JLG 800S Operation And Safety Manual
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JLG 800S Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
800S
810SJ
860SJ
S/N 0300182743 &
B300001328 to Present
AS/NZS
ANSI
3121630
®
June 29, 2018 - Rev I

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Summary of Contents for JLG 800S

  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 800S 810SJ 860SJ S/N 0300182743 & B300001328 to Present AS/NZS ANSI 3121630 ® June 29, 2018 - Rev I...
  • Page 2 NOTE: This manual also applies to machines with the following Serial Num- bers: 0300174290, 0300180894, and 0300181347. WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
  • 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 FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS This is the Safety Alert Symbol. It is used to alert you to the potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death INDICATES A POTENTIALLY HAZARDOUS SITUATION.
  • Page 5 Modifications Product Safety JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES, INC. TO ENSURE THAT THE Contact: CURRENT OWNER RECORDS ARE UPDATED AND ACCURATE. Product Safety and Reliability Department JLG Industries, Inc.

  • Page 6: Revision Log

    FOREWORD REVISION LOG Original Issue A - March 20, 2014 Revised B - January 5, 2015 Revised C - July 30, 2015 Revised D - June 21, 2016 Revised E - September 1, 2016 Revised F - November 15, 2016 Revised G - March 23, 2018 Revised...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS SkyGuard Function Test......2-6 General .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE STEERING..........4-9 Boom Movement Prevented By Boom PLATFORM .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SKYGLAZIER™ ........6-8 MAINTENANCE Capacity Specifications .
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally 3121630...
  • Page 11 Serial Number Locations ......7-10 3-1. Ground Control Console - 800S ..... . . 3-3 7-2.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121630...
  • Page 13 Skyguard Function Table ......4-13 Decal Location Legend, 800S ......4-26 Decal Location Legend, 810SJ .
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121630...

  • Page 15: Section 1 - Safety Precautions

    JLG Industries, Inc. completed under the supervision of an experienced and quali- fied operator.

  • Page 16: Workplace Inspection

    JLG. unit. • Before operation, check work area for overhead hazards such •...

  • Page 17: Machine Inspection

    • Check the machine for modifications to original components. opposite direction. Always return switch to neutral and stop Ensure that any modifications have been approved by JLG. before moving the switch to the next function. Operate con- trols with slow and even pressure.

  • Page 18: Trip And Fall Hazards

    • Do not carry materials directly on platform railing unless the machine will remain stationary, hydraulic oil temperature, approved by JLG. ambient air temperature, and boom and platform position. • When two or more persons are in the platform, the operator Trip and Fall Hazards shall be responsible for all machine operations.

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Before operating the machine, make sure all gates are closed Electrocution Hazards and fastened in their proper position. • This machine is not insulated and does not provide protection from contact or proximity to electrical current. •...
  • Page 20 SECTION 1 - SAFETY PRECAUTIONS Table 1-1. Minimum Approach Distances (M.A.D.) Voltage Range MINIMUM APPROACH DISTANCE (Phase to Phase) in Feet (Meters) 0 to 50 KV 10 (3) Over 50KV to 200 KV 15 (5) Over 200 KV to 350 KV 20 (6) Over 350 KV to 500 KV 25 (8)

  • Page 21: Tipping Hazards

    SECTION 1 - SAFETY PRECAUTIONS • The minimum approach distance may be reduced if insulating Tipping Hazards barriers are installed to prevent contact, and the barriers are • The user must be familiar with the surface before driving. Do rated for the voltage of the line being guarded. These barriers not exceed the allowable sideslope and grade while driving.
  • Page 22 Keep all loads within the confines of the platform, gusts, may exceed 28 mph (12.5 m/s). Factors affecting wind unless authorized by JLG. speed are; platform elevation, surrounding structures, local weather events, and approaching storms. Refer to Table 1-2, •...
  • Page 23 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/ Table 1-2. Beaufort Scale (For Reference Only) Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm. Smoke rises vertically 0.3-1.5 Light air Wind motion visible in smoke 1.6-3.3 Light breeze...

  • Page 24: Crushing And Collision Hazards

    SECTION 1 - SAFETY PRECAUTIONS Crushing and Collision Hazards • Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations. • Approved head gear must be worn by all operating and • Under all travel conditions, the operator must limit travel ground personnel.

  • Page 25: Towing, Lifting, And Hauling

    SECTION 1 - SAFETY PRECAUTIONS TOWING, LIFTING, AND HAULING MAINTENANCE • Never allow personnel in platform while towing, lifting, or This sub-section contains general safety precautions which must hauling. be observed during maintenance of this machine. Additional pre- cautions to be observed during machine maintenance are •...
  • Page 26 SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of card- • Do not use machine as a ground for welding. board or paper to search for leaks. Wear gloves to help protect •...

