JLG 800A Operation And Safety Manual
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JLG 800A Operation And Safety Manual

JLG 800A Operation And Safety Manual

Boom lift models
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See also: Safety and Operating Manual
Operation and Safety Manual
Keep this manual with the machine at all times.
Boom Lift Models
800A
800AJ
3121209
ANSI
July 17, 2006
®

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Summary of Contents for JLG 800A

  • Page 1 Operation and Safety Manual Keep this manual with the machine at all times. Boom Lift Models 800A 800AJ 3121209 ANSI July 17, 2006 ®...
  • Page 3 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.
  • Page 4 ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE WILL HAVE A RED BACKGROUND. A YELLOW BACKGROUND. INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACKGROUND. – JLG Lift – 3121209...
  • Page 5 • Accident Reporting • Standards and Regulations THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE- Compliance Information TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED • Product Safety Publica- JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY- tions • Questions Regarding Spe-...
  • Page 6 FOREWORD REVISION LOG Original Issue - May 4, 2005 Revised - September 1, 2005 Revised - March 7, 2006 Revised - July 17, 2006 – JLG Lift – 3121209...

  • Page 7: Table Of Contents

    Function Check......2-5 STEERING....... . 4-7 3121209 – JLG Lift –...
  • Page 8 OPERATOR MAINTENANCE ....6-20 TIRES & WHEELS ......6-28 – JLG Lift – 3121209...
  • Page 9 4-12. Decal Installation - Sheet 5 of 5 ....4-24 2-1. Machine Nomenclature - 800A. (Sheet 1 of 2) ..2-6 6-1. Engine Operating Temperature Specifications - 2-2.
  • Page 10 Inspection and Maintenance Table ... . . 2-3 Decal Legend - 800A ..... . . 4-25 Decal Legend - 800AJ .

  • Page 11: Section 1. Safety Precautions

    If there are any questions with regard to safety, training, inspection, maintenance, application, and operation, please contact JLG Industries, Inc. (“ JLG”). • Do not operate this machine until complete training is per- formed by authorized persons.

  • Page 12: Workplace Inspection

    • Do not operate or raise the platform while on trucks, trail- ers, railway cars, floating vessels, scaffolds or other equip- MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM ment unless approved in writing by JLG. SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU- FACTURER •...

  • Page 13: Operation

    SECTION 1 - SAFETY PRECAUTIONS OPERATION • Supplies or tools which extend outside the platform are prohibited unless approved by JLG. General • When driving, always position boom over rear axle in line with the direction of travel. Remember, if boom is over the •...

  • Page 14: Electrocution Hazards

    • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach. • Never use the boom assembly to enter or leave the plat- form. – JLG Lift – 3121209...

  • Page 15: Minimum Approach Distances (M.a.d.)

    50,000 volts. One foot additional clearance is required for • Allow for machine movement and electrical line swaying. every additional 30,000 volts or less. 3121209 – JLG Lift –...

  • Page 16: Tipping Hazards

    DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE. – JLG Lift – 3121209...

  • Page 17: Crushing And Collision Hazards

    Increase of the area exposed to the wind will decrease stability. • Do not increase the platform size with unauthorized deck extensions or attachments. • During operation, keep all body parts inside platform rail- ing. 3121209 – JLG Lift –...

  • Page 18: Towing, Lifting, And Hauling

    Disconnect power to overhead cranes. • Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if neces- sary. – JLG Lift – 3121209...

  • Page 19: Additional Hazards / Safety

    • Do not refuel the machine with the engine running. • Battery fluid is highly corrosive. Avoid contact with skin and clothing at all times. • Charge batteries only in a well ventilated area. 3121209 – JLG Lift –...
  • Page 20 SECTION 1 - SAFETY PRECAUTIONS This page left blank intentionally. 1-10 – JLG Lift – 3121209...

