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Oshkosh JLG 860SJ Operation And Safety Manual

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Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Models
800S
860SJ
PVC 2107
ANSI
AS/NZS MOL70
31219073
July 12, 2021 - Rev A
®

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  • Page 1 Operation and Safety Manual Original Instructions - Keep this manual with the machine at all times. Models 800S 860SJ PVC 2107 ANSI AS/NZS MOL70 31219073 July 12, 2021 - Rev A ®...
  • Page 2 WARNING Operating, servicing and maintaining this vehicle or equipment can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle or equipment in a well-ventilated area and wear gloves or wash your hands frequently when servicing.
  • Page 3 FOREWORD FOREWORD The Mobile Elevating Work Platform (MEWP) models covered in this manual are designed and tested to meet or exceed var- ious compliance standards. Please refer to the manufacturer’s nameplate affixed to the subject MEWP for specific standard compliance information. This manual is a very important tool! Keep it with the machine at all times.
  • 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 FOREWORD For: THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG • Accident Reporting • Standards and Regulations Compliance Information INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA- • Product Safety Publica- TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR tions •...
  • Page 6 FOREWORD REVISION LOG Original Issue A - July 12, 2021 31219073...

  • Page 7: Table Of Contents

    TABLE OF CONTENTS SECTION - 1 - SAFETY PRECAUTIONS HORIZONTAL AND CAPACITY LIMIT SWITCHES ..2-10 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)..2-14 GENERAL ..........1-1 PRE-OPERATION .
  • Page 8 TABLE OF CONTENTS DPF Filter Replacement due to Ash Load ..4-11 SECTION - 5 - EMERGENCY PROCEDURES TRAVELING (DRIVING) ....... 4-16 GENERAL .
  • Page 9 TABLE OF CONTENTS Preparation and Inspection ......6-8 SOFT TOUCH........6-14 Operation .
  • Page 10 TABLE OF CONTENTS Wheel Installation ....... . 7-27 PROPANE FUEL FILTER REPLACEMENT ....7-29 Removal .
  • Page 11 LIST OF FIGURES 7-1. Serial Number Locations ......7-10 2-1. Basic Nomenclature........2-4 2-2.
  • Page 12 LIST OF FIGURES 31219073...
  • Page 13 LIST OF TABLES Minimum Approach Distances (M.A.D.) ....1-6 Beaufort Scale (For Reference Only)....1-9 Inspection and Maintenance Table .
  • Page 14 LIST OF TABLES viii 31219073...

  • Page 15: Section 1. Safety Precautions

    SECTION 1 - SAFETY PRECAUTIONS SECTION 1. SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAMAGE, PERSONAL INJURY OR safe machine usage and maintenance.

  • Page 16: Workplace Inspection

    SECTION 1 - SAFETY PRECAUTIONS Workplace Inspection • Only personnel who have received proper training regarding the inspection, application and operation of MEWPs (including • Precautions to avoid all hazards in the work area must be recognition and avoiding hazards associated with their opera- taken by the user before and during operation of the machine.

  • Page 17: Machine Inspection

    SECTION 1 - SAFETY PRECAUTIONS Machine Inspection OPERATION • Do not operate this machine until the inspections and func- General tional checks as specified in Section 2 of this manual have been performed. • Machine operation requires your full attention. Bring the machine to a full stop before using any device, i.e.

  • Page 18: Trip And Fall Hazards

    SECTION 1 - SAFETY PRECAUTIONS • Do not carry materials directly on platform railing unless • Hydraulic cylinders are subject to thermal expansion and con- traction. This may result in changes to the platform position approved by JLG. while the machine is stationary. Factors affecting thermal •...

  • Page 19: Electrocution Hazards

    SECTION 1 - SAFETY PRECAUTIONS Electrocution Hazards • Enter and exit only through gate area. Use extreme caution when entering or leaving platform. Ensure that the platform • This machine is not insulated and does not provide protection assembly is fully lowered. Face the platform when entering or from contact or proximity to electrical current.

  • Page 20: Minimum Approach Distances (M.a.d.)

    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 Tipping Hazards • The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are • Ensure that the ground conditions are adequate to support rated for the voltage of the line being guarded. These barriers the maximum tire load indicated on the tire load decals shall not be part of (or attached to) the machine.
  • Page 22 SECTION 1 - SAFETY PRECAUTIONS • Before driving on floors, bridges, trucks, and other surfaces, • Wind speed can be significantly greater at height than at ground level. check allowable capacity of the surfaces. • Never exceed the maximum platform capacity as specified on •...
  • Page 23 SECTION 1 - SAFETY PRECAUTIONS DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED SPECIFICATIONS SHOWN IN SECTION 7.2 OR AS SHOWN ON THE CAPACITY PLACARD ON THE PLAT- FORM BILLBOARD. Wind Speed Beaufort Description Land Conditions Number 0-0.2 Calm Calm.

  • 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 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: Battery Hazards

    SECTION 1 - SAFETY PRECAUTIONS • DO NOT use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help pro- MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT- TEN PERMISSION FROM THE MANUFACTURER.

  • Page 27: 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 The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, The Mobile Elevating Work Platform (MEWP) is a personnel han- depressions, holes, and drop-offs exist.