  • Page 27: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS Battery Hazards • Always disconnect batteries when servicing electrical compo- BATTERY FLUID IS HIGHLY CORROSIVE. AVOID CONTACT WITH SKIN AND nents or when performing welding on the machine. CLOTHING AT ALL TIMES. IMMEDIATELY RINSE ANY CONTACTED AREA WITH CLEAN WATER AND SEEK MEDICAL ATTENTION.
  • Page 28 SECTION 1 - SAFETY PRECAUTIONS NOTES: 1-14 3121630...

  • Page 29: Section 2. User Responsibilities, Machine Preparation, And Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.1 PERSONNEL TRAINING 6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The aerial platform is a personnel handling device; so it is neces- depressions, holes, dropoffs.

  • Page 30: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance required by JLG Industries, Inc.
  • Page 31 Preventative Maintenance At intervals as specified in the Service and Maintenance Owner, Dealer, or User Qualified JLG Mechanic Service and Maintenance Manual Manual. NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections. 3121630...

  • Page 32: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-3. and Figure 2-4. The Pre-Start Inspection should include each of the following: 6. Battery – Charge as required. 1. Cleanliness – Check all surfaces for leakage (oil, fuel, or bat- 7.

  • Page 33: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check 3. With the platform in the transport (stowed) position: a. Drive the machine on a grade, not to exceed the rated Perform the Function Check as follows: gradeability, and stop to ensure the brakes hold; 1.

  • Page 34: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard Function Test NOTE: If the machine is equipped with both SkyGuard and Soft Touch, functions will not reverse, only stop. From the Platform Console: NOTE: If equipped, ensure the SkyGuard beacon illuminates when Sky- Test the SkyGuard feature by operating the telescope out func- Guard is activated.
  • Page 35 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Basic Nomenclature - Sheet 1 of 2 3121630...
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Steer Wheels 2. Drive Wheels 3. Lift Cylinder 4. Tower 5. Level Link 6. Upright 7. Base Boom Section 8. Mid Boom Section 9. Fly Boom Section 10. Boom Assembly 11.
  • Page 37 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-3. Daily Walk-Around Inspection - Sheet 1 of 2 3121630...

  • Page 38: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 5. Wheel/Tire Assemblies - No loose or missing lug nuts, proper inflation (pneumatic). Inspect for worn tread, cuts, Begin the "Walk-Around Inspection" at Item 1, as noted on the dia- tears or other discrepancies.

  • Page 39: 2.3 Horizontal And Capacity Limit Switches

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES Figure 2-5. Horizontal and Capacity Limit Switches - Sheet 1 of 2 3121630 2-11...
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Item Description Operation Characteristic Boom Capacity Activates platform capacity light to indicate the platform capacity at a designated boom length. Length Switch Boom Extension Reduces drive speed when boom reaches a designated length. Switch Boom Capacity Activates platform capacity light to indicate the platform capacity at a designated boom height.
  • Page 41 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION BOOM CAPACITY BOOM CAPACITY ANGLE SWITCH ANGLE SWITCH BOOM ELEVATION SWITCH BOOM ELEVATION SWITCH 810SJ 800S 860SJ Figure 2-7. Limiting and Cut-Out Switches - Sheet 1 of 2 3121630 2-13...
  • Page 42 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-8. Limiting and Cut-Out Switches - Sheet 2 of 2 2-14 3121630...

  • Page 43: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 3. Place the Drive control lever to the forward position and carefully drive machine up ascension ramp until left front wheel is on top of block. 4.
  • Page 44 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 8. Place the 6 inches (15.2 cm) high block with ascension ramp 12. Carefully activate Swing control lever and return boom to in front of right front wheel. stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders 9.

  • Page 45: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below. Indicates a potentially hazardous situation, which if THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND not corrected, could result in serious injury or death.

