more powerthan it was designed to do.

c. There is some other fault in one of the circuits. Refer tothe service manual.

4. Posi-Track Indicator

This indicator lights when posi-traction is operating.

5. Footswitch/Enable Indicator

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next func-

tion, threlease

Releasiand ap

TO AVOID SERIOUS INBY BLOCKING OR ANY

FOOTSWITCH MUST OPERATES WITHIN LA

6. Low Ba

This ligand flabelow

7. Creep

When tpositioare set


3-17

ft Touch Indicator (If Equipped)

hen illuminated (Yellow) the Soft Touch bumper is against object. All controls are disabled until the override buttonpushed, at which time controls are active in the Creepode.

SECTIO

3121217 – JLG Lift –

8. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or fur-ther in either direction, the Drive Orientation indicator willilluminate when the drive function is selected. This is a signalfor the operator to activate the Drive Orientation OverrideSwitch and verify the drive control direction is correct.

9. So

Wanis m


3-1 3121217
8 – JLG Lift –
NOTES:

SECTION 4 - MACHINE OPERATION

4-1

RATION

RATING CHARACTERISTICS AND LIMITATIONS

om can be raised above horizontal with or without any platform, if:

achine is positioned on a smooth, firm and level surface.

ad is within manufacturer’s rated capacity.

l machine systems are functioning properly.

oper tire pressure.

achine is as originally equipped from JLG.

e stability is based on two (2) conditions which are calledRD and BACKWARD stability. The machine’s position ofRWARD stability is shown in (See Figure 4-1.), and its posi-

least BACKWARD stability is shown in (See Figure 4-2.)

3121217 – JLG Lift –

SECTION 4. MACHINE OPE

4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating, articulating and rotat-ing boom.

The primary operator control station is in the platform. From thiscontrol station, the operator can drive and steer the machine inboth forward and reverse directions. The operator can raise orlower the upper or lower boom or swing the boom to the left orright. Standard boom swing is 400 degree non-continuous leftand right of the stowed position. The machine has a Ground Con-trol Station which will override the Platform Control Station.Ground Controls operate Boom Lift and Swing, and are to beused in an emergency to lower the platform to the groundshould the operator in the platform be unable to do so. TheGround Control is also to be used in Pre-Start Inspection.

4.2 OPE

Capacities

The boload in

1. M

2. Lo

3. Al

4. Pr

5. M

Stability

MachinFORWAleast FOtion of


4-2 3121217

TO AVATE T

4.3

Pow

nd Select Switch

/Ground Select switch directs power to the Ground controls as selected. For power, the POWER/EMER-P switch must also be pulled out (on).

– JLG Lift –

OID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER-HE MACHINE ON AN OUT-OF-LEVEL SURFACE.

MOTOR OPERATION

er/Emergency Stop

This red, mushroom-shaped switch provides battery power,when pulled out (on), for all machine functions. The switchshould be pushed in (off ) when recharging the batteries or park-ing the machine overnight.

Within about 2 seconds of pulling the switch out, the machinewill perform a diagnostic check of the various electrical circuits,and if everything is OK, the platform alarm will beep once. Duringthis time the lights on the indicator panel will also blink once as abulb check.

Platform/Grou

The Platformor PlatformGENCY STO


4-3

Stability

LEVEL SURFACE

3121217 – JLG Lift –

Figure 4-1. Position of Least Forward

BOOM FULLY EXTENDED@ 5° ELEVATION

MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR

OPERATED ON AN OUT-OF-LEVEL SURFACE


4-4 3121217

.

Figu

re 4

-2. P

osit

ion

of L

east

Bac

kwar

d St

abili

ty

LEVE

L SUR

FACE

– JLG Lift –

MAI

N BOO

M FU

LLY

RETR

ACTE

D AND

ELEV

ATED

MACH

INE W

ILL TI

P OVE

R IN

THIS

DIRE

CTIO

N IF O

VERL

OADE

D OR

OPER

ATED

ON AN

OUT-

OF-L

EVEL

SURF

ACE

PLAT

FORM

ROTA

TED 9

0°


4-5

Forward and Reverse

Platform Controls, pull out Emergency Stop switch andtivate footswitch.

sition Drive controller to FORWARD or REVERSE as desired.

achine is equipped with a Drive Orientation Indicator. The light on the platform control console indicates that theis swung beyond the rear drive tires and the machine mayteer in the opposite direction from the movement of the

ls. If the indicator is illuminated, operate the Drive functionollowing manner:

atch the black and white direction arrows on both plat-rm control panel and the chassis to determine the direc-n the machine will travel.

sh and release the Drive Orientation Override switch. ithin 3 seconds, slowly move the Drive control toward the row matching the intended direction of machine travel. e indicator light will flash during the 3 second interval til the drive function is selected.

3121217 – JLG Lift –

4.4 TRAVELING (DRIVING)

NOTE: When the upper boom is raised approximately 11 degrees abovehorizontal, the high drive function will automatically be in lowdrive.

IF THE MACHINE IS OPERATED AT A VERY SLOW SPEED OR STALLED WHEN CLIMBING AGRADE OF 20% OR GREATER, DRIVE FUNCTION WILL STOP. REMOVE YOUR FOOT FROMFOOT-SWITCH, AND PUSH THE FOOTSWITCH DOWN AGAIN TO RESET IT.

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM ANDLEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER” , DO NOT DRIVE MACHINE ONGRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THEPLATFORM IS ELEVATED.

BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR DRIVE AXLE. IFBOOM IS OVER FRONT WHEELS, STEER AND DRIVE CONTROLS WILL BE REVERSED.

Traveling

1. Atac

2. Po

This myellowboom Drive/Scontroin the f

1. Mfotio

2. PuWarThun


4-6 3121217

FACTURER’S NAMEPLATE

SIDESLOPE

– JLG Lift –

Figure 4-3. Grade and Side Slopes

DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON MANU

GRADE

LEVEL


4-7

ERINGn thumb switch on Drive/Steer controller to RIGHT forg right, or to LEFT for steering left.

TFORM

evel Adjustment

l Up or Down - Position the Platform/Level control switchown and hold until the platform is level.

PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELINGRM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR

TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

otation

te the platform to the left or right, use the Platform Rotatel switch to select the direction and hold until desired posi-reached.

