JLG 600a 600aj

Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models

600A
600AJ
ANSI ®
3121204
April 30, 2012
ADE Identification
All 600A and 600AJ machines from S/N 64249 incorporate ADE. The following machine serial
numbers prior to S/N 64249 also utilize ADE: 63908, 63912, 63932, 63936, 63938, 63954,
63959, and 63963.
A Machine that incorporates

ADE (Advanced Design Elec-
tronics) can be outwardly identi-
fied by the analyzer connection
at the base of the platform con-
trol box as shown by the arrow.
FOREWORD
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and
operating procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes
without prior notification. Contact JLG Industries, Inc. for updated information.
3121204 – JLG Lift – a

FOREWORD
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal
injury hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY
WILL HAVE A RED BACKGROUND. ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A
YELLOW BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES
DECAL WILL HAVE AN ORANGE BACKGROUND. DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-
TECTION OF PROPERTY.
b – JLG Lift – 3121204

FOREWORD
For:
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- • Accident Reporting • Standards and Regulations
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED Compliance Information
• Product Safety Publica-
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions • Questions Regarding Spe-
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
cial Product Applications
PRODUCT. • Current Owner Updates
• Questions Regarding Prod-
• Questions Regarding
uct Modifications
Product Safety
JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE
OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,
Contact:
INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE Product Safety and Reliability Department
UPDATED AND ACCURATE. JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
or Your Local JLG Office
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
(See addresses on inside of manual cover)
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR
WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP- In USA:
ERTY OR THE JLG PRODUCT.
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA:
Phone: 240-420-2661
Fax: 301-745-3713
E-mail: [email protected]
3121204 – JLG Lift – c

FOREWORD
REVISION LOG
Original Issue - April 1, 2005

Revised - October 6, 2005
Revised - February 27, 2006
Revised - May 8, 2006
Revised - February 22, 2008
Revised - January 1, 2009
Revised - September 17, 2009
Revised - November 25, 2009
Revised - July 22, 2010
Revised - August 25, 2010
Revised - September 27, 2011
Revised - April 30, 2012
d – JLG Lift – 3121204

TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS 2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . 2-5

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . 1-1 SECTION - 3 - MACHINE CONTROLS AND INDICATORS
Workplace Inspection . . . . . . . . . . . . . . . . . . . . . 1-2 3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2 3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3 Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Ground Control Indicator Panel . . . . . . . . . . . . . 3-6
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3 Platform Control . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4 Platform Control Indicator Panel . . . . . . . . . . . . 3-16
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . 1-7 SECTION - 4 - MACHINE OPERATION
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8 4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9 4.2 OPERATING CHARACTERISTICS AND
LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA- Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
RATION, AND INSPECTION Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1 4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2
Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1 Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3
Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1 4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5
2.2 PREPARATION, INSPECTION, AND Traveling Forward and Reverse . . . . . . . . . . . . . 4-6
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2 4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4 4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5 Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-6
3121204 – JLG Lift – i

TABLE OF CONTENTS

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-6 4.16 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-20
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8 SECTION - 5 - EMERGENCY PROCEDURES
Raising and Lowering the Tower Boom . . . . . . 4-9 5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1
Raising and Lowering the Main Boom . . . . . . 4-10 5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1
Telescoping the Main Boom . . . . . . . . . . . . . . 4-10 5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1
4.8 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-10 Operator Unable to Control Machine . . . . . . . . . 5-1
4.9 OSCILLATING AXLE LOCKOUT TEST Platform or Boom Caught Overhead . . . . . . . . . 5-2
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13 5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2
4.10 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . 4-13 5.5 MANUAL DESCENT (MACHINES PRIOR TO
4.11 TOWING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 4-13 S/N 70975) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
4.12 AUXILIARY POWER - NON ADE EQUIPPED
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR
Activating from the Platform Control Station . . 4-17 MAINTENANCE
Activating from the Ground Control Station . . 4-17
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
4.13 AUXILIARY POWER - ADE EQUIPPED
6.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . .6-2
MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Activating from the Platform Control Station . . 4-18
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Activating from the Ground Control Station . . 4-18
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-19
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Changing From Gasoline to LP Gas . . . . . . . . 4-19
Torque Requirements . . . . . . . . . . . . . . . . . . . . . 6-9
Changing From LP Gas to Gasoline . . . . . . . . 4-19
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
4.15 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER4-19
Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-12
Level Override Valve . . . . . . . . . . . . . . . . . . . . 4-19
Serial Number Locations . . . . . . . . . . . . . . . . . 6-12
ii – JLG Lift – 3121204

TABLE OF CONTENTS
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-23 LIST OF FIGURES

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-33
2-1. Machine Nomenclature - 600AJ . . . . . . . . . . . . . . . 2-9
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
2-2. Machine Nomenclature - 600A . . . . . . . . . . . . . . . 2-10
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
2-3. Daily Walk-Around Inspection Diagram . . . . . . . . 2-11
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-33
2-4. Daily Walk-Around Inspection Points -
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-34
Sheet 1 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.5 OSCILLATING AXLE LOCKOUT TEST
Sheet 2 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36
6.6 DRAINING OIL BUILD UP FROM THE PROPANE REG-
Sheet 3 of 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
ULATOR (PRIOR TO S/N 0300132529) . . . . . . . .6-38
3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-3
6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-39
3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . . 3-7
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . . 3-8
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
3-4. Malfunction Indicator Light and Test Button . . . . . 3-9
6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-41
3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-11
6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-42
3-6. Platform Control Console - w/Drive Orientation . . 3-12
3-7. Platform Control Indicator Panel . . . . . . . . . . . . . 3-17
SECTION - 7 - INSPECTION AND REPAIR LOG
3-8. Platform Control Indicator Panel - w/Drive
Orientation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
4-1. Position of Least Forward Stability . . . . . . . . . . . . . 4-4
4-2. Position of Least Backward Stability . . . . . . . . . . . 4-5
4-3. Grade and Sideslope . . . . . . . . . . . . . . . . . . . . . . . 4-7
4-4. Boom Upright Positioning - Sheet 1 of 2 . . . . . . . 4-11
4-5. Boom Upright Positioning - Sheet 2 of 2 . . . . . . . 4-12
4-6. Towbar Connecting Points - Prior to S/N 81836 . 4-14
3121204 – JLG Lift – iii

TABLE OF CONTENTS

4-7. Towbar Connecting Points - S/N 81836 6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . .6-40
to Present. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-8. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . 4-16
4-9. Machine Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . 4-21
4-10. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
4-11. 600A & 600AJ Decal Installation - Sheet 1 of 4. . . 4-23
6-1. Serial Number Locations. . . . . . . . . . . . . . . . . . . . 6-12
6-2. Engine Operating Temperature Specifications - Deutz
- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-3. Engine Operating Temperature Specifications - Deutz
- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
6-4. Engine Operating Temperature Specifications - Ford -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
6-5. Engine Operating Temperature Specifications - Ford -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-6. Engine Operating Temperature Specifications -
Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-18
6-7. Engine Operating Temperature Specifications -
Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-19
6-8. Engine Operating Temperature Specifications - GM -
Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
6-9. Engine Operating Temperature Specifications - GM -
Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6-10. Lubrication and Maintenance Point Location . . . . 6-22
iv – JLG Lift – 3121204

TABLE OF CONTENTS
LIST OF TABLES 6-15 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-10

1-1 Minimum Approach Distances (M.A.D.). . . . . . . . . 1-5 6-16 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . 6-10
1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10 6-17 Exxon Univis HVI 26 Specs. . . . . . . . . . . . . . . . . . 6-11
2-1 Inspection and Maintenance Table . . . . . . . . . . . . 2-3 6-18 Quintolubric 888-46. . . . . . . . . . . . . . . . . . . . . . . . 6-11
4-1 600A Decal Legend - Prior to S/N 0300140401 . . 4-27 6-19 Critical Stability Weights . . . . . . . . . . . . . . . . . . . . 6-12
4-2 600A Decal Legend - S/N 0300140401 to Present 4-31 6-20 Lubrication Specifications. . . . . . . . . . . . . . . . . . . 6-23
4-3 600AJ Decal Legend - Prior to S/N 0300140401 . 4-35 6-21 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-36
4-4 600AJ Decal Legend - S/N 0300140401 to 7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1
Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
6-1 Operating Specifications - Prior to
S/N 0300140401 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-2 Operating Specifications - S/N 0300140401
to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-3 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-4 Continental TMD27 Specifications . . . . . . . . . . . . . 6-4
6-5 Ford LRG-423 Specifications . . . . . . . . . . . . . . . . . 6-5
6-6 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-5
6-7 Deutz F4M1011F/F4M2011 Specifications . . . . . . 6-6
6-8 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . 6-6
6-9 Caterpillar 3044C / 3.4 . . . . . . . . . . . . . . . . . . . . . . 6-7
6-10 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-11 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-12 Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6-13 Torque Requirements. . . . . . . . . . . . . . . . . . . . . . . 6-9
6-14 Hydraulic Oil Specifications . . . . . . . . . . . . . . . . . . 6-9
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This page left blank intentionally.
vi – JLG Lift – 3121204

SECTION 1 - SAFETY PRECAUTIONS
SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL 1.2 PRE-OPERATION
This section outlines the necessary precautions for proper
and safe machine operation and maintenance. For proper
Operator Training and Knowledge
machine use, it is mandatory that a daily routine is estab- • Read and understand this manual before operating the
lished based on the content of this manual. A maintenance machine.
program, using the information provided in this manual and
the Service and Maintenance Manual, must also be estab-
lished by a qualified person and followed to ensure the
machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine
should not operate the machine until this manual has been
read, training is accomplished, and operation of the machine
has been completed under the supervision of an experi-
enced and qualified operator.
If there are any questions with regard to safety, training,
inspection, maintenance, application, and operation, please
contact JLG Industries, Inc. (“JLG”). • Do not operate this machine until complete training is per-
formed by authorized persons.
• Only authorized and qualified personnel can operate the
FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN machine.
THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-
AGE, PERSONAL INJURY OR DEATH.
3121204 – JLG Lift – 1-1

• Read, understand, and obey all DANGERS, WARNINGS, Machine Inspection

CAUTIONS, and operating instructions on the machine
and in this manual. • Before machine operation, perform inspections and func-
tional checks. Refer to Section 2 of this manual for
• Use the machine in a manner which is within the scope of
detailed instructions.
its intended application set by JLG.
• Do not operate this machine until it has been serviced and
• All operating personnel must be familiar with the emer-
maintained according to requirements specified in the
gency controls and emergency operation of the machine
Service and Maintenance Manual.
as specified in this manual.
• Be sure the footswitch and all other safety devices are
• Read, understand, and obey all applicable employer,
operating properly. Modification of these devices is a
local, and governmental regulations as they pertain to
safety violation.
operation of the machine.
Workplace Inspection
MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM
• The operator is to take safety measures to avoid all haz- SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU-
ards in the work area prior to machine operation.
FACTURER
• Do not operate or raise the platform while on trucks, trail-
ers, railway cars, floating vessels, scaffolds or other equip- • Do not operate any machine on which safety or instruction
ment unless approved in writing by JLG. placards or decals are missing or illegible.
• Do not operate the machine in hazardous environments • Avoid any buildup of debris on the platform floor. Keep
unless approved for that purpose by JLG. mud, oil, grease, and other slippery substances from foot-
wear and platform floor.
• Be sure that the ground conditions are able to support the
maximum load shown on the decals located on the
machine.
1-2 – JLG Lift – 3121204

1.3 OPERATION • Supplies or tools which extend outside the platform are
prohibited unless approved by JLG.
General • When driving, always position boom over rear axle in line
with the direction of travel. Remember, if boom is over the
• Do not use the machine for any purpose other than posi- front axle, steer and drive functions will be reversed.
tioning personnel, their tools, and equipment.
• Do not assist a stuck or disabled machine by pushing,
• Never operate a machine that is not working properly. If a pulling, or by using boom functions. Only pull the unit
malfunctions occurs, shut down the machine. from the tie-down lugs on the chassis.
• Never slam a control switch or lever through neutral to an • Do not place boom or platform against any structure to
opposite direction. Always return switch to neutral and steady the platform or to support the structure.
stop before moving the switch to the next function. Oper-
ate controls with slow and even pressure. • Stow boom and shut off all power before leaving machine.
• Do not allow personnel to tamper with or operate the Trip and Fall Hazards
machine from the ground with personnel in the platform,
except in an emergency. During operation, occupants in the platform must wear a full
body harness with a lanyard attached to an authorized lan-
• Do not carry materials directly on platform railing. Contact
yard anchorage point. Attach only one (1) lanyard per lan-
JLG for approved material handling accessories.
yard anchorage point.
• When two or more persons are in the platform, the opera-
tor shall be responsible for all machine operations.
• Always ensure that power tools are properly stowed and
never left hanging by their cord from the platform work
area.
3121204 – JLG Lift – 1-3

• Before operating the machine, make sure all gates are • Use extreme caution when entering or leaving platform.
closed and fastened in their proper position. Be sure that the boom is fully lowered. It may be neces-
sary to telescope out to position the platform closer to the
ground for entry/exit. Face the machine, maintain “three
point contact” with the machine, using two hands and one
foot or two feet and one hand during entry and exit.
Electrocution Hazards
• This machine is not insulated and does not provide pro-
tection from contact or proximity to electrical current.
• Keep both feet firmly positioned on the platform floor at all

times. Never use ladders, boxes, steps, planks, or similar
items on platform to provide additional reach.
• Never use the boom assembly to enter or leave the plat-
form.
1-4 – JLG Lift – 3121204

Table 1-1. Minimum Approach Distances (M.A.D.)
Voltage Range MINIMUM APPROACH DISTANCE

(Phase to Phase) in Feet (Meters)
0 to 50 KV 10 (3)
Over 50KV to 200 KV 15 (5)
Over 200 KV to 350 KV 20 (6)
Over 350 KV to 500 KV 25 (8)
Over 500 KV to 750 KV 35 (11)
Over 750 KV to 1000 KV 45 (14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations
are more stringent.
• Maintain distance from electrical lines, apparatus, or any
energized (exposed or insulated) parts according to the • Maintain a clearance of at least 10 ft. (3m) between any part
Minimum Approach Distance (MAD) as shown in Table 1- of the machine and its occupants, their tools, and their
1. equipment from any electrical line or apparatus carrying up
• Allow for machine movement and electrical line swaying. to 50,000 volts. One foot additional clearance is required for
every additional 30,000 volts or less.
3121204 – JLG Lift – 1-5

• The minimum approach distance may be reduced if insulat- Tipping Hazards

ing barriers are installed to prevent contact, and the barriers
are rated for the voltage of the line being guarded. These • The user must be familiar with the surface before driving.
barriers shall not be part of (or attached to) the machine. The Do not exceed the allowable sideslope and grade while
minimum approach distance shall be reduced to a distance driving.
within the designed working dimensions of the insulating
barrier. This determination shall be made by a qualified per-
son in accordance with the employer, local, or governmental
requirements for work practices near energized equipment
DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED

ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE
ENERGIZED UNLESS KNOWN OTHERWISE.
1-6 – JLG Lift – 3121204

• Do not elevate platform or drive with platform elevated • If boom assembly or platform is in a position that one or
while on a sloping, uneven, or soft surface. more wheels are off the ground, all persons must be
removed before attempting to stabilize the machine. Use
• Before driving on floors, bridges, trucks, and other sur-
cranes, forklift trucks, or other appropriate equipment to
faces, check allowable capacity of the surfaces.
stabilize machine.
• Never exceed the maximum platform capacity. Distribute
loads evenly on platform floor. Crushing and Collision Hazards
• Do not raise the platform or drive from an elevated posi- • Approved head gear must be worn by all operating and
tion unless the machine is on firm, level and smooth sur- ground personnel.
faces.
• Check work area for clearances overhead, on sides, and
• Keep the chassis of the machine at least 2 ft. (0.6m) from bottom of platform when lifting or lowering platform, and
holes, bumps, drop-offs, obstructions, debris, concealed driving.
holes, and other potential hazards on the floor/surface.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tie-
off machine to any adjacent structure.
• Do not operate the machine when wind conditions exceed
28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For
Reference Only).
• Do not increase the surface area of the platform or the
load. Increase of the area exposed to the wind will
decrease stability.
• Do not increase the platform size with unauthorized deck
• During operation, keep all body parts inside platform rail-
extensions or attachments.
ing.
3121204 – JLG Lift – 1-7