  • Page 46: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel. The LED Indicator Panel contains indicator lights that signal TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR problem conditions or functions operating during machine TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE operation.
  • Page 47 5. Platform/Ground Select Switch 6. Hourmeter 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power/Function Enable 9. Not Used 10. Platform Leveling Override 11. Platform Rotate 12. Not Used 13. Air Shutoff Valve (ASOV) (If Equipped) Figure 3-1. Ground Control Console - 800S 3121630...
  • Page 48 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power/Function Enable 9. Not Used 10. Platform Leveling Override 11. Platform Rotate 12. Machine Safety System Override (MSSO) Figure 3-2. Ground Control Console - 800S with Machine Safety System Override (MSSO) (CE Only) 3121630...
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Telescope 3. Swing 4. Lift 5. Platform/Ground Select Switch 6. Hourmeter 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power/Function Enable 9. Articulating Jib Boom 10. Platform Leveling Override 11. Platform Rotate 12.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Indicator Panel 2. Telescope 3. Swing 4. Lift 5. Platform/Ground Select Switch 6. Hourmeter 7. Power/Emergency Stop 8. Engine Start/Auxiliary Power/Function Enable 9. Articulating Jib Boom 10. Platform Leveling Override 11. Platform Rotate 12.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS 3. Swing Control NOTE: When the Platform/Ground Select Switch is in the center position, power is shut off to the controls at Provides 360 degrees continuous both operating consoles. Remove the key to pre- turntable rotation.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Hourmeter 8. Engine Start/Auxiliary Power Switch Registers the amount of time the Engine Start/ Auxiliary Power Switch /Function Enable. machine has been in use, with engine To start the engine, the switch must be held "Up" running.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS 9. Jib (If Equipped) 11. Platform Rotate This switch provides raising and low- Provides rotation of the platform. ering of the jib. 12. Machine Safety System Override (MSSO) (CE Only) ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM.

  • Page 54: Ground Control Indicator Panel

    5. Malfunction Indicator and service is required. 2. Engine Oil Pressure Indicator Indicates that the JLG Control System has detected a malfunction and a Diagnostic Trou- Indicates that engine oil pressure is below nor- ble Code has been set. Refer to the Service mal and service is required.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. No Alternator Output 4. Engine Oil Temp. 7. Platform Overload 2. Engine Oil Pressure 5. Malfunction Indicator 8. Drive and Steer Disable 3. Engine Water Temp. 6. Glow Plug/Wait to Start Figure 3-5. Ground Control Indicator Panel 3121630 3-11...

  • Page 56: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Platform Overload Indicator. (If Equipped) Platform Console Indicates the platform has been overloaded. (See Figure 3-6., Platform Console) 8. Drive and Steer Disable Indicator (If equipped) Indicates the Drive and Steer Disable function TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR has been activated.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS 2. Steer Select (If Equipped) When equipped with four wheel steering, the ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF action of the steering system is operator THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR selectable.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1 7 0 26 7 6 -B 17 0 49 97 1 7 0 2 5 6 7 A 1 7 0 2 9 3 8 1 70 517 0 A 13 12 1.
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Engine Start/Auxiliary Power 8. Drive Orientation Override When pushed forward, the switch energizes When the boom is swung over the rear tires or the starter motor to start the engine. further in either direction, the Drive Orienta- tion indicator will illuminate when the drive The Auxiliary Power control switch energizes function is selected.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Lift, Swing, and Drive control levers are spring-loaded and will 10. Main Boom Telescope automatically return to neutral (off) position when released. Provides extension and retraction of the main boom. 11. Lights (If Equipped) TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE This switch operates accessory lights if the...
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 13. Soft Touch/SkyGuard Override Switch (If equipped) 14. Soft Touch/SkyGuard Indicator (If Equipped) The machine can be equipped with one of three options. It Indicates the Soft Touch bumper is against an object or the may have Soft Touch, SkyGuard, or both Soft Touch and Sky- SkyGuard sensor has been activated.

  • Page 62: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Main Boom Lift/Swing joystick, Platform Control Indicator Panel pull up on the locking ring below the handle. (See Figure 3-7., Platform Control Indicator Panel) NOTE: The Main Boom Lift/Swing joystick is spring 1.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Capacity Indicator 5. Tilt Alarm Warning Light and Alarm This illuminator indicates that the chassis is on Indicates the maximum platform capacity for a slope. An alarm will also sound when the the current position of the platform.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS * UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY 1. Level System 5. Tilt Alarm Warning 9. Creep Speed 2. AC Generator 6. Glow Plug 10. System Distress 3. Overload 7. Enable 11. Cable Service 4. Capacity 8.
  • Page 65 SECTION 3 - MACHINE CONTROLS AND INDICATORS 7. Footswitch/Enable Indicator NOTE: Refer to Fuel Reserve/Shut-Off System in Section 4 for more detailed information concerning the Low Fuel Indicator. To operate any function, the footswitch must be depressed and the function selected within 8.
  • Page 66 10. System Distress Indicator the proper direction (i.e. controls reversed situations). 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.