3121217 – JLG Lift –

Traveling on a Grade

When traveling a grade, maximum braking and traction are obtainedwith the boom stowed, in position over the rear (drive) axle, and inline with the direction of travel. Drive the machine forward whenclimbing a grade, and in reverse when descending a grade. Do notexceed the machine's maximum rated gradability.

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

4.5 STEPositiosteerin

4.6 PLA

Platform L

To LeveUp or D

ONLY USE THEOF THE PLATFOFALL. FAILURE

Platform R

To rotacontrotion is

Figure 4-4. Traveling on a Grade


4-8 3121217

4.7

DO NLEVE

DO N

TO AVA LEV

TO ATOGG‘OFF’

IF THREMMACH

Boom

om, use SWING control switch to select RIGHT or LEFT

E BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TOG WALLS, PARTITIONS AND EQUIPMENT.

wering the Upper Boom

ower the Upper Boom, use Upper Boom Lift switch to DOWN movement.

TOR (OPTIONAL)

erating Mode

tor will operate in automatic mode when:

Control EMS is pulled out (on), and:

nerator Enable switch on the platform control con-in the On or Enable position.

bove conditions apply, the generator’s controller willtus of the batteries, will turn on automatically when

– JLG Lift –

BOOM

OT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OFL.

OT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.

OID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TOEL SURFACE BEFORE RAISING BOOM.

VOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER ORLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE OR NEUTRAL POSITION WHEN RELEASED.

E PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED,OVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE

INE.

Swinging the

To swing bodirection.

WHEN SWINGING THCLEAR SURROUNDIN

Raising and Lo

To raise or lselect UP or

4.8 GENERA

Automatic Op

The genera

1. Ground

2. The Gesole is

When the amonitor sta


4-9

CTION SPEED CONTROLntrol affects the speed of all boom functions and Platform. When in the CCW maximum position, Drive is placed inpeed.

CHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE LY)achine Safety System Override (MSSO) is override function controls for Emergency

rm Retrieval only. Refer to Section 5.6,ne Safety System Override (MSSO)(CEr operating procedures.

3121217 – JLG Lift –

the battery voltage drops as a result of discharge and will turn offwhen batteries are fully charged.

Battery Only Operating Mode

The machine will operate in the battery only mode when:

1. Ground Control EMS is pulled out, and:

2. The switch on the platform control console is in the Off orDisable position.

The batteries can be used until they are fully discharged.

Manual (Charge) Operating Mode

The generator will operate in manual mode when:

1. Ground Control EMS is pulled out, and:

2. The switch on the platform control console is in the On orEnable position and:

3. The Manual Charge push button is activated.

Activation of the Manual Charge button will start the engine andbegin the charging cycle even if the batteries are charged abovethe level of automatic start.

4.9 FUNThis coRotatecreep s

4.10 MAON

The Mused toPlatfoMachiOnly)fo


4-1 3121217

4.1 TING AXLE LOCKOUT TEST (IF EQUIPPED)

ST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM-, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

tion 6.4, Oscillating Axle Lockout Test (If Equipped) for

MainLift

R

R = In

C = Ind

I = Inp

Note: W

* Reve

0 – JLG Lift –

1 SKYGUARD OPERATIONSkyguard is used to provide enhanced control panel protection.When the SkyGuard sensor is activated, functions that were inuse at the time of actuation will reverse or cutout. The tablebelow outlines these functions.

4.12 OSCILLA

LOCKOUT SYSTEM TEPONENT IS REPLACED

Refer to Secprocedure.

Table 4-1. Skyguard Function Table

MainTele

SwingDrive

ForwardDrive

ReversePlatform

LevelPlatform

RotateJibLift

JibRotate

JibTele

C/R* R R I R R C C C C C

dicates Reversal is Activated

icates Cutout is Activated

ut is Ignored

hen Soft Touch is enabled with SkyGuard all functions are cut out only.

rsal only applies to Main Tele Out. Main Tele In would be cut out


4-11

TING AND TIE DOWN

fer to the Machine Serial Number Plate, call JLG Industries, weigh the individual unit to find out the Gross Vehicleeight.

ace the boom in the stowed position.

move all loose items from the machine.

operly adjust the rigging to prevent damage to theachine and so the machine remains level.

ORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTOT.

ace the boom in the stowed position.

move all loose items from the machine.

cure the chassis and the platform using straps or chains ofequate strength.

3121217 – JLG Lift –

4.13 SHUT DOWN AND PARK

NOTE: When parking overnight, batteries should be charged properlyto ensure readiness for following workday.

NOTE: Electric machines are equipped with a static strap due to staticelectricity build-ups. Strap is located under rear of machine chas-sis.

To shut down and park the machine, the procedures are as fol-lows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. PositionPlatform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instructionplacards, warning decals and operating controls from hostileenvironment.

4.14 LIF

Lifting

1. ReorW

2. Pl

3. Re

4. Prm

Tie Down

WHEN TRANSPTHE BOOM RES

1. Pl

2. Re

3. Sead


4-1 3121217

t

2 – JLG Lift –

Figure 4-5. Lifting and Tie Down Char


4-13

sengage the drive hubs.

sition the steer/tow selector to the towing (out) position.

return the machine to the self-propelled mode, follow theove steps in the reverse order.

STEER/TOWSELECTOR

TOW BAR

3121217 – JLG Lift –

4.15 TOWING INSTRUCTIONS

THE MACHINE HAS NO TOWING BRAKES. THE TOWING VEHICLE MUST BE ABLE TOCONTROL THE MACHINE AT ALL TIMES. TOWING IS NOT PERMITTED ON HIGHWAY.

KEEP ALL BODY PARTS AWAY FROM MOVING COMPONENTS.

FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DEATH OR SERIOUSINJURY.

MAXIMUM TOWING SPEED: 5 MPH (8 KPH) FOR A DISTANCE OF 5 MILES (8K).

MAXIMUM TOWING GRADE: 25%

The following instructions are for towing using the optional towbar.

1. Lock the turntable in the travel position, with the boom fullylowered and retracted.

2. Lower the tow bar to the towing position and connect to thetowing vehicle.

3. Di

4. Po

5. Toab


4-1 3121217

4.1

Dis

MAKAT A

e the cover.