  • Page 21: Section 2. User Responsibilities, Machine Preparation, And Inspection

    4. Use of approved fall protection device. or the job site. 5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal- function. 3121209 – JLG Lift –...

  • Page 22: Preparation, Inspection, And Maintenance

    JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED The following table covers the periodic machine inspections THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- and maintenance required by JLG Industries, Inc. Consult UCT MODEL.

  • Page 23: Inspection And Maintenance Table

    At intervals as specified in the Service and Main- Owner, Dealer, or User Qualified JLG Service and Maintenance tenance Manual. Mechanic Manual NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121209 – JLG Lift –...

  • Page 24: Pre-Start Inspection

    IT IS DECLARED SAFE FOR OPERATION. 4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities – JLG Lift – 3121209...

  • Page 25: Function Check

    Check that all guards protecting the switches or locks are in place; c. Operate all functions and check all limiting and cut- out switches; d. Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in. 3121209 – JLG Lift –...

  • Page 26: Machine Nomenclature - 800A. (Sheet 1 Of 2)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Machine Nomenclature - 800A. (Sheet 1 of 2) – JLG Lift – 3121209...

  • Page 27: Machine Nomenclature - 800Aj. (Sheet 2 Of 2)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION ARTICULATING JIB ARTICULATING JIB LIFT CYLINDER ALL OTHER COMPONENTS ARE SIMILAR TO MODEL 800A ON PRECEDING PAGE Figure 2-2. Machine Nomenclature - 800AJ. (Sheet 2 of 2) 3121209 – JLG Lift –...

  • Page 28: Daily Walk-Around Inspection. (Sheet 1 Of 4)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection. (Sheet 1 of 4) – JLG Lift – 3121209...

  • Page 29: General

    Inspect wheels for damage 2. Platform Control Console - Switches and levers return and corrosion. to neutral, decals/placards secure and legible, control markings legible. Figure 2-4. Daily Walk-Around Inspection. (Sheet 2 of 4) 3121209 – JLG Lift –...

  • Page 30: Daily Walk-Around Inspection. (Sheet 3 Of 4)

    29. Oscillating Axle - See Inspection Note. (If Equipped) 20. Hydraulic Oil Breather - Element in place, not clogged, no sign of overflow. Figure 2-5. Daily Walk-Around Inspection. (Sheet 3 of 4) 2-10 – JLG Lift – 3121209...

  • Page 31: Daily Walk-Around Inspection. (Sheet 4 Of 4)

    42. Platform Pivot Pin - See Inspection Note. 37. LP Gas Tank - Brackets, hose and fittings secure; no visible damage, no missing parts. (If Equipped) Figure 2-6. Daily Walk-Around Inspection. (Sheet 4 of 4) 3121209 – JLG Lift – 2-11...

  • Page 32: Daily Functional Check

    Figure 2-7. Tower Boom Vertical Limit Switch NOTE: If plunger is not fully extended, contact a qualified service technician to further evaluate this condition before operat- ing the machine. 2. Attempt to extend the tower boom assembly. 2-12 – JLG Lift – 3121209...

  • Page 33: Tower Boom Horizontal Limit Switch

    Figure 2-8. Tower Boom Horizontal Limit Switch NOTE: If the plunger is not fully extended, contact a qualified ser- vice technician to further evaluate this condition. 4. Attempt to lower the base boom with the tower fly boom extended. 3121209 – JLG Lift – 2-13...
  • Page 34 Extend main boom until the capacity indicator lights change from 1000 lb. (450 kg) to 500 lb. (230 kg). —TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM 2-14 – JLG Lift – 3121209...
  • Page 35 The bottom of the upright should not be above the NOTE: For adjustments see Service Manual. hood level of the machine it is, DO NOT DRIVE THE MACHINE. 3121209 – JLG Lift – 2-15...
  • Page 36 Return snap pin to lock pin to hold lock 13. Check platform level adjustment system for proper oper- pin in the disengaged position. Reverse procedure to ation. engage turntable lock. 2-16 – JLG Lift – 3121209...
  • Page 37 JLG service technician. b. With footswitch depressed, operate LIFT and hold control. Remove foot from footswitch, motion should stop. If it does not, shut down machine and contact a certified JLG service technician. 3121209 – JLG Lift – 2-17...

