Oshkosh Corporation JLG E600, Operation And Safety Manual

Page 1: ...ANSI Operation and Safety Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models E600 E600J E600JP M600 M600J M600JP 3121217 September 1 2010 www duma rent com...

Page 2: ...www duma rent com...

Page 3: ...sers 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...

Page 4: ...ED 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...

Page 5: ...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 Depa...

Page 6: ...FOREWORD d JLG Lift 3121217 REVISION LOG Original Issue June 7 2005 Revised July 21 2006 Revised December 7 2009 Revised March 2 2010 Revised September 1 2010 www duma rent com...

Page 7: ...aining Supervision 2 1 Operator Responsibility 2 1 2 2 PREPARATION INSPECTION AND MAINTENANCE 2 2 Pre Start Inspection 2 4 Function Check 2 5 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 GENERAL 3 1...

Page 8: ...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...

Page 9: ...east Forward Stability 4 3 4 2 Position of Least Backward Stability 4 4 4 3 Grade and Side Slopes 4 6 4 4 Lifting and Tie Down Chart 4 11 4 5 Decal Installation Sheet 1 of 4 4 16 4 6 Decal Installatio...

Page 10: ...TABLE OF CONTENTS iv JLG Lift 3121217 SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE This page left blank intentionally www duma rent com...

Page 11: ...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...

Page 12: ...s approved for that purpose by JLG Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine This machine can be operated in temperatures of 0o...

Page 13: ...pera 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 Supplies or tools which ext...

Page 14: ...om assembly to enter or leave the plat form Use extreme caution when entering or leaving platform Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform...

Page 15: ...upants their tools and their equipment from any electrical line or apparatus carrying up to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less Table 1 1 M...

Page 16: ...distance 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 fo...

Page 17: ...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 o...

Page 18: ...king 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...

Page 19: ...welding or metal cutting operations precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter Do not refuel the machine with the engine running Battery fl...

Page 20: ...xposedskin Leavesrustle 3 8 12 3 4 5 4 Gentle breeze Leavesandsmallertwigsin constantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze...

Page 21: ...loyer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 6 The safes...

Page 22: ...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...

Page 23: ...tInspection Inservicefor3monthsor150hours whichever comesfirst or Outofserviceforaperiodofmorethan3months or Purchasedused Owner Dealer orUser QualifiedJLG Mechanic ServiceandMaintenance Manualandappl...

Page 24: ...estic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container 4 Walk Around Inspection Refer to Figure 2 4 Fig ure 2 5 and Figure 2 7 5 Battery Ch...

Page 25: ...ergency Stop Button is activated 2 From the platform control console a Ensure that the control console is firmly secured in the proper location b Check that all guards protecting the switches or locks...

Page 26: ...INSPECTION 2 6 JLG Lift 3121217 Figure 2 1 Basic Nomenclature Sheet 1 of 3 1 BatteryPack 2 FuelTank 3 Hydraulic Tank 4 MainTerminalBox 5 SwingDrive 6 TurntableLock 7 Frame 8 Turntable 9 BatteryCharge...

Page 27: ...MACHINE PREPARATION AND INSPECTION 3121217 JLG Lift 2 7 Figure 2 2 Basic Nomenclature Sheet 2 of 3 1 Frame 2 MainValve 3 GeneratorStartBattery MModels 4 Generator MModels 5 BatteryPack 6 GroundContro...

Page 28: ...D INSPECTION 2 8 JLG Lift 3121217 Figure 2 3 Basic Nomenclature Sheet 3 of 3 1 Platform 2 Rotator 3 Boom 4 Lift Cylinder 5 Upright 6 Tower Boom 7 Tower Lift 8 Boom Link 9 Master Cylinder 10 Slave Cyli...

Page 29: ...SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121217 JLG Lift 2 9 Figure 2 4 Daily Walk Around Inspection Sheet 1 of 4 www duma rent com...

Page 30: ...ria men tioned 1 Platform Assembly Platform mounting pins secure Footswitch in good working order not modified dis abled or blocked 2 Platform Ground Control Console Switches and control levers placar...

Page 31: ...reather cap dipstick secure and working 12 Manual Descent Valve See Note 13 Control Valve No unsupported or damaged wires or hoses 14 Generator Start Battery See Note 15 Engine Oil Supply Full mark on...

Page 32: ...nded as shown below 21 Battery Compartment See Note 22 Fuel Supply Fuel filler cap secure Tank Decals secure and legible 23 Hydraulic Oil Filter Housing See Note 24 Battery Charger See Note 25 Turntab...