BOLT

4 – JLG Lift –

6 DRIVE HUB

engaging for Towing

E SURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINESTANDSTILL.

1. Remove the two hex head bolts from the cover.

2. Remov


4-15

stall the bolts and torque 6.3 ft. lbs. (8.8 Nm) until they aresh with the cover.

e machine is ready to be towed.

ACHINE IS SEPARATED FROM THE TOWING VEHICLE, EITHER THE DRIVEE REENGAGED OR PROPER STEPS MUST BE TAKEN TO PREVENT THE MOVING.

COVERROTATED

3121217 – JLG Lift –

3. Rotate the cover to show the inside diameter 4. Influ

5. Th

BEFORE THE MHUB HAS TO BMACHINE FROM

COVER


4-1 3121217

Eng

6 – JLG Lift –

aging after Towing is Complete

THE COVER IS UNDER SPRING FORCE

1. Remove the 2 hex head bolts securing the cover evenly andremove the cover.

2. Rotate the cover 180 degrees and secure with the two hexhead bolts.

3. Torque the hex head bolts 6.3 ft.lbs. (8.8 Nm).

4. The gear drive should now be reengaged and the machinecan be disconnected from the towing vehicle.


4-17

Sheet 1 of 4

3121217 – JLG Lift –

Figure 4-6. Decal Installation -


4-1 3121217

t 2 of 4

8 – JLG Lift –

Figure 4-7. Decal Installation - Shee


4-19

et 3 of 4

3121217 – JLG Lift –

Figure 4-8. Decal Installation - She


4-2 3121217

4 of 4

0 – JLG Lift –

Figure 4-9. Decal Installation - Sheet


4-21

300141450

nish0-13

Eng/French0270152-14

Chinese/Eng0270154-13

Port./Spa0270156-13

23 1703924 1703925 1703928

- - - - - -

35 1703936 1703937 1703940

47 1703948 1703949 1703952

61 1704661 - - - -

35 1707035 - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

01 1704000 - - 1704002

77 1704277 1704277 1704277

56 1707055 1707060 1707134

49 1707047 1707044 1707133

13 3251813 - - 3251813

02 1701502 1701502 1701502

03 1701503 1701503 1701503

3121217 – JLG Lift –

Table 4-2. Decal Legend - Prior to S/N 0

Item # ANSI0270129-14

CE/Aus0275062-5

Japan0270146-12

Korean/Eng0270148-13

Eng/Spa027015

1 1703797 1705921 1703926 1703927 17039

2 1704575 1705822 1704667 1704668 - -

3 1703805 - - 1703938 1703939 17039

4 1703804 1701518 1703950 1703951 17039

5 1704661 - - - - - - 17046

6 1707035 - - - - - - 17070

7 - - - - - - - - - -

8 - - - - - - - - - -

9 - - - - - - - - - -

10 - - - - - - - - - -

11 1702868 - - - - - - 17040

12 1704277 1704277 1704277 1704277 17042

13 1701645 1705978 1701645 1707058 17070

14 1707013 1705978 1707013 1707042 17070

15 3251813 1705084 - - - - 32518

16 1701502 1701502 1701502 1701502 17015

17 1701503 1701503 1701503 1701503 17015


4-2 3121217

1701504 1701504 1701504

1704006 - - 1704008

1702631 1702631 1702631

- - - - - -

1706948 1706948 1706948

1701509 1701509 1701509

1702300 1702300 1702300

1701500 1701500 1701500

1701529 1701529 1701529

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1703942 1703943 1703946

- - - - - -

- - - - - -

1703984 1703982 1703985

- - 1704708 1704708

141450



Port./Spa0270156-13

2 – JLG Lift –

18 1701504 1701504 1701504 1701504 1701504

19 - - - - - - - - 1704007

20 1702631 1702631 1702631 1702631 1702631

21 - - - - - - - - - -

22 1706948 3252523 1706948 1706948 1706948

23 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529

27 - - - - - - - - - -

28 - - - - - - - - - -

29 - - - - - - - - - -

30 - - - - - - - - - -

31 1703953 1701518 1703944 1703945 1703941

32 - - - - - - - - - -

33 - - - - - - - - - -

34 3252347 1705828 1703980 1703981 1703983

35 1704708 1704708 1704708 1704708 1704708


Item # ANSI0270129-14

CE/Aus0275062-5

Japan0270146-12


Eng/Spanish0270150-13


4-23

44 1701644 1701644 1701644

05 1704705 1704705 1704705

17 1704116 1704121 1704118

1705514 - - - -

01 1701501 1701501 1701501

28 1704329 1704333 1704330

55 1702155 1702155 1702155

12 1704412 1704412 1704412

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

39 1704340 1704344 1704341

40 3252743 3252741 3252742

- - - - - -

300141450

nish0-13



Port./Spa0270156-13

3121217 – JLG Lift –

36 1701644 1701644 1701644 1701644 17016

37 1704705 1704705 1704705 1704705 17047

38 1702901 1706392 1704119 1704120 17041

39 - - - - - - - - - -

40 1701501 1701501 1701501 1701501 17015

41 1704248 1706378 1704331 1704332 17043

42 1702155 - - 1702155 1702155 17021

43 1704412 - - 1704412 1704412 17044

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 - - - - - - - - - -

48 - - - - - - - - - -

49 - - - - - - - - - -

50 - - - - - - - - - -

51 1703813 1705670 1704342 1704343 17043

52 3252673 1706377 3252738 3252739 32527

53 - - - - - - - - - -


Item # ANSI0270129-14

CE/Aus0275062-5

Japan0270146-12


Eng/Spa027015


4-2 3121217

1704254 1704254 1704254

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1703930 1703931 1703934

- - - - - -

1701499 1701499 1701499

1701517 1701517 1701517

1704733 1704371 1704618

- - - - - -

1704885 1704885 1704885

- - - - - -

- - - - - -

1705429 - - - -

- - - - - -

141450



Port./Spa0270156-13

4 – JLG Lift –

54 1704254 - - 1704254 1704254 1704254

55 - - - - - - - - - -

56 - - - - - - - - - -

57 - - - - - - - - - -

58 - - - - - - - - - -

59 - - - - - - - - - -

60 - - - - - - - - 1703929

61 - - - - - - - - - -

62 1701499 1701499 1701499 1701499 1701499

63 1702391 1701517 1701517 1701517 1701517

64 1704728 1704728 1704671 1704670 1704732

65 - - - - - - - - - -