  • Page 28: Operator Responsibility

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Operator Responsibility Operating characteristics and limitations; Features and devices; The operator must be instructed that he/she has the responsibil- Accessories and optional equipment. ity and authority to shut down the machine in case of a malfunc- tion or other unsafe condition of either the machine or the job PREPARATION, INSPECTION, AND MAINTENANCE site.

  • Page 29: Inspection And Maintenance Table

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Table 2-1. Inspection and Maintenance Table Primary Service Type Frequency Reference Responsibility Qualification Before using each day; or Pre-Start Inspection User or Operator User or Operator Operation & Safety Manual whenever there’s an Operator change. Service and Maintenance Manual Pre-Delivery Inspection (See Note) Before each sale, lease, or rental delivery.

  • Page 30: Basic Nomenclature

    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 31: Pre-Start Inspection

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Pre-Start Inspection Operation and Safety Manuals – Make sure a copy of the Operation and Safety Manual, EMI Safety Manual (Domestic The Pre-Start Inspection should include each of the following: only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container.
  • Page 32 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Platform Gate – Keep gate and surrounding area clean and unobstructed. Verify the gate closes properly and is not bent or damaged. Keep gate closed at all times except when entering/exiting the platform and loading/unloading mate- rials.
  • Page 33 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Walk-Around Inspection O AC 01940 31219073...
  • Page 34 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Platform Control Console - Begin the Walk-Around Inspection at Item 1, as noted on the dia- Switches and levers return to gram. Continue to the right (counterclockwise viewed from top) neutral when activated and released, decals/placards secure checking each item in sequence for the conditions listed in the fol- and legible, control markings legible.

  • Page 35: Function Check

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Function Check Turntable Bearing - Evidence of proper lubrication. No evi- dence of loose bolts or looseness between bearing and Perform the Function Check as follows: machine. Ground Control Console - From the ground control console with no load in the plat- Switches and levers return to neu- form:...
  • Page 36 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION From the platform control console: With the platform in the transport (stowed) position: a. Ensure the control console is firmly secured in the a. Drive the machine on a grade, not beyond the maxi- proper location.

  • Page 37: Skyguard Function Test

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION SkyGuard® Function Test NOTE: If SkyGuard is enabled with the Soft Touch system, functions will cut out instead of reversing. NOTE: Refer to Section 4.12 for additional information on SkyGuard Disengage the SkyGuard sensor, release controls, then recy- operation.
  • Page 38 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2.3 HORIZONTAL AND CAPACITY PROXIMITY SWITCHES OAC02300 Figure 2-2. Horizontal and Capacity Proximity Sensors- Sheet 1 of 2 2-12 31219073...
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Item Description Operation Characteristic Lower Assembly Communicates that the boom is no longer in the transport position and also when the limits of the Sensor capacity zone has been reached. Boom Transport Communicates that the boom is no longer in the transport position.

  • Page 40: Oscillating Axle Lockout Test (If Equipped)

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) 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. Place the 6 in (15.2 cm) high block with ascension ramp in LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- front of right front wheel.

  • Page 41: Section 3 - Machine Controls And Indicators

    SECTION 3 - MACHINE CONTROLS AND INDICATORS SECTION 3. MACHINE CONTROLS AND INDICATORS GENERAL CONTROLS AND INDICATORS NOTE: The indicator panels use different shaped symbols to alert the operator to different types of operational situations that could THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND arise.

  • Page 42: Ground Control Console - 800S Without Msso

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Not Used 2. Platform Rotate 3. Platform Leveling Override 4. Not Used 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Not Used 10. Swing 11. Lift 12.

  • Page 43: Ground Control Console - 800S With Msso

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Not Used 2. Platform Rotate 3. Platform Leveling Override 4. Not Used 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Machine Safety System Override (MSSO) 10.

  • Page 44: Ground Control Console - 800S With Msso And Dpf

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Diesel Particulate Filter (DPF) 2. Platform Rotate 3. Platform Leveling Override 4. Not Used 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Machine Safety System Override (MSSO) 10.

  • Page 45: Ground Control Console - 860Sj Without Msso

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Not Used 2. Platform Rotate 3. Platform Leveling Override 4. Articulating Jib Boom 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Not Used 10. Swing 11.

  • Page 46: Ground Control Console - 860Sj With Msso

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Not Used 2. Platform Rotate 3. Platform Leveling Override 4. Articulating Jib Boom 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Machine Safety System Override (MSSO) 10.

  • Page 47: Ground Control Console - 860Sj With Msso And Dpf

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1. Diesel Particulate Filter (DPF) 2. Platform Rotate 3. Platform Leveling Override 4. Articulating Jib Boom 5. Power/Emergency Stop 6. Engine Start/Auxiliary Power 7. Platform/Ground Select Switch 8. Display Gauge 9. Machine Safety System Override (MSSO) 10.

  • Page 48: Ground Control Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Diesel Particulate Filter (DPF) (If Equipped) TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR This button initiates the standstill exhaust sys- tem cleaning. TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.
  • Page 49 SECTION 3 - MACHINE CONTROLS AND INDICATORS Jib (If Equipped) NOTE: Functions will operate at a slower than normal rate because of the lesser flow of hydraulic fluid delivered. Provides raising and lowering of the jib. WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME.
  • Page 50 SECTION 3 - MACHINE CONTROLS AND INDICATORS Display Gauge Lift Control Registers engine hours, fuel level (if applica- Provides raising and lowering of the ble), and Diagnostic Trouble Codes (DTCs) boom. from the JLG Control System and the engine control system. Machine Safety System Override (MSSO) (If Equipped) Indicator Panel.