  • Page 67: Section 4 - Machine Operation

    4. Proper tire pressure. used in an emergency to lower the platform to the ground 5. Machine is as originally equipped from JLG. should the operator in the platform be unable to do so. The Ground Control is also to be used in Pre-Start Inspection.

  • Page 68: Engine Operation

    SECTION 4 - MACHINE OPERATION 1. Turn key of Platform/Ground Select switch to Ground. TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOAD MACHINE OR OPER- ATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE. 2. Pull the Power/Emergency Stop switch to On. ENGINE OPERATION NOTE: Initial starting should always be per-...

  • Page 69: Shutdown Procedure

    Fuel Reserve / Shut-Off System NOTE: Reference the Service and Maintenance Manual along with a qualified JLG Mechanic to verify your machine setup. NOTE: Footswitch must be in released (up) position before starter will operate. If starter operates with footswitch in the depressed posi- The Fuel Shutoff System monitors the fuel in the tion, DO NOT OPERATE MACHINE.

  • Page 70: Air Shutoff Valve (Asov) (If Equipped)

    SECTION 4 - MACHINE OPERATION After the 2 minute run time is complete or if the engine is Air Shutoff Valve (ASOV) (If Equipped) shut down by the operator prior to the completion of the 2 minute run time, it cannot be restarted until fuel is added Air Shutoff Valve (ASOV ) is an overspeed protection device to the tank.
  • Page 71 SECTION 4 - MACHINE OPERATION DO NOT USE ASOV AS AN ALTERNATIVE TO SHUTTING DOWN MACHINE PROPERLY. ROTATE PLATFORM 90 DEGREES MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT-OF-LEVEL SURFACE BOOM FULLY ELEVATED TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION Figure 4-1.
  • Page 72 SECTION 4 - MACHINE OPERATION TELESCOPE FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED TURNTABLE ROTATED ON AN OUT-OF-LEVEL SURFACE 90 DEGREES FROM STOWED POSITION Figure 4-3. Position of Least Forward Stability 3121630...

  • Page 73: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND NOTE: When the upper boom is raised approximately 11 degrees above LEVEL SURFACE. horizontal, the high drive function will automatically be in low drive.

  • Page 74: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse 1. Match the black and white direction arrows on both platform con- 1. At Platform Controls, pull out Emergency Stop trol panel and the chas- switch and activate footswitch. sis to determine the direction the machine will travel.

  • Page 75: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION Traveling on a Grade STEERING Position thumb switch on Drive/Steer controller When traveling a grade, maximum braking and traction are obtained to Right for steering right, or to Left for steering with the boom stowed, in position over the rear (drive) axle, and in left.
  • Page 76 SECTION 4 - MACHINE OPERATION Figure 4-5. Grade and Side Slopes 4-10 3121630...

  • Page 77: Platform

    SECTION 4 - MACHINE OPERATION PLATFORM BOOM Platform Level Adjustment DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINE IS OUT OF LEVEL. ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. THE PLATFORM.

  • Page 78: Swinging The Boom

    SECTION 4 - MACHINE OPERATION Swinging the Boom Telescoping the Main Boom To swing boom, use Swing control switch to select To extend or retract the boom, use the Telescope Right or Left direction. Control Switch to select In or Out movement. FUNCTION SPEED CONTROL WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

  • Page 79: 4.10 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.10 SKYGUARD OPERATION 4.11 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) SkyGuard is used to provide enhanced control panel protection. When the SkyGuard sensor is activated, functions that were in use at the time of actuation will reverse or cutout. The table LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- below outlines these functions.

  • Page 80: 4.12 Emergency Towing

    SECTION 4 - MACHINE OPERATION 4.12 EMERGENCY TOWING RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH. MAXIMUM TOWING SPEED 5 M.P.H.

  • Page 81: Tow Bar (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.13 TOW BAR (IF EQUIPPED) RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOLLOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.
  • Page 82 SECTION 4 - MACHINE OPERATION After towing the machine, complete the following: 1. Actuate steer/tow selector valve for steering; push valve knob IN to the actuated position. 2. Reconnect drive hubs by inverting disconnect cap. 3. Disconnect towbar from towing vehicle and place it in the stowed position as shown below.

  • Page 83: 4.14 Shut Down And Park

    Lifting lows: 1. Drive machine to a reasonably well protected area. 1. Call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight. 2. Ensure boom is lowered over rear drive axle. 2. Place the boom in the stowed position with the turntable 3.

