JLG 600A Gebrauchs- und Pflegehandbuch

ANSI

Operation and Safety Manual

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

Boom Lift Models

600A

600AJ

3121204

August 1, 2016

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.

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.

FOREWORD

3121204 – JLG Lift – a

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.

FOREWORD

b– JLG Lift – 3121204

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A

YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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

FOREWORD

3121204 – JLG Lift – c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR

WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-

ERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

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

Outside USA:

Phone: 240-420-2661

Fax: 301-745-3713

E-mail: Pr[email protected]

For:

• Accident Reporting

• Product Safety Publica-

tions

• Current Owner Updates

• Questions Regarding

Product Safety

• Standards and Regulations

Compliance Information

• Questions Regarding Spe-

cial Product Applications

• Questions Regarding Prod-

uct Modifications

FOREWORD

d– JLG Lift – 3121204

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

Revised - August 1, 2016

TABLE OF CONTENTS

3121204 – JLG Lift – i

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

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPA-

RATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE.

2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

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

2.3 LIMIT SWITCH FUNCTIONAL CHECK . . . . . . . . . . 2-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Controls . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Ground Control Indicator Panel . . . . . . . . . . . . . 3-6

Platform Control . . . . . . . . . . . . . . . . . . . . . . . . 3-10

Platform Control Indicator Panel . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATING CHARACTERISTICS

AND LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

TABLE OF CONTENTS

ii – JLG Lift – 3121204

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

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-6

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

Raising and Lowering the Tower Boom . . . . . . 4-9

Raising and Lowering the Main Boom . . . . . . 4-10

Telescoping the Main Boom . . . . . . . . . . . . . . 4-10

4.8 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-10

4.9 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

4.10 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . 4-13

4.11 TOWING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . 4-13

4.12 AUXILIARY POWER - NON ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

Activating from the Platform Control Station . . 4-17

Activating from the Ground Control Station . . 4-17

4.13 AUXILIARY POWER - ADE EQUIPPED

MACHINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Activating from the Platform Control Station . . 4-18

Activating from the Ground Control Station . . 4-18

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-19

Changing From Gasoline to LP Gas . . . . . . . . 4-19

Changing From LP Gas to Gasoline . . . . . . . . 4-19

4.15 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER4-19

Level Override Valve . . . . . . . . . . . . . . . . . . . . . 4-19

4.16 TIE DOWN AND LIFTING . . . . . . . . . . . . . . . . . . . .4-20

4.17 SKYGUARD OPERATION. . . . . . . . . . . . . . . . . . . .4-21

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-1

Operator Unable to Control Machine . . . . . . . . . 5-1

Platform or Boom Caught Overhead . . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-2

5.5 MANUAL DESCENT (MACHINES PRIOR TO

S/N 70975) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . 6-8

Torque Requirements. . . . . . . . . . . . . . . . . . . . . 6-9

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9

TABLE OF CONTENTS

3121204 – JLG Lift – iii

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

Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-12

Serial Number Locations . . . . . . . . . . . . . . . . . 6-12

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-23

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-33

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-33

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-34

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.5 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-36

6.6 DRAINING OIL BUILD UP FROM THE PROPANE REG-

ULATOR (PRIOR TO S/N 0300132529) . . . . . . . .6-38

6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-39

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-41

6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-42

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Machine Nomenclature - 600AJ . . . . . . . . . . . . . . 2-10

2-2. Machine Nomenclature - 600A . . . . . . . . . . . . . . . 2-11

2-3. Daily Walk-Around Inspection Diagram . . . . . . . . 2-12

2-4. Daily Walk-Around Inspection Points -

Sheet 1 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

2-5. Daily Walk-Around Inspection Points -

Sheet 2 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

2-6. Daily Walk-Around Inspection Points -

Sheet 3 of 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-3

3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . . 3-7

3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . . 3-8

3-4. Malfunction Indicator Light and Test Button . . . . . 3-9

3-5. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-11

3-6. Platform Control Console - w/Drive Orientation . . 3-12

3-7. Platform Control Indicator Panel . . . . . . . . . . . . . 3-17

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

TABLE OF CONTENTS

iv – JLG Lift – 3121204

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

4-7. Towbar Connecting Points - S/N 81836

to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-8. Drive Disconnect Hub . . . . . . . . . . . . . . . . . . . . . . 4-16

4-9. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4-10. 600A & 600AJ Decal Installation - Sheet 1 of 4. . . 4-23

4-11. 600A & 600AJ Decal Installation - Sheet 2 of 4. . . 4-24

4-12. 600A & 600AJ Decal Installation - Sheet 3 of 4. . . 4-25

4-13. 600A & 600AJ Decal Installation - Sheet 4 of 4. . . 4-26

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

6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-40

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