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JLG 800S Operation & Safety Manual

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Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
Model
800S, 860SJ
PVC 2307
31222372
July 26, 2023 - Rev B
Copyright ©
ANSI
AS/NZS MOL70

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Summary of Contents for JLG 800S

  • Page 1 Operation & Safety Manual Original Instructions - Keep this manual with the machine at all times. Model 800S, 860SJ PVC 2307 31222372 July 26, 2023 - Rev B Copyright © ANSI AS/NZS MOL70...
  • Page 2 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 re- productive 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.

  • Page 3: Foreword

    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.
  • Page 4 It may also alert against unsafe practices. This decal will have a yellow background. NOTICE Indicates information or a company policy that relates directly or indirectly to the safety of personnel or protection of property. 31222372 800S, 860SJ...
  • Page 5 NOTICE 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.
  • Page 6 Questions Regarding Product Modifications Contact: Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 or Visit www.jlg.com to find your local JLG office. In USA: Toll Free: 877-JLG-SAFE (877-554-7233) Outside USA: Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com...

  • Page 7: Revision Log

    REVISION LOG Description Date Revision July 10, 2023 Original Issue July 26, 2023 Revision Other Publications Available Publication Publication Number 31222373 Service & Maintenance Manual 31222374 Illustrated Parts Manual 800S, 860SJ 31222372...
  • Page 8 This Page is intentionally left blank...

  • Page 9: Table Of Contents

    SECTION 3 MACHINE CONTROLS AND INDICATORS........37 General................37 Controls and Indicators ............38 Ground Control Station............39 Ground Control Indicator Panel..........47 Platform Control Station ............. 49 Platform Control Indicator Panel .......... 54 Beacons ................56 800S, 860SJ 31222372...
  • Page 10 EMERGENCY PROCEDURES ............93 General................93 Incident Notification ............93 Emergency Operation ............94 Emergency Towing Procedures ..........95 ClearSky Smart Fleet™ - Locked Out State ......96 Machine Safety System Override (MSSO) (If Equipped) .... 97 31222372 800S, 860SJ...
  • Page 11 Specifications ..............142 Deutz (T4F/Stage V) Engine Oil Operating Temperature Specifications ..............143 Ford Engine Oil Operating Temperature Specifications ..143 7.10 Operator Maintenance and Lubrication Diagrams ....144 7.11 Operator Maintenance ............145 7.12 Tires and Wheels.............. 154 800S, 860SJ 31222372...
  • Page 12 7.14 Propane Fuel System Pressure Relief ........157 7.15 Radio Frequency (RF) Information........158 7.16 Supplemental Information Only Applicable to CE/UKCA Machines ................ 159 7.17 EC Declaration of Conformity..........160 7.18 UKCA Declaration of Conformity ........161 31222372 800S, 860SJ...

  • Page 13: Safety Precautions

    Read, understand, and study the Operation and Safety Manual in its entirety before operating the machine. For clarification, questions, or additional information regarding any portions of this manual, contact JLG Industries, Inc. • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including recognizing and avoiding hazards associated with their operation) shall be authorized to operate a MEWP.
  • Page 14 • Check the work area for hazardous locations. Do not operate the machine in hazardous environments unless approved for that purpose by JLG. • Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel.

  • Page 15: Operation

    Do not allow personnel to tamper with or operate the machine from the ground with personnel in the platform, except in an emergency. • Do not carry materials directly on platform railing unless approved by JLG. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.
  • Page 16 Ensure that the platform assembly is fully lowered. Face the platform when entering or leaving the platform. Always maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand at all times during entry and exit. 31222372 800S, 860SJ...
  • Page 17 10 (3) 0 to 50 KV 15 (5) Over 50K V to 200 KV 20 (6) Over 200 KV to 350 KV 25 (8) Over 350 KV to 500 KV 35 (11) Over 500 KV to 750 KV 800S, 860SJ 31222372...
  • Page 18 The user must be familiar with the operating surface before driving. Do not exceed the allowable side slope and grade while driving. • Do not elevate platform or drive with platform elevated while on or near a sloping, uneven, or soft surface. 31222372 800S, 860SJ...
  • Page 19 • Never exceed the maximum platform capacity as specified on the platform. Keep all loads within the confines of the platform, unless authorized by JLG. • Keep the chassis of the machine a minimum of 2 ft (0.6m) from holes, bumps, drop- offs, obstructions, debris, concealed holes, and other potential hazards at the ground level.
  • Page 20 Use the boom functions, not the drive function, to position the platform close to obstacles. • Always post a lookout when driving in areas where vision is obstructed. • Keep non-operating personnel at least 6 ft (1.8 m) away from machine during all operations. 31222372 800S, 860SJ...

  • Page 21: Towing, Lifting, And Hauling

    1.5.1 Maintenance Hazards • Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs. 800S, 860SJ 31222372...
  • Page 22 Wear gloves to help protect hands from spraying fluid. • Use only replacement parts or components that are approved by JLG. To be considered approved, replacement parts or components must be identical or equivalent to original parts or components.
  • Page 23 Immediately rinse any contacted area with clean water and seek medical attention. • Charge batteries only in a well ventilated area. • Avoid overfilling the battery fluid level. Add distilled water to batteries only after the batteries are fully charged. 800S, 860SJ 31222372...
  • Page 24 This Page is intentionally left blank...