  • Page 51: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS ½ OAC 01900 1. Battery Charge 4. Platform Capacity 7. Fuel Level 10. Engine Error 2. System Distress 5. Generator 8. Platform Overload 11. Emissions Temperature 3. Drive Steer Disable 6. Glow Plug 9.

  • Page 52: Ground Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Ground Control Indicator Panel Drive Steer Disable Indicator Indicates the Drive and Steer Disable function (See Figure 3-7., Ground Control Indicator Panel.) has been activated. NOTE: Indicator lights illuminate as a self test for approximately 1 second when key is turned to the on position.
  • Page 53 SECTION 3 - MACHINE CONTROLS AND INDICATORS Glow Plug Indicator Wire Rope Service Indicator Indicates the glow plugs are on. The glow plugs When illuminated, the light indicates the wire are automatically turned on with the ignition ropes are loose or broken and must be repaired circuit and remain in for approximately 7 seconds.

  • Page 54: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS 1702676-B 1704997 1001131168 B 1702566 1702565 A 1702567 A 1702938 1705170 A 13 12 1. Drive Speed / Torque Select 6. Power/Emergency Stop 10. Telescope 14. Soft Touch/SkyGuard/SkySense 2. Steer Select 7. Engine Start /Auxiliary Power 11.

  • Page 55: Platform Console

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Console both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This can be used for positioning the machine in aisle ways or (See Figure 3-8., Platform Console) against buildings.
  • Page 56 SECTION 3 - MACHINE CONTROLS AND INDICATORS Fuel Select (Dual Fuel Engine Only) Engine Start/Auxiliary Power (If Equipped) When pushed forward, the switch energizes Gasoline or liquid propane fuel may be the starter motor to start the engine. selected by moving the switch to the appropriate position. It The Auxiliary Power control switch energizes is unnecessary to purge the fuel system before switching the electrically operated hydraulic pump.
  • Page 57 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTE: Lift, Swing, and Drive control levers are spring-loaded and will Main Boom Telescope automatically return to neutral (off) position when released. Provides extension and retraction of the main boom. 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 the accessory lights...
  • Page 58 SECTION 3 - MACHINE CONTROLS AND INDICATORS Soft Touch/SkyGuard/SkySense Override Switch Soft Touch/SkyGuard/SkySense Indicator For machines equipped with SkyGuard: Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated. All controls are cut out The SkyGuard override switch enables until the override button is pushed.
  • Page 59 SECTION 3 - MACHINE CONTROLS AND INDICATORS Function Speed Control NOTE: To operate the Main Boom Lift/Swing joystick, pull up on the locking ring below the handle. This control knob affects the speed of Tele- NOTE: scope, Jib (If Equipped), and Platform The Main Boom Lift/Swing joystick is spring Rotate functions.
  • Page 60 SECTION 3 - MACHINE CONTROLS AND INDICATORS ½ OAC 01890 1. System Distress 4. Tilt Alarm/Warning 7. Footswitch 10. Level System 13. Wire Rope Service 2. Drive Orientation 5. Generator 8. Glow Plug 11. Emissions Failure 14. Engine Error 3. Capacity Zone Indicator 6.

  • Page 61: Platform Control Indicator Panel

    SECTION 3 - MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel Platform Capacity Indicator Indicates the platform capacity zone for the (See Figure 3-9., Platform Control Indicator Panel) current position of the platform. Restricted NOTE: Indicator lights illuminate as a self test for approximately capacities are permitted at restricted platform 1 second when key is turned to the on position.
  • Page 62 SECTION 3 - MACHINE CONTROLS AND INDICATORS Footswitch Enable Indicator IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, To operate any function, the footswitch must be depressed, and the function selected within RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT seven seconds.
  • Page 63 SECTION 3 - MACHINE CONTROLS AND INDICATORS Glow Plug Indicator Platform Overload Indicator Indicates the glow plugs are operating. After Indicates the platform has been overloaded. turning on ignition, wait until light goes out before cranking engine. Wire Rope Service Indicator Fuel Level Indicator Indicates the wire ropes are loose or broken and Indicates the level of the fuel in the fuel tank.
  • Page 64 SECTION 3 - MACHINE CONTROLS AND INDICATORS 3-24 31219073...

  • Page 65: Section 4 - Machine Operation

    SECTION 4 - MACHINE OPERATION SECTION 4. MACHINE OPERATION DESCRIPTION OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a mobile elevating work platform used to posi- Capacities tion personnel, along with their necessary tools and materials at work locations. Raising boom above horizontal with or without any load in plat- The primary operator control console is in the platform.

  • Page 66: Platform Load Sensing System (Lss)

    SECTION 4 - MACHINE OPERATION Platform Load Sensing System (LSS) The Platform Load Sensing System provides the platform capac- ity to the control system. If the LSS system senses an overload condition, boom functions ROTATE PLATFORM will be disabled, the overload indicator is illuminated at both con- 90 DEGREES trol stations, and the overload alarm will sound.