• Use the boom functions, not the drive function, to position 1.4 TOWING, LIFTING, AND HAULING
the platform close to obstacles.
• Never allow personnel in platform while towing, lifting, or
• Always post a lookout when driving in areas where vision
hauling.
is obstructed.
• This machine should not be towed, except in the event of
• Keep non-operating personnel at least 6 ft. (1.8m) away
emergency, malfunction, power failure, or loading/unload-
from machine during all driving and swing operations.
ing. Refer to the Emergency Procedures section of this
• Limit travel speed according to conditions of ground sur- manual for emergency towing procedures.
face, congestion, visibility, slope, location of personnel,
• Ensure boom is in the stowed position and the turntable
and other factors which may cause collision or injury to
locked prior to towing, lifting or hauling. The platform must
personnel.
be completely empty of tools.
• Be aware of stopping distances in all drive speeds. When
• When lifting machine, lift only at designated areas of the
driving in high speed, switch to low speed before stop-
machine. Lift the unit with equipment of adequate capac-
ping. Travel grades in low speed only.
ity.
• Do not use high speed drive in restricted or close quarters
• Refer to the Machine Operation section of this manual for
or when driving in reverse.
lifting information.
• Exercise extreme caution at all times to prevent obstacles
from striking or interfering with operating controls and per-
sons in the platform.
• Be sure that operators of other overhead and floor level
machines are aware of the aerial work platform’s pres-
ence. Disconnect power to overhead cranes.
• Warn personnel not to work, stand, or walk under a raised
boom or platform. Position barricades on floor if neces-
sary.
1-8 – JLG Lift – 3121204

1.5 ADDITIONAL HAZARDS / SAFETY • Do not refuel the machine with the engine running.
• Battery fluid is highly corrosive. Avoid contact with skin
• Do not use machine as a ground for welding.
and clothing at all times.
• When performing welding or metal cutting operations,
• Charge batteries only in a well ventilated area.
precautions must be taken to protect the chassis from
direct exposure to weld and metal cutting spatter.
3121204 – JLG Lift – 1-9

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28

MPH (12.5 M/S).
Table 1-2. Beaufort Scale (For Reference Only)
Beaufort Wind Speed

Description Land Conditions
Number mph m/s
0 0 0-0.2 Calm Calm. Smoke rises vertically
1 1-3 0.3-1.5 Light air Wind motion visible in smoke
2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves rustle
3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion
4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.
5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.
6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.
Umbrella use becomes difficult.
7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind.
8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.
9 47-54 20.8-24.4 Strong Gale Light structure damage.
1-10 – JLG Lift – 3121204

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION
SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where over-
head obstructions, other moving equipment, and obsta-
The aerial platform is a personnel handling device; so it is cles, depressions, holes, drop-offs.
necessary that it be operated and maintained only by trained
7. Means to avoid the hazards of unprotected electrical
personnel.
conductors.
Persons under the influence of drugs or alcohol or who are
8. Specific job requirements or machine application.
subject to seizures, dizziness or loss of physical control must
not operate this machine.
Training Supervision
Operator Training Training must be done under the supervision of a qualified
person in an open area free of obstructions until the trainee
Operator training must cover:
has developed the ability to safely control and operate the
1. Use and limitations of the controls in the platform and at machine.
the ground, emergency controls and safety systems.
2. Control labels, instructions, and warnings on the
Operator Responsibility
machine. The operator must be instructed that he/she has the respon-
sibility and authority to shut down the machine in case of a
3. Rules of the employer and government regulations.
malfunction or other unsafe condition of either the machine
4. Use of approved fall protection device. or the job site.
5. Enough knowledge of the mechanical operation of the
machine to recognize a malfunction or potential mal-
function.
3121204 – JLG Lift – 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-QUALIFIED SERVICE
TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED
The following table covers the periodic machine inspections
THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT
and maintenance recommended by JLG Industries, Inc.
MODEL.
Consult local regulations for further requirements for aerial
work platforms. The frequency of inspections and mainte-
nance must be increased as necessary when the machine is
used in a harsh or hostile environment, if the machine is
used with increased frequency, or if the machine is used in a
severe manner.
2-2 – JLG Lift – 3121204

Table 2-1.Inspection and Maintenance Table
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Before using each day; or User or Operator User or Operator Operator and Safety Manual
whenever there’s an Operator change.
Pre-Delivery Inspection Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Service and Maintenance
(See Note) Mechanic Manual and applicable JLG
inspection form
Frequent Inspection In service for 3 months or 150 hours, whichever Owner, Dealer, or User Qualified JLG Service and Maintenance
comes first; Mechanic Manual and applicable JLG
or inspection form
Out of service for a period of more than 3 months;
or
Purchased used.
Annual Machine Annually, no later than 13 months from the date Owner, Dealer, or User Factory-Qualified Service and Maintenance
Inspection of prior inspection. Service Technician Manual and applicable JLG
inspection form
Preventative At intervals as specified in the Service and Main- Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance tenance Manual. Mechanic Manual
NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.
3121204 – JLG Lift – 2-3

Pre-Start Inspection (Domestic only) is enclosed in the weather resistant

storage container.
The Pre-Start Inspection should include each of the follow-
ing: 5. “Walk-Around” Inspection – Refer to Figure 2-3.
1. Cleanliness – Check all surfaces for leakage (oil, fuel, 6. Battery – Charge as required.
or battery fluid) or foreign objects. Report any leakage to 7. Fuel (Combustion Engine Powered Machines) – Add the
the proper maintenance personnel. proper fuel as necessary.
2. Structure - Inspect the machine structure for dents, 8. Hydraulic Oil – Check the hydraulic oil level. Ensure
damage, weld or parent metal cracks or other discrep- hydraulic oil is added as required.
ancies.
9. Function Check – Once the “Walk-Around” Inspection
is complete, perform a functional check of all systems in
an area free of overhead and ground level obstructions.
Refer to Section 4 for more specific instructions.
IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE

Parent Metal Crack Weld Crack MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER
MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT
3. Decals and Placards – Check all for cleanliness and IS DECLARED SAFE FOR OPERATION.
legibility. Make sure none of the decals and placards are
missing. Make sure all illegible decals and placards are
cleaned or replaced.
4. Operators and Safety Manuals – Make sure a copy of
the Operator and Safety Manual, EMI Safety Manual
(Domestic only), and ANSI Manual of Responsibilities
2-4 – JLG Lift – 3121204

Function Check a. Drive the machine on a grade, not to exceed the

rated gradeability, and stop to ensure the brakes
Perform the Function Check as follows: hold;
1. From the ground control panel with no load in the plat- b. Check the tilt sensor alarm to ensure proper opera-
form: tion.
a. Check that all guards protecting the switches or 2.3 LIMIT SWITCH FUNCTIONAL CHECK
locks are in place;
b. Operate all functions and check all limiting and cut-
out switches;
TO AVOID MACHINE UPSET DO NOT USE MACHINE IF TOWER BOOM
c. Check auxiliary power (or manual descent);
SWITCHING IS OUT OF SEQUENCE.
d. Ensure that all machine functions are disabled
when the Emergency Stop Button is activated. IF THE TOWER BOOM LIFTS ‘DOWN’ WITH THE TOWER BOOM TELE-
2. From the platform control console: SCOPED ‘OUT’, SHUT DOWN MACHINE AND CONTACT A CERTIFIED JLG
TECHNICIAN.
a. Ensure that the control console is firmly secured in
the proper location; IF THE TOWER BOOM ‘TELESCOPES’ WITH THE TOWER BOOM LESS
b. Check that all guards protecting the switches or THAN FULLY ELEVATED ‘UP’, SHUT DOWN MACHINE AND CONTACT
locks are in place; QUALIFIED JLG TECHNICIAN.
c. Operate all functions and check all limiting and cut-
out switches; TO AVOID UPSET IF TOWER BOOM SWITCHING MALFUNCTIONS:
d. Ensure that all machine functions are disabled — LOWER THE PLATFORM TO GROUND VIA MAIN BOOM LIFT AND
when the Emergency Stop Button is pushed in. TELESCOPE FUNCTIONS.
3. With the platform in the transport (stowed) position:
— HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH-
NICIAN BEFORE CONTINUING USE OF MACHINE.
3121204 – JLG Lift – 2-5

6. Place TOWER TELESCOPE to ‘in’ position and fully

retract the TOWER BOOM. Place TOWER BOOM to
TO AVOID COLLISION AND INJURY IF PLATFORM DOES NOT STOP ‘down’ and fully lower the TOWER BOOM. Upright in
WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT vertical position. If Tower Boom does not rest on stop
FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE with machine in the stowed position, this indicates
MACHINE. upright is out of plumb. See Section 4, Boom Synchro-
nizing Procedure, in Service Manual.
1. Check hydraulic boom sequence cam valves. Raise,
extend, retract and lower tower boom. Check for smooth
and proper operation.
TO AVOID TIPPING OVER DO NOT USE MACHINE IF TOWER BOOM
NOTE: Perform checks from ground controls first, then from plat- SWITCHING IS OUT OF SEQUENCE.
form controls.
NOTE: For adjustments see Service Manual - Limit Switch Adjust-
2. Operate machine from ground control. ments.
3. Move TOWER TELESCOPE to ‘out’ position. Tower 7. Check elevation limit switch as follows:
should not telescope with TOWER BOOM less than fully
elevated ‘up’. (Must be approximately 13 degrees from Main Boom Angle Limit Switch.
vertical to move TOWER TELESCOPE ‘out’.)
a. Lift boom up to 5 degrees above horizontal. Limit
4. Move TOWER BOOM to ‘up’ position and hold until the switch should activate at this point.
TOWER BOOM is completely elevated. Move TOWER
TELESCOPE to ‘out’ position and hold until the TOWER b. Lift main boom down until limit switch resets. This
BOOM is fully extended. should be 4 degrees to 9 degrees below horizontal.
5. With TOWER BOOM completely extended, place NOTE: Angle indicator should be placed between the main boom
TOWER LIFT in ‘down’ position. Tower boom should not pivot pin and the main boom lift cylinder attach point on
LIFT ‘down’ unless the TOWER BOOM is fully retracted. the base boom. On machines not equipped with ADE, the
main boom angle limit switch activation may be checked
2-6 – JLG Lift – 3121204

by using test light in terminal # 24 in the main terminal b. Telescope boom out until 500 lb. (227 kg for ANSI
box. Tower angle switch must be reset before main boom markets and 230 kg for CE and Australia markets)
angle switch can be activated. light comes on (may need to used auxiliary power
to position boom correctly).
Tower Boom Angle Limit Switch. c. Mark the wear pad location on the main fly boom.
a. Place machine on level surface. d. Telescope the main boom to full extension.
b. Using the bottom of the upright and the ground as a e. Measure from the mark on the fly boom to the wear
reference, lift the tower boom 40" to 42" (101.6 to pad. The dimension should be 125" to 127" (317.5
106.6 cm) from the stowed position. The tower to 322.6 cm).
boom angle limit switch should activate at this
Main Boom Angle Switch.
point.
c. Lower the tower boom 25" to 30" (63.5 to 76.2 cm) a. Lift main boom to approximately horizontal.
from where the switch activated. This switch should b. Telescope boom out until 500 lb. (227 kg for ANSI
reset at this point. markets and 230 kg for CE and Australia markets)
light comes on (may need to used auxiliary power
NOTE: On machines not equipped with ADE, the tower boom
to position boom correctly).
angle limit switch activation may be checked by using a
test light in terminal #43 on the main terminal box. c. Lift main boom up until 1000 lb. (454 kg for ANSI
markets and 450 kg for CE and Australia markets)
NOTE: Step 8 is only applicable for 600A ANSI market machines. light comes on. The boom angle at this point should
be 55 degrees to 60 degrees.
8. Check capacity limit switch as follows: d. Lift main boom down until 500 lb. (227 kg for ANSI
markets and 230 kg for CE and Australia markets)
Main Boom Length Switch. light comes on. The boom angle at this point should
be 45 degrees to 50 degrees.
a. Lift main boom to approximately horizontal.
3121204 – JLG Lift – 2-7

NOTE: If limit switch settings need to be changed, you will need NOTE: Step 12 is applicable for machines with an internal tilt sen-
to recheck that the 500 lb. (227 kg for ANSI markets and sor.
230 kg for CE and Australia markets) light comes on at 45
degrees to 50 degrees when lifting down. 12. Check the chassis out of level indicator located on the
platform control console by driving, with the machine in
9. Raise, extend, retract and lower main boom. Check for level position, up a suitable ramp of at least 5° slope.
smooth operation. Check the out of level indicator, with the machine on the
ramp. If the light does not illuminate, return the machine
10. Swing turntable to LEFT and RIGHT a minimum of 45
to a level surface, shut down the machine, and contact a
degrees. Check for smooth motion.
qualified technician before resuming operation.
NOTE: Step 11 is only applicable for machines with an external
tilt sensor.
11. With the aid of an assistant to monitor the CHASSIS

OUT OF LEVEL indicator light on the platform control
console, manually activate the indicator light by com-
pressing any one of the three tilt indicator mounting
springs. If the light does not illuminate, shut down
machine and contact a qualified service technician
before continuing operation.
2-8 – JLG Lift – 3121204

1. Platform
2. Platform Control Box
3. Rotator
4. Articulating Jib
5. Fly Boom
6. Base Boom
7. Main Boom Assembly
8. Telescope Cylinder (Inside)
9. Upright
10. Fly Boom
11. Base Boom
12. Lower Lift Cylinder
13. Ground Control Box
14. Steer Wheels
15. Frame
16. Drive Wheels
17. Swing Bearing
18. Turntable
19. Tower Telescope Cylinder (Inside)
20. Boom Assembly
21. Upright Level Cylinder
22. Main Lift Cylinder
23. Slave Level Cylinder
24. Articulating Fly Lift Cylinder
25. Footswitch
Figure 2-1. Machine Nomenclature - 600AJ
3121204 – JLG Lift – 2-9

1. Platform
2. Platform Control Box
3. Rotator
4. Fly Boom
5. Base Boom
6. Main Boom Assembly
7. Telescope Cylinder (Inside)
8. Upright
9. Fly Boom
10. Base Boom
11. Lower Lift Cylinder
12. Ground Control Box
13. Steer Wheels
14. Frame
15. Drive Wheels
16. Swing Bearing
17. Turntable
18. Tower Telescope Cylinder Inside)
19. Boom Assembly
20. Upright Level Cylinder
21. Main Lift Cylinder
22. Slave Level Cylinder
23. Footswitch
Figure 2-2. Machine Nomenclature - 600A
2-10 – JLG Lift – 3121204

Figure 2-3. Daily Walk-Around Inspection Diagram
3121204 – JLG Lift – 2-11

General 1. Platform Assembly - Platform Assembly and Gate -

Footswitch works properly, not modified, disabled or
Begin the “Walk-Around Inspection” at Item 1, as noted on blocked. Latch, stop, and hinges in working condition.
the diagram. Continue to the right (counterclockwise
2. Platform Control Console - Switches and levers return
viewed from top) checking each item in sequence for the
to neutral and are properly secured, decals/placards
conditions listed in the “Walk-Around Inspection Check-
secure and legible, control marking legible.
list”.
3. Rotator - See Note.
4. Rotator Motion Control Valve - See Note.
TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF
DURING "WALK-AROUND INSPECTION". 5. Articulating Jib Boom - See Note.
6. Transport Position Switch (If equipped) - Arm free to
move, and free from dirt and grease.
DO NOT OVERLOOK VISUAL INSPECTION OF CHASSIS UNDERSIDE. 7. Power Track - See Note.
CHECKING THIS AREA MAY RESULT IN DISCOVERY OF CONDITIONS 8. Steer Cylinder Assembly - See Note.
WHICH COULD CAUSE EXTENSIVE MACHINE DAMAGE.
9. Spindle - Evidence of proper lubrication. See Note.
NOTE: On each item, make sure there are no loose or missing
10. Drive Motor and Brake - See Note.
parts, that they are securely fastened and that no visible
damage exists in addition to any other criteria men- 11. Drive Hub - See Note.
tioned.
Figure 2-4. Daily Walk-Around Inspection Points - Sheet 1 of 3
2-12 – JLG Lift – 3121204