66 1704885 1704885 1704885 1704885 1704885

67 - - - - - - - - - -

68 - - - - - - - - - -

69 1705351 - - - - 1705427 1705910

70 - - - - - - - - - -


Item # ANSI0270129-14

CE/Aus0275062-5

Japan0270146-12




4-25

50 to Present

nish0-14



Port./Spa0270156-14

23 1703924 1703925 1703928

- - - - - -

35 1703936 1703937 1703940

47 1703948 1703949 1703952

61 1704661 - - - -

35 1707035 - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

01 1704000 - - 1704002

77 1704277 1704277 1704277

805 1001121803 1001121810 1001121920

818 1001121816 1001121823 1001121923

13 3251813 - - 3251813

02 1701502 1701502 1701502

03 1701503 1701503 1701503

3121217 – JLG Lift –

Table 4-3. Decal Legend - S/N 03001414

Item # ANSI0270129-15

CE/Aus0275062-5

Japan0270146-13


Eng/Spa027015

1 1703797 1705921 1703926 1703927 17039

2 1704575 1705822 1704667 1704668 - -

3 1703805 - - 1703938 1703939 17039

4 1703804 1701518 1703950 1703951 17039

5 1704661 - - - - - - 17046

6 1707035 - - - - - - 17070

7 - - - - - - - - - -

8 - - - - - - - - - -

9 - - - - - - - - - -

10 - - - - - - - - - -

11 1702868 - - - - - - 17040

12 1704277 1704277 1704277 1704277 17042

13 1001121801 1705978 1001121801 1001121918 1001121

14 1001121814 1705978 1001121814 1001121921 1001121

15 3251813 1705084 - - - - 32518

16 1701502 1701502 1701502 1701502 17015

17 1701503 1701503 1701503 1701503 17015


4-2 3121217

1701504 1701504 1701504

1704006 - - 1704008

1702631 1702631 1702631

- - - - - -

1706948 1706948 1706948

1701509 1701509 1701509

1702300 1702300 1702300

1701500 1701500 1701500

1701529 1701529 1701529

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1703942 1703943 1703946

- - - - - -

- - - - - -

1703984 1703982 1703985

- - 1704708 1704708

Present



Port./Spa0270156-14

6 – JLG Lift –

18 1701504 1701504 1701504 1701504 1701504

19 - - - - - - - - 1704007

20 1702631 1702631 1702631 1702631 1702631

21 - - - - - - - - - -

22 1706948 3252523 1706948 1706948 1706948

23 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500

26 1701529 1701529 1701529 1701529 1701529

27 - - - - - - - - - -

28 - - - - - - - - - -

29 - - - - - - - - - -

30 - - - - - - - - - -

31 1703953 1701518 1703944 1703945 1703941

32 - - - - - - - - - -

33 - - - - - - - - - -

34 3252347 1705828 1703980 1703981 1703983

35 1704708 1704708 1704708 1704708 1704708

Table 4-3. Decal Legend - S/N 0300141450 to

Item # ANSI0270129-15

CE/Aus0275062-5

Japan0270146-13




4-27

44 1701644 1701644 1701644

05 1704705 1704705 1704705

17 1704116 1704121 1704118

1705514 - - - -

01 1701501 1701501 1701501

28 1704329 1704333 1704330

55 1702155 1702155 1702155

12 1704412 1704412 1704412

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

39 1704340 1704344 1704341

40 3252743 3252741 3252742

- - - - - -

50 to Present

nish0-14



Port./Spa0270156-14

3121217 – JLG Lift –

36 1701644 1701644 1701644 1701644 17016

37 1704705 1704705 1704705 1704705 17047

38 1702901 1706392 1704119 1704120 17041

39 - - - - - - - - - -

40 1701501 1701501 1701501 1701501 17015

41 1704248 1706378 1704331 1704332 17043

42 1702155 - - 1702155 1702155 17021

43 1704412 - - 1704412 1704412 17044

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 - - - - - - - - - -

48 - - - - - - - - - -

49 - - - - - - - - - -

50 - - - - - - - - - -

51 1703813 1705670 1704342 1704343 17043

52 3252673 1706377 3252738 3252739 32527

53 - - - - - - - - - -

Table 4-3. Decal Legend - S/N 03001414

Item # ANSI0270129-15

CE/Aus0275062-5

Japan0270146-13


Eng/Spa027015


4-2 3121217

1704254 1704254 1704254

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1703930 1703931 1703934

- - - - - -

1701499 1701499 1701499

1701517 1701517 1701517

1704733 1704371 1704618

- - - - - -

1704885 1704885 1704885

- - - - - -

- - - - - -

1705429 - - - -

- - - - - -

Present



Port./Spa0270156-14

8 – JLG Lift –

54 1704254 - - 1704254 1704254 1704254

55 - - - - - - - - - -

56 - - - - - - - - - -

57 - - - - - - - - - -

58 - - - - - - - - - -

59 - - - - - - - - - -

60 - - - - - - - - 1703929

61 - - - - - - - - - -

62 1701499 1701499 1701499 1701499 1701499

63 1702391 1701517 1701517 1701517 1701517

64 1704728 1704728 1704671 1704670 1704732

65 - - - - - - - - - -

66 1704885 1704885 1704885 1704885 1704885

67 - - - - - - - -

68 - - - - - - - -

69 1705351 - - - - 1705427 1705910

70 - - - - - - - -

Table 4-3. Decal Legend - S/N 0300141450 to

Item # ANSI0270129-15

CE/Aus0275062-5

Japan0270146-13



SECTION 5 - EMERGENCY PROCEDURES

5-1

OCEDURES

NY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALLST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON-

LIFT ABOVE 10 FT. (3 M) UNTIL YOU ARE SURE THAT ALL DAMAGE HASD, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR-

ERGENCY OPERATION

nable to Control MachinePLATFORM OPERATOR IS PINNED, TRAPPED OR UNABLE TOTE OR CONTROL MACHINE:

ther personnel should operate the machine from ground ntrols only as required.

ther qualified personnel on the platform may use the plat-rm controls. DO NOT CONTINUE OPERATION IF CONTROLS

NOT FUNCTION PROPERLY.

anes, forklift trucks or other equipment can be used to move platform occupants and stabilize motion of the achine.