  • Page 67: Position Of Least Forward Stability

    SECTION 4 - MACHINE OPERATION TELESCOPE FULLY EXTENDED MACHINE WILL TIP OVER IN THIS DIRECTION IF OVERLOADED OR OPERATED BEYOND THE LIMITS OF THE MAXIMUM OPERATING SLOPE. TURNTABLE ROTATED 90 DEGREES FROM STOWED POSITION O AC01920 Figure 4-2. Position of Least Forward Stability 31219073...

  • Page 68: Engine Operation

    SECTION 4 - MACHINE OPERATION ENGINE OPERATION Starting Procedure NOTE: When operating a machine at high altitudes, a decrease in machine performance may occur due to a decrease in air den- sity. IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOW STARTER TO “COOL OFF”...

  • Page 69: Shutdown Procedure

    SECTION 4 - MACHINE OPERATION ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING NOTE: Footswitch must be in released (up) position before starter will ANY LOAD. operate. If starter operates with footswitch in the depressed posi- tion, DO NOT OPERATE MACHINE.

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

    SECTION 4 - MACHINE OPERATION Air Shutoff Valve (ASOV) (If Equipped) DO NOT USE ASOV AS AN ALTERNATIVE TO SHUTTING DOWN MACHINE PROPERLY. Air Shutoff Valve (ASOV ) is an overspeed protection device mounted to the engine’s air intake system. When the valve is actuated, it obstructs airflow intake and stops the engine.

  • Page 71: Fuel Reserve / Shut-Off System

    SECTION 4 - MACHINE OPERATION Fuel Reserve / Shut-Off System • Engine Restart - When the engine shuts down, the opera- tor will be permitted to cycle power and restart the engine for approximately 2 minutes of run time. After the 2 min- NOTE: Reference the Service and Maintenance Manual along with a utes of run time is complete, the operator may cycle power...

  • Page 72: Diesel Particulate Filter (If Equipped)

    SECTION 4 - MACHINE OPERATION DIESEL PARTICULATE FILTER (IF EQUIPPED) Standstill Cleaning The following conditions must be met to perform Standstill Diesel Particulate Filter (DPF) is an emissions control system used Cleaning. in diesel engines and requires operator interaction to make sure proper operation of the system.
  • Page 73 SECTION 4 - MACHINE OPERATION Launch the cleaning process by pressing the DPF button on the Ground Console for 3 seconds. The Indicator Gauge will display the following screen. The Main Cleaning process will begin and last for approxi- mately 30 to 60 minutes. The following screen will show that the process has begun and includes a status bar that indi- cates the progress of the cleaning process.

  • Page 74: Maintenance Standstill Cleaning

    SECTION 4 - MACHINE OPERATION Canceling Maintenance Standstill After the cleaning process is complete, the engine will run for approximately 5 minutes to allow the engine and Maintenance Standstill Cleaning will be stopped immediately if: Exhaust After Treatment (EAT) to cool down. The Indicator Gauge will display the "Regen Complete"...

  • Page 75: Unsuccessful Cleaning Event

    SECTION 4 - MACHINE OPERATION Unsuccessful Cleaning Event DPF Filter Replacement due to Ash Load If there is an unsuccessful cleaning event, the DPF icon will show The DPF collects non-burnable particulates which cannot be on the display gauge. Possible causes of an Unsuccessful Clean- removed by the Standstill Cleaning process.
  • Page 76 SECTION 4 - MACHINE OPERATION Table 4-1. Ash Load DPF Filter Replacement DPF Filter Engine Error Ash Load Derate Exchange Indicator Indicator Normal Operation <100% None Filter Exchange Required ≥100% None DPF Filter E xchange Blinking Warning Level ≥105% None DPF Filter E xchange Blinking Continuous...
  • Page 77 SECTION 4 - MACHINE OPERATION Machine Hours Emissions Standstill Cleaning Engine Error Since Last DPF Indicator Temperature Derate Comments Levels Indicator Cleaning Indicator* 0-500 Between 500 and 650 hours, Normal None cleaning cycle can be initiated Operation 500-650 with JLG analyzer. Standstill 650-750 None...
  • Page 78 SECTION 4 - MACHINE OPERATION Emissions Soot Load/ DPF Cleaning Engine Error Soot Levels DPF Indicator Temperature Derate Comments Time Initiation Methods Indicator Indicator* Normal Opera- <99% None tion Will remain in Stand- 100% to 109% Switch in JLG Machine Standstill still mode for 100 hours None...
  • Page 79 SECTION 4 - MACHINE OPERATION 31219073 4-15...

  • Page 80: Traveling (Driving)

    SECTION 4 - MACHINE OPERATION TRAVELING (DRIVING) DO NOT DRIVE THE MEWP OUT OF TRANSPORT MODE EXCEPT ON A SMOOTH, FIRM NOTE: When the upper boom is raised approximately 11 degrees above horizontal, the high drive function will automatically be in low SURFACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE.

  • Page 81: Traveling Forward And Reverse

    SECTION 4 - MACHINE OPERATION Traveling Forward and Reverse This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond At Platform Controls, pull out Emergency Stop the rear drive tires and the machine may Drive/ switch and activate footswitch.