12. Wheel/Tire Assembly - No loose or missing lug nuts. 22. Hydraulic Oil Supply - Recommended oil level sight
Inspect for worn tread, cuts, tears or other discrepan- gauge. (Check level with cold oil, systems shut down,
cies. Inspect wheels for damage and corrosion. machine in stowed position) Cap in place and secure.
13. Tie Rod and Steering Linkage (4 Wheel Steer) - Tie 23. Hydraulic Oil Breather - Element in place, not
rod end studs locked. clogged, no sign of overflow.
14. Turntable Lock - Operable. 24. Ground Controls - Switches operable, decals secure
and legible.
15. Auxiliary Power Pump - See Note.
25. Fuel Supply - Fuel filler cap secure. Tank - See Note.
16. Control Valve (Tank Compartment) - See Note.
26. Swing Drive Motor and Brake - See Note.
17. Turntable Bearing and Pinion - No evidence of loose
bolts or looseness between bearing and structure. 27. Door and Latches - Hood door and latches in working
condition.
18. Hydraulic Oil Medium Pressure Filter Housing - Hous-
ing secure. 28. Oscillating Cam Valve (If Equipped) - See Note.
19. Hydraulic Oil Return Filter Housing - Housing secure.
20. Manual Descent - See Note.
21. LP Gas Tank (If Equipped) - See Note.
3121204 – JLG Lift – 2-13

29. Oscillating Axle Cylinder (If Equipped) - See Note. 38. Hydraulic Swivel - See Note.
30. Dual Capacity and Horizontal Cutout Limit Switch - No 39. LP Gas Tank (If Equipped) - See Note.
damage to the switch, arm free to move, and free from
40. Flow Valves - See Note.
dirt and grease.
41. Tower Boom/Upright - Wear pads secure. All cylinders
31. Oscillating Axle (If Equipped)- See Note.
- rod end shafts and barrel-end shafts properly
32. Engine Air Filter - Element clean. secured. Upright in vertical position. If Tower Boom
does not rest on stop with machine in the stowed
33. Battery - Proper electrolyte levels; cables tight, no visi-
position, this indicates upright is out of plumb.
ble damage or corrosion.
42. Frame - See Note.
34. Engine Oil Supply - Full mark on dipstick; filler cap
secure. 43. Main Boom Sections - Wear pads secure. All cylinders
- rod end shafts and barrel-end shafts properly
35. Muffler and Exhaust System - See Note.
secured.
36. Hydraulic Pump - See Note.
44. Platform Pivot Pin - See Note.
37. Engine Tray Pivot - See Note.
2-14 – JLG Lift – 3121204

SECTION 3 - MACHINE CONTROLS AND INDICATORS
SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL NOTE: The indicator panels use different shaped symbols to alert
the operator to different types of operational situations
that could arise. The meaning of those symbols are
explained below.
THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE Indicates a potentially hazardous situation, which
APPLICATION AND OPERATION. THE USER AND OPERATOR ARE if not corrected, could result in serious injury or
RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES. death. This indicator will be red.
This section provides the necessary information needed to Indicates an abnormal operating condition,
understand control functions. which if not corrected, may result in machine
interruption or damage. This indicator will be yel-
3.2 CONTROLS AND INDICATORS low.
Indicates important information regarding the
NOTE: All machines are equipped with control panels that use
operating condition, i.e. procedures essential for
symbols to indicate control functions. On ANSI machines
safe operation. This indicator will be green with
refer to decal located on the control box guard in front of the exception of the capacity indicator which will
the control box or by the ground controls for these sym- be green or yellow depending upon platform
bols and the corresponding functions. position.
3121204 – JLG Lift – 3-1

Ground Controls 3. Jib (If Equipped)
(See Figure 3-1., Ground Control Station) This switch provides raising and lowering of the jib.
NOTE: If equipped, the Function Enable switch must NOTE: When Power/Emergency Stop switch is in the “ON” posi-
be held down in order to operate Main Boom tion and engine is not running, an alarm will sound, indi-
Telescope, Tower Lift, Swing, Main Lift, Jib cating Ignition is “ON”.
Lift, Platform Level Override, and Platform Rotate func-
tions.
WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP
1. Platform Rotate
SWITCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENT
DRAINING THE BATTERY.
A three position switch permits rotation of the platform.
NOTE: On machines with diesel engines, when Glow Plug Indi-
cator is lighted (Yellow), wait until light goes out before
cranking engine.
ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD 4. Power/Emergency Stop Switch
CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO
COULD RESULT IN DEATH OR SERIOUS INJURY. Pull out ON-OFF POWER/EMERGENCY STOP SWITCH
to turn on engine ignition and power to the electrical
2. Platform Leveling Override system. Push in to shut off engine and remove power
from the controls. The Ground Control Emergency Stop
A three position switch allows the operator to compen- Switch must be pulled out to operate the machine from
sate for any difference in the automatic self leveling sys- either Ground Control or Platform Control. This allows
tem. the machine to be shut down in emergency situations by
those untrained in the operation of the lift but who rec-
ognize the Emergency Stop Switch. The keyed Master
Switch can also be used for the same purpose.
3-2 – JLG Lift – 3121204

1
1. Platform Rotate
2. Platform Leveling Override
3. Jib 2
4. Power/Emergency Stop 12
5. Engine Start/Auxiliary Power
3
or
Engine Start/Auxiliary Power/Function Enable
OR 4 11
6. Tower Telescope
7. Hourmeter
8. Platform/Ground Select Switch
9. Swing 5 10
10. Tower Lift
11. Main Boom Lift 6
12. Main Boom Telescope
7 9
8
1706913 A
Figure 3-1. Ground Control Station
3121204 – JLG Lift – 3-3

5. Engine Start/Auxiliary Power Switch 7. Hourmeter

or
Engine Start/ Auxiliary Power Switch /Function Enable. Registers the amount of time the machine has been in
use, with engine running. By connecting into the oil
To start the engine, the switch must be held "UP"
pressure circuit of the engine, only engine run hours are
until the engine starts.
recorded. The hourmeter registers up to 9,999.9 hours
and cannot be reset.
To use auxiliary power, the switch must be held
“DOWN” for duration of auxiliary pump use. Aux 8. Platform/Ground Select Switch
power can only be used if the engine is not run-
ning. A three position, center off, key activated PLATFORM/
GROUND SELECT switch supplies power to the plat-
If equipped, the enable switch must be held form control console when positioned to PLATFORM.
"DOWN" to enable all boom controls when the With the switch in GROUND position, power is shut off to
engine is running. the platform control console, and only the controls on
the ground control panel are operable.
6. Tower Telescope
NOTE: With the Platform/Ground Select Switch in the center posi-
This switch provides raising and lowering of the tower tion, power is shut off to controls at both operating sta-
boom. This function works only when the tower boom is tions.
fully elevated (lift up).
9. Swing Control
Provides 360 degrees continuous turntable rotation.

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF
TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Tele-
ABOVE SEQUENCE. scope, Tower Telescope, Platform Rotator and Auxiliary
Power control switches are spring-loaded and will auto-
matically return to neutral (off) when released.
3-4 – JLG Lift – 3121204

11. Main Lift Control
WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL Provides raising and lowering of the main boom.
AROUND OR UNDER PLATFORM.
12. Main Telescope Control
Provides extension and retraction of the boom, when

positioned to IN or OUT.
TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-
TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM
MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.
10. Tower Lift
This switch provides raising and lowering of the tower

boom. This function works only when the tower boom is
fully retracted (telescope in).
3121204 – JLG Lift – 3-5

Ground Control Indicator Panel 5. Engine Malfunction Indicator (Ford Engines

S/N 48907 to S/N 64249 - refer to ADE System Identifica-
(See Figure 3-2., Ground Control Indicator Panel - Sheet 1 of 2 tion page at the front of the book).
and Figure 3-3., Ground Control Indicator Panel - Sheet 2 of 2)
Indicates that the Engine Control Module has detected a
1. Battery Charging Indicator
malfunction in the Electronic Fuel Injection System and
a Diagnostic Trouble Code has been set in the ECM.
Indicates a problem in the battery or charging circuit,
Refer to the Service Manual for instructions concerning
and service is required.
the trouble codes and trouble code retrieval.
2. Engine Oil Pressure Indicator
The malfunction indicator light will illuminate for 2-3 sec-
Indicates that engine oil pressure is below normal and onds when the key is positioned to the on position to act
service is required. as a self test.
3. Engine Coolant Temperature (Ford and Continental) 6. Low Fuel Level Indicator
Indicator
Indicates that the fuel level is 1/8 full or less. When the
Indicates that engine coolant temperature is abnormally light first turns on, there are approximately four usable
high and service is required. gallons of fuel remaining.
4. Engine Oil Temperature Indicator (Deutz) 7. Glow Plug Indicator (Diesel)
Indicates the temperature of the engine oil, which also Indicates glow plugs are on. The glow plugs are auto-
serves as engine coolant, is abnormally high and ser- matically turned on with the ignition circuit and remain
vice is required. on for approximately about seven seconds. Start the
engine only after the light goes out.
3-6 – JLG Lift – 3121204

Prior to S/N 0300099061
1. Battery Charging 5. Engine Malfunction Indicator 9. Hyd. Filter Bypass

2. Engine Oil Pressure 6. Low Fuel 10. Transmission Filter By-Pass
3. Engine Water Temp. 7. Glow Plug 11. Engine Air Filter By-Pass
4. Engine Oil Temp. 8. Platform Overload
Figure 3-2. Ground Control Indicator Panel - Sheet 1 of 2
3121204 – JLG Lift – 3-7

S/N 0300099061 to Present
1. Battery Charging 6. Low Fuel 10. Not Used

2. Engine Oil Pressure 7. Glow Plug 11. Not Used
3. Engine Water Temp. 8. Platform Overload 12. Not Used
4. Engine Oil Temp. 9. Not Used 13. Drive and Steer Disable
5. Engine Malfunction Indicator
Figure 3-3. Ground Control Indicator Panel - Sheet 2 of 2
3-8 – JLG Lift – 3121204

8. Platform Overload (If equipped) Codes will be displayed on the Malfunction Indicator
Light. Refer to the Service Manual for instructions con-
Indicates the platform has been overloaded. cerning the trouble codes and trouble code retrieval.
9. Hydraulic Oil Filter Indicator (Prior to S/N 84829)
Indicates the return oil filter is too restrictive and needs

to be replaced.
10. Transmission Pump Oil Filter Indicator
(Prior to S/N 84829)
Indicates that charge pump filter is too restrictive and

needs to be replaced. This indicator has an integral tem-
perature sensor (70 degrees F.) so that false signals are
not generated when the hydraulic oil is below normal
operating temperature.
11. Engine Air Filter Indicator (Prior to S/N 84829)
Indicates that the air filter is too restrictive and needs to

be replaced.
12. EFI System Test Button (Ford Engines S/N 48907 to S/N
Figure 3-4. Malfunction Indicator Light and Test Button
64249 - refer to ADE System Identification page at the
front of the book).
13. Drive and Steer Disable Indicator (If equipped)
By pushing and holding the system test button on the
side of the ground control box, the Diagnostic Trouble Indicates the Drive and Steer Disable function has been
activated.
3121204 – JLG Lift – 3-9

Platform Control rear drive wheels to the forward drive position by select-
ing either crab or compound steer, then select front
(See Figure 3-5. and Figure 3-6.) steer (center switch position) to operate the normal
steering function.
1. Drive Speed/Torque Select
The machine has a two position switch — The forward

position produces maximum speed and torque by giv- ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
ing speed when the drive controller is moved. The back- SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD
ward position allows the machine to be driven with the CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO
engine at mid speed. COULD RESULT IN DEATH OR SERIOUS INJURY.
2. Steer Select (If Equipped)
3. Platform Leveling Override
When equipped with four wheel steering, the action of
This switch allows the operator to adjust the level of the
the steering system is operator selectable. The center
platform.
switch position gives conventional front wheel steering
with the rear wheels unaffected. This is for normal driv- 4. Horn
ing at maximum speeds. The forward position is for
“crab” steering. When in this mode both front and rear Supplies electrical power to the horn when pressed.
axles steer in the same direction, which allows the chas-
5. Power/Emergency Stop
sis to move sideways as it goes forward. This can be
used for positioning the machine in aisle ways or against
An ON-OFF POWER/EMERGENCY STOP switch and a
buildings. The back switch position is for “coordinated”
separate ENGINE START/AUXILIARY POWER toggle
steering. In this mode the front and rear axles steer in
switch on the platform console supply electrical power
the opposite directions to produce the tightest turning
to the starter solenoid, when the ignition switch is placed
circle for maneuvering in confined areas.
in the “ON” position and the ENGINE START switch is
push forward.
To re-synchronize the front and rear axles, position the
3-10 – JLG Lift – 3121204

1. Drive Speed 5. Power/Emergency Stop 9. Drive/Steer 13. Tower Lift

2. Steer Select 6. Aux. Power 10. Telescope 14. Platform Rotate
3. Platform Leveling Override 7. Fuel Select 11. Jib 15. Function Speed
4. Horn 8. Lights 12. Tower Telescope 16. Main Lift/Swing
Figure 3-5. Platform Control Console
3121204 – JLG Lift – 3-11

1 2 3 4 5 6 7 17
1702676-B 1704997
1702567 A
1702938 1705170 A
16 15 14 19 13 12 18 11 8 10 9
1. Drive Speed 5. Power/Emergency Stop 9. Drive/Steer 13. Tower Lift 17. Drive Orientation Override
2. Steer Select 6. Aux. Power 10. Telescope 14. Platform Rotate 18. Soft Touch Override
3. Platform Leveling Override 7. Fuel Select 11. Jib 15. Function Speed 19. Soft Touch Indicator
4. Horn 8. Lights 12. Tower Telescope 16. Main Lift/Swing
Figure 3-6. Platform Control Console - w/Drive Orientation
3-12 – JLG Lift – 3121204

6. Auxiliary Power 8. Lights (If Equipped)
Energizes the electrically operated hydraulic pump, This switch operates control console panel lights and
when actuated. (Switch must be held ON for duration of head lights if the machine is so equipped. The ignition
auxiliary pump use.) switch does not have to be on to operate the lights, so
care must be taken to avoid draining the battery if left
The auxiliary pump functions to provide sufficient oil flow unattended. The master switch and / or the ignition
to operate the basic machine functions should the main switch at the ground control will turn off power to all
pump or engine fail. The auxiliary pump will operate lights.
tower boom lift, tower telescope, main boom lift, main
telescope and swing. 9. Drive/Steer
7. Fuel Select (Dual Fuel Engine Only) (If Equipped) The DRIVE joystick provides for driving either forward or
backward. The controller is ‘ramped’ to allow variable
Gasoline or liquid propane fuel may be selected by mov- drive speed.
ing the switch to the appropriate position. It is unneces-
sary to purge the fuel system before switching fuels, so Steering is controlled by a thumb operated switch on
there is no waiting period when switching fuels while the top of the joystick.
engine is running.
NOTE: When boom is positioned above horizontal and any of the
following switches, DRIVE SPEED/TORQUE SELECT or
FUNCTION SPEED, are positioned to HIGH, high function
speeds are automatically cut out and the machine contin-
ues to operate at a lower speed.
3121204 – JLG Lift – 3-13

10. Main Telescope Control 13. Tower Lift
This control allows extension and retraction of the main This three position switch provides for raising and lower-
boom. ing of the tower boom. TOWER LIFT must be fully ele-
vated “UP” before operating TOWER TELESCOPE.
11. Jib (If Equipped)
(TOWER LIFT should not function when TOWER TELE-
SCOPE is extended).
Push forward to lift up, pull back to lift down. Variable lift
speed is using the Function Speed Control. NOTE: MAIN LIFT, SWING, and DRIVE control levers are spring-
loaded and will automatically return to neutral (OFF) posi-
12. Tower Telescope
tion when released.
This three position switch provides for extending and
retracting of the tower boom. TOWER TELESCOPE
must be fully RETRACTED before operating TOWER
LIFT. (TOWER TELESCOPE should not function when
TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM
TOWER LIFT is not fully elevated “UP”).
MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION
WHEN RELEASED.
TO AVOID TIPPING OVER AND SERIOUS INJURY, DO NOT OPERATE

MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE
ORDER PRESCRIBED IN (12) AND (13) ABOVE.
3-14 – JLG Lift – 3121204

