JLG 800a Operation And Safety Manual
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JLG 800a 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
800A
800AJ
S/N 0300183034 to
Present
ANSI
3121627
®
November 5, 2018 - Rev I

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Boom Lift Models 800A 800AJ S/N 0300183034 to Present ANSI 3121627 ® November 5, 2018 - Rev I...
  • Page 2 NOTE: This manual also applies to machines with the following Serial Num- bers: 0300174954, 0300180871, and 0300181353. 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 FOREWORD REVISION LOG Original Issue A - March 20, 2014 Revised B - April 30, 2014 Revised C - June 4, 2014 Revised D - January 5, 2015 Revised E - June 30, 2017 Revised F - March 23, 2018 Revised G - May 30, 2018 Revised...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE SECTION - 1 - SAFETY PRECAUTIONS FUNCTION CHECK........2-9 From the Ground Control Station with No Load in the GENERAL .
  • Page 8 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE TRAVELING (DRIVING) ....... . 4-8 4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) .
  • Page 9 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Safety Precautions ....... . . 6-4 SKYWELDER™...
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE Tire Replacement....... . . 7-24 Wheel Replacement .
  • Page 11 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE 2-1. Basic Nomenclature........2-5 4-13.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally 3121627...
  • Page 13 Inspection and Maintenance Table ....2-3 Decal Legend - 800A ....... .4-29 Decal Legend - 800AJ .
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally viii 3121627...

  • 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 3121627...

  • 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, or drop-offs exist.

  • Page 30: 2.2 Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.2 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. 3121627...

  • Page 32: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection 5. “Walk-Around” Inspection – Refer to Figure 2-2. and Figure 2-3. 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 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 1. Chassis 2. Ground Console 3. Tower Lift Cylinder 4. Upright Level Cylinder 5. Upright 6. Main Boom Lift Cylinder 7. Master Cylinder 8. Main Boom Base Section 9. Main Boom Fly Section 10.
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 11 12 OAC00390 Figure 2-2. Daily Walk-Around Inspection (Sheet 1 of 3) 3121627...

  • Page 35: General

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION General 4. Jib - See Inspection Note. 5. Dual Capacity Limit Switch (ANSI, Australia, if equipped); Begin the "Walk-Around Inspection" at Item 1, as noted on the Transport Position Limit Switch (CE) - Properly secured, no diagram.
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 13. Fuel Tank - See Inspection Note. 20. Tower Boom - No visible damage; wear pads secure. All cyl- inders - rod end pins and barrel-end pins properly secured. 14. Swing Drive Motor and Brake - See Inspection Note.

  • Page 37: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION FUNCTION CHECK a. Place machine on level ground with the tower boom assembly in the stowed position. Identify the tower Perform a function check of all systems, once the walk-around boom vertical limit switch adjacent to the tower lift cyl- inspection is complete, in an area free of overhead and ground inder at the bottom end (rear) of the tower base boom.
  • Page 38 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION the tower boom horizontal limit switch at the end of the tower base boom section is fully extended. The plunger is shown fully extended in Figure 2-6. DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED b.
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121627 2-11...
  • Page 40 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-12 3121627...

  • Page 41: From The Platform Control Station

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2. Check the footswitch adjustment and operation as follows: e. Attempt to lower the tower base boom while the tower fly boom is extended. The tower base boom should not a. With engine power shut down, attempt to start engine. lower and the red boom malfunction light should illu- Engine should not attempt to start when footswitch is minate when pressing the tower down switch.
  • Page 42 8. Check the high-drive cutout for the tower boom assembly as NOTE: Step 5 is only applicable for 800A ANSI market machines. follows: 5. If equipped with a dual capacity system, check the limit a. Place machine on level surface with booms retracted switch as follows: and lowered.
  • Page 43 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 9. Check the high-drive cutout for the main boom assembly as 11. Check the Tilt Alarm and Warning System as follows: follows: a. Place machine on level surface with booms retracted and lowered.