  • Page 82: Traveling On A Grade

    SECTION 4 - MACHINE OPERATION Traveling on a Grade STEERING Position thumb switch on Drive/Steer controller to When traveling a grade, maximum braking and traction are obtained Right for steering right, or to Left for steering left. with the boom stowed, in position over the rear (drive) axle, and in line with the direction of travel.

  • Page 83: Boom

    SECTION 4 - MACHINE OPERATION BOOM TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMER- GENCY STOP SWITCH TO STOP THE MACHINE. A RED TILT WARNING LIGHT IS LOCATED ON THE PLATFORM CONTROL INDICATOR PANEL WHICH LIGHTS WHEN THE CHASSIS IS ON AN EXCESSIVE SLOPE.

  • Page 84: Telescoping The Main Boom

    SECTION 4 - MACHINE OPERATION Telescoping the Main Boom 4.10 USB CHARGING PORT The machine is equipped with a USB charging port for the To extend or retract the boom, use the Telescope operator. Control Switch to select In or Out movement. FUNCTION SPEED CONTROL This control knob affects the speed of Tele- scope, Jib (If Equipped), and Platform Rotate...

  • Page 85: Machine Safety System Override (Msso)

    SECTION 4 - MACHINE OPERATION 4.11 MACHINE SAFETY SYSTEM OVERRIDE (MSSO) 4.12 SKYGUARD® OPERATION (IF EQUIPPED) SkyGuard provides enhanced control panel protection. When the SkyGuard sensor is activated, functions in use at the time of actu- The Machine Safety System Override (MSSO) is ation will reverse or cutout.

  • Page 86: Skyguard

    SECTION 4 - MACHINE OPERATION SkyGuard SkyGuard SkyEye® Operator passes through path of sensor beam. Approximately 50 lb (222 Nm) of force is applied to yellow bar. SkyGuard SkyLine® O AC 03970 Rod is pressed, breaking the connection between the rod and right bracket.

  • Page 87: Skyguard Function Table

    SECTION 4 - MACHINE OPERATION SkyGuard Function Table Boom Drive Drive Boom Boom Boom Basket Basket Steer Swing Lift Jib Lift Forward Reverse Lift Up Tele Out Tele In Level Rotate Down R * / C * * R = Indicates Reversal is Activated C = Indicates Cutout is Activated * DOS (Drive Orientation System) Enabled * * DOS Not Enabled, machine is driving straight without steering, and any other hydraulic function is active...

  • Page 88: Oscillating Axle Lockout Test (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.13 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) Disconnect drive hubs by inverting disconnect cap. LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COM- PONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED. Refer to Section 2.4, Oscillating Axle Lockout Test (If Equipped) for procedure.

  • Page 89: Tow Bar (If Equipped)

    SECTION 4 - MACHINE OPERATION 4.15 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 90 SECTION 4 - MACHINE OPERATION After towing the machine, complete the following: Actuate steer/tow selector valve for steering; push valve knob IN to the actuated position. Reconnect drive hubs by inverting disconnect cap. Disconnect towbar from towing vehicle and place it in the stowed position as shown below.

  • Page 91: 4.16 Shut Down And Park

    SECTION 4 - MACHINE OPERATION 4.16 SHUT DOWN AND PARK To shut down and park the machine, the procedures are as fol- lows: Drive machine to a reasonably well protected area. Ensure boom is fully retracted and lowered over rear axle. Shut down Emergency Stop at Platform Controls.

  • Page 92: 4.17 Lifting And Tie Down

    SECTION 4 - MACHINE OPERATION 4.17 LIFTING AND TIE DOWN Ensure the platform is lowered so the wear pad on the bot- tom rests on the surface of the transportation vehicle. Lifting NOTE: Secure through the tie downs on the boom using straps or chains of adequate strength.

  • Page 93: Lifting And Tie Down Chart

    SECTION 4 - MACHINE OPERATION MODE LS 1001158084 800S 66” (168cm) 76” (189cm) 57” (145cm) 860S J 62” (157cm) 80” (203cm) 53” (135cm) 680S 70” (178cm) 72” (183cm) 61” (155cm) 1001175354 B Figure 4-6. Lifting and Tie Down Chart 31219073 4-29...

  • Page 94: Decal Location Legend, 860Sj

    SECTION 4 - MACHINE OPERATION Table 0-1. Decal Location Legend, 860SJ O AC02030 Figure 4-7. Decal Location - 800S Decal Location Sheet 1 of 5 4-30 31219073...
  • Page 95 SECTION 4 - MACHINE OPERATION 60 AUS 101 104 OAC02040 Figure 4-8. Decal Location - 800S Decal Location Sheet 2 of 5 31219073 4-31...
  • Page 96 SECTION 4 - MACHINE OPERATION O AC 02050 Figure 4-9. Decal Location - 800S Decal Location Sheet 3 of 5 4-32 31219073...
  • Page 97 SECTION 4 - MACHINE OPERATION OAC02060 Figure 4-10. Decal Location - 800S Decal Location Sheet 4 of 5 31219073 4-33...
  • Page 98 SECTION 4 - MACHINE OPERATION ANSI/ ANSI EXPORT CE / AUS O AC 02070 Figure 4-11. Decal Location - 800S Decal Location Sheet 5 of 5 4-34 31219073...