14. Platform Rotate 17. Drive Orientation Override
This switch allows the operator to rotate the basket to When the boom is swung over the rear tires or further in
the left or right. either direction, the Drive Orientation indicator will illumi-
nate when the drive function is selected. Push and
release the switch, and within 3 seconds move the
Drive/Steer control to activate drive or steer. Before driv-
DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR
ing, locate the black/white orientation arrows on both
FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORI-
the chassis and the platform controls and match the
ZONTAL.
control direction arrow to the intended chassis direction.
15. Function Speed Control 18. Soft Touch Override Switch (If equipped)
Controls the speed of Boom and Swing Functions. This switch enables the functions that were cut out by
Rotate CCW for slower speed and CW for faster speed. the Soft Touch system to operate again at creep speed,
To adjust to creep, turn knob fully CCW until it clicks. allowing the operator to move the platform away from
the obstacle that caused the shutdown situation.
16. Main Lift/Swing Controller
19. Soft Touch Indicator (If Equipped)
An infinitely proportional dual axis joystick is provided
for main lift and swing. Push forward to lift up, pull back- Indicates the Soft Touch bumper is against an object. All
ward to lift down. Move right to swing right, move left to controls are cut out until the override button is pushed,
swing left. at which time controls are active in the Creep Mode.
3121204 – JLG Lift – 3-15

Platform Control Indicator Panel 2. Platform Overload (If equipped)
(See Figure 3-7. and Figure 3-8.) Indicates the platform has been overloaded.
1. Tilt Alarm Warning Light and Alarm 3. Capacity Indicator
This orange illuminator indicates that the chassis is on a Indicates the maximum platform capacity for the current
slope. An alarm will also sound when the chassis is on a position of the platform. Restricted capacities are permit-
slope and the boom is above horizontal. If lit when boom ted at restricted platform positions (shorter boom
is raised or extended, retract and lower to below hori- lengths and higher boom angles).
zontal then reposition machine so that it is level before
continuing operation. If the boom is above horizontal NOTE: Refer to the capacity decals on the machine for restricted
and the machine is on a slope, the tilt alarm warning and unrestricted platform capacities.
light will illuminate and an alarm will sound and CREEP
is automatically activated.
IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR

EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN
REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING
BOOM OR RAISING BOOM ABOVE HORIZONTAL.
3-16 – JLG Lift – 3121204

1. Tilt 5. Glow Plug 9. Soft Touch

2. Overload 6. Low Fuel 10. Creep
3. Capacity 7. Engine Malfunction
4. Enable 8. AC Generator
Figure 3-7. Platform Control Indicator Panel
3121204 – JLG Lift – 3-17

1 2 * 3 4
1001107927 A
10 11 8 ** 7 6 5
* UNRESTRICTED CAPACITY
** RESTRICTED CAPACITY
1. Tilt 5. Glow Plug 9. Not Used

2. Overload 6. Low Fuel 10. Creep
3. Capacity 7. Malfunction 11. Drive Orientation
4. Enable 8. AC Generator
Figure 3-8. Platform Control Indicator Panel - w/Drive Orientation
3-18 – JLG Lift – 3121204

4. Enable Indicator/Footswitch 5. Glow Plug Indicator
To operate any function, the footswitch must be When illuminated the glow plugs are operating. After
depressed and the function selected within seven sec- turning on ignition, wait until light goes out before crank-
onds. The enable indicator shows that the controls are ing engine.
enabled. If a function is not selected within seven sec-
6. Low Fuel Indicator (Yellow)
onds, or if a seven second lapse between ending one
function and beginning the next function, the enable
Indicates the fuel tank is 1/8 full or less. When the light
light will go out and the footswitch must be released and
first turns on, there are approximately four usable gal-
depressed again to enable the controls.
lons of fuel remaining.
Releasing the footswitch removes power from all con-
trols and applies the drive brakes.
TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE

THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.
FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN

SWITCH ONLY OPERATES WITHIN LAST 1/4" (6.3 MM) OF TRAVEL, TOP
OR BOTTOM.
3121204 – JLG Lift – 3-19

7. Malfunction Indicator 8. AC Generator (Green)
On all machines prior to S/N 48907 and machines with a Indicates the generator is in operation.
Deutz engine prior to S/N 64249, the light turns on and
9. Soft Touch Indicator (If Equipped)
an alarm sounds when machine’s power system
requires immediate service. Any of the following condi-
Indicates the Soft Touch bumper is against an object. All
tions will turn on light and alarm: low engine oil pres-
controls are cut out until the override button is pushed,
sure, high engine coolant temperature, clogged engine
at which time controls are active in the Creep mode.
air filter, low alternator output, clogged hydraulic oil
return filter, or clogged charge pump filter. 10. Creep Speed Indicator
On machines with Ford engines from S/N 48907 to S/N When the Function Speed Control is turned to the creep
64249, the light indicates that the Engine Control Sys- position, the indicator acts as a reminder that all func-
tem has detected a malfunction and a Diagnostic Trou- tions are set to the slowest speed.
ble Code has been set in the system memory.
11. Drive Orientation Indicator
On machines after S/N 64249, the light indicates that the
JLG Control System has detected an abnormal condi- When the boom is swung beyond the rear drive tires or
tion and a Diagnostic Trouble Code has been set in the further in either direction, the Drive Orientation indicator
system memory. will illuminate when the drive function is selected. This is
a signal for the operator to activate the Drive Orientation
Refer to the Service Manual for instructions concerning Override Switch and verify the drive control direction is
the trouble codes and trouble code retrieval. correct.
The malfunction indicator light will illuminate for 2-3 sec-

onds when the key is positioned to the on position to act
as a self test.
3-20 – JLG Lift – 3121204

SECTION 4 - MACHINE OPERATION
SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION 4.2 OPERATING CHARACTERISTICS AND
This machine is a self-propelled hydraulic lift equipped with a LIMITATIONS
work platform on the end of an elevating, articulating and
rotating boom. Capacities
The primary operator control station is in the platform. From
The boom can be raised above horizontal with or without any
this control station, the operator can drive and steer the
load in platform, if:
machine in both forward and reverse directions. The opera-
tor can raise or lower the upper or lower boom or swing the 1. Machine is positioned on a smooth, firm and level sur-
boom to the left or right. Standard boom swing is 360° con- face.
tinuous left and right of the stowed position. The machine
has a Ground Control Station which will override the Platform 2. Load is within manufacturer’s rated capacity.
Control Station. Ground Controls operate Boom Lift and 3. All machine systems are functioning properly.
Swing, and are to be used in an emergency to lower the plat-
form to the ground should the operator in the platform be 4. Proper tire pressure.
unable to do so. The Ground Control is also to be used in 5. Machine is as originally equipped from JLG.
Pre-Start Inspection.
3121204 – JLG Lift – 4-1

Stability 4.3 ENGINE OPERATION

Machine stability is based on two positions which are called NOTE: Initial starting should always be performed from the
FORWARD and BACKWARD stability. The machine’s posi- Ground Control station.
tion of least BACKWARD stability is shown in Figure 4-2.,
Position of Least Backward Stability and its position of least Starting Procedure
FORWARD stability is shown in Figure 4-1., Position of Least
Forward Stability.
IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN

EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW
TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD
STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER
MACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.
SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.
NOTE: Diesel engines only: After turning on ignition, operator

must wait until glow plug indicator light goes out before
cranking engine.
1. Turn key of SELECT switch to GROUND. Position

POWER/EMERGENCY STOP switch to ON, then push
the ENGINE START switch until engine starts.
ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED

BEFORE APPLYING ANY LOAD.
4-2 – JLG Lift – 3121204

2. After engine has had sufficient time to warm up, shut Shutdown Procedure
engine off.
3. Turn SELECT switch to PLATFORM.
4. From Platform, pull POWER/EMERGENCY STOP switch IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN,
out, then push the ENGINE START switch until engine DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THE
starts. ENGINE.
NOTE: Footswitch must be in released (up) position before 1. Remove all load and allow engine to operate at low
starter will operate. If starter operates with footswitch in speed for 3-5 minutes; this allows further reduction of
the depressed position, DO NOT OPERATE MACHINE. internal engine temperature.
2. Push POWER/EMERGENCY STOP switch in.
3. Turn MASTER switch to Off.
Refer to Engine Manufacturer’s manual for detailed informa-
tion.
3121204 – JLG Lift – 4-3

MAIN BOOM LEVEL AND FULLY EXTENDED
UPRIGHT
MACHINE WILL TIP OVER IN THIS

DIRECTION IF OVERLOADED OR
OPERATED ON AN OUT-OF-LEVEL
SURFACE
13 DEGREES FROM VERTICAL

TOWER BOOM
FULLY ELEVATED
AND FULLY RETRACTED
Figure 4-1. Position of Least Forward Stability
4-4 – JLG Lift – 3121204

4.4 TRAVELING (DRIVING)
DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A

SMOOTH, FIRM AND LEVEL SURFACE.
TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE

MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL
NUMBER PLATE.
BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED

TRAVELING.
DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.
USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL

TIMES WHEN THE PLATFORM IS ELEVATED.
BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REAR

DRIVE AXLE. IF BOOM IS OVER FRONT WHEELS, STEER AND DRIVE
CONTROLS WILL BE REVERSED.
Figure 4-2. Position of Least Backward Stability
3121204 – JLG Lift – 4-5

Traveling Forward and Reverse 4.5 STEERING

Position thumb switch on Drive/Steer controller to RIGHT for
1. At Platform Controls, pull out Emergency Stop switch
steering right, or to LEFT for steering left.
and activate footswitch.
2. Position Drive controller to FORWARD or REVERSE as 4.6 PLATFORM
desired.
This machine is equipped with a Drive Orientation Indicator. Platform Level Adjustment
The yellow light on the platform control console indicates
that the boom is swung beyond the rear drive tires and the To Level Up or Down - Position the Platform/Level control
machine may Drive/Steer in the opposite direction from the switch Up or Down and hold until the platform is level.
movement of the controls. If the indicator is illuminated,
operate the Drive function in the following manner:
1. Match the black and white direction arrows on both plat- ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR
form control panel and the chassis to determine the SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD
direction the machine will travel. CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO
COULD RESULT IN DEATH OR SERIOUS INJURY.
2. Push and release the Drive Orientation Override switch.
Within 3 seconds, slowly move the Drive control toward
the arrow matching the intended direction of machine
Platform Rotation
travel. The indicator light will flash during the 3 second
interval until the drive function is selected. To rotate the platform to the left or right, use the Platform
Rotate control switch to select the direction and hold until
desired position is reached.
4-6 – JLG Lift – 3121204

Figure 4-3. Grade and Sideslope
3121204 – JLG Lift – 4-7

4.7 BOOM Swinging the Boom

To swing boom, use SWING control switch to select RIGHT
or LEFT direction.
DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE
IS OUT OF LEVEL.
DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR
CHASSIS. THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIP-
MENT.
TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN
DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM. NOTE: When boom functions are being operated there an inter-
lock prevents the use of DRIVE and STEER functions.
TROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE-
MENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN
RELEASED.
IF THE PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR

LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE
EMERGENCY STOP SWITCH TO STOP THE MACHINE.
4-8 – JLG Lift – 3121204

Raising and Lowering the Tower Boom

TO AVOID TILTING MACHINE IF TOWER BOOM SWITCHING MALFUNC-
This machine will have two controls for the tower boom (two
TIONS:
toggle switches), one controls tower lift, the other tower tele-
scope. The switching system will sequence its LIFT and
— LOWER PLATFORM TO GROUND USING MAIN BOOM LIFT AND TELE-
TELESCOPE functions as follows:
SCOPE FUNCTIONS.
1. Sequence while RAISING the TOWER BOOM from the
fully lowered position. — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECH-
NICIAN BEFORE CONTINUING USE OF MACHINE.
a. The TOWER BOOM must be fully elevated “up”
(approximately 13 degrees from vertical) before the
TOWER BOOM can be extended from the fully
retracted position.
b. The TOWER TELESCOPE “out” or “in” will only be
operable when the TOWER BOOM is fully elevated
“up”.
2. Sequence while LOWERING the TOWER BOOM from
the fully elevated “up” position.
a. Operate TOWER TELESCOPE “in” until TOWER
BOOM is fully retracted. (TOWER must not lift
“down until boom is telescoped ”in” or “up” fully.
b. The TOWER lift “down” will only operate when the
TOWER BOOM is fully retracted.
3121204 – JLG Lift – 4-9

Raising and Lowering the Main Boom 4.8 SHUT DOWN AND PARK
1. Drive machine to a protected area.
To raise and lower Main Boom, position MAIN LIFT control
switch or controller to UP OR DOWN and hold until desired 2. Assure main boom is fully retracted and lowered over
height is reached. rear (Drive) axle; all access panels and doors closed
and secured.
Telescoping the Main Boom
3. Remove all load and allow engine to operate 3-5 min-
utes at LOW setting to permit reduction of engine inter-
To extend or retract Main Boom, position MAIN TELESCOPE
nal temperatures.
control switch to IN or OUT and hold until platform reaches
desired position. 4. At Ground Controls, turn KEY SELECT switch to (center)
OFF. Position, POWER/EMERGENCY STOP switch
(down) to OFF. Remove key.
5. Cover Platform Control console to protect instruction
placards, warning decals and operating controls from
hostile environment.
4-10 – JLG Lift – 3121204

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

3121204 – JLG Lift – 4-11
Figure 4-5. Boom Upright Positioning - Sheet 2 of 2

4-12 – JLG Lift – 3121204
4.9 OSCILLATING AXLE LOCKOUT TEST (IF 4.11 TOWING (IF EQUIPPED)
EQUIPPED)
RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING
LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT
A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL-
OPERATION IS SUSPECTED. LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.
Refer to Section 6.5, Oscillating Axle Lockout Test (If MAXIMUM TOWING SPEED 10 M.P.H. (16 K.M.H.)
Equipped) for procedure.
MAXIMUM TOWING GRADE 25%.
4.10 STEER/TOW SELECTOR (IF EQUIPPED)
Prior to towing the machine, complete the following:
(See Figure 4-6.)
DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS

ENGAGED.
DO NOT ATTEMPT TO TOW MACHINE UNLESS EQUIPPED WITH COM-
PLETE TOW PACKAGE FROM MANUFACTURER.
1. Retract, lower and position boom over rear drive wheels
in line with direction of travel; lock turntable.
A push-pull type selector valve located adjacent to the steer
cylinder and linkage regulates oil flow in the steer circuit for 2. Connect tow bar to front of frame with attach pins, and
steering and towing. When steering the unit the valve knob is tow bar to towing vehicle.
pushed IN. When towing the unit the valve knob is pulled
OUT to the float position.
3121204 – JLG Lift – 4-13

STEER SELECT
VALVE
Figure 4-6. Towbar Connecting Points - Prior to S/N 81836
4-14 – JLG Lift – 3121204

STEER SELECT
VALVE
Figure 4-7. Towbar Connecting Points - S/N 81836 to Present
3121204 – JLG Lift – 4-15

3. Disconnect drive hubs by inverting disconnect cap.

4. Actuate steer/tow selector valve for towing; pull valve
knob OUT to float position. (This opens the steer circuit
to reservoir, allowing the steer cylinder rod free travel.)
The machine is now in the towing mode.
After towing the machine, complete the following:
1. Actuate steer/tow selector valve for steering; push valve
knob IN to the actuated position.
2. Reconnect drive hubs by inverting disconnect cap.
3. Disconnect tow bar from steering hitch and from towing
vehicle. The machine is now in the driving mode.
Figure 4-8. Drive Disconnect Hub
4-16 – JLG Lift – 3121204