  • Page 38: Oscillating Axle Lockout Test (If Equipped)

    Attempt to start engine. Engine should not EQUIPPED attempt to start when footswitch is depressed. If starter engages or engine turns over, shut down machine and contact a certified JLG service techni- IMPORTANT cian. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUAR- TERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN 20.
  • Page 39 10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block. 3121209 – JLG Lift – 2-19...
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION This page intentionally left blank. 2-20 – JLG Lift – 3121209...

  • Page 41: Section 3. Machine Controls And Indicators

    LEFT or RIGHT. corresponding functions. 2. Platform Leveling Override The platform LEVEL control switch allows the operator to compensate for any difference in the automatic self leveling system by positioning the control switch to UP or DOWN. 3121209 – JLG Lift –...

  • Page 42: Ground Control Station

    5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Tower Telescope 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Tower Lift 11. Main Boom Lift 12. Main Boom Telescope Figure 3-1. Ground Control Station – JLG Lift – 3121209...
  • Page 43 (on). When pushed in (off), power is shut off to the PLATFORM/GROUND SELECT switch. WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.) 3121209 – JLG Lift –...
  • Page 44 The hour meter registers WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL up to 9,999.9 hours and cannot be reset. AROUND OR UNDER PLATFORM. – JLG Lift – 3121209...
  • Page 45 IN The TOWER LIFT control switch provides raising and or OUT. lowering of the tower boom when positioned to UP or DOWN. This function works only when the tower boom is fully retracted (telescope in). 3121209 – JLG Lift –...

  • Page 46: Ground Control Indicator Panel

    3. High Engine Water Temp. 9. Platform Overload 4. High Engine Oil Temp. 10. Hyd. Filter Bypass 5. Engine Malfunction Indicator 11. Transmission Filter By-Pass 6. Low Fuel 12. Engine Air Filter By-Pass Figure 3-2. Ground Control Indicator Panel – JLG Lift – 3121209...
  • Page 47 When illuminated the glow plugs are operating. After When illuminated indicates that the air filter is too restric- turning on ignition, wait until light goes out before crank- tive and needs to be replaced. ing engine. 3121209 – JLG Lift –...

  • Page 48: Platform Station

    Push forward to lift up, pull backward to lift chassis. down. Move right to swing right, move left to swing left. NOTE: Main boom lift and swing functions may be selected in combination. Maximum speed is reduced when multiple functions are selected. – JLG Lift – 3121209...
  • Page 49 LEFT or RIGHT. 9. Platform Leveling Override The PLATFORM LEVEL control switch allows the operator to compensate for any difference in the automatic self lev- eling system by positioning the ground control switch to UP or DOWN. 3121209 – JLG Lift –...

  • Page 50: Platform Control Console

    15. Tower Telescope 3. Main Lift / Swing 8. Platform Rotate 12. Lights 16. Tower Lift 4. Telescope 9. Platform Level Override 13. Steer Select 17. Light Panel 5. Drive/Steer Figure 3-3. Platform Control Console 3-10 – JLG Lift – 3121209...
  • Page 51 The master switch and / or the ignition the end of their stroke. This can be done in either crab or switch at the ground control will turn off power to all coordinated mode. lights. 3121209 – JLG Lift – 3-11...
  • Page 52 “UP” or “DOWN”. TOWER LIFT must be fully elevated IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER “UP” before operating TOWER TELESCOPE. (TOWER DESCRIBED ABOVE. LIFT should not function when TOWER TELESCOPE is extended). 3-12 – JLG Lift – 3121209...

