Jlg 601S Operator Manual User Manual

ANSI®Operation and Safety ManualKeep this manual with the machine at all times.Boom Lift Models601S3121218June 22, 2006

TABLE OF CONTENTSiv – JLG Lift – 3121218SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGELIST OF TABLES1-1 Minimum Approach Distance

SECTION 7 - INSPECTION AND REPAIR LOG7-2 – JLG Lift – 3121218Table 7-1. Inspection and Repair LogDate Comments

JLG Worldwide LocationsJLG Industries (UK)Unit 12, SouthsideBredbury Park Industrial EstateBredburyStockportSK6 2sPEnglandPhone: (44) 870 200 7700Fax:

SECTION 1 - SAFETY PRECAUTIONS3121218 – JLG Lift – 1-1SECTION 1. SAFETY PRECAUTIONS1.1 GENERALThis section outlines the necessary precautions for pro

SECTION 1 - SAFETY PRECAUTIONS1-2 – JLG Lift – 3121218• Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the m

SECTION 1 - SAFETY PRECAUTIONS3121218 – JLG Lift – 1-31.3 OPERATION General • Do not use the machine for any purpose other than posi-tioning personnel

SECTION 1 - SAFETY PRECAUTIONS1-4 – JLG Lift – 3121218• Before operating the machine, make sure all gates areclosed and fastened in their proper posit

SECTION 1 - SAFETY PRECAUTIONS3121218 – JLG Lift – 1-5• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) par

SECTION 1 - SAFETY PRECAUTIONS1-6 – JLG Lift – 3121218• The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent

SECTION 1 - SAFETY PRECAUTIONS3121218 – JLG Lift – 1-7• Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft sur

SECTION 1 - SAFETY PRECAUTIONS1-8 – JLG Lift – 3121218• Use the boom functions, not the drive function, to positionthe platform close to obstacles. •

SECTION 1 - SAFETY PRECAUTIONS3121218 – JLG Lift – 1-91.5 ADDITIONAL HAZARDS / SAFETY• Do not use machine as a ground for welding.• When performing we

A Machine that incorporates ADE (JLG Con-trol System) can be outwardly identified bythe analyzer connection at the base of theplatform control box as

SECTION 1 - SAFETY PRECAUTIONS1-10 – JLG Lift – 3121218This page left blank intentionally.

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-1SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION,

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-2 – JLG Lift – 31212182.2 PREPARATION, INSPECTION, AND MAINTENANCEThe followin

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-3Table 2-1.Inspection and Maintenance TableType Frequency

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-4 – JLG Lift – 3121218Pre-Start InspectionThe Pre-Start Inspection should incl

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-5Function CheckPerform the Function Check as follows:1. F

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-6 – JLG Lift – 31212182.3 LIMIT SWITCH FUNCTIONAL CHECKTO AVOID COLLISION AND

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-74. Swing turntable to LEFT and RIGHT a minimum of 45degr

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-8 – JLG Lift – 3121218Figure 2-1. Machine Nomenclature1. Platform Control

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-9Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 4

FOREWORD3121218 – JLG Lift – aFOREWORDThis manual is a very important tool! Keep it with the machine at all times. The purpose of this manual is to p

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-10 – JLG Lift – 3121218GeneralBegin the "Walk-Around Inspection" at

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION3121218 – JLG Lift – 2-1115. Hydraulic Oil Return Filter Housing - See Inspectio

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION2-12 – JLG Lift – 312121831. Muffler and Exhaust System - See Inspection Note.32

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-1SECTION 3. MACHINE CONTROLS AND INDICATORS3.1 GENERALIMPORTANTTHE MANUFACTURER HAS

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-2 – JLG Lift – 3121218Ground Control StationSee Figure 3-1., Ground Control Panel.NOTE: If equipped, the

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-3Figure 3-1. Ground Control Panel1. Platform Rotate2. Platform Leveling Override3. P

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-4 – JLG Lift – 3121218NOTE: Lift, Swing, Platform Level, Telescope, Platform Rotatorand Auxiliary control

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-5Ground Control Indicator Panel(See Figure 3-2., Ground Control Indicator Panel)1. B

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-6 – JLG Lift – 31212186. Platform Overload (If equipped)Indicates the platform has been overloaded.7. EFI

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-7Platform Station(See Figure 3-4., Platform Control Console)DO NOT OPERATE MACHINE I

FOREWORDb – JLG Lift – 3121218SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDSINDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTAVOIDED, WILL RESULT IN S

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-8 – JLG Lift – 31212181. Drive Speed/Torque Select2. Platform Leveling Override3. Horn4. Power/Emergency

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-95. Auxiliary PowerEnergizes the electrically operated hydraulic pump,when actuated.