  • Page 99: Decal Location Legend, 800S

    SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242459-D 1001242595-D 1001242654-D 1001242694-D 1001242700-D 1001242753-D 1001257320-B 1001242826-D 1001257322-B 1705980 1705980 3252347 3251813 3251813 3251813 3251813 3251813 3251813 1702631 1702631 1702631...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242459-D 1001242595-D 1001242654-D 1001242694-D 1001242700-D 1001242753-D 1001257320-B 1001242826-D 1001257322-B 1702774 1702774 1702774 1702774 1702774 1702774 1702774 0274518 1702773 1702773 1702773 1702773...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Location Legend, 800S ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242459-D 1001242595-D 1001242654-D 1001242694-D 1001242700-D 1001242753-D 1001257320-B 1001242826-D 1001257322-B 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 3251243 3251243 3251243...
  • Page 102 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Location Legend, 860SJ ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242586-D 1001242597-D 1001242655-D 1001242695-D 1001242701-D 1001242754-D 1001257321-B 1001242827-D 1001257323-B 1705980 1705980 3252347 3251813 3251813 3251813 3251813 3251813 3251813 1702631 1702631 1702631...
  • Page 103 SECTION 4 - MACHINE OPERATION ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242586-D 1001242597-D 1001242655-D 1001242695-D 1001242701-D 1001242754-D 1001257321-B 1001242827-D 1001257323-B 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1700818 1700818 1700818 1700818 1700818 1700818 1700818 1700818 1001231801 0641406...
  • Page 104 SECTION 4 - MACHINE OPERATION ANSI Korean Chinese Spanish Portuguese French CE/UKCA Japanese Australian Item # 1001242586-D 1001242597-D 1001242655-D 1001242695-D 1001242701-D 1001242754-D 1001257321-B 1001242827-D 1001257323-B 1703797 1703927 1703925 1703923 1705895 1703924 1705822 1703926 1705822 1705336 1705345 1001116849 1705917 1705896 1705347 1701518 1705344 1701518...

  • Page 105: Section 5 - Emergency Procedures

    SECTION 5 - EMERGENCY PROCEDURES SECTION 5. EMERGENCY PROCEDURES GENERAL FOLLOWING ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINE AND TEST ALL This section explains the steps to be taken in case of an emer- FUNCTIONS FIRST FROM THE GROUND CONTROLS, THEN FROM THE PLATFORM CON- gency situation while operating.

  • 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)

    SECTION 5 - EMERGENCY PROCEDURES MACHINE SAFETY SYSTEM OVERRIDE (MSSO) (IF EQUIPPED) The Machine Safety System Override (MSSO) is only to be used to retrieve an operator that is pinned, trapped, or unable to operate the machine and function controls are locked out from the platform due to a platform overload sit- uation.
  • Page 108 SECTION 5 - EMERGENCY PROCEDURES 31219073...

  • Page 109: Section 6 - Accessories

    SECTION 6 - ACCESSORIES SECTION 6. ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI CE/UKCA MOL 70 China (GB) (USA Only) Fall Arrest Platform (36" x 96")      Fall Arrest Platform (36" x 72")  ...
  • Page 110 SECTION 6 - ACCESSORIES Table 6-1. Available Accessories Market Accessory ANSI ANSI CE/UKCA MOL 70 China (GB) (USA Only) Nite Bright®         Platform Work Lights         Platform Mesh to Top Rail ...

  • Page 111: Options/Accessories Relationship Table

    SECTION 6 - ACCESSORIES Table 6-2. Options/Accessories Relationship Table COMPATIBLE WITH ACCESSORY REQUIRED ITEM INCOMPATIBLE WITH INTERCHANGABLE WITH (Note 2) (Note 1) Pipe Racks SkyPower Platform Mesh to Mid Rail, Platform Mesh to Top Rail, SkySense, Soft Touch SkyCutter, SkyGlazier, SkyWelder SkyCutter, SkyGlazier, SkyAir SkyPower...

  • Page 112: Fall Arrest Platform

    SECTION 6 - ACCESSORIES 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 113: 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 114: 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 115: 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 is capable of cutting up to a thickness of 3/8"...

  • Page 116: 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 117: Preparation And Inspection

    SECTION 6 - ACCESSORIES SKYGLAZIER® • Ensure no personnel are beneath platform. • 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 118: 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 lb 150 lb 250 lb (227 kg) (68 kg) (113 kg) 550 lb 150 lb 250 lb...

  • Page 119: Preparation And Inspection

    SECTION 6 - ACCESSORIES Preparation and Inspection SKYPOWER® 7.5 KW AND GENERATOR 4 KW • Check for cracked welds and damage to tray. • Ensure tray is properly secured to platform. • Ensure strap is not torn or frayed. Operation Load SkyGlazier tray with panel.

  • Page 120: Operation

    SECTION 6 - ACCESSORIES Safety Precautions All power regulation components are located in a watertight box 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 two-pole, 20 A (4 kW) DO NOT OVERLOAD PLATFORM.

  • Page 121: Skywelder

    SECTION 6 - ACCESSORIES SKYWELDER® Generator Output Engine Speed of 1800 rpm +/- 10%. Specifications: • 3-phase: 240 V, 60 Hz, 7.5 kW • 1-phase: 240 V/120 V, 60 Hz, 6 kW Welding Accessories • 12 ft welding leads with clamp and stinger (stored in the platform) •...