  • Page 53: Platform Control Indicator Panel

    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 and beginning the next function, the enable 3121209 – JLG Lift – 3-13...
  • Page 54 TOM. ble code retrieval. The malfunction indicator light will illuminate for 2-3 sec- onds when the key is positioned to the on position to act as a self test. 3-14 – JLG Lift – 3121209...

  • Page 55: Platform Light Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Enable 6. Capacity 2. Engine Malfunction 7. Creep Speed 3. Soft Touch 8. Glow Plug 4. AC Generator 9. Tilt Alarm Warning 5. Fuel Level 10. Overload Figure 3-4. Platform Light Panel 3121209 – JLG Lift – 3-15...
  • Page 56 When the light first turns on, there are approximately four usable gallons of fuel remaining. 8. Glow Plug Indicator (If Equipped) When illuminated the glow plugs are operating. After turning on ignition, wait until light goes out before crank- ing engine. 3-16 – JLG Lift – 3121209...
  • Page 57 IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL. 3121209 – JLG Lift – 3-17...
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS This page left blank intentionally. 3-18 – JLG Lift – 3121209...

  • Page 59: Section 4. Machine Operation

    4. Proper tire pressure exists in the tires. has a Ground Control Station which will override the Platform 5. Machine is as originally equipped from JLG. Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the plat-...

  • Page 60: Engine Operation

    If starter operates with footswitch in ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS the depressed position, DO NOT OPERATE MACHINE. AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MAN- UAL. – JLG Lift – 3121209...

  • Page 61: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION Figure 4-1. Position of Least Forward Stability 3121209 – JLG Lift –...
  • Page 62 SECTION 4 - MACHINE OPERATION Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2) – JLG Lift – 3121209...
  • Page 63 SECTION 4 - MACHINE OPERATION Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2) 3121209 – JLG Lift –...

  • Page 64: Shutdown Procedure

    3. Turn key of MASTER switch to OFF position. NOTE: Refer to Engine Manufacturer’s manual for detailed infor- mation. TRAVELING (DRIVING) (See Figure 4-4.) DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE. – JLG Lift – 3121209...

  • Page 65: Traveling Forward And Reverse

    TIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE (STEER WHEELS), STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTION. THE DIRECTION WILL MATCH THE ARROW DECAL OF THE HAND CONTROLLER WITH THE ARROW DECAL ON THE FRAME. 3121209 – JLG Lift –...

  • Page 66: Platform

    1. Determine what the total rated capacity weight will be after additional weight is loaded (personnel, tools and supplies). 2. If total weight in platform will be less then rated capacity, proceed with distributing weight uniformly on platform floor. – JLG Lift – 3121209...

  • Page 67: Grade And Sideslopes

    SECTION 4 - MACHINE OPERATION Figure 4-4. Grade and Sideslopes. 3121209 – JLG Lift –...

  • Page 68: Boom

    TO AVOID UPSET, IF ORANGE TILT ALARM WARNING LIGHT LIGHTS WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTEND- ING OR RAISING MAIN BOOM. 4-10 – JLG Lift – 3121209...

  • Page 69: Boom Upright Positioning

    SECTION 4 - MACHINE OPERATION Figure 4-5. Boom Upright Positioning. 3121209 – JLG Lift – 4-11...

  • Page 70: Swinging The Boom

    (approximately 12 degrees from vertical) before the TOWER BOOM can be extended from the fully retracted position. b. The TOWER TELESCOPE “out” will only be opera- ble when the TOWER BOOM is fully elevated “up”. 4-12 – JLG Lift – 3121209...

  • Page 71: Telescoping The Main Boom

    SCOPE. fully lowered position. a. The TOWER BOOM must be fully elevated “up” — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE (approximately 12 degrees from vertical) before the TECHNICIAN BEFORE CONTINUING USE OF MACHINE. TOWER BOOM can be extended from the fully retracted position.