4.12 AUXILIARY POWER - NON ADE EQUIPPED 5. Position AUXILIARY POWER switch to ON and hold.
MACHINES 6. Release AUXILIARY POWER switch, selected control

switch, lever or controller, and footswitch.
7. Position POWER/EMERGENCY STOP switch to OFF.
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE
THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN Activating from the Ground Control Station
OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.)
1. Position PLATFORM/GROUND SELECT KEY SWITCH to
A toggle type auxiliary power control switch is located on the GROUND.
platform control station and another is located on the ground 2. Position POWER/EMERGENCY STOP switch to ON.
control station. Operation of either switch turns on the electri-
cally driven auxiliary hydraulic pump. This should be used in 3. Operate appropriate control switch or controller for
case of failure of the main power plant. The auxiliary pump desired function and hold.
will operate boom lift, telescope and swing. To activate auxil-
4. Position AUXILIARY POWER switch to ON and hold.
iary power:
5. Release AUXILIARY POWER switch, and appropriate
Activating from the Platform Control Station control switch or controller.
6. Position POWER/EMERGENCY STOP switch to OFF.
1. Position PLATFORM/GROUND SELECT KEY SWITCH to
PLATFORM.
2. Position POWER/EMERGENCY STOP switch to ON.
3. Depress and hold footswitch.
4. Operate appropriate control switch, lever or controller
for desired function and hold.
3121204 – JLG Lift – 4-17

4.13 AUXILIARY POWER - ADE EQUIPPED 5. Operate appropriate control switch, lever or controller
for desired function and hold.
MACHINES
6. Release AUXILIARY POWER switch, selected control
switch, lever or controller, and footswitch.
WHEN OPERATING ON AUXILIARY POWER, DO NOT OPERATE MORE 7. Position POWER/EMERGENCY STOP switch to OFF.
THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN
OVERLOAD THE 12-VOLT AUXILIARY PUMP MOTOR.) Activating from the Ground Control Station
A toggle type auxiliary power control switch is located on the 1. Position PLATFORM/GROUND SELECT KEY SWITCH to
platform control station and another is located on the ground GROUND.
control station. Operation of either switch turns on the electri- 2. Position POWER/EMERGENCY STOP switch to ON.
cally driven auxiliary hydraulic pump. This should be used in
case of failure of the main power plant. The auxiliary pump 3. Position AUXILIARY POWER switch to ON and hold.
will operate boom lift, telescope and swing. To activate auxil-
4. Operate appropriate control switch or controller for
iary power:
desired function and hold.
Activating from the Platform Control Station 5. Release AUXILIARY POWER switch, and appropriate
control switch or controller.
1. Position PLATFORM/GROUND SELECT KEY SWITCH to 6. Position POWER/EMERGENCY STOP switch to OFF.
PLATFORM.
2. Position POWER/EMERGENCY STOP switch to ON.
3. Depress and hold footswitch.
4. Position AUXILIARY POWER switch to ON and hold.
4-18 – JLG Lift – 3121204

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) Changing From LP Gas to Gasoline
The dual fuel system enables the standard gasoline engine
1. With engine operating on LP under a no-load condition,
to run on either gasoline or LP gas.
position FUEL SELECT switch at Platform Control Sta-
tion to GASOLINE position.
2. Close hand valve on LP gas supply tank by turning
IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER
clockwise.
WITHOUT ALLOWING THE ENGINE TO STOP. EXTREME CARE MUST BE
TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.
4.15 RE-SYNCHRONIZE THE LOWER LIFT
Changing From Gasoline to LP Gas CYLINDER
1. Start engine from Ground Control Station. Level Override Valve

2. Open hand valve on LP gas supply tank by turning A pull type control valve allows the operator to adjust the
counterclockwise. tower lift cylinder and the upright cylinder if the upright cylin-
3. While engine is operating on GASOLINE under a no- der is not fully retracted when boom is in the stowed posi-
load condition, place FUEL SELECT switch at Platform tion. This valve is located in the engine compartment area.
Control to LP position. To Operate:
1. Pull the red knob
2. Using the ground control raise the lower boom 6 feet.
3. Release the knob.
4. Fully lower the boom.
5. Repeat if necessary.
3121204 – JLG Lift – 4-19

4.16 TIE DOWN AND LIFTING NOTE: Lifting eyes are provided at the front and rear in the frame
slab. Each of the four chains or slings used for lifting
machine must be adjusted individually so machine
When transporting machine, boom must be in the stowed
remains level when elevated.
mode with turntable lock pin engaged and machine securely
tied down to truck or trailer deck. Four tie down eyes are pro-
vided in the frame slab, one at each corner of the machine.
(See Figure 4-9. Machine Tie Down.)
SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING
If it becomes necessary to lift the machine using an over- LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER.
head or mobile crane, it is very important that the lifting
devices are attached only to the designated lifting eyes, and
that the turntable lock pin is engaged. (See Figure 4-10. Lift-
ing Chart.)
4-20 – JLG Lift – 3121204

NOTE: When transporting machine over rough terrain or

long distance the boom needs to be chocked and
strapped whenever the base boom is unable to rest on
its pad. This prevents the boom from "Bouncing"
up and down preventing possible damage while transporting.
Figure 4-9. Machine Tie Down
3121204 – JLG Lift – 4-21

Figure 4-10. Lifting Chart
4-22 – JLG Lift – 3121204

Aus 22
68
26 36 28 27
36
64 44
10 33
11 22
61
7
16
17 10
49 35 39 11
48
43 6
62 21 34
Figure 4-11. 600A & 600AJ Decal Installation - Sheet 1 of 4
3121204 – JLG Lift – 4-23

4-24 – JLG Lift – 3121204

13
63
12
66
12 3
4
66
12
47
22 67
12
51
55 52
12 58 54
55
24 58
29
5
37 53 25
43 37
42 39
3121204 – JLG Lift – 4-25

4-26 – JLG Lift – 3121204

Table 4-1. 600A Decal Legend - Prior to S/N 0300140401
Canadian
Item # ANSI CE Spanish Portuguese Japanese Australian
French
0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 1001114388-1
0273893-9
1 -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- --
4 -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 -- -- -- -- -- -- --
8 -- -- -- -- -- -- --
9 -- -- -- -- -- -- --
10 1703811 1703811 1703811 1703811 1703811 1703811 1703811
11 1703814 1703814 1703814 1703814 1703814 1703814 1703814
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1704412 1704412 1704412 1704412 1704412 1704412 1704412
14 -- -- -- -- -- -- 1705084
15 -- 1705514 1705514 -- -- -- 1705514
16 -- -- -- -- -- -- --
3121204 – JLG Lift – 4-27

Canadian
French
0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 1001114388-1
0273893-9
17 3251243 3251243 -- 3251243 -- 3251243 --
18 -- -- -- -- -- -- --
19 -- -- -- -- -- -- --
20 -- -- -- -- -- -- --
21 -- 1704006 -- 1704007 1705901 --
22 1703953 1703942 -- 1703941 1705903 1703944 --
23 -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- --
25 1703797 1703924 1705921 1703923 1705895 1703926 1705921
26 1705336 1705347 1705822 1705917 1705896 1705344 1705822
27 1703804 1703948 1701518 1703947 1705898 1703950 1701518
28 1703805 1703936 1705961 1703935 1705897 1703938 1705961
29 1703984 1705828 1703983 1705902 1703980 1705828
30 3251813 3251813 -- 3251813 3251813 3251813 --
31 -- -- -- -- -- -- --
32 -- -- -- -- -- -- --
33 1703469 1703469 1703469 1703469 1703469 1703469 1703469
34 1702631 1702631 -- 1702631 1702631 1702631 1702631
4-28 – JLG Lift – 3121204

Canadian
French
0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 1001114388-1
0273893-9
35 1702818 1702818 1702818 1702818 1702818 1702818 1702818
36 1707014 1707046 1705978 1707048 1707051 1707053 1705978
37 1704096 1704099 1705978 1704098 1706380 1704102 1705978
38 -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1706948 1706948 -- 1706948 1706948 1706948 --
41 -- -- -- -- -- -- --
42 -- -- -- -- -- -- --
43 -- -- -- -- -- -- --
44 -- -- -- -- -- -- --
45 -- -- -- -- -- -- --
46 -- -- -- -- -- -- --
47 -- -- -- -- -- -- --
48 -- -- -- -- -- -- --
49 -- -- -- -- -- -- --
50 -- -- -- -- -- -- --
51 -- -- -- -- -- -- --
52 -- -- -- -- -- -- --
3121204 – JLG Lift – 4-29

Canadian
French
0273891-9 0273895-5 0273899-9 0273901-9 0273903-10 1001114388-1
0273893-9
53 -- -- -- -- -- -- --
54 -- -- -- -- -- -- --
55 -- -- -- -- -- -- --
56 -- -- -- -- -- -- --
57 -- -- -- -- -- -- --
58 -- -- -- -- -- -- --
59 -- -- -- -- -- -- --
60 -- -- -- -- -- -- --
61 -- -- -- -- -- -- --
62 1700584 1700584 1700584 1702573 1700584 1700584 1700584
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 --
64 1706941 1706941 -- 1706941 1706941 1706941 --
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1705977
67 1705351 1705429 -- 1705910 1705905 1705426 --
68 -- -- -- -- -- -- 1001112551
4-30 – JLG Lift – 3121204

Table 4-2. 600A Decal Legend - S/N 0300140401 to Present
Canadian Chinese Chinese

French Simplified Traditional
0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001114388-1
0273893-9 1001116840-3 1001116841-3
1 -- -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 -- -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- -- --
10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
14 -- -- -- -- -- -- 1705084 1705084 1705084
15 -- 1705514 1705514 -- -- -- 1705514 1705514 1705514
16 -- -- -- -- -- -- -- -- --
3121204 – JLG Lift – 4-31


0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001114388-1
0273893-9 1001116840-3 1001116841-3
17 3251243 3251243 -- 3251243 -- 3251243 -- -- --
18 -- -- -- -- -- -- -- -- --
19 -- -- -- -- -- -- -- -- 1001117034
20 -- -- -- -- -- -- -- -- 1001117035
21 -- 1704006 -- 1704007 1705901 -- -- --
22 1703953 1703942 -- 1703941 1705903 1703944 -- 1001116845 1703943
23 -- -- -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- -- 1706968 1001116846
25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 1001116847 1703925
26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 1001116848 1001116849
27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 1001116850 1703949
28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851
29 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982
30 3251813 3251813 -- 3251813 3251813 3251813 -- 3251813 3251813
31 -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- --
33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469
34 1702631 1702631 -- 1702631 1702631 1702631 1702631 1702631 1702631
4-32 – JLG Lift – 3121204


0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001114388-1
0273893-9 1001116840-3 1001116841-3
35 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818 1702818
36 1001121813 1001121815 1705978 1001121817 1001121819 1001121820 1705978 1001121824 1001121822
37 1001121800 1001121802 1705978 1001121804 1001121806 1001121807 1705978 1001121811 1001121809
38 -- -- -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1706948 1706948 -- 1706948 1706948 1706948 -- -- --
41 -- -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- --
3121204 – JLG Lift – 4-33


0273891-10 0273895-6 0273899-10 0273901-9 0273903-11 1001114388-1
0273893-9 1001116840-3 1001116841-3
53 -- -- -- -- -- -- -- -- --
54 -- -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- -- --
61 -- -- -- -- -- -- -- -- --
62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 -- 1001108493 1001108493
64 1706941 1706941 -- 1706941 1706941 1706941 -- 1706941 1706941
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862
67 1705351 1705429 -- 1705910 1705905 1705426 -- 1705430 1001116863
68 -- -- -- -- -- -- 1001112551 -- --
4-34 – JLG Lift – 3121204

Table 4-3. 600AJ Decal Legend - Prior to S/N 0300140401
Canadian
French
0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9
1 -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- --
4 -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 -- -- -- -- -- -- --
8 -- -- -- -- -- -- --
9 -- -- -- -- -- -- --
10 1703811 1703811 1703811 1703811 1703811 1703811 1703811
11 1703814 1703814 1703814 1703814 1703814 1703814 1703814
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1704412 1704412 1704412 1704412 1704412 1704412 1704412
14 -- -- -- -- -- -- 1705084
15 -- -- -- -- -- -- 1705514
16 -- -- -- -- -- -- --
17 3251243 3251243 3251243 3251243 -- 3251243 --
3121204 – JLG Lift – 4-35

Canadian
French
0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9
18 -- -- -- -- -- -- --
19 -- -- -- -- -- -- --
20 -- -- -- -- -- -- --
21 -- 1704006 -- 1704007 1705901 -- --
22 1703953 1703942 -- 1703941 1705903 1703944 --
23 -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- --
25 1703797 1703924 1705921 1703923 1705895 1703926 1705921
26 1705336 1705347 1705822 1705917 1705896 1705344 1705822
27 1703804 1703948 1701518 1703947 1705898 1703950 1701518
28 1703805 1703936 1705961 1703935 1705897 1703938 1705961
29 -- 1703984 1705828 1703983 1705902 1703980 1705828
30 3251813 3251813 -- 3251813 3251813 3251813 --
31 -- -- -- -- -- -- --
32 -- -- -- -- -- -- --
33 1703469 1703469 1703469 1703469 1703469 1703469 1703469
34 1702631 1702631 1702631 1702631 1702631 1702631 1702631
35 1702819 1702819 1702819 1702819 1702819 1702819 1702819
4-36 – JLG Lift – 3121204

Canadian
French
0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9
36 1707013 1707046 1705978 1707049 1707052 1707054 1705978
37 1701645 1703996 1705978 1707056 1707057 1707059 1705978
38 -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1706948 1706948 -- 1706948 1706948 1706948 --
41 -- -- -- -- -- -- --
42 -- -- -- -- -- -- --
43 -- -- -- -- -- -- --
44 -- -- -- -- -- -- --
45 -- -- -- -- -- -- --
46 -- -- -- -- -- -- --
47 -- -- -- -- -- -- --
48 -- -- -- -- -- -- --
49 -- -- -- -- -- -- --
50 -- -- -- -- -- -- --
51 -- -- -- -- -- -- --
52 -- -- -- -- -- -- --
53 -- -- -- -- -- -- --
3121204 – JLG Lift – 4-37

Canadian
French
0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9
54 -- -- -- -- -- -- --
55 -- -- -- -- -- -- --
56 -- -- -- -- -- -- --
57 -- -- -- -- -- -- --
58 -- -- -- -- -- -- --
59 -- -- -- -- -- -- --
60 -- -- -- -- -- -- --
61 -- -- -- -- -- -- --
62 1700584 1700584 1700584 1702573 1700584 1700584 1700584
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 --
64 1706941 1706941 -- 1706941 1706941 1706941 --
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1705977
67 1705351 1705429 -- 1705910 1705905 1705426 --
68 -- -- -- -- -- -- 1001112551
4-38 – JLG Lift – 3121204

Table 4-4. 600AJ Decal Legend - S/N 0300140401 to Present

0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9 1001116842-3 1001116843-3
1 -- -- -- -- -- -- -- -- --
2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499
3 -- -- -- -- -- -- -- -- --
4 -- -- -- -- -- -- -- -- --
5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509
6 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529
7 -- -- -- -- -- -- -- -- --
8 -- -- -- -- -- -- -- -- --
9 -- -- -- -- -- -- -- -- --
10 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811
11 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814
12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277
13 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412
14 -- -- -- -- -- -- 1705084 1705084 1705084
15 -- -- -- -- -- -- 1705514 1705514 1705514
16 -- -- -- -- -- -- -- -- --
17 3251243 3251243 3251243 3251243 -- 3251243 -- -- --
3121204 – JLG Lift – 4-39


0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9 1001116842-3 1001116843-3
18 -- -- -- -- -- -- -- -- --
19 -- -- -- -- -- -- -- -- 1001117034
20 -- -- -- -- -- -- -- -- 1001117035
21 -- 1704006 -- 1704007 1705901 -- -- -- --
22 1703953 1703942 -- 1703941 1705903 1703944 -- 1001116845 1703943
23 -- -- -- -- -- -- -- -- --
24 1702868 1704000 -- 1704001 1705967 -- -- 1706968 1001116846
25 1703797 1703924 1705921 1703923 1705895 1703926 1705921 1001116847 1703925
26 1705336 1705347 1705822 1705917 1705896 1705344 1705822 1001116848 1001116849
27 1703804 1703948 1701518 1703947 1705898 1703950 1701518 1001116850 1703949
28 1703805 1703936 1705961 1703935 1705897 1703938 1705961 1703937 1001116851
29 -- 1703984 1705828 1703983 1705902 1703980 1705828 1001116852 1703982
30 3251813 3251813 -- 3251813 3251813 3251813 -- 3251813 3251813
31 -- -- -- -- -- -- -- -- --
32 -- -- -- -- -- -- -- -- --
33 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469 1703469
34 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631
35 1702819 1702819 1702819 1702819 1702819 1702819 1702819 1702818 1702818
4-40 – JLG Lift – 3121204