  • Page 84: Tie Down

    1. Remove all loose items from the machine. 3. Secure the chassis and the platform using straps or chains of 2. When transporting an 800S/810SJ/860SJ a step-deck or sin- adequate strength. gle-drop trailer is required. To avoid damage to the platform and to obtain proper weight distribution, load the machine onto the trailer as follows;...
  • Page 85 SECTION 4 - MACHINE OPERATION Figure 4-7. Typical 800S/810SJ/860SJ Transport 3121630 4-19...
  • Page 86 SECTION 4 - MACHINE OPERATION Figure 4-8. Lifting and Tie Down Chart 4-20 3121630...
  • Page 87 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Location - Sheet 1 of 5 3121630 4-21...
  • Page 88 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Location - Sheet 2 of 5 4-22 3121630...
  • Page 89 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Location - Sheet 3 of 5 3121630 4-23...
  • Page 90 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Location - Sheet 4 of 5 4-24 3121630...
  • Page 91 SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Location - Sheet 5 of 5 3121630 4-25...
  • Page 92 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274499-F 0274501-E 0274503-E 0274513-E 0274505-E 0274507-E 0274509-H 0274511-E 1001114371-F 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509...
  • Page 93 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274499-F 0274501-E 0274503-E 0274513-E 0274505-E 0274507-E 0274509-H 0274511-E 1001114371-F 1702868 1705969 1702868 1704001 1705967 1704000 1703797 1703927 1703925 1703923 1705895...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274499-F 0274501-E 0274503-E 0274513-E 0274505-E 0274507-E 0274509-H 0274511-E 1001114371-F 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 1706941 1706941 1706941 1706941...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274499-F 0274501-E 0274503-E 0274513-E 0274505-E 0274507-E 0274509-H 0274511-E 1001114371-F 1705351 1705427 1705430 1705910 1705905 1705429 1705426 3121630 4-29...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Location Legend, 810SJ Table 4-3. Decal Location Legend, 810SJ ANSI ANSI Item # Item # 1001118210-E 1001118210-E 1702868 1701499 1703797 1705336 1703804 1701509 1703805 3252347 1703811 1703814 1704277 1704412 1001118212 1702631 1001118211 1701501 1001122508 1001122516...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Location Legend, 810SJ Table 4-3. Decal Location Legend, 810SJ ANSI ANSI Item # Item # 1001118210-E 1001118210-E 1001108496 1706941 1001175354 1701691 1705351 3121630 4-31...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Location Legend, 860SJ ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274500-F 0274502-E 0274504-E 0274514-E 0274506-E 0274508-E 0274510-H 0274512-E 1001114372-F 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509 1701509 1701509 1701509...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Location Legend, 860SJ ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274500-F 0274502-E 0274504-E 0274514-E 0274506-E 0274508-E 0274510-H 0274512-E 1001114372-F 1702868 1705969 1705968 1704001 1705967 1704000 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Location Legend, 860SJ ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274500-F 0274502-E 0274504-E 0274514-E 0274506-E 0274508-E 0274510-H 0274512-E 1001114372-F 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 1706941 1706941 1706941 1706941 1706941 1706941 1706941...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-4. Decal Location Legend, 860SJ ANSI Korean Chinese Spanish Portuguese French Japanese Item # 0274500-F 0274502-E 0274504-E 0274514-E 0274506-E 0274508-E 0274510-H 0274512-E 1001114372-F 1705351 1705427 1705430 1705910 1705905 1705429 1705426 3121630 4-35...
  • Page 102 SECTION 4 - MACHINE OPERATION NOTES: 4-36 3121630...

  • Page 103: Section 5 - Emergency Procedures

    BEEN REPAIRED, IF REQUIRED, AND THAT ALL CONTROLS ARE OPERATING COR- RECTLY. JLG Industries, Inc. must be notified immediately of any incident involving a JLG product. Even if no injury or property damage is EMERGENCY OPERATION evident, the factory should be contacted by telephone and pro- vided with all necessary details.

  • Page 104: Platform Or Boom Caught Overhead

    SECTION 5 - EMERGENCY PROCEDURES Platform or Boom Caught Overhead EMERGENCY TOWING PROCEDURES If the platform or boom becomes jammed or snagged in over- Towing this machine is prohibited, unless properly equipped. head structures or equipment, rescue platform occupants prior to However, provisions for moving the machine have been incorpo- freeing the machine.

  • Page 105: Machine Safety System Override (Msso)

    NOTE: If the MSSO functionality is used, the fault indicator will flash and a fault code is set 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 106 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121630...