  • Page 72: Shut Down And Park

    NOTE: When transporting machine over rough terrain or long dis- tance, the boom needs to be chocked and strapped. This prevents the boom from bouncing up causing possible damage. 4-14 – JLG Lift – 3121209...

  • Page 73: Machine Tie Down

    SECTION 4 - MACHINE OPERATION NOTE: Rig chains so as not to rub. NOTE: Block rotator and platform. Secure platform w/o over- tightening. Figure 4-6. Machine Tie Down 3121209 – JLG Lift – 4-15...

  • Page 74: Lifting Chart

    SECTION 4 - MACHINE OPERATION Figure 4-7. Lifting Chart. 4-16 – JLG Lift – 3121209...

  • Page 75: Oscillating Axle Lockout Test (If Equipped)

    4.12 TOWING IMPORTANT The machine is not equipped with a tow package. Refer to SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING Section 5 for emergency towing procedures. LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER. 3121209 – JLG Lift – 4-17...

  • Page 76: Welding Lead (If Equipped)

    LP position. IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOPPING THE ENGINE. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED. 4-18 – JLG Lift – 3121209...

  • Page 77: Changing From Gasoline To Lp Gas

    Release the knob. position FUEL SELECT switch at Platform Control Sta- d. Fully lower the boom. tion to GASOLINE position. e. Repeat if necessary. 2. Close hand valve on LP gas supply tank by turning clockwise. 3121209 – JLG Lift – 4-19...

  • Page 78: Decal Installation - Sheet 1 Of 5

    SECTION 4 - MACHINE OPERATION Figure 4-8. Decal Installation - Sheet 1 of 5 4-20 – JLG Lift – 3121209...

  • Page 79: Decal Installation - Sheet 2 Of 5

    SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 2 of 5 3121209 – JLG Lift – 4-21...

  • Page 80: Decal Installation - Sheet 3 Of 5

    SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 3 of 5 4-22 – JLG Lift – 3121209...

  • Page 81: Decal Installation - Sheet 4 Of 5

    SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 4 of 5 3121209 – JLG Lift – 4-23...

  • Page 82: Decal Installation - Sheet 5 Of 5

    SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Installation - Sheet 5 of 5 4-24 – JLG Lift – 3121209...

  • Page 83: Decal Legend - 800A

    SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-4 0274464-4 0274470-4 0274466-4 0274468-5 0274472-4 0274474-2 0274462-4 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701502 1701502 1701502...
  • Page 84 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-4 0274464-4 0274470-4 0274466-4 0274468-5 0274472-4 0274474-2 0274462-4 1702153 1704007 1705901 1704006 1703953 1703945 1703943 1703941 1705903 1703942 1703944...
  • Page 85 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-4 0274464-4 0274470-4 0274466-4 0274468-5 0274472-4 0274474-2 0274462-4 1707014 1707043 1707045 1707048 1707051 1707046 1705978 1707053 1704885 1704885 1704885...

  • Page 86: Decal Legend - 800Aj

    1703811 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705514 1705337 1705339 1705342 1702153 1704007 1705901 1704006 4-28 – JLG Lift – 3121209...
  • Page 87 1703773 1703773 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701645 1707058 1707060 1707056 1703996 1707055 1705978 1707059 1707013 1707042 1707044 1707049 1704112 1707047 1705978 1707054 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 3121209 – JLG Lift – 4-29...
  • Page 88 1706439 1703990 1705977 1703986 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1707110 1707110 1707110 1707110 1707110 1707110 1707110 1706941 1706941 1706941 1706941 1706941 1706941 1706941 4-30 – JLG Lift – 3121209...

  • Page 89: Section 5. Emergency Procedures

    IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR- JLG Industries, Inc. must be notified immediately of any inci- RECTLY. dent involving a JLG product. Even if no injury or property damage is evident, the factory should be contacted by tele- EMERGENCY TOWING PROCEDURES phone and provided with all necessary details.