0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9 1001116842-3 1001116843-3
36 1001121814 1001121816 1705978 1001121818 1001121655 1001121821 1705978 1001121825 1001121823
37 1001121801 1001121803 1705978 1001121805 1001121656 1001121808 1705978 1001121812 1001121810
38 -- -- -- -- -- -- -- -- --
39 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885
40 1706948 1706948 -- 1706948 1706948 1706948 -- -- --
41 -- -- -- -- -- -- -- -- --
42 -- -- -- -- -- -- -- -- --
43 -- -- -- -- -- -- -- -- --
44 -- -- -- -- -- -- -- -- --
45 -- -- -- -- -- -- -- -- --
46 -- -- -- -- -- -- -- -- --
47 -- -- -- -- -- -- -- -- --
48 -- -- -- -- -- -- -- -- --
49 -- -- -- -- -- -- -- -- --
50 -- -- -- -- -- -- -- -- --
51 -- -- -- -- -- -- -- -- --
52 -- -- -- -- -- -- -- -- --
53 -- -- -- -- -- -- -- -- --
3121204 – JLG Lift – 4-41


0273892-10 0273896-5 0273900-10 0273902-9 0273904-11 1001114389-1
0273894-9 1001116842-3 1001116843-3
54 -- -- -- -- -- -- -- -- --
55 -- -- -- -- -- -- -- -- --
56 -- -- -- -- -- -- -- -- --
57 -- -- -- -- -- -- -- -- --
58 -- -- -- -- -- -- -- -- --
59 -- -- -- -- -- -- -- -- --
60 -- -- -- -- -- -- -- -- --
61 -- -- -- -- -- -- -- -- --
62 1700584 1700584 1700584 1702573 1700584 1700584 1700584 1700584 1700584
63 1001108493 1001108493 -- 1001108493 1001108493 1001108493 -- 1001108493 1001108493
64 1706941 1706941 -- 1706941 1706941 1706941 -- 1706941 1706941
65 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687 1703687
66 1702265 1703990 1705977 1702617 1703544 1702271 1705977 1001116861 1001116862
67 1705351 1705429 -- 1705910 1705905 1705426 -- 1705430 1001116863
68 -- -- -- -- -- -- 1001112551 -- --
4-42 – JLG Lift – 3121204

SECTION 5 - EMERGENCY PROCEDURES
SECTION 5. EMERGENCY PROCEDURES

5.1 GENERAL Failure to notify the manufacturer of an incident involving a
JLG Industries product within 48 hours of such an occur-
This section explains the steps to be taken in case of an rence may void any warranty consideration on that particular
emergency situation while operating. machine.
5.2 INCIDENT NOTIFICATION
JLG Industries, Inc. must be notified immediately of any inci- FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE
dent involving a JLG product. Even if no injury or property AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS,
damage is evident, the factory should be contacted by tele- THEN FROM THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 10 FT. (3
phone and provided with all necessary details. M) UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IF
In USA: REQUIRED, AND THAT ALL CONTROLS ARE OPERATING CORRECTLY.
JLG Phone: 877-JLG-SAFE (554-7233)
(8am till 4:45pm EST) 5.3 EMERGENCY OPERATION
Outside USA: Operator Unable to Control Machine
240-420-2661
IF THE PLATFORM OPERATOR IS PINNED, TRAPPED OR
UNABLE TO OPERATE OR CONTROL MACHINE:
E-mail:
1. Other personnel should operate the machine from
[email protected]
ground controls only as required.
2. Other qualified personnel on the platform may use the
platform controls. DO NOT CONTINUE OPERATION IF
CONTROLS DO NOT FUNCTION PROPERLY.
3121204 – JLG Lift – 5-1

SECTION 5 - EMERGENCY PROCEDURES
3. Cranes, forklift trucks or other equipment can be used to 2. To retract the lower boom, turn knob #1, #2 and #4
remove platform occupants and stabilize motion of the clockwise until tight. Turn knob #3 counterclockwise 3
machine. turns. Locate a knurled head screw, attached to a wire
cable on the right side of the main valve bank assembly.
Platform or Boom Caught Overhead Thread this into the end of the coil assembly that it is
attached to. Pump the hand pump until the lower boom
If the platform or boom becomes jammed or snagged in
is completely lowered. When this operation is complete,
overhead structures or equipment, rescue platform occu-
remove the knurled head screw from the end of the
pants prior to freeing the machine.
valve coil. (THE KNURLED HEAD SCREW “MUST” BE
5.4 EMERGENCY TOWING PROCEDURES REMOVED FROM THE END OF THE VALVE BEFORE
NORMAL OPERATION OF THE MACHINE CAN
Towing this machine is prohibited, unless properly equipped. RESUME.)
However, provisions for moving the machine have been
incorporated. For specific procedures, refer to Section 4. When this operation has been completed, turn #1, #2,
and #4 counterclockwise 3 turns. Turn #3 clockwise
5.5 MANUAL DESCENT (MACHINES PRIOR TO S/N until tight.
70975)
3. To lower the upper boom: (THE LOWER BOOM MUST
The manual descent valves are used, in the event of total BE COMPLETELY LOWERED BEFORE STARTING THIS
power failure, to retract and lower the boom using gravity. OPERATION IN ORDER TO MAINTAIN STABILITY OF
The manual descent valves are located on the right side of THE MACHINE.) Turn knob #1 and #2 clockwise until
the turntable (in tank compartment). Look for the instruction tight. Pump the hand pump until tight. When this opera-
decal located on the right side of turntable below control tion has been completed, turn #1 and #2 counterclock-
valve. The procedure is as follows: wise 3 turns.
1. To retract the lower boom telescope function: turn knob 4. When the manual descent operation has been com-
#1 and knob #4 clockwise until tight. Pump the hand pleted, knob #1, #2, and #4 should be open (counter-
pump until tight. When this operation has been com- clockwise) 3 turns. Knob #3 should be closed
pleted, turn #1 and #4 counterclockwise 3 turns. (clockwise).
5-2 – JLG Lift – 3121204

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE
SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION Other Publications Available:
Service and Maintenance Manual - ANSI Spec
This section of the manual provides additional necessary
(Prior to s/n 0300080000) ...................................... 3120718
information to the operator for proper operation and mainte-
nance of this machine. Service and Maintenance Manual (Euro Spec)
(Prior to s/n 0300080000) ...................................... 3120841
The maintenance portion of this section is intended as infor-
mation to assist the machine operator to perform daily main- Service and Maintenance Manual - Global Spec
tenance tasks only, and does not replace the more thorough (s/n 0300080000 to Present).................................. 3121201
Preventive Maintenance and Inspection Schedule included
in the Service and Maintenance Manual. Illustrated Parts Manual - ANSI Spec
(Prior to s/n 0300068000) ...................................... 3120719
Illustrated Parts Manual - Euro Spec
(Prior to s/n 0300068000) ...................................... 3120841
Illustrated Parts Manual - ANSI Spec
(s/n 0300068000 to s/n 0300087000) .................... 3121177
Illustrated Parts Manual - Euro Spec
(s/n 0300068000 to s/n 0300087000) .................... 3121855
Illustrated Parts Manual - Global Spec
(s/n 0300087000 to Present).................................. 3121206
3121204 – JLG Lift – 6-1

6.2 OPERATING SPECIFICATIONS Table 6-1. Operating Specifications - Prior to S/N 0300140401
Ground Bearing Pressure
Table 6-1. Operating Specifications - Prior to S/N 0300140401
600A 77 psi (5.4 kg/cm2)
Maximum Work Load (Capacity) 600AJ 75 psi (5.3 kg/cm2)
Unrestricted: 500 lb (230 kg) 600A - narrow chassis 94 psi (6.6 kg/cm2)
Restricted: 1000 lb (450 kg)
600AJ - narrow chassis 94 psi (6.6 kg/cm2)
Maximum Travel Grade (Gradeability)
Maximum Drive Speed - A Models
2WD 30%
2WD 3.6 MPH (5.80 Km/hr.)
4WD 45%
4WD 4 MPH (6.44 Km/hr.)
Maximum Travel Grade (Side Slope) 5°
Gross Machine Weight (Approximate)
Turning Radius - (outside) 600A 21,500 lbs. (9,752 kg)
2WS 17 ft. 8 in. (5.38 m) 600AJ 22,200 lbs. (10,025 kg)
4WS 11 ft. 8 in. (3.56 m) 600A - narrow chassis 23,900 lbs. (10,841 kg)
Turning Radius - (outside) narrow chassis 600AJ - narrow chassis 24,000 lbs. (10,886 kg)
2WS 16 ft. 6 in. (5.03 m)
4WS 11 ft. 2 in. (3.4 m)
Turning Radius - (inside)
2WS 11 ft. 5 in. (3.48 m)
4WS 5 ft. 6 in. (1.68 m)
Turning Radius - (inside) narrow chassis
2WS 12 ft. 2 in. (3.71 m)
4WS 5 ft. 7 in. (1.7 m)
Maximum Tire Load: 11,500 lbs. (5227 kg)
6-2 – JLG Lift – 3121204

Table 6-2. Operating Specifications - S/N 0300140401 to Table 6-2. Operating Specifications - S/N 0300140401 to
Present Present
Maximum Work Load (Capacity) - ANSI Maximum Tire Load: 11,500 lbs. (5216 kg)
Unrestricted: 500 lb (227 kg) Ground Bearing Pressure
Restricted: 1000 lb (454 kg) 600A 77 psi (5.4 kg/cm2)
Maximum Work Load (Capacity) - CE & 600AJ 75 psi (5.3 kg/cm2)
Australia 600A - narrow chassis 94 psi (6.6 kg/cm2)
Unrestricted: 500 lb (230 kg)
600AJ - narrow chassis 94 psi (6.6 kg/cm2)
Restricted: 1000 lb (450 kg)
Maximum Drive Speed - A Models
Maximum Travel Grade (Gradeability)
2WD 3.6 MPH (5.80 Km/hr.)
2WD 30%
4WD 4 MPH (6.44 Km/hr.)
4WD 45%
Gross Machine Weight (Approximate)
Maximum Travel Grade (Side Slope) 5°
600A 21,500 lbs. (9,752 kg)
Turning Radius - (outside) 600AJ 22,200 lbs. (10,025 kg)
2WS 17 ft. 8 in. (5.38 m) 600A - narrow chassis 23,900 lbs. (10,841 kg)
4WS 11 ft. 8 in. (3.56 m) 600AJ - narrow chassis 24,000 lbs. (10,886 kg)
Turning Radius - (outside) narrow chassis
2WS 16 ft. 6 in. (5.03 m)
4WS 11 ft. 2 in. (3.4 m)
Turning Radius - (inside)
2WS 11 ft. 5 in. (3.48 m)
4WS 5 ft. 6 in. (1.68 m)
Turning Radius - (inside) narrow chassis
2WS 12 ft. 2 in. (3.71 m)
4WS 5 ft. 7 in. (1.7 m)
3121204 – JLG Lift – 6-3

Capacities Engine Data

Table 6-3. Capacities Table 6-4. Continental TMD27 Specifications
Fuel Tank 30 U.S. Gallons (113.6 L) Fuel Diesel
Hydraulic Oil Tank 30.6 Gallons (115.8 L) with 10% air Oil Capacity
space w/Filter 7.00 Quarts (6.65 l)
w/o Filter 6.00 Quarts (5.7 l)
Hydraulic System (Including Tank) 36.72 Gallons (139 L)
Low RPM 1800
Torque Hub, Drive* 17 ounces (0.50 L)
High RPM 2800
Engine Crankcase
Ford LRG-425 Gas w/Filter 4.5 quarts (4.25L) Alternator 63 Amps, Belt Drive
Ford LRG-423 Gas w/Filter 5.0 quarts (4.73 L)
Battery 85 Amphour, 550 Cold Cranking
Deutz F4M1011F Diesel w/Filter 11 quarts (10.5 L)
Amps, 12 VDC
Deutz F4M2011F Diesel w/Filter 11 quarts (10.5 L)
Deutz D2011L04 11 quarts (10.5 L) Fuel Consumption
Continental TMD27 Diesel w/Filter 7.0 quarts (6.65 L) Low RPM 1.80 GPH (6.81 lph)
Caterpillar 3044C Diesel w/Filter 10.6 quarts (10 L) High RPM 2.30 GPH (8.71 lph)
GM 4.5 qts. (4.25 L) w/Filter
Horsepower 66.5 @ 3000 RPM
Cooling System 16 Quarts (15.14 L.)
Coolant 3.8 Gallons (3.6 l)
*Torque hubs should be one half full of lubricant.
6-4 – JLG Lift – 3121204

Table 6-5. Ford LRG-423 Specifications Table 6-6. Ford LRG-425 Specifications
Fuel Gasoline Fuel Gasoline
Crankcase Capacity Crankcase Capacity 4.5 Quarts (4.25 L) w/Filter

w/Filter 5.00 Quarts (4.73 L)
w/o Filter 4.00 Quarts (3.79 L) Idle RPM 1000
Idle RPM 1000 Low RPM 1800
Low RPM 1800 High RPM 2800
High RPM 2800 Alternator 40 Amp, Belt Drive
Alternator 40 Amp, Belt Drive Battery 85 Amphour, 550 Cold Cranking

Amps, 12 VDC
Battery 85 Amphour, 550 Cold Cranking
Amps, 12 VDC Fuel Consumption
Low RPM 3.45 GPH (13.06 lph)
Fuel Consumption High RPM 4.60 GPH (17.41 lph)
Low RPM 3.45 GPH (13.06 lph)
High RPM 4.60 GPH (17.41 lph) Horsepower 54 @ 2400 RPM, full load
Horsepower 54 @ 2400 RPM, full load Cooling System 16 Quarts (15.14 L.)
Cooling System 16 Quarts (15.14 L.) Spark Plug AWSF-52-C
Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm)
Spark Plug Gap 0.044 in. (1.117 mm)
3121204 – JLG Lift – 6-5

Table 6-7. Deutz F4M1011F/F4M2011 Specifications Table 6-8. Deutz D2011L04 Specifications
Fuel Diesel Fuel Diesel

Oil Capacity Oil Capacity
Cooling System 5 Quarts (4.5 L) Cooling System 5 Quarts (4.5 L)
Crankcase w/Filter 11 Quarts (10.5 L) Crankcase 11 Quarts (10.5 L) w/Filter
Total Capacity 16 Quarts (15 L) Total Capacity 16 Quarts (15 L)
Idle RPM 1000 Idle RPM 1000
Low RPM 1800 Low RPM 1800
High RPM 2800 High RPM 2500
Alternator 60 Amp, belt drive Alternator 60 Amp, belt drive
Battery 950 Cold Cranking Amps, 205 Battery 950 Cold Cranking Amps, 205
Minutes Reserve Capacity, 12 VDC Minutes Reserve Capacity, 12 VDC
Fuel Consumption Fuel Consumption
Low RPM 1.90 GPH (7.19 lph) Low RPM 1.90 GPH (7.19 lph)
High RPM 2.50 GPH (9.46 lph) High RPM 2.50 GPH (9.46 lph)
Horsepower 65 Horsepower 49
6-6 – JLG Lift – 3121204

Table 6-9. Caterpillar 3044C / 3.4 Table 6-10. GM 3.0L
Type Four Stroke Cycle Fuel Gasoline or Gasoline/LP Gas

Cylinders 4 in-line No. of Cylinders 4
Bore 3.70 inch (94 mm) BHP
Stroke 4.72 inch (120 mm) Gasoline 83 hp @ 3000 rpm
LP 75 hp @ 3000 rpm
Aspiration turbocharged
Bore 4.0 in. (101.6 mm)
Compression ratio 19:1
Stroke 3.6 in. (91.44 mm)
Displacement 203 in3 (3.33 L)
Displacement 181 cu.in. (3.0 L, 2966 cc)
Firing Order 1-3-4-2
Oil Capacity w/filter 4.5 qts. (4.25 L)
Rotation (viewed from flywheel) Counterclockwise
Minimum Oil Pressure
Oil Capacity (w/filter) 10.6 quarts (10 L) at idle 6 psi (0.4 Bar) @ 1000 rpm
Cooling System (Engine Only) 5.8 quarts (5.5 L) Hot 18 psi (1.2 Bar) @ 2000 rpm
Idle RPM - 3044C 1000 Compression Ratio 9.2:1
Idle RPM - 3.4 1200 Firing Order 1-3-4-2
Low RPM 1800 Max. RPM 2800
High RPM 2600
Alternator 60 Amp, belt drive
Battery 930 Cold Cranking Amps, 205
Minutes Reserve Capacity, 12 VDC
3121204 – JLG Lift – 6-7