  • Page 107: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI Japan China (USA Only) Fall Arrest Platform (36" x 96")     Fall Arrest Platform (36" x 72")   Pipe Racks  ...
  • Page 108 SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Platform MMR**, Platform MTR*, Pipe Racks SkyPower™ SkyCutter, SkyGlazier, SkyWelder Soft Touch SkyCutter™, SkyGlazier™, SkyAir™ SkyPower™ SkyWelder™ 4’ Platform, Pipe Racks, Platform SkyCutter™...

  • Page 109: Fall Arrest Platform

    FALL ARREST PLATFORM PIPE RACKS NOTE: Refer to 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 110: Capacity Specifications (Australia Only)

    SECTION 6 - ACCESSORIES Capacity Specifications (Australia Only) • Ensure no personnel are beneath the platform. • Do not exit platform over rails or stand on rails. Max. Platform Capacity Max. Capacity in Racks * • Do not drive machine without material secured (With Max.

  • Page 111: Skyair

    SECTION 6 - ACCESSORIES SKYAIR™ Compressor Specifications • Single stage with dual control • CFM displacement: 9.3 • Motor: 230 V, 2 hp, 3-phase Accessory Ratings CONTROL MODE VOLUME Automatic Start-Stop Control 100 - 130 psi Constant Run Control 105 - 120 psi Safety Precautions DO NOT OVERLOAD PLATFORM.

  • Page 112: Preparation And Inspection

    SECTION 6 - ACCESSORIES Preparation and Inspection SKYCUTTER™ • Ensure compressor and hoses are secure. • Check condition of belt and wiring. Operation Start the engine, turn on the generator, then turn on the air com- pressor. Refer to the J-Air Manual (PN 3128970) for more information. SkyCutter™...

  • Page 113: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Amperes Input @ Plasma Gas Flow/ Rated Cutting Spec. Rated Output Rated Output, 60 kVa/kW Plasma Gas Max. OCV Pressure Capacity @ 10 IPM Hz, 1-Phase 120 Volts ±10% 27 A @ 91 VDC @ 20% 28.8 max;...

  • Page 114: Preparation And Inspection

    SECTION 6 - ACCESSORIES • Ensure no personnel are beneath platform. SKYGLAZIER™ • 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. •...

  • Page 115: Capacity Specifications

    SECTION 6 - ACCESSORIES Capacity Specifications Safety Precautions Max. Platform Capacity Capacity Zone * Max. Tray Capacity (With Max. Weight in Tray) ENSURE PANEL IS SECURED WITH STRAP. 500 lbs 150 lbs 250 lbs (227 kg) (68 kg) (113 kg) 550 lbs 150 lbs 250 lbs...

  • Page 116: Preparation And Inspection

    SECTION 6 - ACCESSORIES Preparation and Inspection SKYPOWER™ • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. • Ensure strap is not torn or frayed. Operation 1. Load SkyGlazier™ tray with panel. 2.

  • Page 117: Generator Output

    SECTION 6 - ACCESSORIES All power regulation components are located in a watertight box Safety Precautions connected by cable to the generator. The generator supplies power when running at the specified speed with the power switch on (switch is located on platform). A three-pole, 30 Amp DO NOT OVERLOAD PLATFORM.

  • Page 118: Skywelder

    SECTION 6 - ACCESSORIES SKYWELDER™ 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 CE Specifications: • 3-phase: 400 V, 50 Hz, 7.5 kW •...

  • Page 119: Accessory Ratings

    SECTION 6 - ACCESSORIES Accessory Ratings Welding Amps Input At Rated Load Output (50/60 Hz) Maximum Open Welding Mode Input Power Rated Output Amperage Circuit Voltage 230 V 460 V 575 V Range 280 Amp at 31.2 V, 15.7 35% Duty Cycle 3- phase 5-250 A 79 VDC...

  • Page 120: Preparation And Inspection

    SECTION 6 - ACCESSORIES • Use correct rod size and current settings. SOFT TOUCH • Do not use electrical cords without ground. A padding kit is mounted to the platform rails and to a frame sus- • Do not use electrical tools in water. pended below the platform.

  • Page 121: Bolt-On External Fall Arrest

    SECTION 6 - ACCESSORIES BOLT-ON EXTERNAL FALL ARREST IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE The bolt-on external fall arrest system is designed to provide a lan- DAMAGED, THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY yard attach point while allowing the operator to access areas outside INSPECTED BEFORE RETURNING TO SERVICE.