  • Page 90: Emergency Controls And Their Locations

    CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS OPERATIONAL AND THAT GROUND CONTROL INSTRUCTIONS ARE IN 3. Depress and hold footswitch. PLACE AND LEGIBLE. 4. Operate appropriate control switch, lever or controller for desired function and hold. – JLG Lift – 3121209...

  • Page 91: Emergency Operation

    3. Operate appropriate control switch or controller for desired function and hold. 4. Position AUXILIARY POWER switch to ON and hold. 5. Release AUXILIARY POWER switch followed by the selected control switch or controller. 6. Position POWER/EMERGENCY STOP switch to OFF. 3121209 – JLG Lift –...

  • Page 92: Operator Unable To Control Machine

    3. Cranes, forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunction when used. – JLG Lift – 3121209...

  • Page 93: Section 6. General Specifications & Operator Maintenance

    Illustrated Parts Manual - ANSI, CSA Spec 800AJ 36 ft.-6 in. (11.13 m) S/N 0300069000 to Present........3121176 Wheel base 10 ft.- 0 in. (3.05 m) Illustrated Parts Manual - CE Spec S/N 0300069000 to Present........3121854 3121209 – JLG Lift –...

  • Page 94: Tires

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tires Table 6-1. Operating Specifications Boom Elevation - 800A Table 6-2. Tire Specifications Above Grade +80 ft.-3 in. (24.46 m) Load Below Grade -15 ft.-7 in. (4.75 m) Size Type Pressure Rating...

  • Page 95: Capacities

    8.5 Quarts (8.0 L) minute reserve Capacity, 12 VDC 4.5 Quarts (4.25 L) w/Filter Horsepower 74 @ 3000 RPM, full load Cooling System 16 Quarts (15.14 L) Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) 3121209 – JLG Lift –...

  • Page 96: Deutz F4M2011F Specifications

    2.50 GPH (9.46 lph) Idle RPM 1000 Battery 1000 Cold Cranking Amps, 210 Low RPM 1800 minutes Reserve Capacity, 12 VDC High RPM 2800 Horsepower 65 @ 3000 RPM, full load Alternator 60 Amp, belt drive – JLG Lift – 3121209...

  • Page 97: Isuzu 4Jb1

    Minimum Oil Pressure Horsepower 66 @ 2800 RPM, full load at idle 6 psi (0.4 Bar) @ 1000 rpm 18 psi (1.2 Bar) @ 2000 rpm Compression Ratio 9.2:1 Firing Order 1-3-4-2 Max. RPM 2800 3121209 – JLG Lift –...

  • Page 98: Hydraulic Oil

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil 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. If use of Table 6-9.

  • Page 99: Mobil Dte 13M Specs

    100° F 169 SUS Viscosity at 210° F 48 SUS at 40° C 37 cSt cp at -20° F 6,200 at 100° C 8.4 cSt Viscosity Index Viscosity Index NOTE: Must be stored above 32°F (14°C) 3121209 – JLG Lift –...
  • Page 100 9.3 cSt at 40° C (104° F) 46 cSt (215SUS) Viscosity Index at 65° C (150° F) 22 cSt (106SUS) NOTE: Mobil/Exxon recommends that this oil be checked Viscosity Index on a yearly basis for viscosity. – JLG Lift – 3121209...