3121217 – JLG Lift –

SECTION 5. EMERGENC Y PR

5.1 GENERALThis section explains the steps to be taken in case of an emer-gency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any incidentinvolving a JLG product. Even if no injury or property damage isevident, the factory should be contacted by telephone and pro-vided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving a JLGIndustries product within 48 hours of such an occurrence mayvoid any warranty consideration on that particular machine.

FOLLOWING AFUNCTIONS FIRTROLS. DO NOTBEEN REPAIRERECTLY.

5.3 EM

Operator UIF THE OPERA

1. Oco

2. OfoDO

3. Crrem


5-2 3121217

Pla

5.4

5.5

Thursy

G IN AND LOWERING THE BOOM

the spool plug in the location shown and push the l lever on the valve up.

the handle into the hand pump and pump the handle e desired platform position is reached.

e control lever down when complete. Remove the from the hand pump and the spool plug from the

– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged in over-head structures or equipment, rescue platform occupants prior tofreeing the machine.

EMERGENCY TOWING PROCEDURESTowing this machine is prohibited, unless properly equipped.However, provisions for moving the machine have been incorpo-rated. For specific procedures, refer to Section 4.

MANUAL DESCENT SYSTEM

e manual descent system is used, in the event of total power fail-e, to lower the boom using gravity. To operate the manual descentstem, proceed as follows:

TELESCOPIN

1. Install contro

2. Install until th

3. Push thhandlevalve.


5-3

RIGHT

stall the spool plug in the location shown.

stall the handle into the hand pump and pump the handle til the desired platform position is reached.

move the handle from the hand pump.

3121217 – JLG Lift –

LOWERING THE BOOM

1. Push the control lever on the valve up.

2. Install the handle into the hand pump and pump the handle until the desired platform position is reached.

3. Push the control lever down when complete. Remove the handle from the hand pump.

SWING

1. In

2. Inun

3. Re


5-4 3121217

REM

– JLG Lift –

SWING LEFT

1. Install the spool plug in the location shown.

2. Install the handle into the hand pump and pump the handle until the desired platform position reached.

3. Remove the handle from the hand pump.

OVE ALL SPOOL PLUGS BEFORE RETURNING UNIT TO SERVICE.


5-5

cal

3121217 – JLG Lift –

Figure 5-1. Manual Descent De


5-6 3121217

5.6

NOT

NOT

he MSSO:

he ground control console, place the Platform/ Select switch in the Ground position.

t the Power/Emergency Stop control.

e engine.

nd hold the MSSO switch and the control switch for ired function.

– JLG Lift –

MACHINE SAFETY SYSTEM OVERRIDE (MSSO)(CE ONLY)

The Machine Safety System Override (MSSO) isonly to be used to retrieve an operator that ispinned, trapped, or unable to operate themachine and function controls are locked outfrom the platform due to a platform overload sit-uation.

E: If the MSSO functionality is used, the fault indicator will flashand a fault code is set in the JLG Control System which must bereset by a qualified JLG Service Technician.

E: No functional checks of the MSSO system are necessary. The JLGControl system will set a Diagnostic Trouble Code if the controlswitch is faulty.

To operate t

1. From tGround

2. Pull ou

3. Start th

4. Press athe des

PECIFICATIONS & OPERATOR MAINTENANCE

6-1

PERATOR MAINTENANCE

RATING SPECIFICATIONS

. Operating Specifications - Prior to S/N 0300141450

ork Load (Capacity)ed: 500 lb (230 kg)

avel Grade (Gradeability) with Boom approximately horizontal. Tower wered.

30%

avel Grade (Side Slope) with Boom approximately horizontal. Tower wered. 5°

tting (See Section 3)

& E/M600JJP

5°4°3°

rtical Platform Height: 60 ft. (18.29 m)

rizontal Platform Reach43 ft. (13.11 m)

42 ft. 9 in. (13.11 m)

th7 ft. 11 7/16 in. (2.42 m)

7 ft. 11 3/8 in. (2.42 m)

SECTION 6 - GENERAL S

3121217 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS & O

6.1 INTRODUCTIONThis section of the manual provides additional necessary infor-mation to the operator for proper operation and maintenance ofthis machine.

The maintenance portion of this section is intended as informa-tion to assist the machine operator to perform daily maintenancetasks only, and does not replace the more thorough PreventiveMaintenance and Inspection Schedule included in the Serviceand Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual- ANSI, CSA.......................3121117

Service and Maintenance Manual - CE ...................................3121813

Illustrated Parts Manual - ANSI, CSA .........................................3121118

Illustrated Parts Manual - CE........................................................3121814

6.2 OPE

Table 6-1

Maximum W Unrestrict

Maximum Trretracted andBoom fully lo

Maximum Trretracted andBoom fully lo

Tilt Alarm Se ANSI, CSA CE E/M600 CE E/M 600

Maximum Ve

Maximum Ho E600 E600J

Machine Wid 2WD 4WD

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121217

M

T

T

M

M

M

E

M

M

M

T

ht (Platform Empty)4944

16,300 lb. (7,393 kg)16,800 lb. (7,620 kg)

ht (Platform Empty) Present

16,710 lb. (7,580 kg)17,210 lb. (7,806 kg)

ating Specifications - S/N 0300141450 to Present

d (Capacity)

500 lb. (227 kg)

d (Capacity)kets

500 lb. (230 kg)

ade (Gradeability) with Boom ximately horizontal. Tower .