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-10 – JLG Lift – 31212188. Te l e s c o p e C on t r o lThis control allows extension and retraction of t

SECTION 3 - MACHINE CONTROLS AND INDICATORS3121218 – JLG Lift – 3-111. Tilt Alarm Warning Light. (Orange)This orange illuminator indicates that the ch

SECTION 3 - MACHINE CONTROLS AND INDICATORS3-12 – JLG Lift – 31212185. Engine Malfunction IndicatorOn all machines prior to S/N 58209 and machines wit

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-1SECTION 4. MACHINE OPERATION4.1 DESCRIPTIONThis machine is a self-propelled hydraulic personnel

SECTION 4 - MACHINE OPERATION4-2 – JLG Lift – 3121218StabilityMachine stability is based on two positions which are calledFORWARD and BACKWARD stabili

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-3Figure 4-2. Position of Least Forward StabilityMACHINE WILL UPSET IN THISDIRECTION IF OVERLOADEDO

SECTION 4 - MACHINE OPERATION4-4 – JLG Lift – 31212184.3 ENGINE OPERATIONNOTE: Initial starting should always be performed from theGround Control stat

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-5Shutdown ProcedureIF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUT-DOWN, DETERMINE THE CAUSE A

FOREWORD3121218 – JLG Lift – cTHIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG RE

SECTION 4 - MACHINE OPERATION4-6 – JLG Lift – 3121218Figure 4-3. Grade and SideslopeLEVELGRADESIDESLOPEDo Not Drive Machine On Grades ExceedingThose A

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-7BEFORE DRIVING, MAKE SURE BOOM IS POSITIONED OVER REARAXLE. IF BOOM IS OVER FRONT AXLE (STEER WHE

SECTION 4 - MACHINE OPERATION4-8 – JLG Lift – 31212184.6 PARKING AND STOWINGPark and stow machine as follows:1. Park machine in travel position; boom

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-9Platform Rotation1. Depress footswitch to rotate platform to the left, PLAT-FORM ROTATE control i

SECTION 4 - MACHINE OPERATION4-10 – JLG Lift – 3121218Swinging the BoomIMPORTANTASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTINGANY SWING OPER

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-11IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHERWITHOUT ALLOWING THE ENGINE TO STOP. E

SECTION 4 - MACHINE OPERATION4-12 – JLG Lift – 31212184.11 LIFTING AND TIE DOWNLifting1. Refer to the Serial Number Tag, call JLG Industries, orweigh

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-13Figure 4-4. Lifting Chart

SECTION 4 - MACHINE OPERATION4-14 – JLG Lift – 3121218Figure 4-5. Machine Tie DownNOTE: When transporting machine over rough terrain or long distance,

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-154.12 TOWINGRUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE A

FOREWORDd – JLG Lift – 3121218REVISION LOGOriginal Issue - June 24, 2005Revised - June 22, 2006

SECTION 4 - MACHINE OPERATION4-16 – JLG Lift – 3121218 Figure 4-7. Decal Installation - Sheet 1 of 4

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-17 Figure 4-8. Decal Installation - Sheet 2 of 4

SECTION 4 - MACHINE OPERATION4-18 – JLG Lift – 3121218Figure 4-9. Decal Installation - Sheet 3 of 4

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-19Figure 4-10. Decal Installation - Sheet 4 of 4

SECTION 4 - MACHINE OPERATION4-20 – JLG Lift – 3121218Table 4-1. 601S Decal LegendItem #CE/Australian0273999-2Portuguese0274001-2Spanish0273995-2Japan

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-2117- -- -3251243- -- -- -- -18- -- -- -- -- -- -- -19- -- -- -- -- -- -- -20- -- -- -- -- -- -- -

SECTION 4 - MACHINE OPERATION4-22 – JLG Lift – 312121835 1703765 1703765 1703765 1703765 1703765 1703765 170376536- -- -- -- -- -- -- -37 1705978 1706

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-2353- -- -- -- -- -- -- -54- -- -- -- -- -- -- -55- -- -- -- -- -- -- -56- -- -- -- -- -- -- -57 1