  • Page 122: Inspection Before Use

    SECTION 6 - ACCESSORIES Inspection Before Use • Cable: Inspect cable for proper tension, broken strands, kinks, or any signs of corrosion. The external fall arrest system must be inspected before each use of GAP SHOWING: GAP SHOWING: the aerial work platform. Replace components if there are any signs INCORRECT INCORRECT of wear or damage.
  • Page 123 SECTION 6 - ACCESSORIES • Attachment Ring: No cracks or signs of wear are acceptable. Any signs of corrosion requires replacement. • Attaching Hardware: Inspect all attaching hardware to ensure there are no missing components and hardware is properly tight- ened.
  • Page 124 SECTION 6 - ACCESSORIES 1,2,3,4 1. Belleville Washer 2. Washer 3. Hex Nut 4. Jam Nut 5. LH Bracket 6. Attachment Ring 7. Cable 8. RH Bracket 9. Decal Figure 6-2. Bolt-On External Fall Arrest System 6-18 3121630...

  • Page 125: Section - 7 - General Specifications & Operator

    1000 lb. (454 kg) 810SJ/860SJ 750 lb. (340 kg) Maximum Travel Grade (Gradeability)* Maximum Travel Grade (Side Slope)* 5° Maximum Vertical Platform Height: 800S - 80 ft. (24.3 m) 810SJ - 80ft.6in. (24.6 m) 860SJ - 86 ft. (26.2 m) 3121630...

  • Page 126: Specifications And Performance Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-1. Operating Specifications Specifications and Performance Data Maximum Horizontal Platform Reach Table 7-2. Specifications and Performance Data 800S 71 ft. (21.6 m) 810SJ 72 ft. (21.9 m) Swing 360° 860SJ 75 ft. (22.9 m) Tail Swing 4’8"...

  • Page 127: Capacities

    Elevated 0.75 mph (1.2 kph) Fuel Tank (Optional) Approx. 52.8 gallons (200 liters) Ground Bearing Pressure - 800S 72 psi (5.06 kgm/cm Hydraulic Tank (to Full Line on Sight Gauge) Ground Bearing Pressure - 810SJ/860SJ S/N 0300182743 to 0300196954 &...

  • Page 128: Engine Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-5. Deutz TD 2.9 Specifications Fuel Ultra Low Sulfur Diesel (15 ppm) Table 7-4. Deutz D2011L04 Specifications Output 67 hp (50 kW) Type Liquid Cooled (Oil) Torque 173 ft.lbs. (234 Nm) @ 1800rpm Fuel Diesel Oil Capacity (Crankcase)

  • Page 129: Battery

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Battery Table 7-6. GM 3.0L Table 7-7. Battery Specifications Fuel Gasoline or Gasoline/LP Gas Voltage 12 Volt No. of Cylinders Type 31-950 Gasoline 83 hp @ 3000 rpm Cold Cranking Amps 950 CCA @ 0° F (-18° C) 75 hp @ 3000 rpm Reserve Capacity 205 Minutes @ 80°...

  • Page 130: Tires

    Fly Boom (SJ) (5 Bar) Fly Boom (S) Mid Boom (SJ) Mid Boom (S) Base Boom (SJ) 1400 Base Boom (S) 1410 Boom Assembly 3337 1514 Telescope Cylinder (800S) Telescope Cylinder (810SJ) Telescope Cylinder (860SJ) Slave Cylinder Torque Hub (2WD) 3121630...

  • Page 131: Hydraulic Oil

    JLG Industries recommends Mobilfluid 424 hydraulic oil, which has an SAE viscosity index of 152. NOTE: When temperatures remain consistently below 20 degrees F. (-7 degrees C.), JLG Industries recommends the use of Mobil DTE13. 3121630...
  • Page 132 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Aside from JLG recommendations, it is not advisable to mix oils of differ- Table 7-12. UCon Hydrolube HP-5046 ent brands or types, as they may not contain the same required addi- Type Synthetic Biodegradable tives or be of comparable viscosities.
  • Page 133 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-14. Mobil EAL 224H Specs Table 7-13. Mobil DTE 10 Excel 32 Specs Type Synthetic Biodegradable ISO Viscosity Grade ISO Viscosity Grade 32/46 Specific Gravity 0.877 Specific Gravity .922 Pour Point, Max -40°F (-40°C) Pour Point, Max -25°F (-32°C)

  • Page 134: Serial Number Location

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SERIAL NUMBER LOCATION Table 7-15. Exxon Univis HVI 26 Specs A serial number plate is affixed to the left rear side of the frame. If the Specific Gravity 32.1 serial number plate is damaged or missing, the machine serial num- Pour Point -76°F (-60°C) ber is stamped on the left side of the frame.

