JLG 800AJ Manuals

Manuals and User Guides for JLG 800AJ. We have 4 JLG 800AJ manuals available for free PDF download: Service And Maintenance Manual, Operation And Safety Manual

JLG 800AJ Operation And Safety Manual (160 pages)

Brand: JLG | Category: Boom Lifts | Size: 4.04 MB

Table of Contents
7
Section 1 - Safety Precautions

15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    17
- Operation
  17
  - General
    17
  - Trip and Fall Hazards
    18
  - Electrocution Hazards
    19
  - Tipping Hazards
    21
  - Crushing and Collision Hazards
    24
- Towing, Lifting, and Hauling
  25
- Maintenance
  25
  - Maintenance Hazards
    25
  - Battery Hazards
    27
Section 2. User Responsibilities, Machine Preparation, and Inspection

29
- 2.1 Personnel Training
  29
  - Operator Training
    29
  - Training Supervision
    29
  - Operator Responsibility
    29
- 2.2 Preparation, Inspection, and Maintenance
  30
  - Pre-Start Inspection
    32
  - General
    35
  - Function Check
    37
  - From the Ground Control Station with no Load in the Platform
    37
  - From the Platform Control Station
    41
  - Skyguard Function Test
    44
- Oscillating Axle Lockout Test (if Equipped)
  45
Section 3 - Machine Controls and Indicators

47
- General
  47
- Controls and Indicators
  47
  - Ground Control Console
    48
  - Ground Control Indicator Panel
    54
  - Platform Console
    57
  - Platform Console Indicator Panel
    64
Section 4 - Machine Operation

69
- Description
  69
- Boom Operating Characteristics and Limitations
  69
  - Capacities
    69
  - Stability
    69
- Engine Operation
  73
- Traveling (Driving)
  76
  - Traveling Forward and Reverse
    78
- Steering
  79
- Platform
  79
  - Platform Level Adjustment
    79
  - Platform Rotation
    79
- Boom
  80
- Shut down and Park
  82
- Machine Safety System Override (Msso)(Ce Only)
  82
- 4.10 Skyguard Operation
  83
  - Skyguard
    83
  - Skyguard - Skyline
    83
  - Skyguard - Skyeye
    84
  - Skyguard Function Table
    84
- 4.11 Lifting and Tie down
  85
  - Lifting
    85
  - Tie down
    85
  - Oscillating Axle Lockout Test (if Equipped)
    87
  - 4.13 Towing
    87
  - Tow Bar (if Equipped)
    87
  - Dual Fuel System (Gas Engine Only)
    89
    
    Description
    89
    
    Changing from Gasoline to LP Gas
    90
    
    Changing from LP Gas to Gasoline
    90
  - 4.16 Re-Synchronize Upright
    90
    
    Releveling Valve
    90
Section 5 - Emergency Procedures

105
- General
  105
- Incident Notification
  105
- Emergency Operation
  105
  - Operator Unable to Control Machine
    105
  - Platform or Boom Caught Overhead
    106
- Emergency Towing Procedures
  106
- Machine Safety System Override (Msso)(Ce Only)
  107
Section 6 - Accessories

109
- Fall Arrest Platform
  111
  - Safety Precautions
    111
- Pipe Racks
  111
  - Capacity Specifications (Australia Only)
    112
- Safety Precautions
  112
- Preparation and Inspection
  112
- Operation
  112
- Skyair
  113
  - Compressor Specifications
    113
  - Accessory Ratings
    113
  - Safety Precautions
    113
  - Preparation and Inspection
    114
  - Operation
    114
- Skycutter
  114
  - Accessory Ratings
    115
  - Generator Output
    115
  - Safety Precautions
    115
  - Operation
    116
- Skyglazier
  116
  - Capacity Specifications
    117
  - Safety Precautions
    117
  - Preparation and Inspection
    118
  - Operation
    118
- Skypower
  118
  - Generator Output
    119
  - Accessory Ratings
    119
  - Safety Precautions
    119
  - Operation
    119
  - Skywelder
    120
    
    Generator Output
    120
    
    Welding Accessories
    120
    
    Accessory Ratings
    121
    
    Safety Precautions
    121
    
    Preparation and Inspection
    122
    
    Operation
    122
  - Soft Touch
    122
  - Bolt-On External Fall Arrest
    123
    