  • Page 25: User Responsibilities, Machine Preparation, And Inspection

    2.1.3 Operator Responsibility The operator must be instructed that they have the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site. 800S, 860SJ 31222372...

  • Page 26: Preparation, Inspection, And Maintenance

    6. Accessories and optional equipment. PREPARATION, INSPECTION, AND MAINTENANCE The following table covers machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for MEWPs. The frequency of inspections and maintenance 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.
  • Page 27 Owner, Dealer, or Qualified JLG Service & Mainte- nance Manual and tion (See Note) lease, or rental User Mechanic delivery applicable JLG in- spection form Frequent Inspection In service for 3 Owner, Dealer, or Qualified JLG Service & Mainte- (See Note) User...
  • Page 28 Manual Service & Mainte- nance Manual Note: Inspection forms are available from JLG. Use the Service & Maintenance Manual to perform inspections. NOTICE JLG Industries, Inc. recognizes a factory trained service technician as a person who has successfully completed the JLG Service Training School for the specified JLG product model.

  • Page 29: Machine Components

    1. Steer Wheels 10. Boom Assembly 2. Drive Wheels 11. Power Track 3. Lift Cylinder 12. Jib (860SJ Only) 4. Tower 13. Platform 5. Level Link 14. Platform Control Console 6. Upright 15. SkyGuard 7. Base Boom Section 800S, 860SJ 31222372...

  • Page 30: Pre-Start Inspection

    9. Hydraulic Oil — Check the hydraulic oil level. Ensure hydraulic oil is added as required. 10. Accessories/Attachments — Refer to the Accessories section in this manual or accessory installed upon the machine for specific inspection, operation, and maintenance instructions. 31222372 800S, 860SJ...

  • Page 31: Walk-Around Inspection

    WALK-AROUND INSPECTION BM000399A Figure 4. Daily Walk-Around Inspection Diagram 2.5.1 Walk-Around Inspection Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue checking each item in sequence for the conditions listed in the following checklist. 800S, 860SJ 31222372...
  • Page 32 15. Tie Rod Ends and Steering Spindles - See Inspection Note. 16. Air Shutoff Valve (ASOV) (If Equipped) - See Inspection Note. 17. Main Hydraulic Pump - See Inspection Note. 31222372 800S, 860SJ...

  • Page 33: Function Check

    5. With the machine positioned on a smooth, firm surface within the limits of the maximum operating slope, elevate the boom above 11° of horizontal. Select high speed drive mode. Carefully attempt to drive and ensure the drive speed is reduced. 800S, 860SJ 31222372...

  • Page 34: Skyguard® Function Test

    Note: On machines equipped with SkyLine, reattach the rod to the right bracket. If SkyGuard remains activated after function reversal or cutout, press and hold the SkyGuard Override Switch to allow normal use of machine functions until the sensor is disengaged. 31222372 800S, 860SJ...

  • Page 35: Horizontal And Capacity Proximity Switches

    2. From platform control station, start engine. 3. Position Drive Speed/Torque Select switch to Slow. 4. Place Drive control lever to Forward position and carefully drive machine up ascension ramp until left front wheel is on top of block. 800S, 860SJ 31222372...
  • Page 36 Drive to release cylinders. 15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation. 31222372 800S, 860SJ...

  • Page 37: Machine Controls And Indicators

    Machine Controls and Indicators GENERAL NOTICE The manufacturer has no direct control over machine application and operation. The user and operator are responsible for conforming with good safety practices. This section provides the necessary information needed to understand control functions. 800S, 860SJ 31222372...

  • Page 38: Controls And Indicators

    This indicator will be yellow. Indicates important information regarding the oper- ating condition, i.e. procedures essential for safe op- eration. This indicator will be green with the exception of the capacity indicator which will be yellow. 31222372 800S, 860SJ...