Tires Dimensional Data

Table 6-11. Tire Specifications Table 6-12. Dimensional Data
Size 14 x 17.5 14 x 17.5 14 x 17.5 Machine Height (Stowed) 8 ft. 3.75 in. (2.53 m)
Load Range G G *
Machine Length (Stowed)
Ply Rating 14 14 N/A 600A Over Drive Axle 26 ft. 5 in. (8.05 m)
Tire Pressure 90 PSI (6 Bar) Foam-Filled Air-Boss 600AJ Over Drive Axle 28 ft. 11.4375 in. (8.82 m)
* Load Capacity - 11,800 lb. (5353 kg) - Static
Machine Width
Standard 8 ft. (2.44 m)
Size IN355/55D 625 IN355/55D 625 Narrow Chassis 7 ft. (2.13 m)
Load Range* G G Wheelbase 8 ft. 0 in. (2.44 m)
Ply Rating 14 14
Boom Elevation - 600A +60 ft. 5 3/8 in. (18.42 m)
Tire Pressure 100 PSI (7 Bar) Foam-Filled -11 in. (0.28 m)
Boom Elevation - 600AJ +60 ft. 6 3/4 in. (18.46 m)
-2 ft. 8 13/16 in. (0.83 m)
Size 18-625
Load Range* H
Ply Rating 16
Tire Pressure 90 PSI (6 Bar)
6-8 – JLG Lift – 3121204

Torque Requirements Hydraulic Oil

Table 6-13. Torque Requirements
Table 6-14. Hydraulic Oil Specifications
Interval HYDRAULIC SYSTEM OPERATING SAE VISCOSITY
Description Torque Value (Dry)
Hours TEMPERATURE RANGE GRADE
Bearing To Chassis See Note 50/600* +0° to +180° F (-18° C to +83° C) 10W
+0° F to +210° F (-18° C to +99° C) 10W-20, 10W-30
Bearing To Turntable See Note 50/600*
+50° F to +210° F (+10° C to +210° C) 20W-20
Wire Rope 15 ft. lbs (20 Nm) 150
NOTE: Hydraulic oils must have anti-wear qualities at least to API
Wheel Lugs See Section 6.4 150
Service Classification GL-3, and sufficient chemical stabil-
Engine Mounting Bolts 165 ft. lbs. (231 Nm) A/R ity for mobile hydraulic system service. JLG Industries
recommends Mobilfluid 424 hydraulic oil, which has an
Engine Manifold Mounting Bolts 30 ft. lbs. (42 Nm) A/R SAE viscosity index of 152.
*Check swing bearing bolts for security after first 50 hours of operation and NOTE: When temperatures remain below 20° F (-7° C), JLG
every 600 hours thereafter. (See Swing Bearing in Section 3.) Industries recommends the use of Mobil DTE 13M.
3121204 – JLG Lift – 6-9

Aside from JLG recommendations, it is not advisable to mix

oils of different brands or types, as they may not contain the Table 6-16. Mobil DTE 13M Specs
same required additives or be of comparable viscosities. If
ISO Viscosity Grade #32
use of hydraulic oil other than Mobilfluid 424 is desired, con-
tact JLG Industries for proper recommendations. Specific Gravity 0.877
Table 6-15. Mobilfluid 424 Specs Pour Point, Max -40°F (-40°C)
Flash Point, Min. 330°F (166°C)
SAE Grade 10W30
Viscosity
Gravity, API 29.0 at 40° C 33cSt
Density, Lb/Gal. 60°F 7.35 at 100° C 6.6 cSt
Pour Point, Max -46°F (-43°C) at 100° F 169 SUS
Flash Point, Min. 442°F (228°C) at 210° F 48 SUS
Viscosity cp at -20° F 6,200
Brookfield, cP at -18°C 2700 Viscosity Index 140
at 40° C 55 cSt
at 100° C 9.3 cSt
Viscosity Index 152
6-10 – JLG Lift – 3121204

Table 6-17. Exxon Univis HVI 26 Specs Table 6-18. Quintolubric 888-46
Specific Gravity 32.1 Density 0.91 @ 15°C (59°F)

Pour Point -76°F (-60°C) Pour Point <-20°C (<-4°F)
Flash Point 217°F (103°C) Flash Point 275°C (527°F)
Viscosity Fire Point 325°C (617°F)
at 40° C 25.8 cSt Autoignition Temperature 450°C (842°F)
at 100° C 9.3 cSt Viscosity
Viscosity Index 376 at 0° C (32°F) 360 cSt
NOTE: Mobil/Exxon recommends that this oil be checked at 20° C (68°F) 102 cSt
on a yearly basis for viscosity.
at 40° C (104°F) 46 cSt
at 100° C (212°F) 10 cSt
Viscosity Index 220
3121204 – JLG Lift – 6-11

Critical Stability Weights Serial Number Locations

A serial number plate is affixed to the left rear side of the
frame. If the serial number plate is damaged or missing, the
DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF- machine serial number is stamped on the left side of the
FERENT WEIGHT OR SPECIFICATION (FOR EXAMPLE: BATTERIES, frame.
FILLED TIRES, COUNTERWEIGHT, ENGINE & PLATFORM) DO NOT MOD-
IFY UNIT IN ANY WAY TO AFFECT STABILITY.
Table 6-19. Critical Stability Weights
600AJ 600A
LB. KG. LB. KG.
Tire and Wheel (Ballasted Only) Size (14-17.5) 165 75 165 75
Engine Ford 460 209 460 209
Deutz 534 242 534 242

Figure 6-1. Serial Number Locations
Continental 558 253 558 253
Counterweight Weight 6200 2812 5700 2586
Platform 6 ft. (1.83 M) 205 93 205 93
8 ft. (2.44 M) 230 105 230 105
6-12 – JLG Lift – 3121204

This page left blank intentionally.
3121204 – JLG Lift – 6-13

AMBIENT AIR
TEMPERATURE
120°F(49°C)
NO OPERATION ABOVE THIS
AMBIENT TEMPERATURE 110°F(43°C)
100°F(38°C)
90°F(32°C)
80°F(27°C)
SUMMER
GRADE 70°F(21°C)
ENGINE FUEL
60°F(16°C)
SPECIFICATIONS 50°F(10°C)
40°F(4°C)
30°F(-1°C)
WINTER 20°F(-7°C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FUEL 10°F(-12°C)
FULLY CHARGED BATTERY.
0°F(-18°C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER
GRADE -10°F(-23°C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER FUEL
-20°F(-29°C)
WITH
PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
ADDED
-40°F(-40°C)
NO OPERATION BELOW THIS
AMBIENT TEMPERATURE
Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2
6-14 – JLG Lift – 3121204

EXTENDED DRIVING WITH

HYDRAULIC OIL TANK
TEMPERATURES OF 180° F
(82°C) OR ABOVE.
180° F (82° C)
(HYD. OIL TANK TEMP.)
IF EITHER OR BOTH CONDITIONS
AMBIENT AIR EXIST JLG HIGHLY RECOMMENDS
TEMPERATURE THE ADDITION OF A HYDRAULIC
OIL COOLER (CONSULT JLG SERVICE
120° F (49° C) PROLONGED OPERATION IN

NO OPERATION ABOVE THIS NOTE:
110° F (43° C) AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES
OF 100°F(38°C) OR ABOVE. 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
100° F (38° C) CONSISTANTLY WITHIN SHOWN LIMITS
MOBIL 424 10W-30

90° F (32° C)
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
80° F (27° C)
EXXON UNIVIS HVI 26

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

40° F (4° C) F C
30° F (-1° C) +32 0
20° F (-7° C)
+23 -5
10° F (-12° C)
0° F (-18° C) DO NOT START UP HYDRAULIC SYSTEM
+14 -10
AMBIENT TEMPERATURE
WITHOUT HEATING AIDS WITH MOBILE 424
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) +5 -15
DO NOT START UP HYDRAULIC SYSTEM
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE -4 -20
-40° F (-40° C)
AMBIENT TEMPERATURE -13 -25
-22 -30
0 10 20 30 40 50 60
% OF ADDED KEROSENE 4150548-E
Figure 6-3. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2
3121204 – JLG Lift – 6-15

AMBIENT AIR
TEMPERATURE
120 F(49 C)
AMBIENT TEMPERATURE 110 F(43 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)
-10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
Figure 6-4. Engine Operating Temperature Specifications - Ford - Sheet 1 of 2
6-16 – JLG Lift – 3121204


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

OF 100° F (38° C) OR ABOVE.
100° F (38° C)
90° F (32° C) MOBIL 424 10W-30
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C)
HYDRAULIC
MOBIL DTE 13
SPECIFICATIONS
40° F (4° C) NOTE:
30° F (-1° C)
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
20° F (-7° C) CONSISTANTLY WITHIN SHOWN LIMITS
10° F (-12° C) C) 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
0° F (-18° C)
-10° F (-23° C) C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C) C)
-30° F (-34° C) C) WITHOUT HEATING AIDS AND COLD WEATHER
HYDRAULIC OIL BELOW THIS TEMPERATURE
-40° F (-40° C) C)
AMBIENT TEMPERATURE
4150548-E
Figure 6-5. Engine Operating Temperature Specifications - Ford - Sheet 2 of 2
3121204 – JLG Lift – 6-17

AMBIENT AIR
TEMPERATURE
120 F(49 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
30 F(-1 C)
20 F(-7 C)
ENGINE WILL START AND OPERATE UNAIDED AT THIS
TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10 F(-12 C)
FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C)
WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY
AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C)
PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND
HYDRAULIC OIL TANK HEATER) -30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
Figure 6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2
6-18 – JLG Lift – 3121204


HYDRAULIC OIL TANK
(82°C) OR ABOVE.
180° F (82° C)
EXIST JLG HIGHLY RECOMMENDS
AMBIENT AIR THE ADDITION OF A HYDRAULIC
TEMPERATURE OIL COOLER (CONSULT JLG SERVICE

OF 100° F (38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
70° F (21° C)
EXXON UNIVIS HVI 26

60° F (16° C)
HYDRAULIC
MOBIL DTE 13
50° F (10° C)
SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE
-20° F (-29° C)
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER
-40° F (-40° C) NOTE:
1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
AMBIENT TEMPERATURE
CONSISTENTLY WITHIN SHOWN LIMITS
2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
4150548-E
Figure 6-7. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2
3121204 – JLG Lift – 6-19

AMBIENT AIR
TEMPERATURE
120 F(49 C)
100 F(38 C)
90 F(32 C)
80 F(27 C)
70 F(21 C)
ENGINE 60 F(16 C)
SPECIFICATIONS
50 F(10 C)
40 F(4 C)
ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 30 F(-1 C)
NOTE: THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG.
20 F(-7 C)
ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 F(-12 C)
WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY.
0 F(-18 C)
ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, -10 F(-23 C)
A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C)
(IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
-30 F(-34 C)
-40 F(-40 C)
AMBIENT TEMPERATURE
Figure 6-8. Engine Operating Temperature Specifications - GM - Sheet 1 of 2
6-20 – JLG Lift – 3121204


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

OF 100° F(38° C) OR ABOVE.
100° F (38° C)
MOBIL 424 10W-30
90° F (32° C)
80° F (27° C)
EXXON UNIVIS HVI 26

70° F (21° C)
60° F (16° C)
50° F (10° C) HYDRAULIC
MOBIL DTE 13
SPECIFICATIONS
40° F (4° C)
30° F (-1° C)
20° F (-7° C)
10° F (-12° C)
0° F (-18° C)
-10° F (-23° C) HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE:
-20° F (-29° C)
DO NOT START UP HYDRAULIC SYSTEM 1) RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES
-30° F (-34° C) WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS
-40° F (-40° C)
NO OPERATION BELOW THIS 2) ALL VALUES ARE ASSUMED TO BE AT SEA LEVEL.
AMBIENT TEMPERATURE
4150548-E
Figure 6-9. Engine Operating Temperature Specifications - GM - Sheet 2 of 2
3121204 – JLG Lift – 6-21

Figure 6-10. Lubrication and Maintenance Point Location
6-22 – JLG Lift – 3121204

6.3 OPERATOR MAINTENANCE 1. Swing Bearing
NOTE: The following numbers correspond to those in Figure 6-

10., Lubrication and Maintenance Point Location.
Table 6-20. Lubrication Specifications
KEY SPECIFICATIONS
MPG Multipurpose Grease having a minimum dripping point of 350° F
(177° C). Excellent water resistance and adhesive qualities, and
being of extreme pressure type.
(Timken OK 40 pounds minimum.)
EPGL Extreme Pressure Gear Lube (oil) meeting API service classifica-
tion GL-5 or MIL-Spec MIL-L-2105
HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424. Lube Point(s) - 2 Grease Fittings
Capacity - A/R
EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Lube - MPG
Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C. Interval - Every 3 months or 150 hrs of operation
Comments - Remote Access
LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION

UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT
OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON-
DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD-
INGLY.
3121204 – JLG Lift – 6-23

2. Wheel Bearings 3. Swing Drive Hub
Lube Point(s) - Repack Lube Point(s) - Level/Fill Plug

Capacity - A/R Capacity - 17 oz. (1/2 Full)
Lube - MPG Lube - EPGL
Interval - Every 2 years or 1200 hours of operation Interval - Check level every 3 months or 150 hrs of oper-
ation; change every 2 years or 1200 hours of operation
6-24 – JLG Lift – 3121204

4. Wheel Drive Hub 5. Hydraulic Return Filter
Lube Point(s) - Level/Fill Plug Interval - Change after first 50 hrs. and every 6 months
Capacity - 17 oz. (1/2 Full) or 300 hrs. thereafter or as indicated by Condition Indi-
Lube - EPGL cator.
Interval - Check level every 3 months or 150 hrs of oper-
ation; change every 2 years or 1200 hours of operation
3121204 – JLG Lift – 6-25

6. Hydraulic Charge Filter 7. Hydraulic Tank
NORMAL OPERATING
RANGE WITH BOOM
IN STOWED POSITION
Interval - Change after first 50 hrs. and every 6 months Lube Point(s) - Fill Cap
or 300 hrs. thereafter or as indicated by Condition Indi- Capacity - 31 gal. (117.3 L) Tank; 37.2 gal. (140.8 L)
cator. System
Lube - HO
Interval - Check Level daily; Change every 2 years or
1200 hours of operation.
6-26 – JLG Lift – 3121204

8. Suction Strainers (in tank) 9. Oil Change w/Filter - Ford LRG423

Lube Point(s) - Fill Cap/Spin-on Element
REMOVE FILL CAP PLATE FROM
Capacity - 5 Quarts
TANK TO GAIN ACCESS TO
Lube - EO
STRAINERS
Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance
with engine manual.
10. Oil Change w/Filter - Ford LRG425
Lube Point(s) - 2
Interval - Every 2 years or 1200 hours of operation,
remove and clean at time of hydraulic oil change.
Capacity - 4.5 Quarts
Lube - EO
Comments - Check level daily/Change in accordance
with engine manual.
3121204 – JLG Lift – 6-27

11. Oil Change w/Filter - Continental 13. Oil Change w/Filter - Caterpillar
Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element
Capacity - 6 Quarts Capacity - 10.6 Quarts
Lube - EO Lube - EO
Interval - 3 Months or 150 hours of operation Interval - 3 Months or 150 hours of operation
Comments - Check level daily/Change in accordance Comments - Check level daily/Change in accordance
with engine manual. with engine manual.
12. Oil Change w/Filter - Deutz

Capacity - 11 Quarts Crankcase; 5 Quarts Cooler
Lube - EO
Interval - Every Year or 1200 hours of operation
Comments - Check oil level, fill oil to max marking on the
dipstick. Check level daily/Change in accordance with
engine manual.
6-28 – JLG Lift – 3121204

14. Oil Change w/Filter - GM 15. Fuel Filter - Ford
Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element

(JLG P/N 7027965) Interval - Every Year or 1200 hours of operation
Capacity - 4.5 qt. (4.25 L) w/filter
Lube - EO 16. Fuel Filter - Continental
Interval - 3 Months or 150 hours of operation Lube Point(s) - Replaceable Element
Comments - Check level daily/Change in accordance Interval - Every Year or 600 hours of operation
with engine manual.
3121204 – JLG Lift – 6-29