Page 33: ...arged or if the Generator Enable switch on the platform console is not in the on position Ground Control Station See Figure 3 1 Ground Control Station w Function Enable DO NOT OPERATE FROM GROUND CONT...

Page 34: ...p 2 Platform Ground Select 3 PlatformRotate 4 PlatformLevelingOverride 5 MainLift 6 Telescope 7 Swing 8 BatteryIndicatorandHourmeter 9 Generator EnabledIndicator 10 Generator EngineStart 11 JibBoom 12...

Page 35: ...d Select 3 PlatformRotate 4 PlatformLevelingOverride 5 MainLift 6 Telescope 7 Swing 8 BatteryIndicatorandHourmeter 9 Generator EnabledIndicator 10 Generator EngineStart 11 JibBoom 12 JibRotate 13 Plat...

Page 36: ...e platform ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR S...

Page 37: ...n electrical system fault NOTE Refer to the Service Manual for the generator fault codes 10 Generator Engine Start Button if equipped The generator engine start push button switch allows the generator...

Page 38: ...he indicator panel will also blink once as a bulb check 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...

Page 39: ...sket left or right 9 Function Speed Control Controls the speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed To adjust to creep turn knob fully CCW until it clicks 10...

Page 40: ...Power EmergencyStop 2 Generator Enable 3 Lights 4 Drive Steer 5 Telescope 6 ArticulatingJibBoom 7 Jib Rotate 8 PlatformRotate 9 FunctionSpeed 10 MainLift Swing 11 PosiTrack 12 PlatformLevelingOverrid...

Page 41: ...wer EmergencyStop 2 Generator Enable 3 Lights 4 Drive Steer 5 Telescope 6 ArticulatingJibBoom 7 JibRotate 8 Platform Rotate 9 FunctionSpeed 10 MainLift Swing 11 PosiTrack 12 PlatformLevelingOverride 1...

Page 42: ...system This switch is used to adjust platform level in situations such as ascending descending a grade 13 Horn If pressed this switch supplies power to the horn 14 Drive Orientation Override When the...

Page 43: ...njury or death This indicator will be red Indicates an abnormal operating condition which if not corrected may result in machine interruption or damage This indicator will be yel low Indicates importa...

Page 44: ...on a slope the tilt alarm warning 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 L...

Page 45: ...on selected within seven sec onds The enable indicator shows that the controls are enabled If a function is not selected within seven sec onds or if a seven second lapse between ending one function an...

Page 46: ...lluminate when the drive function is selected This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct 9 Soft Touch Indicat...

Page 47: ...n Ground Controls operate Boom Lift and Swing and are to be used in an emergency to lower the platform to the ground should the operator in the plat form be unable to do so The Ground Control is also...

Page 48: ...charging the batteries or parking the machine overnight Within about 2 seconds of pulling the switch out the machine will perform a diagnostic check of the various elec trical circuits and if everythi...

Page 49: ...ERATION 3121217 JLG Lift 4 3 Figure 4 1 Position of Least Forward Stability BOOMFULLYEXTENDED 5 ELEVATION MACHINEWILLTIPOVER IN THISDIRECTION IFOVERLOADEDOR OPERATEDONANOUT OF LEVELSURFACE LEVELSURFAC...

Page 50: ...3121217 Figure 4 2 Position of Least Backward Stability MAIN BOOM FULLY RETRACTED AND ELEVATED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE LEVEL SURFA...

Page 51: ...AXLE IF BOOM IS OVER FRONT WHEELS STEER AND DRIVE CONTROLS WILL BE REVERSED Traveling Forward and Reverse 1 At Platform Controls pull out Emergency Stop switch and activate footswitch 2 Position Driv...

Page 52: ...SECTION 4 MACHINE OPERATION 4 6 JLG Lift 3121217 Figure 4 3 Grade and Side Slopes DONOTDRIVEMACHINEONGRADESEXCEEDING THOSESPECIFIEDONMANUFACTURER SNAMEPLATE GRADE SIDESLOPE LEVEL www duma rent com...

Page 53: ...ate 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 7 BOOM DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHE...

Page 54: ...r s controller will monitor status of the batteries will turn on automatically when the battery voltage drops as a result of discharge and will turn off when batteries are fully charged Battery Only O...