  • Page 122: 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 123: Operation

    SECTION 6 - ACCESSORIES SOFT TOUCH® • Use correct rod size and current settings. • 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 124: Skysense

    SECTION 6 - ACCESSORIES SKYSENSE™ Preparation and Inspection Pre-Operation Inspection: Inspect each of the SkySense tubes for dents, cracks, or other SKYSENSE IS NOT INTENDED TO REPLACE OR REDUCE THE NEED FOR THE OPERATOR damage. TO BE AWARE OF THE ENVIRONMENT AROUND THE MACHINE. HAZARDS THAT WILL Inspect each SkySense sensor for any damage to the hous- CAUSE SERIOUS INJURY OR DEATH MAY NOT BE PREVENTED OR REDUCED BY SKY- SENSE.

  • Page 125: Operation

    SECTION 6 - ACCESSORIES Operation Ensure the area below the platform is clear of obstructions and lower the platform. The machine should slow down, SkySense slows a machine’s function to creep speed when it is a (SkySense Status LED will blink yellow with increasing fre- certain distance away from an object, known as the "warning quency) and stop, (SkySense Status LED will be illuminated zone."...
  • Page 126 SECTION 6 - ACCESSORIES NOTE: During active DOS (Drive Orientation System), SkySense is active when driving in both forward and reverse directions. There are two LED indicators on the platform control box that sig- nal SkySense activity. • No LED: Normal operation. •...

  • Page 127: Skysense Alarm

    SECTION 6 - ACCESSORIES SkySense Alarm Override Button Activation of SkySense is signaled by an audible alarm and the The yellow override button allows operators to bypass normal LEDs on the platform console that indicate SkySense activity SkySense operation in order to move closer to an object in the when reaching the warning or stop zones.

  • Page 128: Skysense Coverage Areas

    SECTION 6 - ACCESSORIES SkySense Coverage Areas Level 2 (3 - Bar) Level 1 (2 - Bar) Sensor Cones shown are approximations for reference only. 6-20 31219073...

  • Page 129: 6.10 Bolt-On External Fall Arrest

    SECTION 6 - ACCESSORIES 6.10 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 130: Inspection Before Use

    SECTION 6 - ACCESSORIES Inspection Before Use • Fittings & Brackets: Ensure all fittings are tight and there are no signs of fractures. Inspect brackets for any damage. The external fall arrest system must be inspected before each use of •...

  • Page 131: Bolt-On External Fall Arrest System

    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 31219073 6-23...
  • Page 132 SECTION 6 - ACCESSORIES 6.11 NITE BRIGHT® 6.12 PLATFORM WORK LIGHTS The Nite Bright light package consists of two 40W lights mounted The Platform Work Lights accessory consists of two 12V lights to the platform railing. mounted to the platform railing. O AC 03990 O AC 04000 6-24...

  • Page 133: Section 7 - General Specifications & Operator Maintenance

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SECTION 7. GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE INTRODUCTION OPERATING SPECIFICATIONS This section of the manual provides additional necessary infor- Table 7-1. Operating Specifications mation to the operator for proper operation and maintenance of this machine.

  • Page 134: Specifications And Performance Data

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Specifications and Performance Data Table 7-1. Operating Specifications Turning Radius (outside) Table 7-2. Specifications and Performance Data 800S/860SJ 19.75 ft. (6.02 m) Turning Radius (inside) 12.5 ft. (3.8 m) Swing 360° Maximum Drive Speed: 3.48 mph (5.6 km/h) Tail Swing 4’8"...

  • Page 135: Capacities

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Engine Data Table 7-2. Specifications and Performance Data Ground Bearing Pressure - 860SJ 81 psi (5.7 kgm/cm Table 7-4. Deutz D2011L04 Specifications Max. Tire Load - 800S 17,350 lb (7870 kg) Type Liquid Cooled (Oil) Max.

  • Page 136: Deutz Td 2.9 Specifications

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 7-5. Deutz TD 2.9 Specifications Table 7-6. Ford 2.5L DF Specifications Fuel Ultra Low Sulfur Diesel (15 ppm) Fuel Gasoline or Gasoline/LP Gas Output 67 hp (50 kW) Gasoline 84 hp @ 3200 rpm Torque 173 ft.lbs.

  • Page 137: Battery

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Battery Major Component Weights Table 7-7. Battery Specifications Table 7-9. Component Weights Voltage 12 Volt Component Pounds Kilograms Type 31-950 Turntable (bare) 3700 1678 Cold Cranking Amps 950 CCA @ 0° F (-18° C) Counterweight (S) 7000 3175...

  • Page 138: Hydraulic Oil

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Oil NOTE: When temperatures remain consistently below 20 degrees F. (-7 degrees C.), JLG Industries recommends the use of premium cold weather hydraulic fluid. Table 7-10. Hydraulic Oil Hydraulic System Aside from JLG recommendations, it is not advisable to mix oils of differ- S.A.E.
  • Page 139 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 1001206353 A Figure 7-1. Hydraulic Oil Operation Chart - Sheet 1 of 2 31219073...
  • Page 140 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Fluid Properties Base Classifications Shell Spirax S4 TXM - Recommended Mobilfluid 424 - Optional Shell Tellus S2 VX 32 - Recommended Mobil DTE 10 Excel 32 - Optional Shell Tellus S4 VX 32 - Recommended Univis HVI 26 - Optional Shell Naturelle HF - E32 - Recommended Mobil EAL Envirosyn H32- Optional...