  • Page 44: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 14. Check platform rotator for smooth operation and assure SkyGuard Function Test platform will rotate 90 degrees in both directions from cen- terline of boom. NOTE: Refer to Section 4.10 for additional information on SkyGuard operation.

  • Page 45: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTE: If SkyGuard is enabled with the Soft Touch system, functions will OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED cut out instead of reversing. 4. Disengage the SkyGuard sensor, release controls, then recy- LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- cle the footswitch.
  • Page 46 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 8. Carefully activate Swing control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate Drive to release cylinders.

  • Page 47: 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 48: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE THE PLATFORM.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Switch/Function Enable 6. Tower Telescope 7. Hourmeter 8. Platform/Ground Select 9. Swing 10. Tower Lift 11. Main Boom Lift 12.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Platform Rotate 2. Platform Leveling Override 3. Jib 4. Power/Emergency Stop 5. Engine Start/Auxiliary Power Switch/Function Enable 6. Tower Telescope 7. Hourmeter 8. Platform/Ground Select 9. Swing 10. Tower Lift 11. Main Boom Lift 12.
  • Page 51 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: When Power/Emergency Stop switch is in the “On” position and 5. Engine Start/ Auxiliary Power Switch /Function engine is not running, an alarm will sound, indicating Ignition is Enable “On”. To start the engine, the switch must be held "Up" until the engine starts.
  • Page 52 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Tower Telescope NOTE: When the Platform/Ground Select Switch is in the center position, power is shut off to the controls at This switch provides extending and both operating stations. Remove the key to pre- retracting of the tower boom.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Main Lift, Tower Lift, Swing, Platform Level, Main Telescope, 10. Tower Lift Tower Telescope, Platform Rotate, and Auxiliary Power control switches are spring-loaded and will automatically return to neu- This switch provides raising and low- tral (off) when released.

  • Page 54: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 13. Machine Safety System Override (MSSO) (CE 3. High Engine Coolant Temperature Indicator Only) (Liquid Cooled Engines) Provides emergency override of function Indicates that engine coolant temperature is controls that are locked out in the event of abnormally high and service is required.
  • Page 55 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. No Alternator Output 4. High Engine Oil Temperature 7. Platform Overload 2. Low Engine Oil Pressure 5. Glow Plug 8. Drive and Steer Disable 3. High Engine Coolant Temperature 6. Boom Malfunction Figure 3-3.
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Boom Malfunction Indicator 7. Platform Overload Indicator. (If Equipped) If the Boom Malfunction Indicator illumi- Indicates the platform has been overloaded. nates when attempting to activate a tower 8. Drive and Steer Disable Indicator (If equipped) boom function, the function is being cutout by tower boom limit switch.

  • Page 57: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console 2. Steer Select (If Equipped) When equipped with four wheel steering, the (See Figure 3-4.) action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaf- TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR fected.
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Drive Speed / Torque Select 6. Engine Start / Aux Power 11. Lights 16. Soft Touch/SkyGuard Indicator 2. Steer Select 7. Fuel Select 12. Jib (800AJ) 17. Platform Rotate 3. Platform Level Override 8.
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS 6. Engine Start/Auxiliary Power When pushed forward, the switch energizes ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF the starter motor to start the engine. THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANTS TO SHIFT OR FALL.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS 8. Drive Orientation Override NOTE: Lift, Swing, and Drive control levers are spring-loaded and will automatically return to neutral (off) position when released. When the boom is swung over the rear tires or further in either direction, the Drive Orienta- tion indicator will illuminate when the drive function is selected.
  • Page 61 SECTION 3 - MACHINE CONTROLS AND INDICATORS 10. Main Boom Telescope 13. Soft Touch/SkyGuard Override Switch (If equipped) Provides extension and retraction of the main The machine can be equipped with one of three options. It boom. may have Soft Touch, SkyGuard, or both Soft Touch and Sky- Guard.
  • Page 62 SECTION 3 - MACHINE CONTROLS AND INDICATORS 14. Tower Telescope 16. Soft Touch/SkyGuard Indicator (If Equipped) This switch provides for extending and retract- Indicates the Soft Touch bumper is against an object or the ing of the tower boom when positioned to in SkyGuard sensor has been activated.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. NOTE: The Main Boom Lift/Swing joystick is spring loaded and will automatically return to neutral (off) position when released. 19.

