JLG 600AJ Use and care manual

ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
AS/NZS
Model
600AJ
PVC 2001
31215030
September 24, 2019 - Rev A
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WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
California to cause cancer and birth defects or other
reproductive harm. To minimize exposure, avoid breathing
exhaust, do not idle the engine except as necessary, service your
vehicle or equipment in a well-ventilated area and wear gloves
or wash your hands frequently when servicing. For more
information go to www.P65Warnings.ca.gov.
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FOREWORD
31215030 a
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var-
ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating
procedures essential for the safe and proper machine operation for its intended purpose.
Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without
prior notification. Contact JLG Industries, Inc. for updated information.
Refer to www.JLG.com for Warranty, Product Registration, and other machine-related documentation.
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FOREWORD
b31215030
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 BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-
GROUND.
INDICATES A POTENTIONALLY 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 INDI-
RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION 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
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FOREWORD
d31215030
REVISION LOG
Original Issue A - September 24, 2019
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31215030 i
TABLE OF CONTENTS
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
SkyGuard® Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3 LIMIT SWITCH FUNCTIONAL CHECK. . . . . . . . . . . . . . . . . . . 2-6
2.4 BASIC NOMENCLATURE - 600AJ . . . . . . . . . . . . . . . . . . . . . . 2-9
2.5 DAILY WALK-AROUND INSPECTION DIAGRAM . . . . . . . 2-10
Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Deutz TD2.9L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Ford DF 2.5L MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 GROUND CONTROL STATION. . . . . . . . . . . . . . . . . . . . . . . . . 3-2
600AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
600AJ with Machine Safety System Override (MSSO)
(CE Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.4 GROUND CONTROL INDICATOR PANEL . . . . . . . . . . . . . . . 3-8
3.5 PLATFORM CONTROL CONSOLE . . . . . . . . . . . . . . . . . . . . 3-12
3.6 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
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ii 31215030
TABLE OF CONTENTS
Air Shutoff Valve (ASOV) (If Equipped). . . . . . . . . . . . . . 4-5
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-6
4.4 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-9
Traveling on a Grade . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-12
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-13
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-13
4.8 RE-SYNCHRONIZE THE LOWER LIFT CYLINDER . . . . . . . 4-14
Level Override Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4.11 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-19
4.13 STEER/TOW SELECTOR (IF EQUIPPED). . . . . . . . . . . . . . . . 4-19
4.14 TOWING (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.15 AUXILIARY POWER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Activating from the Platform Control Station . . . . . . 4-23
Activating from the Ground Control Station . . . . . . . 4-23
4.16 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-24
Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-24
Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-24
4.17 TIE DOWN AND LIFTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25
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 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
SECTION - 6 - ACCESSORIES
6.1 FALL ARREST PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2 PIPE RACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacity Specifications (Australia Only) . . . . . . . . . . . . 6-4
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31215030 iii
TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 SKYCUTTER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 SKYGLAZIER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 SKYPOWER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.6 SKYWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Welding Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-12
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
6.7 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
6.8 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 6-13
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTE-
NANCE
7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Serial Number Locations . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7.3 OPERATOR MAINTENANCE AND LUBRICATION
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Deutz D2011L04. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Deutz TD 2.9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Ford DF 2.5L, MSG 425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
7.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-28
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29
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iv 31215030
TABLE OF CONTENTS
7.6 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 7-30
7.6 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 7-31
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
7.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-33
7.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-33
SECTION - 8 - INSPECTION AND REPAIR LOG
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