  • Page 39: Ground Control Station

    5. Machine Safety System Override (MSSO) 6. Hourmeter 7. Platform/Ground Select Switch 8. Engine Start/Auxiliary Power Switch 9. Power/Emergency Stop Switch 10. Platform Leveling Override Figure 6. 800S with MSSO Ground Con- 11. Platform Rotate trol Station 800S, 860SJ 31222372...
  • Page 40 6. Hourmeter 7. Platform/Ground Select Switch 8. Engine Start/Auxiliary Power Switch 9. Power/Emergency Stop Switch 10. Platform Leveling Override Figure 7. 800S with MSSO and DPF 11. Platform Rotate Ground Control Station 12. Diesel Particulate Filter (DPF) 31222372 800S, 860SJ...
  • Page 41 5. Machine Safety System Override (MSSO) 6. Hourmeter 7. Platform/Ground Select Switch 8. Engine Start/Auxiliary Power Switch 9. Power/Emergency Stop Switch 10. Jib Lift Figure 9. 860SJ with MSSO Ground 11. Platform Leveling Override Control Station 12. Platform Rotate 800S, 860SJ 31222372...
  • Page 42 When operating the boom ensure there are no personnel around or under platform. WARNING To avoid serious injury, do not operate machine if any control levers or toggle switches controlling platform movement do not return to the off or neutral position when released. 31222372 800S, 860SJ...
  • Page 43 Registers the amount of time the machine has been in use with the engine running. By connecting into the oil pressure circuit of the engine, only engine hours are recorded. The hourmeter registers up to 9,999.9 hours and cannot be reset. 800S, 860SJ 31222372...
  • Page 44 Provides raising and lowering of the jib. Machine Safety System Override (MSSO) (If Equipped) Provides emergency override of function controls that are locked out in the event of Load Sense System activation. Main Boom Lift Provides raising and lowering of the main boom. 31222372 800S, 860SJ...
  • Page 45 Provides rotation of the platform. Platform/Ground Select Switch The three position, key operated switch supplies power to the platform control console when positioned to Platform. With the switch key turned to the Ground position only ground controls are operable. 800S, 860SJ 31222372...
  • Page 46 On. NOTICE Always position emergency stop switch to the Off position (pushed in) when machine is not in use. Swing Provides 360 degrees continuous turntable rotation. 31222372 800S, 860SJ...

  • Page 47: Ground Control Indicator Panel

    (shorter boom lengths and higher boom angles). Note: Refer to the capacity decals on the machine for restricted and unrestricted platform capacities. Drive and Steer Disable Indicates the Drive and Steer Disable function has been activated. 800S, 860SJ 31222372...
  • Page 48 Indicates the glow plugs are on. The glow plugs are automatically turned on with the ignition circuit and remain on for approximately seven seconds. Start the engine only after the light goes out. Platform Overload Indicates the platform has been overloaded. 31222372 800S, 860SJ...

  • Page 49: Platform Control Station

    Machine Controls and Indicators System Distress Indicates the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.
  • Page 50 The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate main boom lift, main telescope, jib (if equipped) and swing. 31222372 800S, 860SJ...
  • Page 51 Note: The Platform/Ground Select Switch does not shut off power to operate the lights. To avoid draining the battery, the lights must be shut off using the light switch. Main Boom Telescope Provides extension and retraction of the main boom. 800S, 860SJ 31222372...
  • Page 52 Soft Touch / SkyGuard / SkySense Override For machines equipped with SkyGuard: The SkyGuard override switch enables functions cut out by the SkyGuard system to be operated again, allowing the operator to resume use of machine functions. 31222372 800S, 860SJ...
  • Page 53 To re-synchronize the front and rear axles, position the rear drive wheels to the forward drive position by selecting either crab or compound steer, then select front steer (center switch position) to operate the normal steering function. 800S, 860SJ 31222372...

  • Page 54: Platform Control Indicator Panel

    When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to verify that the drive control is being operated in the proper direction (i.e. controls reversed situations). 31222372 800S, 860SJ...
  • Page 55 Indicates the platform has been overloaded. System Distress The light indicates that the JLG Control System has detected an abnormal condition and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

  • Page 56: Beacons

    Note: Image for reference only. Beacon design may vary based on beacon type, ma- chine model and installation location. 3.7.1 ClearSky® LED Motion / Amber Beacon (CS550) The ClearSky® CS550 is installed on ClearSky Smart Fleet™ equipped machines. 31222372 800S, 860SJ...
  • Page 57 Blue or Red SkyGuard® Beacon The SkyGuard beacon is available in blue or red lamp options. The beacon will flash in conjunction with an audible alarm when the SkyGuard sensor is activated. Refer to the SkyGuard Operation section for more information. 800S, 860SJ 31222372...
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  • Page 59: Machine Operation

    2. Load is within manufacturer’s rated capacity. 3. All machine systems are functioning properly. 4. Machine is as originally equipped from JLG. 4.2.2 Platform Load Sensing System (LSS) The Platform Load Sensing System (LSS) measures platform load from a sensor in the platform support.

  • Page 60: Stability

    Figure 11. Position of Least Backward Stability 1. Rotate platform 90°. 2. Boom fully elevated. 3. Turntable rotated 90° from stowed position. 4. Machine will tip over in the direction if overloaded or operated beyond the limits of the maximum operating slope. 31222372 800S, 860SJ...
  • Page 61 Figure 12. Position of Least Forward Stability 1. Telescope fully extended. 2. Turntable rotated 90° from stowed position. 3. Machine will tip over in the direction if overloaded or operated beyond the limits of the maximum operating slope. 800S, 860SJ 31222372...