  • Page 64: Platform Console Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console Indicator Panel 2. Platform Overload (If equipped) Indicates the platform has been overloaded. (See Figure 3-5., Platform Console Indicator Panel) 1. Tilt Alarm Warning Light and Alarm 3. Boom Malfunction Indicator This illuminator indicates that the chassis is on When an audible alarm sounds and the Boom a slope.
  • Page 65 SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Tilt 5. Enable 9. AC Generator 2. Overload 6. Glow Plug 10. Drive Orientation 3. Boom Malfunctgion 7. Low Fuel 11. Creep 4. Capacity 8. System Distress Figure 3-5. Platform Console Indicator Panel 3121627 3-19...
  • Page 66 SECTION 3 - MACHINE CONTROLS AND INDICATORS 4. Capacity Indicator 5. Footswitch/Enable Indicator Indicates the maximum platform capacity for To operate any function, the footswitch must the current position of the platform. be depressed and the function selected within Restricted capacities permitted seven seconds.
  • Page 67 8. System Distress Indicator the proper direction (i.e. controls reversed situations). The light indicates that the JLG Control System 11. Creep Speed Indicator has detected an abnormal condition and a...
  • Page 68 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 3121627...

  • Page 69: Section 4 - Machine Operation

    4. Proper tire pressure. boom. 5. Machine is as originally equipped from JLG The primary operator control station is in the platform. From this Stability control station, the operator can drive and steer the machine in both forward and reverse directions.
  • Page 70 SECTION 4 - MACHINE OPERATION Figure 4-1. Position of Least Forward Stability 3121627...
  • Page 71 SECTION 4 - MACHINE OPERATION Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2) 3121627...
  • Page 72 SECTION 4 - MACHINE OPERATION Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2) 3121627...

  • Page 73: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION 2. Pull the Power/Emergency Stop switch to On. NOTE: Initial starting should always be per- formed from the Ground Control station. 3. Push the Engine Start switch until engine starts. Starting Procedure ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD.

  • Page 74: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION 7. Push the Engine Start switch until engine starts. Air Shutoff Valve (ASOV) (If Equipped) Air Shutoff Valve (ASOV ) is an overspeed protection device mounted to the engine’s air intake system. When the valve is NOTE: Footswitch must be in released (up) position before starter will actuated, it obstructs airflow intake and stops the engine.

  • Page 75: Fuel Reserve / Shut-Off System

    JLG Mechanic to verify your machine setup. The Fuel Shutoff System monitors the fuel in the tank and senses when the fuel level is getting low. The JLG Control System auto- matically shuts the engine down before the fuel tank is emptied unless the machine is set up for Engine Restart.

  • Page 76: Traveling (Driving)

    All ratings for Gradeability and Sideslope are based upon the machine’s boom being in the stowed position, fully lowered, and retracted. CONTACT A QUALIFIED JLG MECHANIC IF THE MACHINE NEEDS RESTARTED AFTER NO MORE FUEL IS AVAILABLE. Traveling is limited by two factors: •...
  • Page 77 SECTION 4 - MACHINE OPERATION LEVEL Figure 4-5. Grade and Sideslopes 3121627...