    Inspection before Use
    124
Section 7 - General Specifications & Operator Maintenance

127
- Introduction
  127
- Operating Specifications and Performance Data
  127
  - Operating Specifications
    127
  - Tires
    128
  - Capacities
    129
  - Engine Data
    129
  - Hydraulic Oil
    131
  - Critical Stability Weights
    134
- Maintenance and Lubrication
  140
- Tires & Wheels
  149
  - Tire Inflation
    149
  - Tire Damage
    149
- Tire Replacement
  150
- Wheel Replacement
  150
- Wheel Installation
  151
- Propane Fuel Filter Replacement
  152
  - Removal
    152
  - Installation
    153
- Propane Fuel System Pressure Relief
  154
- Supplemental Information
  154

JLG 800AJ Service And Maintenance Manual (172 pages)

Brand: JLG | Category: Boom Lifts | Size: 36.61 MB

General
3
Bhydraulic System Safety
3
Maintenance
3
Table of Contents
5
Specifications

24
- Operating Specifications
  24
- Capacities
  24
- Tires
  24
- Engine Data
  24
- Component Data
  26
  - Drive System
    26
  - Swing System
    26
  - Auxiliary Power Pump
    26
- Torque Requirements
  26
- Hydraulic Oil
  27
- Major Component Weights
  28
  - Critical Stability Weights
    29
- Operator Maintenance
  31
General

42
- Machine Preparation, Inspection, and Maintenance
  42
- Service and Guidelines
  43
  - General
    43
  - Safety and Workmanship
    43
  - Cleanliness
    43
  - Components Removal and Installation
    43
  - Component Disassembly and Reassembly
    43
  - Pressure-Fit Parts
    43
  - Bearings
    44
  - Gaskets
    44
  - Bolt Usage and Torque Application
    44
  - Hydraulic Lines and Electrical Wiring
    44
  - Hydraulic System
    44
  - Lubrication
    44
  - Battery
    44
  - Lubrication and Servicing
    44
- Lubrication and Information
  44
  - Hydraulic Oil
    45
  - Changing Hydraulic Oil
    45
  - Lubrication Specifications
    45
- Cylinder Drift Test
  46
  - Theory
    46
  - Cylinder Leakage Test
    46
  - Cylinder Thermal Drift
    46
- Pins and Composite Bearing Repair Guidelines
  47
- Welding on JLG Equipment
  47
  - Do the Following When Welding on JLG Equipment
    47
  - Do NOT Do the Following When Welding on JLG Equipment
    47
Chassis & Turntable

55
- Tires & Wheels
  55
  - Tire Inflation
    55
  - Tire Damage
    55
  - Tire Replacement
    55
  - Wheel Replacement
    55
  - Wheel Installation
    55
- Lockout Cylinder Bleeding
  56
- Oscillating Axle Lockout Test
  59
- Drive Hub (Torque)
  62
  - Disassembly
    62
  - Cleaning and Inspection
    62
  - Repair
    62
  - Assembly
    64
- Drive Brake
  70
  - Disassembly
    70
  - Inspection
    70
  - Assembly
    70
- Drive Motor
  72
  - Description
    72
  - Shaft Seal Replacement
    72
  - Loop Flushing Valve
    73
  - Troubleshooting
    74
  - Disassembly
    75
  - Inspection
    79
  - Assembly
    81
  - Initial Start-Up Procedures
    86
- Swing Drive
  88
  - Roll, Leak and Brake Testing
    88
  - Tightening and Torquing Bolts
    88
  - Motor Control Valve Disassembly
    89
  - Motor and Brake Disassembly
    91
  - Main Drive Disassembly
    92
  - Hub-Shaft Disassembly
    93
  - Carrier Disassembly
    94
  - Hub-Shaft Assembly
    95
  - Carrier Assembly
    95
  - Main Drive Assembly
    96
  - Motor and Brake Assembly
    97
  - Motor Control Valve Assembly
    97
- Swing Motor
  100
  - Disassembly and Inspection
    100
  - Assembly
    107
  - One Piece Stator Construction
    115
- Swing Hub Installation
  116
  - Procedure for Setting Swing Gear Backlash
    116
  - Swing Drive Lubrication
    117
- Swing Hub Removal
  117
- Swing Bearing
  118
  - Turntable Bearing Mounting Bolt Condition Check
    118
  - Wear Tolerance
    121
  - Swing Bearing Replacement
    121
  - Swing Bearing Torque Values
    122
- Tilt Indicator System
  125
- Spark Arrester Cleaning Instructions
  125
- Rotary Coupling
  126
  - Generator
    132
    