30%

ade (Side Slope) with Boom ximately horizontal. Tower . 5°

rating Specifications - Prior to S/N 0300141450

– JLG Lift –

achine Length E/M600 E/M600J E/M600JP

30 ft. 11 5/16 in. (9.43 m)30 ft. 8 15/16 in. (9.37 m)

33 ft. 3 3/4 in. (10.15 m)

urning Radius (outside) 15 ft. 3 in. (4.65 m)

urning Radius (inside) 4 ft. (1.23 m)

aximum Tire Load: 7700 lbs. (3493 kg)

aximum Ground Bearing Pressure

E600J/M600J

E600JP/M600JP 52 psi (3.7 kg/cm2)

51 psi (3.6 kg/cm2)

aximum Drive Speed: 3.0 mph (1.3 m/s)

lectrical System Voltage 48 volts

aximum Hydraulic System Pressure 3200 psi (221 Bar)

aximum Wind Speed 28 mph (12.5 m/s)

aximum Manual Force 400N

able 6-1. Operating Specifications - Prior to S/N 0300141450

Gross Machine WeigPrior to S/N 030010

E600J/M600J

E600JP/M600JP

Gross Machine WeigS/N 0300104944 to

E600J/M600J

E600JP/M600JP

Table 6-2. Oper

Maximum Work Loa ANSI Markets Unrestricted:

Maximum Work Loa CE & Australia Mar Unrestricted:

Maximum Travel Grretracted and approBoom fully lowered

Maximum Travel Grretracted and approBoom fully lowered

Table 6-1. Ope


6-3

draulic System Pressure 3200 psi (221 Bar)

ind Speed 28 mph (12.5 m/s)

anual Force 400N

e Weight (Platform Empty)300104944

0J

00JP

16,300 lb. (7,393 kg)16,800 lb. (7,620 kg)

e Weight (Platform Empty)944 to Present

0J

00JP

16,710 lb. (7,580 kg)17,210 lb. (7,806 kg)

Operating Specifications - S/N 0300141450 to Present


3121217 – JLG Lift –

Tilt Alarm Setting (See Section 3) ANSI, CSA CE E/M600 & E/M600J CE E/M 600JP

5°4°3°

Maximum Vertical Platform Height: 60 ft. (18.29 m)

Maximum Horizontal Platform Reach E600 E600J

43 ft. (13.11 m)42 ft. 9 in. (13.11 m)

Machine Width 2WD 4WD

7 ft. 11 7/16 in. (2.42 m)7 ft. 11 3/8 in. (2.42 m)

Machine Length E/M600 E/M600J E/M600JP

30 ft. 11 5/16 in. (9.43 m)30 ft. 8 15/16 in. (9.37 m)

33 ft. 3 3/4 in. (10.15 m)

Turning Radius (outside) 15 ft. 3 in. (4.65 m)

Turning Radius (inside) 4 ft. (1.23 m)

Maximum Tire Load: 7700 lbs. (3493 kg)

Maximum Ground Bearing Pressure

E600J/M600J

E600JP/M600JP 52 psi (3.7 kg/cm2)

51 psi (3.6 kg/cm2)

Maximum Drive Speed: 3.0 mph (1.3 m/s)

Electrical System Voltage 48 volts

Table 6-2. Operating Specifications - S/N 0300141450 to Present

Maximum Hy

Maximum W

Maximum M

Gross MachinPrior to S/N 0

E600J/M60

E600JP/M6

Gross MachinS/N 0300104

E600J/M60

E600JP/M6

Table 6-2.


6-4 3121217

Cap

Table 6-4. Tires

Size Type Pressure

14 LL-22.5 pneumatic 55 psi (4.0 Bar)

14 LL-22.5 foam filled N/A

– JLG Lift –

acities Tires

Table 6-3. Capacities

Generator Fuel Tank (M Models Only) 13 gallons (49.2 liters)

Hydraulic Tank Prior to S/N 51941 S/N 51941 to Present

15 gallons (57 liters)15.9 gal.(60.2 L)

12.4 gal. (46.9 L) to full mark

Drive Hub 0.4 gal. (1.5 liters)

36/

36/


6-5

Table 6-6. Mobil DTE 11M Specs

Viscosity Grade #15

Gravity API 31.9

our Point, Max -40°F (-40°C)

lash Point, Min. 330°F (166°C)

Viscosity

at 40° C 15 cSt

at 100° C 4.1 cSt

at 100° F 80 SUS

at 210° F 43 SUS

cp at -30° F 3.200

iscosity Index 140


3121217 – JLG Lift –

Hydraulic Oil

NOTE: Hydraulic oils must have anti-wear qualities at least to API Ser-vice Classification GL-3, and sufficient chemical stability formobile hydraulic system service.

Aside from JLG recommendations, it is not advisable to mix oilsof different brands or types, as they may not contain the samerequired additives or be of comparable viscosities. If use ofhydraulic oil other than Mobil DTE 11M is desired, contact JLGIndustries for proper recommendations.

Table 6-5. Hydraulic Oil

Hydraulic SystemOperating

Temperature Range

S.A.E. ViscosityGrade

+0° to + 180° F(-18° to +83° C)

10W

+0° to + 210° F(-18° to +99° C)

10W-20, 10W30

+50° to + 210° F(+10° to +99° C

20W-20

ISO

P

F

V


6-6 3121217

Ma r Locationr plate is affixed to the right side of the frame. If thelate is damaged or missing, the machine serial num-

on the left side of the frame at the top.

F

T

B

B

T

S

S

P

S

S

C

Figure 6-1. Serial Number Location

SERIAL NUMBERPLATE

SERIAL NUMBERSTAMPED ON FRAME

– JLG Lift –

jor Component Weights Serial NumbeA serial numbeserial number pber is stamped

Table 6-7. Component Weights

Component Pounds Kilograms

rame (bare) 1381 626

/T (bare) 2093 950

oom Assembly (E/M 600) 4464 2025

oom Assembly (E/M 600J) 4464 2025

ire & Wheel 226 102.5

wing Drive 70 32

wing Bearing 100 45.4

latform Console 25 11

ide Entry Platform - 30x72 (bare) 175 80

ide Entry Platform - 30x48 (bare) 144 66

ounterweight 2560 1161


6-7

rication Diagram


3121217 – JLG Lift –

Figure 6-2. Operator Maintenance and Lub

12

3,4

6

5

6


6-8 3121217

6.3

NOT VALS ARE BASED ON MACHINE OPERATION UNDER NORMALACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED

MENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BENGLY.

mmended as a good practice to replace all filters at thee.