  • Page 62: Engine Operation

    CAUTION For every 8 hours of low intensity machine operation or extended engine idle time, drive the machine continuously for 15 minutes. Note: Contact JLG Customer Service for operation under abnormal conditions. 4.4.1 Starting Procedure Note: Initial starting should always be performed from the Ground Control station.
  • Page 63 Allow engine to warm-up for a few minutes at low speed before applying any load. After engine has had sufficient time to warm up, push in the Power/ Emergency Stop switch and shut engine off. Turn Platform/Ground Select switch to Platform. From Ground Control Console, pull Power/ Emergency Stop switch out. 800S, 860SJ 31222372...
  • Page 64 Remove all load and allow engine to operate at low speed for 3-5 minutes; this allows further reduction of internal engine temperature. Push Power/Emergency Stop switch in. Turn Platform/Ground Select switch to Off. Note: Refer to Engine Manufacturer’s manual for detailed information. 31222372 800S, 860SJ...

  • Page 65: Air Shutoff Valve (Asov) (If Equipped)

    Note: The handle cannot be turned unless the machine is off. Ensure the ignition power is OFF. WARNING Do not use ASOV as an alternative to shutting down machine properly. Figure 13. ASOV Reset (Closed to Open Position) 800S, 860SJ 31222372...

  • Page 66: Fuel Shutoff System (Reserve)

    The Fuel Shutoff System monitors the fuel in the tank and senses when the fuel level is getting low. The JLG Control System automatically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

  • Page 67: Traveling (Driving)

    Use extreme caution when driving in reverse and at all times when the platform is elevated. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls. Move the drive controls in a direction matching the directional arrows for the intended direction of travel. 800S, 860SJ 31222372...

  • Page 68: Traveling (Grade/Side Slope)

    Traveling is limited by two factors: 1. Gradeability, which is the percent of grade of the incline the machine can climb. 2. Side slope, which is the angle of the slope the machine can be driven across. 31222372 800S, 860SJ...
  • Page 69 (drive) axle, and in line with the direction of travel. Drive the machine forward when climbing a grade, and in reverse when descending a grade. Do not exceed the machine's maximum rated gradeability. BM000411A Figure 14. Traveling on a Grade 800S, 860SJ 31222372...
  • Page 70 Machine Operation NOTICE If the boom is over the front (steer) axle, direction of steer and drive movement will be opposite from the movement of the controls. BM000412A Figure 15. Grade and Side Slope 31222372 800S, 860SJ...

  • Page 71: Steering

    To Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the platform is level. 4.11.2 Platform Rotation To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction. 800S, 860SJ 31222372...

  • Page 72: Boom

    When swinging the boom make sure there is ample room for the boom to clear surrounding walls, partitions and equipment. Note: On CE/UKCA market machines, when boom functions are being operated there is an interlock which prevents the use of Drive and Steer functions. 31222372 800S, 860SJ...

  • Page 73: Function Speed Control

    Creep Mode puts the functions listed above, as well as the Drive/Steer and Main Lift/Swing functions into the slowest speed setting. 4.14 USB CHARGING PORT The machine is equipped with a USB charging port for the operator. 800S, 860SJ 31222372...

  • Page 74: Clearsky Smart Fleet

    Refer to the Access Control and Beacons sections of this manual for more information. Visit the ClearSky section of the JLG website for more resources and information about accessing web portal or mobile app data. 4.16 ACCESS CONTROL - CLEARSKY SMART FLEET™ (IF...

  • Page 75: Machine Safety System Override (Msso) (If Equipped)

    The Locked Out state will override the machine capability to use auxiliary power. Note: Restricted functionality may occur if the CS550 (ClearSky® LED Motion / Amber Beacon) is damaged or removed. A protective cage is available through JLG. Machines equipped with ClearSky Smart Fleet Access Control are also equipped with the CS550.
  • Page 76 Approximately 50 lb (222 Nm) of force is applied to yellow bar. 4.18.2 SkyGuard - SkyLine OAC03970 Rod is pressed, breaking the connection between the rod and right bracket. 4.18.3 SkyGuard - SkyEye OAC00140 Operator passes through path of sensor beam. 31222372 800S, 860SJ...
  • Page 77 Machine Operation 800S, 860SJ 31222372...

  • Page 78: Oscillating Axle Lockout Test (If Equipped)

    Refer to General Specifications & Operator Maintenance Section — Oscillating Axle Lockout Test for procedure (if equipped). 4.20 EMERGENCY TOWING Towing this machines is prohibited unless properly equipped. However, provisions to move the machine have been incorporated. For specific procedures, refer to Section 5. 31222372 800S, 860SJ...

  • Page 79: Towing (If Equipped)

    Failure to follow instructions could cause serious injury or death. WARNING Maximum towing speed 5 mph (8 km/h). Maximum towing grade 25%. BM000168A Figure 16. Towbar 1. Steer Select Valve *Chassis layout may vary depending on machine. 800S, 860SJ 31222372...
  • Page 80 1. Drive Hub 3. Disconnect Cap B — Drive Hub Engaged 2. Disconnect Cap (REVERSED) After towing the machine, complete the following: 1. Actuate steer/tow selector valve for steering; push valve knob In to the actuated position. 31222372 800S, 860SJ...

  • Page 81: Shut Down And Park

    3. Shut down Emergency Stop at Platform Controls. 4. Shut down Emergency Stop at Ground Controls. Position Platform/Ground Select switch to center OFF (center position). 5. If necessary, cover Platform Controls to protect instruction placards, warning decals, and operating controls from hostile environment. 800S, 860SJ 31222372...