Page 55: ...n parking overnight batteries should be charged properly to ensure readiness for following workday NOTE Electric machines are equipped with a static strap due to static electricity build ups Strap is...

Page 56: ...n the stowed position 3 Remove all loose items from the machine 4 Properly adjust the rigging to prevent damage to the machine and so the machine remains level Tie Down WHEN TRANSPORTING THE MACHINE T...

Page 57: ...SECTION 4 MACHINE OPERATION 3121217 JLG Lift 4 11 Figure 4 4 Lifting and Tie Down Chart www duma rent com...

Page 58: ...UM TOWING SPEED 5 MPH 8 KPH FOR A DISTANCE OF 5 MILES 8K MAXIMUM TOWING GRADE 25 The following instructions are for towing using the optional tow bar 1 Lock the turntable in the travel position with t...

Page 59: ...1217 JLG Lift 4 13 4 14 DRIVE HUB Disengaging for Towing MAKE SURE THE DISCONNECT MECHANISM IS ONLY OPERATED WITH THE MACHINE AT A STANDSTILL 1 Remove the two hex head bolts from the cover 2 Remove th...

Page 60: ...he bolts and torque 6 3 ft lbs 8 8 Nm until they are flush with the cover 5 The machine is ready to be towed BEFORE THE MACHINE IS SEPARATED FROM THE TOWING VEHICLE EITHER THE DRIVE HUB HAS TO BE REEN...

Page 61: ...E 1 Remove the 2 hex head bolts securing the cover evenly and remove the cover 2 Rotate the cover 180 degrees and secure with the two hex head bolts 3 Torque the hex head bolts 6 3 ft lbs 8 8 Nm 4 The...

Page 62: ...SECTION 4 MACHINE OPERATION 4 16 JLG Lift 3121217 Figure 4 5 Decal Installation Sheet 1 of 4 www duma rent com...

Page 63: ...SECTION 4 MACHINE OPERATION 3121217 JLG Lift 4 17 Figure 4 6 Decal Installation Sheet 2 of 4 www duma rent com...

Page 64: ...SECTION 4 MACHINE OPERATION 4 18 JLG Lift 3121217 Figure 4 7 Decal Installation Sheet 3 of 4 www duma rent com...

Page 65: ...SECTION 4 MACHINE OPERATION 3121217 JLG Lift 4 19 Figure 4 8 Decal Installation Sheet 4 of 4 www duma rent com...

Page 66: ...703935 1703936 1703937 1703940 4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 5 1704661 1704661 1704661 6 1707035 1707035 1707035 7 8 9 10 11 1702868 1704001 1704000 1704002 12 1704...

Page 67: ...300 1702300 1702300 25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 27 28 29 30 31 1703953 1701518 1703944 1703945...

Page 68: ...4331 1704332 1704328 1704329 1704333 1704330 42 1702155 1702155 1702155 1702155 1702155 1702155 1702155 43 1704412 1704412 1704412 1704412 1704412 1704412 1704412 44 45 46 47 48 49 50 51 1703813 17056...

Page 69: ...17 1701517 1701517 1701517 1701517 1701517 64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618 65 66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 67 68 69 1705351 170...

Page 70: ...37 1703940 4 1703804 1701518 1703950 1703951 1703947 1703948 1703949 1703952 5 1704661 1704661 1704661 6 1707035 1707035 1707035 7 8 9 10 11 1702868 1704001 1704000 1704002 12 1704277 1704277 1704277...

Page 71: ...00 1702300 1702300 25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 26 1701529 1701529 1701529 1701529 1701529 1701529 1701529 1701529 27 28 29 30 31 1703953 1701518 1703944 1703945...

Page 72: ...331 1704332 1704328 1704329 1704333 1704330 42 1702155 1702155 1702155 1702155 1702155 1702155 1702155 43 1704412 1704412 1704412 1704412 1704412 1704412 1704412 44 45 46 47 48 49 50 51 1703813 170567...

Page 73: ...7 1701517 1701517 1701517 1701517 1701517 64 1704728 1704728 1704671 1704670 1704732 1704733 1704371 1704618 65 66 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 67 68 69 1705351 1705...

Page 74: ...SECTION 4 MACHINE OPERATION 4 28 JLG Lift 3121217 NOTES www duma rent com...

Page 75: ...an occur rence may void any warranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE...

Page 76: ...pecific procedures refer to Section 4 5 5 MANUAL DESCENT SYSTEM The manual descent system is used in the event of total power failure to lower the boom using gravity To operate the manual descent syst...