Bearing - Internal Ball Bearing

oint(s) - 1 Grease Fittingsty - A/RMPGl - Every 3 months or 150 hrs of operation

– JLG Lift –

OPERATOR MAINTENANCE

E: The following numbers correspond to those in Figure 6-2., Oper-ator Maintenance and Lubrication Diagram.

*MPG may be substituted for these lubricants, if necessary, butservice intervals will be reduced.

LUBRICATION INTERCONDITIONS. FOR MTO HOSTILE ENVIRONINCREASED ACCORDI

NOTE: It is recosame tim

1. Swing

Lube PCapaciLube - Interva

Table 6-8. Lubrication Specifications.

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350 degrees F. Excellent water resistance and adhesive qualities; and being of extreme pressure type (Timken OK 40 pounds minimum).

EPGL Extreme Pressure Gear Lube (oil) meeting API Service Classification GL-5 or Mil-Spec Mil-L-2105.

HO Hydraulic Oil. Mobil DTE-11M

OG* Open Gear Lube - Tribol Molub-Alloy 936 Open Gear Compound. (JLG Part No. 3020027)

BG* Bearing Grease (JLG Part No. 3020029) Mobilith SHA 460.

LL Synthetic Lithium Lubricant, Gredag 741 Grease. (JLG Part No. 3020022)

EO Engine (crankcase) Oil. Gas - API SF/SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.


6-9

be Point(s) - Fill Cappacity - Refer to engine manualbe - EOterval - Check daily. Change in accordance with engine manual.


3121217 – JLG Lift –

2. Generator Engine (If Equipped)

LuCaLuIn


6-1 3121217

lic Filter

l - Change after first 50 hrs. and every 6 months 0 hrs. thereafter or as indicated by Condition ator.

ents - Under certain conditions, it may be ssary to replace the filter on a more frequent

s.

0 – JLG Lift –

3. Hydraulic Tank

Lube Point(s) - Fill CapCapacity - Prior to S/N 51941 - 15 gal. tank (56.7 L) S/N 51941 to present - 15.9 gal. system (56.7L) 12.4 gal. (46.9 L) to Full MarkLube - HOInterval - Check Level daily; Change every 2 years or 1200hours of operation.

4. Hydrau

Interva or 30 IndicComm nece basi


6-11

heel Drive Hub

be Point(s) - Level/Fill Plugpacity - 0.4 gal. (1.5 L)be - EPGLterval - Check level every 3 months or 150 hrs of operation; change every 2 years or 1200 hours of operation


3121217 – JLG Lift –

5. Swing Drive Hub (S/N 58845 to Present)

Lube Point(s) - Level/Fill PlugCapacity - 24 oz. (0.7 L)Lube - EPGLInterval - Check level every 3 months or 150 hrs of operation;change every 2 years or 1200 hours of operation

6. W

LuCaLuIn

FILL

DRAIN


6-1 3121217

6.4

LOCKPONE

NOT

release and allow wheel to rest on ground, it may beary to activate Drive to release cylinders.

he 6 inches (15.2 cm) high block with ascension rampt of right front wheel.

Drive control lever to Forward and carefully drivee up ascension ramp until right front wheel is on top

k.

oom over left side of machine, place Drive control Reverse and drive machine off of block and ramp.

n assistant check to see that right front or left rearremains elevated in position off of ground.

lly activate Swing control lever and return boom to position (centered between drive wheels). Whenreaches center, stowed position, lockout cylinders release and allow wheel to rest on ground, it may beary activate Drive to release cylinders.

ut cylinders do not function properly, have qualifiednel correct the malfunction prior to any further oper-

2 – JLG Lift –

OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

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

E: Ensure boom is fully retracted, lowered, and centered betweendrive wheels prior to beginning lockout cylinder test.

1. Place a 6 inches (15.2 cm) high block with ascension ramp infront of left front wheel.

2. From platform control station, start engine

3. Place the Drive control lever to the forward position andcarefully drive machine up ascension ramp until left frontwheel is on top of block.

4. Carefully activate Swing control lever and position boomover right side of machine.

5. With boom over right side of machine, place Drive controllever to Reverse and drive machine off of block and ramp.

6. Have an assistant check to see that left front or right rearwheel remains elevated in position off of ground.

7. Carefully activate Swing control lever and return boom tostowed position (centered between drive wheels). Whenboom reaches center, stowed position, lockout cylinders

shouldnecess

8. Place tin fron

9. Place machinof bloc

10. With blever to

11. Have awheel

12. Carefustowedboom shouldnecess

13. If lockopersonation.


6-13

any damage to the bead area cords of the tire

damaged but is within the above noted criteria, the tirenspected on a daily basis to insure the damage has notd beyond the allowable criteria.

cement

mends a replacement tire be the same size, ply and brandlly installed on the machine. Please refer to the JLG Partsr the part number of the approved tires for a particular

odel. If not using a JLG approved replacement tire, wed that replacement tires have the following characteris-

Equal or greater ply/load rating and size of original

Tire tread contact width equal or greater than original

Wheel diameter, width, and offset dimensions equal to theoriginal

Approved for the application by the tire manufacturer(including inflation pressure and maximum tire load)

cifically approved by JLG Industries Inc. do not replace a or ballast filled tire assembly with a pneumatic tire. When

and installing a replacement tire, ensure that all tires are the pressure recommended by JLG. Due to size variationsire brands, both tires on the same axle should be the same.


3121217 – JLG Lift –

6.5 TIRES & WHEELS

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

Tire Damage

For pneumatic tires, JLG Industries, Inc. recommends that when anycut, rip, or tear is discovered that exposes sidewall or tread area cordsin the tire, measures must be taken to remove the JLG product fromservice immediately. Arrangements must be made for replacementof the tire or tire assembly.

For polyurethane foam filled tires, JLG Industries, Inc. recommendsthat when any of the following are discovered, measures must betaken to remove the JLG product from service immediately andarrangements must be made for replacement of the tire or tireassembly.