  • Page 82: Lifting And Tie Down

    4.23 LIFTING AND TIE DOWN 4.23.1 Lifting 1. Refer to the Machine Serial Number Plate, call JLG Industries, or weigh the individual unit to find out the Gross Vehicle Weight. 2. Place the boom in the stowed position. 3. Remove all loose items from the machine.

  • Page 83: Lifting Chart

    Note: Secure through the tie downs on the boom using straps or chains of adequate strength. OAC014470 NOTICE Secure turntable with turntable lock (if equipped) before traveling long distances or hauling machine on truck/trailer. 4.24 LIFTING CHART BM001115B 800S, 860SJ 31222372...

  • Page 84: Safety Decals

    Machine Operation 4.25 SAFETY DECALS 4.25.1 Safety Decal Locations and Legend 55 54 83 35 BM001203A Figure 19. Safety Decals — 1 of 6 31222372 800S, 860SJ...
  • Page 85 Machine Operation 54 55 67 BM001204A Figure 20. Safety Decals — 2 of 6 BM001205B Figure 21. Safety Decals — 3 of 6 800S, 860SJ 31222372...
  • Page 86 Machine Operation BM001206A Figure 22. Safety Decals — 4 of 6 BM001207A Figure 23. Safety Decals — 5 of 6 31222372 800S, 860SJ...
  • Page 87 Machine Operation BM001208A Figure 24. Safety Decals — 6 of 6 800S, 860SJ 31222372...
  • Page 88 Machine Operation 31222372 800S, 860SJ...
  • Page 89 Machine Operation 800S, 860SJ 31222372...
  • Page 90 Machine Operation 31222372 800S, 860SJ...
  • Page 91 Machine Operation 800S, 860SJ 31222372...
  • Page 92 This Page is intentionally left blank...

  • Page 93: Emergency Procedures

    This section explains the steps to be taken in case of an emergency situation during operation. INCIDENT NOTIFICATION JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by telephone and provided with all necessary details.

  • Page 94: Emergency Operation

    6. Inspect the machine for damage. If the machine is damaged or does not operate properly, turn off the machine immediately. Report the problem to the proper maintenance personnel. Do not operate the machine until it is declared safe for operation. 31222372 800S, 860SJ...

  • Page 95: Emergency Towing Procedures

    1. Retract, lower and position boom over rear drive wheels in line with direction of travel; lock turntable. 2. Disconnect drive hubs by inverting disconnect cap. Refer to Figure — Drive Disconnect Hub, page 3. Reconnect the drive hubs by inverting the disconnect cap when towing is complete. 800S, 860SJ 31222372...

  • Page 96: Clearsky Smart Fleet™ - Locked Out State

    If the CS550 (ClearSky® LED Motion / Amber Beacon) is removed from a machine or disconnected from the control system through damage, the machine may also be placed into a Locked Out state. NOTICE Contact the ClearSky Smart Fleet™ account owner if the machine is in a Locked Out state. 31222372 800S, 860SJ...

  • Page 97: Machine Safety System Override (Msso) (If Equipped)

    Note: If the MSSO functionality is used, a fault indicator is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician. Note: No functional checks of the MSSO system are necessary. The JLG Control System will set a Diagnostic Trouble Code if the control switch is faulty.
  • Page 98 This Page is intentionally left blank...

  • Page 99: Accessories

    (36” x 72”) (36” x 96”) Fall Arrest Platform √ √ (36” x 72”) Fall Arrest Platform √ √ √ √ √ (36” x 96”) Nite Bright® √ √ √ √ √ √ √ √ Pipe Racks √ √ 800S, 860SJ 31222372...
  • Page 100 √ √ √ √ 7.5 kW Generator √ √ √ √ √ √ √ 4 kW SkySense® √ √ √ √ √ √ √ √ SkySense® Platform √ √ √ √ √ √ √ √ Bumper Padding 31222372 800S, 860SJ...
  • Page 101 Accessories Table 6. Available Accessories Table (continued) Market ANSI Accessory MOL 70 (USA ANSI (Japan) (China) Only) SkyWelder® √ √ √ √ √ √ Soft Touch √ √ √ √ √ √ √ 800S, 860SJ 31222372...
  • Page 102 Accessories 31222372 800S, 860SJ...
  • Page 103 Accessories 800S, 860SJ 31222372...

  • Page 104: Bolt-On External Fall Arrest

    6 ft (1.8 m) in length, that limits the maximum arrest force to 900 lb (408 kg). External Fall Arrest System capacity is 310 lb (140 kg) - one (1) person maximum. Do not move platform during use of the external fall arrest system. 31222372 800S, 860SJ...
  • Page 105 If any gap is shown between the two Belleville washers, the cable tension is incorrect. • Fittings & Brackets: Ensure all fittings are tight and there are no signs of fractures. Inspect brackets for any damage. 800S, 860SJ 31222372...