  • Page 78: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND 1. At Platform Controls, pull out Emergency Stop LEVEL SURFACE. switch and activate footswitch. TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER”, DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

  • Page 79: Steering

    SECTION 4 - MACHINE OPERATION 1. Match the black and STEERING white direction arrows on both platform con- Position thumb switch on Drive/Steer controller to trol panel and the chas- Right for steering right, or to Left for steering left. sis to determine the PLATFORM direction the machine...

  • Page 80: Boom

    SECTION 4 - MACHINE OPERATION BOOM Swinging the Boom To swing boom, use Swing control switch to select Right or Left direction. AN RED TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE. DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT.

  • Page 81: Raising And Lowering The Tower Boom

    TIONS. (approximately 12 degrees from vertical) before the Tower Boom can be extended — HAVE CONDITION CORRECTED BY A CERTIFIED JLG SERVICE TECHNICIAN BEFORE from the fully retracted position. CONTINUING USE OF MACHINE. b. The Tower Telescope “out” or “in” will only be operable when the Tower Boom is fully elevated “up”.

  • Page 82: Raising And Lowering The Main Boom

    SECTION 4 - MACHINE OPERATION Raising and Lowering the Main Boom SHUT DOWN AND PARK To raise or lower the Main Boom, position the Main 1. Drive machine to a protected area. Boom Lift switch to Up or Down until the desired 2.

  • Page 83: 4.10 Skyguard Operation

    SECTION 4 - MACHINE OPERATION 4.10 SKYGUARD OPERATION SkyGuard SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- ation will reverse or cutout. The SkyGuard Function Table pro- vides more details on these functions. During activation, the horn will sound and, if equipped with a SkyGuard beacon, the beacon will illuminate until sensor and footswitch are disengaged.

  • Page 84: Skyguard - Skyeye

    SECTION 4 - MACHINE OPERATION SkyGuard - SkyEye Reattach magnetic end of cable to bracket if it becomes discon- nected. Operator passes through path of sensor beam. SkyGuard Function Table Drive Drive Tower Tower Tower Tower Boom Boom Lift Boom Boom Basket Basket...

  • Page 85: 4.11 Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.11 LIFTING AND TIE DOWN Tie Down See Figure 4-6. Lifting WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST. 1. Refer to the Serial Number Plate, refer to the Specifications section of this manual, or weigh the individual unit to find 1.
  • Page 86 SECTION 4 - MACHINE OPERATION "A" Dimension Steer Axle To Center Of Gravity 53" (1350 mm) LIFT HERE (SPREADER BAR REQUIRED) CENTER GRAVITY "A" L ROTATION Figure 4-6. Lifting Chart 4-18 3121627...

  • Page 87: Oscillating Axle Lockout Test (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 4.14 TOW BAR (IF EQUIPPED) LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWING BRAKES. TOWING PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. VEHICLE MUST BE ABLE TO CONTROL MACHINE AT ALL TIMES.
  • Page 88 SECTION 4 - MACHINE OPERATION Figure 4-7. Tow Bar 4-20 3121627...

  • Page 89: Dual Fuel System (Gas Engine Only)

    SECTION 4 - MACHINE OPERATION 4. Position steer/tow selector valve for towing; pull valve knob 4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY) out for towing. The machine is now in the towing mode. Description After towing the machine, complete the following: 1.