17. Fuel Filter - Deutz 18. Fuel Filter - Caterpillar
Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element

Interval - Every Year or 600 hours of operation Interval - Every Year or 600 hours of operation
19. Fuel Filter (Gasoline) - GM
Lube Point(s) - Replaceable Element
Interval - Every 6 months or 300 hours of operation
6-30 – JLG Lift – 3121204

20. Air Filter 21. Electronic Pressure Regulator (LP only)

Lube Point(s) - Replaceable Element Comments - Drain oil build up. Refer to Section 6.6,
Interval - Every 6 months or 300 hours of operation or as DRAINING OIL BUILD UP FROM THE PROPANE REG-
indicated by the condition indicator ULATOR (Prior to S/N 0300132529)
3121204 – JLG Lift – 6-31

22. Fuel Filter (Propane) - GM Engine

Comments - Replace filter. Refer to Section 6.7, Propane
Fuel Filter Replacement
6-32 – JLG Lift – 3121204

6.4 TIRES & WHEELS • any damage to the bead area cords of the tire
If a tire is damaged but is within the above noted criteria, the tire
Tire Inflation must be inspected on a daily basis to insure the damage has
The air pressure for pneumatic tires must be equal to the air not propagated beyond the allowable criteria.
pressure that is stenciled on the side of the JLG product or
rim decal for safe and proper operational characteristics. Tire Replacement
JLG recommends a replacement tire be the same size, ply and
Tire Damage brand as originally installed on the machine. Please refer to the
For pneumatic tires, JLG Industries, Inc. recommends that when JLG Parts Manual for the part number of the approved tires for a
any cut, rip, or tear is discovered that exposes sidewall or tread particular machine model. If not using a JLG approved replace-
area cords in the tire, measures must be taken to remove the ment tire, we recommend that replacement tires have the follow-
JLG product from service immediately. Arrangements must be ing characteristics:
made for replacement of the tire or tire assembly. • Equal or greater ply/load rating and size of original
For polyurethane foam filled tires, JLG Industries, Inc. recom- • Tire tread contact width equal or greater than original
mends that when any of the following are discovered, measures
• Wheel diameter, width, and offset dimensions equal to
must be taken to remove the JLG product from service immedi-
the original
ately and arrangements must be made for replacement of the
tire or tire assembly. • Approved for the application by the tire manufacturer
(including inflation pressure and maximum tire load)
• a smooth, even cut through the cord plies which
exceeds 3 inches (7.5 cm) in total length Unless specifically approved by JLG Industries Inc. do not
replace a foam filled or ballast filled tire assembly with a pneu-
• any tears or rips (ragged edges) in the cord plies
matic tire. When selecting and installing a replacement tire,
which exceeds 1 inch (2.5 cm) in any direction
ensure that all tires are inflated to the pressure recommended
• any punctures which exceed 1 inch in diameter
3121204 – JLG Lift – 6-33

by JLG. Due to size variations between tire brands, both tires Wheel Installation
on the same axle should be the same.
It is extremely important to apply and maintain proper wheel
Wheel Replacement mounting torque.
The rims installed on each product model have been designed

for stability requirements which consist of track width, tire pres-
WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER
sure, and load capacity. Size changes such as rim width, center
TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI-
piece location, larger or smaller diameter, etc., without written
BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SURE
factory recommendations, may result in an unsafe condition
TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE
regarding stability.
WHEEL.
Tighten the lug nuts to the proper torque to prevent wheels from
coming loose. Use a torque wrench to tighten the fasteners. If
you do not have a torque wrench, tighten the fasteners with a
lug wrench, then immediately have a service garage or dealer
tighten the lug nuts to the proper torque. Over-tightening will
result in breaking the studs or permanently deforming the
mounting stud holes in the wheels. The proper procedure for
attaching wheels is as follows:
1. Start all nuts by hand to prevent cross threading. DO
NOT use a lubricant on threads or nuts.
6-34 – JLG Lift – 3121204

2. Tighten nuts in the following sequence:
1 8
8 LUG PATTERN
3 6 9 LUG PATTERN
5 4
7 2
9
3. The tightening of the nuts should be done in stages. Fol-

lowing the recommended sequence, tighten nuts per
wheel torque chart.
3121204 – JLG Lift – 6-35

Table 6-21. Wheel Torque Chart 6.5 OSCILLATING AXLE LOCKOUT TEST (IF
TORQUE SEQUENCE EQUIPPED)
1st Stage 2nd Stage 3rd Stage
40 ft. lbs. 95 ft. lbs. 170 ft. lbs.
(55 Nm) (130 Nm) (230 Nm) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME
A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM
4. Wheel nuts should be torqued before first road use and OPERATION IS SUSPECTED.
after each wheel removal. Check and torque every 3
months or 150 hours of operation. NOTE: Ensure boom is fully retracted, lowered, and centered
between drive wheels prior to beginning lockout cylinder
test.
1. Place a 6 inches (15.2 cm) high block with ascension

ramp in front of left front wheel.
2. From platform control station, start engine
3. Place the Drive control lever to the forward position and
carefully drive machine up ascension ramp until left front
wheel is on top of block.
6-36 – JLG Lift – 3121204

4. Carefully activate Swing control lever and position boom 10. With boom over left side of machine, place Drive control
over right side of machine. lever to Reverse and drive machine off of block and
ramp.
5. With boom over right side of machine, place Drive con-
trol lever to Reverse and drive machine off of block and 11. Have an assistant check to see that right front wheel
ramp. remains locked in position off of ground.
6. Have an assistant check to see that left front wheel 12. Carefully activate Swing control lever and return boom
remains locked in position off of ground. to stowed position (centered between drive wheels).
When boom reaches center, stowed position, lockout
7. Carefully activate Swing control lever and return boom
cylinders should release and allow wheel to rest on
to stowed position (centered between drive wheels).
ground, it may be necessary activate Drive to release
When boom reaches center, stowed position, lockout
cylinders.
cylinders should release and allow wheel to rest on
ground, it may be necessary to activate Drive to release 13. If lockout cylinders do not function properly, have quali-
cylinders. fied personnel correct the malfunction prior to any fur-
ther operation.
8. Place the 6 inches (15.2 cm) high block with ascension
ramp in front of right front wheel.
9. Place Drive control lever to Forward and carefully drive
machine up ascension ramp until right front wheel is on
top of block.
3121204 – JLG Lift – 6-37

6.6 DRAINING OIL BUILD UP FROM THE 4. Push in the Emergency Switch once the engine stops.
PROPANE REGULATOR (PRIOR TO S/N 5. Disconnect the electrical connection to the LPG fuel
temperature sensor in the auxiliary fuel port of the EPR.
0300132529)
During the course of normal operation oils may build inside
the primary and secondary chambers of the propane pres-
sure regulator. These oils may be a result of poor fuel quality,
contamination of the fuel supply chain, or regional variation
in the make up of the fuel. If the build up of the oil is signifi-
cant this can effect the operation of the fuel control system.
Refer to Section 6.3, Operator Maintenance for maintenance
intervals. More frequent draining may be required if the fuel
supply has been contaminated.
FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERA-

TURE BEFORE DRAINING. THIS WILL ALLOW THE OILS TO FLOW
FREELY FROM THE REGULATOR.
1. Move the equipment to a well ventilated area. Ensure

there are no external ignition sources.
2. Start the engine and bring to operating temperature.
3. With the engine running, close the manual tank valve
and run the engine out of fuel.
6-38 – JLG Lift – 3121204

6. Remove the retainer clip for the LPG fuel temperature 6.7 PROPANE FUEL FILTER REPLACEMENT
sensor and remove the sensor from the regulator body.
Removal
1. Relieve the propane fuel system pressure. Refer to Pro-
pane Fuel System Pressure Relief.
2. Disconnect the negative battery cable.
3. Slowly loosen the Filter housing and remove it.
4. Pull the filter housing from the Electric lock off assembly.
5. Remove the filter from the housing.
6. Locate Filter magnet and remove it.
7. Remove and discard the housing seal.
NOTE: Have a small container ready to collect oil that will drain 8. If equipped, remove and discard the retaining bolt seal.
freely from the regulator at this point.
9. Remove and discard mounting plate to lock off O-ring
seal.
7. Once all of the oil has been drained, reinstall the LPG
fuel temperature sensor and reconnect the electrical
connector.
8. Open the fuel tank manual valve.
9. Start the engine and verify all connections are secure.
10. Dispose of any drained oil per local regulations in a safe
and proper fashion.
3121204 – JLG Lift – 6-39

1 7 1 7
8 8
2 13
9 9
3 3
10 10
4 OR 4
5 5
11
6
11
12
1. Electric Lock Off Solenoid 6. Seal 10. Filter

2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet
3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt
4. Filter Magnet 9. O-ring 13. Ring
5. Filter Housing
Figure 6-11. Filter Lock Assembly
6-40 – JLG Lift – 3121204

Installation 6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF
BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312
BEFORE INSTALLING NEW SEAL PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL
INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE
1. Install the mounting plate to lock off O-ring seal. APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COM-
PONENTS.
2. If equipped, install the retaining bolt seal.
3. Install the housing seal. To relieve propane fuel system pressure:
4. Drop the magnet into the bottom of the filter housing. 1. Close the manual shut-off valve on the propane fuel
tank.
5. Install the filter into the housing.
2. Start and run the vehicle until the engine stalls.
6. If equipped, install the retaining bolt into the filter hous-
ing. 3. Turn the ignition switch OFF.
7. Install the filter up to the bottom of the electric lock off.
8. Tighten the filter bowl retainer to 106 in lbs (12 Nm).
RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS-
9. Open manual shut-off valve. Start the vehicle and leak TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS-
check the propane fuel system at each serviced fitting. CONNECTING ANY FUEL LINE.
Refer to Propane Fuel System Leak Test.
3121204 – JLG Lift – 6-41

6.9 SUPPLEMENTAL INFORMATION

The following information is provided in accordance with the
requirements of the European Machinery Directive 2006/42/
EC and is only applicable to CE machines.
For electric powered machines, the equivalent continuous A-
Weighted sound pressure level at the work platform is less
than 70dB(A)
For combustion engine powered machines, guaranteed
Sound Power Level (LWA) per European Directive 2000/14/
EC (Noise Emission in the Environment by Equipment for
Use Outdoors) based on test methods in accordance with
Annex III, Part B, Method 1 and 0 of the directive, is 104 dB.
The vibration total value to which the hand-arm system is
subjected does not exceed 2,5 m/s2. The highest root mean
square value of weighted acceleration to which the whole
body is subjected does not exceed 0,5 m/s2.
6-42 – JLG Lift – 3121204

SECTION 7 - INSPECTION AND REPAIR LOG
SECTION 7. INSPECTION AND REPAIR LOG

Machine Serial Number _______________________________________
Table 7-1. Inspection and Repair Log
Date Comments
3121204 – JLG Lift – 7-1

SECTION 7 - INSPECTION AND REPAIR LOG
Table 7-1. Inspection and Repair Log
Date Comments
7-2 – JLG Lift – 3121204

TRANSFER OF OWNERSHIP
An Oshkosh Corporation Company
To Product Owner:
If you now own but ARE NOT the original purchaser of the product covered by this
manual, we would like to know who you are. For the purpose of receiving safety-related
bulletins, it is very important to keep JLG Industries, Inc. updated with the current
ownership of all JLG products. JLG maintains owner information for each JLG product
and uses this information in cases where owner notification is necessary.
Please use this form to provide JLG with updated information with regard to the
current ownership of JLG products. Please return completed form to the JLG Product
Safety & Reliability Department via facsimile or mail to address as specified below.
Thank You,
Product Safety & Reliability Department
JLG Industries, Inc.
13224 Fountainhead Plaza
Hagerstown, MD 21742
USA
Telephone: +1-717-485-6591
Fax: +1-301-745-3713
NOTE: Leased or rented units should not be included on this form.
Mfg. Model: _______________________________________________________________
Serial Number: ____________________________________________________________
Previous Owner: ___________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Date of Transfer: _________________________________
Current Owner: ____________________________________________________________
Address: _________________________________________________________________
_________________________________________________________________________
Country: _________________________ Telephone: (_______) ____________________
Who in your organization should we notify?
Name: ___________________________________________________________________
Title:____________________________________________________________________
Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161
(717) 485-6417
3121204
JLG Worldwide Locations

JLG Industries (Australia) JLG Latino Americana Ltda. JLG Industries (UK) Ltd JLG France SAS
P.O. Box 5119 Rua Eng. Carlos Stevenson, Bentley House Z.I. de Baulieu
11 Bolwarra Road 80-Suite 71 Bentley Avenue 47400 Fauillet
Port Macquarie 13092-310 Campinas-SP Middleton France
N.S.W. 2444 Brazil Greater Manchester +33 (0)5 53 88 31 70
Australia +55 19 3295 0407 M24 2GP - England
+33 (0)5 53 88 31 79
+61 2 65 811111 +55 19 3295 1025 +44 (0)161 654 1000
+61 2 65813058 +44 (0)161 654 1001
JLG Deutschland GmbH JLG Equipment Services Ltd. JLG Industries (Italia) s.r.l. Oshkosh-JLG Singapore Technology
Max-Planck-Str. 21 Rm 1107 Landmark North Via Po. 22 Equipment Pte Ltd
D - 27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue 20010 Pregnana Milanese - MI 29 Tuas Ave 4,
Germany Sheung Shui N. T. Italy Jurong Industrial Estate
+49 (0)421 69 350 20 Hong Kong +39 029 359 5210 Singapore, 639379
+49 (0)421 69 350 45 (852) 2639 5783 +39 029 359 5845 +65-6591 9030
(852) 2639 5797 +65-6591 9031
Plataformas Elevadoras JLG Sverige AB

JLG Iberica, S.L. Enkopingsvagen 150
Trapadella, 2 Box 704
P.I. Castellbisbal Sur SE - 176 27 Jarfalla
08755 Castellbisbal, Barcelona Sweden
Spain +46 (0)850 659 500
+34 93 772 4700 +46 (0)850 659 534
+34 93 771 1762
www.jlg.com

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Operation and Safety Manual

Boom Lift Models

A Machine that incorporates

3121204 – JLG Lift – a

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

b – JLG Lift – 3121204

3121204 – JLG Lift – c

Original Issue - April 1, 2005

d – JLG Lift – 3121204

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

SECTION - 1 - SAFETY PRECAUTIONS 2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . 2-5

3121204 – JLG Lift – i

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

ii – JLG Lift – 3121204

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

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-23 LIST OF FIGURES

3121204 – JLG Lift – iii

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

iv – JLG Lift – 3121204

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

LIST OF TABLES 6-15 Mobilfluid 424 Specs. . . . . . . . . . . . . . . . . . . . . . . 6-10

3121204 – JLG Lift – v

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

This page left blank intentionally.

vi – JLG Lift – 3121204

SECTION 1. SAFETY PRECAUTIONS

3121204 – JLG Lift – 1-1

• Read, understand, and obey all DANGERS, WARNINGS, Machine Inspection

1-2 – JLG Lift – 3121204

3121204 – JLG Lift – 1-3

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

1-4 – JLG Lift – 3121204

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

Voltage Range MINIMUM APPROACH DISTANCE

3121204 – JLG Lift – 1-5

• The minimum approach distance may be reduced if insulat- Tipping Hazards

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED

1-6 – JLG Lift – 3121204

3121204 – JLG Lift – 1-7

1-8 – JLG Lift – 3121204

3121204 – JLG Lift – 1-9

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28

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

Beaufort Wind Speed

1-10 – JLG Lift – 3121204

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121204 – JLG Lift – 2-1

2.2 PREPARATION, INSPECTION, AND

2-2 – JLG Lift – 3121204

Table 2-1.Inspection and Maintenance Table

3121204 – JLG Lift – 2-3

Pre-Start Inspection (Domestic only) is enclosed in the weather resistant

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE

2-4 – JLG Lift – 3121204

Function Check a. Drive the machine on a grade, not to exceed the

3121204 – JLG Lift – 2-5

6. Place TOWER TELESCOPE to ‘in’ position and fully

2-6 – JLG Lift – 3121204