  • Page 106: Cable Ladder Carrier

    Platform Rails: No visible damage is acceptable. CABLE LADDER CARRIER BM000362A Figure 29. Cable Ladder Carrier The Cable Ladder Carrier accessory consists of two vertical brackets mounted to the outside of the platform used to carry a “ladder” style cable tray. 31222372 800S, 860SJ...

  • Page 107: Fabric Mesh To Mid Or Top Rail

    FALL ARREST PLATFORM Note: See the JLG External Fall Arrest System manual (PN 3128935) for more detailed information. The external fall arrest system is designed to provide a lanyard attach point while allowing the operator to access areas outside the platform.

  • Page 108: Nite Bright

    Do not operate any machine functions while outside the platform. Use caution when entering/exiting the platform at elevation. NITE BRIGHT® BM001032A Figure 32. Nite Bright The Nite Bright light package* consists of two 40W lights mounted to the platform railing. * Appearance of Nite Bright lights may vary. 31222372 800S, 860SJ...

  • Page 109: Pipe Racks

    This accessory consists of two racks with adjustable straps to secure the load in place. 6.7.1 Capacity Specifications (Australia Only) Max. Platform Capacity Max. Capacity in Racks (With Max. Weight in Racks) 80 kg 184 kg 800S, 860SJ 31222372...
  • Page 110 2. Loosen and remove tie-down straps. Place material on racks with weight evenly distributed between both racks. 3. Route the tie-down straps at each end across loaded material and tighten. 31222372 800S, 860SJ...

  • Page 111: Platform Mesh To Mid Or Top Rail

    Figure 35. Platform Mesh to Top Rail The Platform Mesh to Mid Rail accessory consists of stainless steel mesh attached to the platform mid rail. The Platform Mesh to Top Rail accessory consists of lightweight, aluminum mesh attached to the platform top rail. 800S, 860SJ 31222372...

  • Page 112: Platform Top Rail Extension

    Accessories PLATFORM TOP RAIL EXTENSION BM000017A Figure 36. Platform Top Rail Extension The Platform Top Rail Extension accessory consists of an additional bar extending from all sides of the platform. 31222372 800S, 860SJ...

  • Page 113: Platform Work Lights

    Accessories 6.10 PLATFORM WORK LIGHTS OAC04000 Figure 37. Platform Work Lights The Platform Work Lights accessory consists of two 12V lights mounted to the platform railing. 800S, 860SJ 31222372...

  • Page 114: Platform Work Surface

    Accessories 6.11 PLATFORM WORK SURFACE BM000276A Figure 38. Platform Work Surface The platform work surface option consists of a corner tray bolted onto the top and mid rails of the platform. 31222372 800S, 860SJ...

  • Page 115: Skyair

    Automatic Start-Stop Control 100 - 130 psi 105 - 120 psi Constant Run Control 6.12.3 Safety Precautions WARNING Do not overload platform. • Ensure no personnel are beneath platform. • This factory-installed option is available only on specified models. 800S, 860SJ 31222372...
  • Page 116 Ensure compressor and hoses are secure. • Check condition of belt and wiring. 6.12.5 Operation Start the engine, turn on the generator, then turn on the air compressor. See the J-Air Manual (PN 3128970) for more information. 31222372 800S, 860SJ...

  • Page 117: Skycutter

    Do not exit platform over rails or stand on rails. • Use this option only on approved models. • Keep lanyard attached at all times. • Use correct cutting settings. • Do not use electrical cords without ground. 800S, 860SJ 31222372...
  • Page 118 Connect ground clamp to metal being cut. • Ensure there is a good ground connection. 6.13.4 Operation Start the engine, turn on the generator, then turn on the plasma cutter. See the Miller Plasma Cutter Owner’s Manual (PN 3128420) for more information. 31222372 800S, 860SJ...
  • Page 119 Accessories 800S, 860SJ 31222372...

  • Page 120: Skyglazier

    150 lb (68 kg) 440 lb (200 kg) 1000 lb (450 kg/454 kg) 250 lb (113 kg) 500 lb (227 kg) * Refer to the capacity decals installed on the machine for capacity zone information. Required Platform Type: Side-Entry 31222372 800S, 860SJ...
  • Page 121 6.14.3 Preparation and Inspection • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. • Ensure strap is not torn or frayed. 6.14.4 Operation 1. Load SkyGlazier tray with panel. 800S, 860SJ 31222372...

  • Page 122: Skypower® 7.5 Kw And Generator 4 Kw

    1-phase: 240 V / 120 V, 60 Hz, 6 kW (Peak: 6 kW) Generator 4 kW Specifications: • 1-phase: 240 V / 120 V, 60 Hz, 4 kW • 1-phase: 230 V / 115 V, 50 Hz, 4 kW 31222372 800S, 860SJ...
  • Page 123 Preparation and Inspection • Ensure generator is secure. • Check condition of belt and wiring. 6.15.4 Operation Start the engine, then turn on the generator. Refer to the Miller Generator Technical Manual (PN 3121677) for more information. 800S, 860SJ 31222372...