  • Page 101: Critical Stability Weights

    SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 6-15. Critical Stability Weights - 800A COMPONENTS LBS. Tire & Wheel Size 365/65D19.5 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF- (Foam Filled Only) 445/55D19.5...
  • Page 102 15 X 19.5 18 X 19.5 Engine Ford Deutz Isuzu GM w/pumps 1030 Counterweight Turntable 4805 2180 Wheel Hubs Rear Front 2WD Front 4WD Platform Size 6 FT. (1.83 M) 8 FT. (2.44 M) 6-10 – JLG Lift – 3121209...
  • Page 103 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-1. Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2 3121209 – JLG Lift – 6-11...
  • Page 104 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-2. Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 6-12 – JLG Lift – 3121209...
  • Page 105 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-3. Engine Operating Temperature Specifications - Ford - Sheet 1 of 2 3121209 – JLG Lift – 6-13...
  • Page 106 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-4. Engine Operating Temperature Specifications - Ford - Sheet 2 of 2 6-14 – JLG Lift – 3121209...
  • Page 107 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-5. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 3121209 – JLG Lift – 6-15...
  • Page 108 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2 6-16 – JLG Lift – 3121209...
  • Page 109 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-7. Engine Operating Temperature Specifications - GM - Sheet 1 of 2 3121209 – JLG Lift – 6-17...
  • Page 110 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4150548-C Figure 6-8. Engine Operating Temperature Specifications - GM - Sheet 2 of 2 6-18 – JLG Lift – 3121209...
  • Page 111 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-9. Operator Maintenance and Lubrication Diagram 3121209 – JLG Lift – 6-19...

  • Page 112: Operator Maintenance

    Interval - Every 3 months or 150 hrs of operation LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION Comments - Remote Access UNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. 6-20 – JLG Lift – 3121209...
  • Page 113 2 years or 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. 3121209 – JLG Lift – 6-21...
  • Page 114 Interval - Change after first 50 hrs. and every 6 months Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indi- or 300 hrs. thereafter or as indicated by Condition Indi- cator. cator. 6-22 – JLG Lift – 3121209...
  • Page 115 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 3121209 – JLG Lift – 6-23...
  • Page 116 Interval - 3 Months or 150 hours of operation Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance Comments - Check level daily/Change in accordance with engine manual. with engine manual. 6-24 – JLG Lift – 3121209...
  • Page 117 Comments - Check level daily/Change in accordance with Capacity - 4.5 qt. (4.25 L) w/filter engine manual. Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 3121209 – JLG Lift – 6-25...
  • Page 118 15. Fuel Filter - Isuzu Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 16. Fuel Filter - Caterpillar Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 6-26 – JLG Lift – 3121209...
  • Page 119 Comments - Drain oil build up. Refer to Section 6.5, DRAINING OIL BUILD UP FROM THE PROPANE REGU- LATOR Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indicated by the condition indicator 3121209 – JLG Lift – 6-27...

  • Page 120: Tires & Wheels

    20. Fuel Filter (Propane) - GM Engine Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc.

  • Page 121: Tire Replacement

    Please refer to the factory recommendations, may result in an unsafe condition JLG Parts Manual for the part number of the approved tires for a regarding stability. particular machine model. If not using a JLG approved replace-...

  • Page 122: Wheel Installation

    The proper procedure for attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 6-30 – JLG Lift – 3121209...

  • Page 123: Regulator

    1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 3121209 – JLG Lift – 6-31...
  • Page 124 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 6-32 – JLG Lift – 3121209...

  • Page 125: Propane Fuel Filter Replacement

    7. Electrical Connector 2. Mounting Plate 8. Fuel Outlet 3. Housing Seal 9. O-ring 4. Filter Magnet 10. Filter 5. Filter Housing 11. Fuel Inlet 6. Seal 12. Retaining Bolt Figure 6-10. Filter Lock Assembly 3121209 – JLG Lift – 6-33...

  • Page 126: Installation

    RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS- check the propane fuel system at each serviced fitting. TEM. ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DIS- Refer to Propane Fuel System Leak Test. CONNECTING ANY FUEL LINE. 6-34 – JLG Lift – 3121209...
  • Page 127 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121209 – JLG Lift –...
  • Page 128 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121209...
  • Page 130 Phone: (717) 485-5161 Fax: (717) 485-6417 JLG Worldwide Locations JLG Industries (UK) JLG Industries (Europe) JLG Industries (Australia) JLG Industries (Pty) Ltd. Unit 12, Southside Kilmartin Place, P .O. Box 5119 Unit 1, 24 Industrial Complex Bredbury Park Industrial Estate...

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