  • Page 141: Serial Number Location

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SERIAL NUMBER LOCATION A serial number plate is affixed to the left rear side of the frame. If the serial number plate is damaged or missing, the machine serial num- ber is stamped on the left side of the frame. Figure 7-3.

  • Page 142: Engine Operating Temperature Specifications - Deutz

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 120°F(49°C) NO OPERATION ABOVE THIS 110°F(43°C) AMBIENT TEMPERATURE 100°F(38°C) 90°F(32°C) 80°F(27°C) SUMMER GRADE 70°F(21°C) ENGINE FUEL 60°F(16°C) SPECIFICATIONS 50°F(10°C) 40°F(4°C) 30°F(-1°C) WINTER 20°F(-7°C) ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A 10°F(-12°C)

  • Page 143: Engine Operating Temperature Specifications - Deutz

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180° F (82°C) OR ABOVE. 180° F (82° C) (HYD. OIL TANK TEMP.) IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER (CONSULT JLG SERVICE...

  • Page 144: Maintenance And Lubrication Diagram

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 7-6. Maintenance and Lubrication Diagram 7-12 31219073...

  • Page 145: Maintenance And Lubrication

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MAINTENANCE AND LUBRICATION Swing Bearing - Internal Ball Bearing NOTE: The following numbers correspond to those in Figure 7-6., Main- tenance and Lubrication Diagram. Table 7-11. 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 146 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Bearings 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 147 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Return Filter 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. 300 hours thereafter or as indicated by Condition Indicator (if equipped).
  • Page 148 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Hydraulic Tank Platform Filter Lube Point(s) - Fill Cap Interval - Change as necessary Capacity - Tank (to Full mark on sight gauge) Approx. 21 gallons (79.5 liters) System Capacity - 59 gallons (223 liters) Lube - HO Interval - Check Level daily;...
  • Page 149 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 150 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE MINIMUM OIL MINIMUM LEVEL OIL LEVEL MAXIMUM LEVEL OIL MINIMUM LEVEL OIL MAXIMUM OIL COLD MAXIMUM LEVEL OIL LEVEL COLD NOTE: Hot oil checks should be made a period of 5 minutes after the engine has been shut down. Figure 7-7.
  • Page 151 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Oil Change w/Filter - Ford 2.5L 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 152 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 Fuel Filter (Gasoline) - GM Lube Point(s) - Replaceable Element...
  • Page 153 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 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 31219073...

  • Page 154: Tires & Wheels

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE TIRES & WHEELS Fuel Filter (Propane) - Ford 2.5L Engine Tire Damage For polyurethane foam filled tires, JLG Industries, Inc. recommends when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrange- ments must be made for replacement of the tire or tire assembly.

  • Page 155: Tire Replacement

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Tire Replacement Wheel Replacement JLG recommends a replacement tire be the same size, ply and brand The rims installed on each product model have been designed for as originally installed on the machine. Please refer to the JLG Parts stability requirements which consist of track width, tire pressure, and Manual for the part number of the approved tires for a particular load capacity.

  • Page 156: Wheel Installation

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Wheel Installation 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 157: 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 Relieve the propane fuel system pressure. Refer to Propane NEW SEAL Fuel System Pressure Relief. Install the mounting plate to lock off O-ring seal.

  • Page 158: 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 159: Supplemental Information Only Applicable To Ce/Ukca Machines

    SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE SUPPLEMENTAL INFORMATION ONLY APPLICABLE TO CE/UKCA MACHINES The following information is provided in accordance with the requirements of the European Machinery Directive 2006/42/EC or Supply of Machinery (Safety) Regulations 2008 No. 1597. The A-Weighted emission sound pressure level at the work plat- form is less than 70dB (A).
  • Page 160 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE EC Declaration of Conformity Machine Type: Mobile Elevating Work Platform Manufacturer: Model Type: 800S, 860SJ Notified Body: Kuiper Certificering b.v. JLG Industries, Inc. EC-Number: 2842 Address: Address: Van Slingelandtstraat 75, 7331 NM Apeldoorn, The Netherlands 1 JLG Drive McConnellsburg, PA 17233 USA...
  • Page 161 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE UKCA Declaration of Conformity Machine Type: Mobile Elevating Work Platform Manufacturer: Model Type: 800S, 860SJ Approved Body: Amtri Veritas JLG Industries, Inc. AB-Number: 0463 Address: Address: Pierce Street, Macclesfield, SK11 6ER, England 1 JLG Drive McConnellsburg, PA 17233 USA Certificate Number:...
  • Page 162 SECTION 7 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE 7-30 31219073...

  • Page 163: 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 31219073...

  • Page 164: Inspection And Repair Log

    SECTION 8 - INSPECTION AND REPAIR LOG Table 8-1. Inspection and Repair Log Date Comments 31219073...
  • Page 166 Corporate Office JLG Industries, Inc. 1 JLG Drive McConnellsburg, PA 17233-9533 USA (717) 485-5161 (Corporate) (877) 554-5438 (Customer Support) (717) 485-6417 Visit our website for JLG Worldwide Locations www.jlg.com...

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