  • Page 124: Skysense

    The machine should stop, and the LED corresponding to that sensor (left LED for left sensor bar; right LED for right sensor bar; both LEDs for center sensor bar or overhead sensor) should be red. 31222372 800S, 860SJ...
  • Page 125 LED Flashing Yellow: Machine is in SkySense warning zone and will reduce function speed to creep. Flash frequency correlates to proximity of object. • LED Red: Machine is in SkySense stop zone and all machine functions will cease. 800S, 860SJ 31222372...
  • Page 126 When the operator overrides the SkySense via the override button to get closer to a work surface, the machine will maintain creep speed and flash the appropriate indicator color based on location in either the warning or stop zones. 31222372 800S, 860SJ...
  • Page 127 SkyGuard will function normally. 6.16.6 SkySense Coverage Areas BM000009A BM000010A Figure 43. SkySense Coverage Level 1 Figure 44. SkySense Coverage Level 2 Areas (2– Bar) Areas (3 — Bar) Note: Sensor Cones shown are approximations for reference only. 800S, 860SJ 31222372...

  • Page 128: Skysense® Platform Bumper Padding

    Accessories 6.17 SKYSENSE® PLATFORM BUMPER PADDING BM001038A Figure 45. Platform Bumper Padding This accessory outfits machines equipped with the SkySense accessory additional padding for the platform. 31222372 800S, 860SJ...

  • Page 129: Skywelder

    See the Miller Welder Owner’s Manual (PN 31215476) for more information. 6.18.2 Generator Output Engine Speed of 1800 rpm +/- 10%. ANSI Specifications: • 3-phase: 240 V, 60 Hz, 7.5 kW • 1-phase: 240 V/120 V, 60 Hz, 6 kW 800S, 860SJ 31222372...
  • Page 130 Accessories 31222372 800S, 860SJ...
  • Page 131 Do not ground through the platform. • Do not use a high frequency arc starter with TIG welder. 6.18.5 Preparation and Inspection • Connect ground clamp to metal being welded. • Ensure there is a good ground connection and observe proper polarity. 800S, 860SJ 31222372...

  • Page 132: Soft Touch

    A button on the platform console allows override of the system. BM000011A Figure 47. Soft Touch System 1. Override Indicator Light 2. Override Button 3. Rail Bumper 4. Limit Switch 5. Suspended Frame and Rail Bumper 6. Limit Switch 31222372 800S, 860SJ...

  • Page 133: General Specifications And Operator Maintenance

    Maximum Operating Slope 4° Maximum Travel Grade (Gradeability)* Maximum Travel Grade (Side Slope)* 4° Maximum Vertical Platform Height: 800S - 80 ft. (24.38 m) 860SJ - 86 ft. (26.20 m) Maximum Horizontal Platform Reach 800S 71 ft. (21.6 m) 860SJ 75 ft.
  • Page 134 10’ (3.04 m) Stowed Length 800S 37’3.25" (11.4 m) 860SJ 40’ (12.2 m) Wheelbase — 800S/860SJ 10’ (3.06 m) Ground Clearance — 800S/860SJ 11" (0.28 m) Drive Speed Stowed 2WD 3.0 mph (5.5 km/h) Stowed 4WD 3.5 mph (5.6 km/h) Elevated 0.75 mph (1.2 km/h)
  • Page 135 General Specifications and Operator Maintenance Ground Bearing Pressure - 860SJ 81 psi (5.7 kgm/cm Max.Tire Load- 800S 17,350 lb (7870 kg) Max.Tire Load- 860SJ 20,200 lb (9163 kg) 7.2.2 Capacities Fuel Tank Approximately 31 gal. (117 L) Fuel Tank (Optional) Approximately 52.8 gal.
  • Page 136 6 psi (0.4 Bar)@ 1000 rpm 18 psi (1.2 Bar)@ 2000 rpm Coolant Capacity 0.63 Gal (2.4 L) Starter Rating 12 V 64.4 A @ 3574 RPM Alternator Rating 12 V, 150 A Fan Ratio 3200 Max. RPM 31222372 800S, 860SJ...
  • Page 137 3700 1678 Counterweight (S) 7000 3175 Counterweight (SJ) 8750 3969 Upright 1050 Tower Fly Boom (SJ) Fly Boom (S) Mid Boom (SJ) Mid Boom (S) Base Boom (SJ) 1400 Base Boom (S) 1410 Boom Assembly 3337 1514 800S, 860SJ 31222372...

  • Page 138: Serial Number Location

    General Specifications and Operator Maintenance Component Kilograms Pounds Telescope Cylinder (800S) Telescope Cylinder (860SJ) Slave Cylinder Torque Hub (2WD) Tire & Wheel (FF) SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial number is stamped on the left side of the frame.