Page 77: ...he handle until the desired platform position is reached 3 Push the control lever down when complete Remove the handle from the hand pump SWING RIGHT 1 Install the spool plug in the location shown 2 I...

Page 78: ...1 Install the spool plug in the location shown 2 Install the handle into the hand pump and pump the handle until the desired platform position reached 3 Remove the handle from the hand pump REMOVE ALL...

Page 79: ...SECTION 5 EMERGENCY PROCEDURES 3121217 JLG Lift 5 5 Figure 5 1 Manual Descent Decal www duma rent com...

Page 80: ...SECTION 5 EMERGENCY PROCEDURES 5 6 JLG Lift 3121217 NOTES www duma rent com...

Page 81: ...Available Service and Maintenance Manual ANSI CSA 3121117 Service and Maintenance Manual CE 3121813 Illustrated Parts Manual ANSI CSA 3121118 Illustrated Parts Manual CE 3121814 6 2 OPERATING SPECIFIC...

Page 82: ...Specifications Prior to S N 0300141450 GrossMachineWeight PlatformEmpty Priorto S N0300104944 E600J M600J E600JP M600JP 16 300lb 7 393kg 16 800lb 7 620kg GrossMachineWeight PlatformEmpty S N030010494...

Page 83: ...ide 4ft 1 23m MaximumTireLoad 7700lbs 3493kg MaximumGroundBearingPressure E600J M600J E600JP M600JP 52psi 3 7kg cm2 51psi 3 6kg cm2 MaximumDriveSpeed 3 0 mph 1 3m s Table 6 2 Operating Specifications...

Page 84: ...ties Generator FuelTank M ModelsOnly 13gallons 49 2liters HydraulicTank Priorto S N51941 S N51941toPresent 15gallons 57liters 15 9gal 60 2L 12 4gal 46 9L tofullmark DriveHub 0 4gal 1 5liters Table 6 4...

Page 85: ...ed additives or be of comparable vis cosities If use of hydraulic oil other than Mobil DTE 11M is desired contact JLG Industries for proper recommen dations Table 6 5 Hydraulic Oil Hydraulic System Op...

Page 86: ...on the left side of the frame at the top Table 6 7 Component Weights Component Pounds Kilograms Frame bare 1381 626 T T bare 2093 950 BoomAssembly E M600 4464 2025 BoomAssembly E M600J 4464 2025 Tire...

Page 87: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 3121217 JLG Lift 6 7 Figure 6 2 Operator Maintenance and Lubrication Diagram 1 2 3 4 6 5 6 www duma rent com...

Page 88: ...t the same time 1 Swing Bearing Internal Ball Bearing Lube Point s 1 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Table 6 8 Lubrication Specifications KEY SPEC...

Page 89: ...FICATIONS OPERATOR MAINTENANCE 3121217 JLG Lift 6 9 2 Generator Engine If Equipped Lube Point s Fill Cap Capacity Refer to engine manual Lube EO Interval Check daily Change in accordance with engine m...

Page 90: ...9 gal system 56 7L 12 4 gal 46 9 L to Full Mark Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 4 Hydraulic Filter Interval Change after first 50 hrs and every 6 mo...

Page 91: ...ty 24 oz 0 7 L Lube EPGL Interval Check level every 3 months or 150 hrs of opera tion change every 2 years or 1200 hours of operation 6 Wheel Drive Hub Lube Point s Level Fill Plug Capacity 0 4 gal 1...

Page 92: ...off of ground 7 Carefully activate Swing control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lockout cylinders should release and al...

Page 93: ...exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire...

Page 94: ...UST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANG...

Page 95: ...ectric 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 E...

Page 96: ...SECTION 6 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 6 16 JLG Lift 3121217 NOTES www duma rent com...

Page 97: ...INSPECTION AND REPAIR LOG 3121217 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG MachineSerialNumber _______________________________________ Table 7 1 Inspection and Repair Log Date Comments www dum...

Page 98: ...SECTION 7 INSPECTION AND REPAIR LOG 7 2 JLG Lift 3121217 Table 7 1 Inspection and Repair Log Date Comments www duma rent com...

Page 99: ...nits should not be included on this form Mfg Model _______________________________________________________________ Serial Number ____________________________________________________________ Previous O...

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Page 102: ...69 350 20 49 0 421 69 350 45 JLG Equipment Services Ltd Rm 1107 Landmark North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pre...