  • Page 90: Changing From Gasoline To Lp Gas

    SECTION 4 - MACHINE OPERATION Changing From Gasoline to LP Gas 4.16 RE-SYNCHRONIZE UPRIGHT Releveling Valve 1. Start engine from Ground Control Console. A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90° (vertical) relative to the chassis (Refer to Figure 2.9 and Figure 2.10).
  • Page 91 SECTION 4 - MACHINE OPERATION 6. Lower the tower boom fully and con- tinue to hold down the switch to Tower Down for an additional 20 sec- onds. 7. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis.
  • Page 92 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 1 of 5 4-24 3121627...
  • Page 93 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 2 of 5 3121627 4-25...
  • Page 94 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 3 of 5 4-26 3121627...
  • Page 95 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Installation - Sheet 4 of 5 3121627 4-27...
  • Page 96 SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Installation - Sheet 5 of 5 4-28 3121627...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-B 0274464-B 0274470-B 0274466-B 0274468-B 0274472-B 0274474-B 0274462-B 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509 1701509...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-B 0274464-B 0274470-B 0274466-B 0274468-B 0274472-B 0274474-B 0274462-B 1703953 1703945 1703943 1703941 1705903 1703942 1703944 1702868 1705969 1705968 1704001...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-B 0274464-B 0274470-B 0274466-B 0274468-B 0274472-B 0274474-B 0274462-B 1001121813 1001122201 1001121822 1001121817 1001121819 1001121815 1705978 1001121820 1706948 1706948 1702265...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-1. Decal Legend - 800A Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-B 0274464-B 0274470-B 0274466-B 0274468-B 0274472-B 0274474-B 0274462-B 1705351 1705427 1705430 1705910 1705905 1705429 1705426 4-32 3121627...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800AJ Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-B 0274465-B 0274471-B 0274467-B 0274469-B 0274473-B 0274475-B 0274463-B 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701509 1701509 1701509 1701509 1701509 1701509...
  • Page 102 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800AJ Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-B 0274465-B 0274471-B 0274467-B 0274469-B 0274473-B 0274475-B 0274463-B 1703953 1703945 1703943 1703941 1705903 1703942 1703944 1702868 1705969 1705968 1704001 1705967 1704000 1703797...
  • Page 103 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800AJ Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-B 0274465-B 0274471-B 0274467-B 0274469-B 0274473-B 0274475-B 0274463-B 1706948 1001096141 1703987 1703990 1703989 1706439 1703990 1705977 1703986 1703959 1703959 1703959 1703959 1703959...
  • Page 104 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800AJ Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-B 0274465-B 0274471-B 0274467-B 0274469-B 0274473-B 0274475-B 0274463-B 1705351 1705427 1705430 1705910 1705905 1705429 1705426 4-36 3121627...

  • Page 105: 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 106: 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, do the following: However, provisions for moving the machine have been incorpo- rated.

  • Page 107: Machine Safety System Override (Msso)(Ce Only)

    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 108 SECTION 5 - EMERGENCY PROCEDURES NOTES: 3121627...

  • Page 109: 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 110 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 111: Fall Arrest Platform

    FALL ARREST PLATFORM PIPE RACKS 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 112: 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 113: 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 114: 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. See the J-Air Manual (PN 3128970) for more information. SkyCutter™...

  • Page 115: 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 116: Operation

    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 117: 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 118: 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 119: 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 120: 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 121: 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 122: 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 123: 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 124: 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 125 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 126 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 3121627...

  • Page 127: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS AND PERFORMANCE DATA This section of the manual provides additional necessary infor- mation to the operator for proper operation and maintenance of Operating Specifications this machine.

  • Page 128: Tires

    Range 800AJ 36 ft.-6 in. (11.13 m) 15-625 pneumatic 95PSI Wheel base 10 ft.- 0 in. (3.05 m) (6.5 Bar) Boom Elevation - 800A 15-625 foam-filled Above Grade +80 ft.(24.38 m) 18-625 foam-filled Below Grade -15 ft.-7 in. (4.75 m)

  • Page 129: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Capacities Engine Data Table 7-3. Capacities Table 7-4. Deutz D2011L04 Specifications Fuel Tank Approx. 39 gallons (147.6 liters) Type Liquid Cooled (Oil) Hydraulic Tank Approx. 40 gallons (151.4 liters) Fuel Diesel Hydraulic System (Including Tank) 77 Gal.
  • Page 130 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-5. Deutz TD 2.9 Specifications Table 7-6. GM 3.0L Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline or Gasoline/LP Gas Output 67 hp (50 kW) No. of Cylinders Torque 173 ft.lbs. (234 Nm) @ 1800rpm Gasoline 83 hp @ 3000 rpm Oil Capacity (Crankcase)