• a smooth, even cut through the cord plies which exceeds 3inches (7.5 cm) in total length

• any tears or rips (ragged edges) in the cord plies whichexceeds 1 inch (2.5 cm) in any direction

• any punctures which exceed 1 inch in diameter

•

If a tire is must be ipropagate

Tire Repla

JLG recomas originaManual fomachine mrecommentics:

•

•

•

•

Unless spefoam filledselecting inflated tobetween t


6-1 3121217

Wh

Thstlolad

WhItm

WHEPREVOF WANGL

Ticonothnustw

ll nuts by hand to prevent cross threading. DO NOT bricant on threads or nuts.

nuts in the following sequence:

htening of the nuts should be done in stages. Follow- recommended sequence, tighten nuts per wheel chart.

nuts should be torqued after first 50 hours of opera-d after each wheel removal. Check torque every 3 s or 150 hours of operation.

4 – JLG Lift –

eel Replacement

e rims installed on each product model have been designed forability requirements which consist of track width, tire pressure, andad capacity. Size changes such as rim width, center piece location,rger or smaller diameter, etc., without written factory recommen-ations, may result in an unsafe condition regarding stability.

eel Installation is extremely important to apply and maintain proper wheelounting torque.

EL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TOENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATIONHEEL FROM THE AXLE. BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONEE OF THE WHEEL.

ghten the lug nuts to the proper torque to prevent wheels fromming loose. Use a torque wrench to tighten the fasteners. If you dot have a torque wrench, tighten the fasteners with a lug wrench,

en immediately have a service garage or dealer tighten the lugts to the proper torque. Over-tightening will result in breaking the

uds or permanently deforming the mounting stud holes in theheels. The proper procedure for attaching wheels is as follows:

1. Start ause a lu

2. Tighten

3. The tiging thetorque

4. Wheel tion anmonth


6-15

PLEMENTAL INFORMATIONllowing information is provided in accordance with thements of the European Machinery Directive 2006/42/ECnly applicable to CE machines.

ctric powered machines, the equivalent continuous A-ted sound pressure level at the work platform is less than)

bustion engine powered machines, guaranteed Sound Level (LWA) per European Directive 2000/14/EC (Noiseon in the Environment by Equipment for Use Outdoors) on test methods in accordance with Annex III, Part B,d 1 and 0 of the directive, is 104 dB.

ration total value to which the hand-arm system is sub-does not exceed 2,5 m/s2. The highest root mean squaref weighted acceleration to which the whole body is sub-

does not exceed 0,5 m/s2.


3121217 – JLG Lift –

6.6 SUPThe forequireand is o

For eleWeigh70dB(A

For comPowerEmissibasedMetho

The vibjected value ojected

Table 6-9. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

40 ft. lbs.(55 Nm)

100 ft. lbs.(130 Nm)

170 ft. lbs.(255 Nm)


6-1 3121217
6 – JLG Lift –
NOTES:

SECTION 7 - INSPECTION AND REPAIR LOG

7-1

REPAIR LOG

ir Log

nts

3121217 – JLG Lift –

SECTION 7. INSPECTION ANDMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121217
– JLG Lift –
Table 7-1. Inspection and Repair Log

Date Comments

TRA

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Mfg

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____

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try:

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____

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____

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____

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JLG Industries, Inc.1 JLG DriveMcConnellsburg PA. 17233-9533USA

(717) 485-5161 (Corporate) (800) 544-5438 (Service) (717) 485-6417

www.jlg.com

JLG Worldwide LocationsJLG Industries 358 Park RoadRegents ParkNSW 2143Sydney 2143Australia

+6 (12) 87186300 +6 (12) 65813058

Email: [email protected]

JLG Ground Support OudeBunders 1034Breitwaterstraat 12A3630 MaasmechelenBelgium

+32 (0) 89 84 82 26Email: [email protected]

JLG Latino Americana LTDARua Antonia Martins Luiz, 580Distrito Industrial Joao NarezziIndiaatuba-SP 13347-404Brasil

+55 (19) 3936 7664 (Parts) +55(19)3936 9049 (Service)

Email: [email protected]: [email protected]

Oshkosh-JLG (Tianjin) Equipment Technology LTDShanghai BranchNo 465 Xiao Nan RoadFeng Xian DistrictShanghai 201204China

+86 (21) 800 819 0050

JLG Industries DubaiJafza ViewPO Box 262728, LB 1920th Floor, Office 05Jebel Ali, Dubai

+971 (0) 4 884 1131 +971 (0) 4 884 7683


JLG France SASZ.I. Guillaume Mon Amy30204 Fauillet47400 TonniensFrance

+33 (0) 553 84 85 86 +33 (0) 553 84 85 74


JLG Deutschland GmbHMax Planck Str. 2127721 Ritterhude - IhlpohlGermany

+49 (0) 421 69350-0 +49 (0) 421 69350-45

Email:[email protected]

JLG Equipment Services Ltd.Rm 1107 Landmark North39 Lung Sum AvenueSheung Shui N. T.Hong Kong

+(852) 2639 5783 +(852) 2639 5797

JLG Industries (Italia) S.R.L.Via Po. 2220010 Pregnana Milanese (MI)Italy

+39 (0) 2 9359 5210 +39 (0) 2 9359 5211


JLG EMEA B.V. Polaris Avenue 632132 JH HoofdorfThe Netherlands

+31 (0) 23 565 5665Email: [email protected]

JLG NZ Access Equipment & Services2B Fisher CresentMt Wellington 1060Auckland, New Zealand

+6 (12) 87186300 +6 (12) 65813058


JLG IndustriesVahutinskoe shosse 24b.KhimkiMoscow Region 141400Russia Federation

+7 (499) 922 06 99 +7 (499) 922 06 99

Oshkosh-JLG Singapore Technology Equipment Pte Ltd.35 Tuas Avenue 2Jurong Industrial Estate Singapore 639454

+65 6591 9030 +65 6591 9045


JLG Iberica S.L.Trapadella, 2Pol. Ind. Castellbisbal Sur08755 Castellbisbal BarcelonaSpain

+34 (0) 93 772 47 00 +34 (0) 93 771 1762


JLG Sverige ABEnkopingsvagen 150176 27 JarfallaSweden

+46 (0) 8 506 595 00 +46 (0) 8 506 595 27


JLG Industries (UK) Ltd.Bentley HouseBentley AvenueMiddleton, Greater ManchesterM24 2GPUnited Kingdom

+44 (0) 161 654 1000 +44 (0) 161 654 1003


3121217

operation and safety manual...ansi ® operation and safety manual original instructions - keep this...

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