  • Page 135: Specifications

    ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10°F(-23°C) GRADE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY FUEL AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20°F(-29°C) WITH PACKAGE (IE. ENGINE BLOCK HEATER, ETHER INJECTION OR KEROSENE -30F°(-34°C)
  • Page 136 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS N O T E : AMBIENT AIR TEMPERATURES 110°...

  • Page 137: Engine Specifications

    -10 F(-23 C) ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE -20 F(-29 C) (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND HYDRAULIC OIL TANK HEATER)
  • Page 138 (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 139 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-6. Maintenance and Lubrication Diagram 3121630 7-15...

  • Page 140: Maintenance And Lubrication

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MAINTENANCE AND LUBRICATION 1. Swing Bearing - Internal Ball Bearing NOTE: The following numbers correspond to those in Figure 7-6., Main- tenance and Lubrication Diagram. Table 7-16. Lubrication Specifications SPECIFICATIONS Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excel- lent water resistance and adhesive qualities, and being of extreme pressure type.
  • Page 141 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Wheel Bearings 3. Wheel Drive Hub Lube Point(s) - Repack Lube Point(s) - Level/Fill Plug Capacity - A/R Capacity - 44 oz. (1.3 L) - 1/2 Full Lube - MPG Lube - EPGL Interval - Every 2 years or 1200 hours of operation Interval - Check level every 3 months or 150 hours of opera- tion;...
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Hydraulic Return Filter 5. Hydraulic Charge Filter Interval - Change after first 50 hours and every 6 months or Interval - Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator.
  • Page 143 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Tank 7. Platform Filter Lube Point(s) - Fill Cap Interval - Change as necessary Capacity - Tank (to Full mark on sight gauge) S/N 0300182743 to 0300196954 & S/N B300001092 to B300001096 - Approx.
  • Page 144 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Deutz B. Oil Change w/Filter - Deutz TD2.9 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Fill Cap/Spin-on Element Capacity - 11 Quarts(10.5 L) Crankcase; Capacity - 9.6 Quarts (9.0 L) Lube - EO Lube - EO Interval - Every Year or 1200 hours of operation...
  • Page 145 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD LEVEL MAXIMUM LEVEL OIL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 7-7.
  • Page 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 9. Oil Change w/Filter - GM 10. Fuel Filter - Deutz D2011 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element Capacity - 4.5 qt. (4.25 L) w/filter Interval - Every Year or 600 hours of operation Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with...
  • Page 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE B. Fuel Filter - Deutz TD2.9 (On Hydraulic Tank) C. Fuel Filter - Deutz TD2.9 (On Engine) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Change in accordance with engine manual Interval - Change in accordance with engine manual 11.
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 12. Air Filter B. Air Filter (Deutz TD 2.9) Lube Point(s) - Replaceable Element Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indi- Interval - Every 6 months or 300 hours of operation or as cated by the condition indicator indicated by the condition indicator...

  • Page 149: Tires & Wheels

    TIRES & WHEELS Tire Inflation The air pressure for pneumatic tires must be equal to the air pres- sure 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 150: Tire Replacement

    JLG product from service immediately and JLG recommends a replacement tire be the same size, ply and brand arrangements must be made for replacement of the tire or tire as originally installed on the machine.

  • Page 151: Wheel Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Replacement Wheel Installation It is extremely important to apply and maintain proper wheel The rims installed on each product model have been designed for mounting torque. stability requirements which consist of track width, tire pressure, and load capacity.
  • Page 152 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 2. Tighten nuts in the following sequence: 3. The tightening of the nuts should be done in stages. Follow- ing the recommended sequence, tighten nuts per wheel torque chart. Table 7-17. Wheel Torque Chart TORQUE SEQUENCE 1st Stage 2nd Stage...

  • Page 153: Propane Fuel Filter Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL FILTER REPLACEMENT Installation Removal BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING 1. Relieve the propane fuel system pressure. Refer to Propane NEW SEAL Fuel System Pressure Relief. 1.

  • Page 154: Propane Fuel System Pressure Relief

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL SYSTEM PRESSURE RELIEF THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY, RELIEVE THE PROPANE FUEL SYSTEM PRESSURE (WHERE APPLICABLE) BEFORE SERVICING THE PROPANE FUEL SYSTEM COMPONENTS.

  • Page 155: Supplemental Information

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC and is only applicable to CE machines. For electric powered machines, the equivalent continuous A- Weighted sound pressure level at the work platform is less than 70dB(A) For combustion engine powered machines, guaranteed Sound...
  • Page 156 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE NOTES: 7-32 3121630...

  • Page 157: Section 8 - Inspection And Repair Log

    SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121630...
  • Page 158 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121630...
  • Page 162 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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