  • Page 131: Hydraulic Oil

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil Aside from JLG recommendations, it is not advisable to mix oils of differ- ent brands or types, as they may not contain the same required addi- tives or be of comparable viscosities. If use of hydraulic oil other than Table 7-7.
  • Page 132 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-10. Mobil EAL 224H Specs Table 7-9. 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 133 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-11. UCon Hydrolube HP-5046 Table 7-12. Exxon Univis HVI 26 Specs Type Synthetic Biodegradable Specific Gravity 32.1 Specific Gravity 1.082 Pour Point -76°F (-60°C) Pour Point, Max -58°F (-50°C) Flash Point 217°F (103°C) Viscosity Viscosity...

  • Page 134: Critical Stability Weights

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Critical Stability Weights Table 7-13. Critical Stability Weights COMPONENTS LBS. Tire & Wheel Size 15-625 DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIFFERENT WEIGHT (Foam Filled Only) 18 -625 OR SPECIFICATION (FOR EXAMPLE: BATTERIES, FILLED TIRES, COUNTER WEIGHT, ENGINE, AND PLATFORM) DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY.
  • Page 135 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 -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 8,9,10,11 Figure 7-5. Maintenance and Lubrication Diagram 3121627 7-13...

  • Page 140: Maintenance And Lubrication

    Super Synthetic-Based Oil, Non-Flammable. Withstands temperatures within -45° to Capacity - A/R Lube® 450°F (-43° to 232° C). JLG P/N 3020042. Lube - MPG Interval - Every 3 months or 150 hrs of operation Comments - Remote Access LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION UNDER NORMAL CONDITIONS.
  • 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 - 17 oz. (0.5 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 hrs of operation;...
  • Page 142 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 4. Swing Drive Hub 5. Hydraulic Return Filter Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. Lube Point(s) - Level/Fill Plug Capacity - 43 oz.
  • Page 143 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 6. Hydraulic Charge Filter 7. Hydraulic Tank Lube Point(s) - Fill Cap Capacity - 40 gallons (151 L) Tank; 77 gallons (291.4 L) Sys- Interval - Change after first 50 hrs. and every 6 months or 300 hrs.
  • Page 144 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 8. Oil Change w/Filter - Deutz D2011 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...
  • 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 7-6.
  • Page 146 9. Oil Change w/Filter - GM 10. Fuel Filter - Deutz D2011 Lube Point(s) - Fill Cap/Spin-on Element Lube Point(s) - Replaceable Element (JLG P/N 7027965) Interval - Every Year or 600 hours of operation Capacity - 4.5 qt. (4.25 L) w/filter Lube - EO...
  • 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

    Tire Replacement dations, may result in an unsafe condition regarding stability. 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.

  • Page 151: Wheel Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation 2. Tighten nuts in the following sequence: It is extremely important to apply and maintain proper wheel mounting torque. WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSIBLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE.

  • Page 152: Propane Fuel Filter Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 3. The tightening of the nuts should be done in stages. Follow- PROPANE FUEL FILTER REPLACEMENT ing the recommended sequence, tighten nuts per wheel torque chart. Removal Table 7-15. Wheel Torque Chart 1.

  • Page 153: Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Installation BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 1. Install the mounting plate to lock off O-ring seal. 2. If equipped, install the retaining bolt seal. 3.

  • Page 154: Propane Fuel System Pressure Relief

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE PROPANE FUEL SYSTEM PRESSURE RELIEF SUPPLEMENTAL INFORMATION The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI (21.5 BAR). TO and is only applicable to CE machines.
  • Page 155 SECTION 8 - INSPECTION AND REPAIR LOG SECTION 8. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 8-1. Inspection and Repair Log Date Comments 3121627...
  • Page 156 SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 3121627...
  • Page 160 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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800aj

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