SECTION 4 - MACHINE OPERATION4-24 – JLG Lift – 3121218Table 4-2. 601SS Decal LegendItem #CE/Australian0274000-2Portuguese0274002-2Spanish0273996-2Japa

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-2517- -- -- -- -- -- -- -18- -- -- -- -- -- -- -19- -- -- -- -- -- -- -20- -- -- -- -- -- -- -21 -

TABLE OF CONTENTS3121218 – JLG Lift – iSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGESECTION - 1 - SAFETY PRECAUTIONS1.1 GENERAL

SECTION 4 - MACHINE OPERATION4-26 – JLG Lift – 312121835 1703765 1703765 1703765 1703765 1703765 1703765 170376536- -- -- -- -- -- -- -37 1706382 1706

SECTION 4 - MACHINE OPERATION3121218 – JLG Lift – 4-2753- -- -- -- -- -- -- -54- -- -- -- -- -- -- -55- -- -- -- -- -- -- -56- -- -- -- -- -- -- -57 1

SECTION 4 - MACHINE OPERATION4-28 – JLG Lift – 3121218This page left blank intentionally.

SECTION 5 - EMERGENCY PROCEDURES3121218 – JLG Lift – 5-1SECTION 5. EMERGENCY PROCEDURES5.1 GENERALThis section explains the steps to be taken in case

SECTION 5 - EMERGENCY PROCEDURES5-2 – JLG Lift – 31212185.3 EMERGENCY OPERATIONOperator Unable to Control MachineIF THE PLATFORM OPERATOR IS PINNED, T

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-1SECTION 6. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6.1

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-2 – JLG Lift – 3121218Capacities Engine DataTable 6-2. CapacitiesFuel Tank 26 Gallons

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-3 TiresTable 6-4. Deutz F4M1011F/F4M2011 SpecificationsFuel Dies

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-4 – JLG Lift – 3121218Dimensional Data Hydraulic OilNOTE: Hydraulic oils must have anti

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-5Aside from JLG recommendations, it is not advisable to mix oilsof

TABLE OF CONTENTSii – JLG Lift – 3121218SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGELoading From Ground Level . . . . . . . . .

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-6 – JLG Lift – 3121218Critical Stability WeightsDO NOT REPLACE ITEMS CRITICAL TO STABIL

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-7Figure 6-2. Engine Operating Temperature Specifications - Deutz -

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-8 – JLG Lift – 3121218Figure 6-3. Engine Operating Temperature Specifications - Deutz -

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-9Figure 6-4. Engine Operating Temperature Specifications - Ford -

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-10 – JLG Lift – 3121218Figure 6-5. Engine Operating Temperature Specifications - Ford -

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-11Figure 6-6. Lubrication and Maintenance Diagram6, 9 THRU 13 ENGI

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-12 – JLG Lift – 31212186.3 OPERATOR MAINTENANCENOTE: The following numbers correspond t

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-132. Wheel BearingsLube Point(s) - RepackCapacity - A/RLube - MPGI

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-14 – JLG Lift – 31212184. Wheel Drive HubLube Point(s) - Level/Fill PlugCapacity - 17 o

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-156. Hydraulic Charge FilterInterval - Change after first 50 hrs.

TABLE OF CONTENTS3121218 – JLG Lift – iiiSECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGELIST OF FIGURES2-1. Machine Nomenclature .

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-16 – JLG Lift – 31212188. Suction Strainers (in tank)Lube Point(s) - 2Interval - Every

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-1710. Oil Change w/Filter - DeutzLube Point(s) - Fill Cap/Spin-on

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-18 – JLG Lift – 312121812. Fuel Filter - DeutzLube Point(s) - Replaceable ElementInterv

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-196.4 TIRES & WHEELSTire InflationThe air pressure for pneumat

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-20 – JLG Lift – 3121218by JLG. Due to size variations between tire brands, both tires

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-212. Tighten nuts in the following sequence: 3. The tightening of

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-22 – JLG Lift – 31212186.5 BATTERY MAINTENANCETO AVOID INJURY FROM AN EXPLOSION, DO NOT

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE3121218 – JLG Lift – 6-236. With boom over right side of machine, place DRIVE con-trol le

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE6-24 – JLG Lift – 3121218This page intentionally left blank.

SECTION 7 - INSPECTION AND REPAIR LOG3121218 – JLG Lift – 7-1SECTION 7. INSPECTION AND REPAIR LOGMachine Serial Number ______________________________