  • Page 139: Hydraulic Oil Specifications

    3 and sufficient chemical stability for mobile hydraulic system service. JLG In- dustries recommends standard UTTO. Note: Aside from JLG recommendations, it is not advisable to mix oils of different brands or types, as they may not contain the same required additives or be of comparable viscosities.
  • Page 140 Mobil DTE 10 Excel 32 — Optional Shell Tellus S4 VX32 — Recommended Univis HVI 26 — Optional Shell Naturelle HF-E32 — Recommended Mobil EAL Envirosyn H32 — Optional Shell Naturelle HF-E46 — Recommended Mobil EAL Envirosyn H46 — Optional 31222372 800S, 860SJ...

  • Page 141: Hydraulic Oil Operating Temperature Specifications

    (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC AMBIENT AIR OIL COOLER (CONSULT JLG SERVICE TEMPERATURE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110°...

  • Page 142: Engine Oil Operating Temperature Specifications

    ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS Note: Machine operation using non-JLG approved engine oil or operation outside of the temperature boundaries outlined in the engine oil operation charts may re- sult in premature wear or damage to components of the engine.

  • Page 143: Deutz (T4F/Stage V) Engine Oil Operating Temperature Specifications

    General Specifications and Operator Maintenance DEUTZ (T4F/STAGE V) ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS FORD ENGINE OIL OPERATING TEMPERATURE SPECIFICATIONS 800S, 860SJ 31222372...

  • Page 144: Operator Maintenance And Lubrication Diagrams

    General Specifications and Operator Maintenance 7.10 OPERATOR MAINTENANCE AND LUBRICATION DIAGRAMS BM000420A 31222372 800S, 860SJ...

  • Page 145: Operator Maintenance

    Note: It is recommended as a good practice to replace all filters at 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 Comments - Remote Access 800S, 860SJ 31222372...
  • Page 146 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port. 31222372 800S, 860SJ...
  • Page 147 Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator. 5. Hydraulic Charge Filter Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator (if equipped). 800S, 860SJ 31222372...
  • Page 148 Approx. 21 gallons (79.5 liters) System Capacity - 59 gallons (223 liters) Lube - HO Interval - Check Level daily; Change every 2 years or 1200 hours of operation. 7. Platform Filter Interval - Change as necessary 31222372 800S, 860SJ...
  • Page 149 B. Oil Change with Filter - Deutz TD2.9 Lube Point(s) - Fill Cap/Spin-on Element Capacity - 9.6 Quarts (9.0 L) Lube - EO Interval - Every Year or 600 hours of operation Comments - Check level daily/Change in accordance with engine manual. 800S, 860SJ 31222372...
  • Page 150 9. Oil Change with Filter - Ford 2.5L Lube Point(s) - Fill Cap/Spin-on Element Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 31222372 800S, 860SJ...
  • Page 151 10. Fuel Filter - Deutz D2011 Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation B. Fuel Filter - Deutz TD2.9 (On Engine) Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual 800S, 860SJ 31222372...
  • Page 152 D. Fuel Filter - China III Lube Point(s) - Replaceable Element Interval - Every year or 600 hours of operation BM000284A 11. Fuel Filter (Gasoline) - GM Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation 31222372 800S, 860SJ...
  • Page 153 Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator B. Air Filter (Deutz TD 2.9) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 800S, 860SJ 31222372...

  • Page 154: Tires And Wheels

    JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics: •...
  • Page 155 When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same.

  • Page 156: Propane Fuel Filter Replacement (Gm Engine)

    1. Relieve the propane fuel system pressure. Refer to Propane 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. 31222372 800S, 860SJ...

  • Page 157: Propane Fuel System Pressure Relief

    To relieve propane fuel system pressure: 1. Close the manual shut-off valve on the propane fuel tank. 2. Start and run the vehicle until the engine stalls. 3. Turn the ignition power Off. 800S, 860SJ 31222372...

  • Page 158: Radio Frequency (Rf) Information

    This device complies with Industry Canada license-exempt RSS standard(s). Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. 31222372 800S, 860SJ...

  • Page 159: Supplemental Information Only Applicable To Ce/Ukca Machines

    The vibration total value to which the hand-arm system is subjected does not exceed 2,5 m/s . The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0,5 m/s 800S, 860SJ 31222372...

  • Page 160: Ec Declaration Of Conformity

    EN 61000-6-2:2005 • EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2006/42/EC — Machinery Directive • 2014/30/EU — EMC Directive • 2014/53/EU — RED Directive (If fitted with optional equipment) •...

  • Page 161: Ukca Declaration Of Conformity

    EN 60204-1:2018 • EN 280:2013+ A1:2015 • EN ISO 12100:2010 JLG Industries, Inc. hereby declares that the above mentioned machine conforms with the requirements of: • 2008 No. 1597 - Supply of Machinery (Safety) Regulations 2008 • 2016 No. 1091 - Electromagnetic Compatibility Regulations 20165 •...
  • Page 162 General Specifications and Operator Maintenance Note: This declaration conforms with the requirements of annex II-A of the Regula- tions 2008 No. 1597. Any modification of the above described machine violates the validity of this declaration. 31222372 800S, 860SJ...
  • Page 163 Inspection, Maintenance and Repair Log Serial Number ___________________________________ Date Comments...
  • Page 164 Inspection, Maintenance and Repair Log...
  • Page 166 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations. www.jlg.com...

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