    Maintenance Schedule
    132
    
    Overload Protection
    132
    
    Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
    132
    
    Troubleshooting
    134
    
    Generator Disassembly and Assembly
    135
    
    Lead Connection List for Generator
    142
  - Auxiliary Power System
    143
  - Deutz Engine
    144
  - Deutz Engine - TD2.9L4
    163
    
    Check Oil Level
    163
    
    Change Engine Oil
    163
    
    Change Oil Filter
    164
    
    Change Fuel Filters
    164
  - Deutz Engine - D2011Lo4
    165
    
    Glow Plugs
    165
    
    Check Oil Level
    165
    
    Replacing Engine Oil
    166
    
    Replacing the Oil Filter
    167
    
    Replacing the Primary Fuel Filter
    167
  - Dual Fuel System
    168
    
    Changing from Gasoline to LP Gas
    168
    
    Changing from LP Gas to Gasoline
    168

JLG 800AJ Operation And Safety Manual (130 pages)

Boom Lift Models

Brand: JLG | Category: Lifting Systems | Size: 3.81 MB

Table of Contents
7
Section 1. Safety Precautions

11
- General
  11
- Pre-Operation
  11
  - Operator Training and Knowledge
    11
  - Workplace Inspection
    12
  - Machine Inspection
    12
- Operation
  13
  - General
    13
  - Trip and Fall Hazards
    13
  - Electrocution Hazards
    14
- Minimum Approach Distances (M.A.D.)
  15
  - Tipping Hazards
    16
  - Crushing and Collision Hazards
    17
  - Towing, Lifting, and Hauling
    18
  - Additional Hazards / Safety
    19
Section 2. User Responsibilities, Machine Preparation, and Inspection

21
- 2.1 Personnel Training
  21
  - Operator Training
    21
  - Training Supervision
    21
  - Operator Responsibility
    21
- Preparation, Inspection, and Maintenance
  22
- Inspection and Maintenance Table
  23
  - Pre-Start Inspection
    24
  - Function Check
    25
Section - 7 - Inspection and Repair Log

26
Section 3. Machine Controls and Indicators

41
- General
  41
- Controls and Indicators
  41
- Ground Control Station
  41
  - Ground Control Station
    42
  - Ground Control Indicator Panel
    46
  - Platform Station
    48
- Platform Control Console
  50
  - Platform Control Indicator Panel
    53
- Platform Light Panel
  55
Section 4. Machine Operation

59
- Description
  59
- Operating Characteristics and Limitations
  59
  - Capacities
    59
  - Stability
    59
- Engine Operation
  60
  - Starting Procedure
    60
- Position of Least Forward Stability
  61
  - Shutdown Procedure
    64
  - Traveling (Driving)
    64
    
    Traveling Forward and Reverse
    65
  - Steering
    65
- Parking and Stowing
  65
- Platform
  66
- Grade and Sideslopes
  67
- Boom
  68
- Boom Upright Positioning
  69
- Shut down and Park
  72
- 4.10 Lifting and Tie down
  72
- Machine Tie down
  73
- Lifting Chart
  74
- Oscillating Axle Lockout Test (if Equipped)
  75
- 4.12 Towing
  75
- Welding Lead (if Equipped)
  76
- Dual Fuel System (Gas Engine Only)
  76
- 4.15 Re-Synchronize Lower Lift Cylinder
  77
  - Level Override Valve
    77
- Decal Installation - Sheet 1 of 5
  78
- Decal Installation - Sheet 2 of 5
  79
- Decal Installation - Sheet 3 of 5
  80
- Decal Installation - Sheet 4 of 5
  81
- Decal Installation - Sheet 5 of 5
  82
- Decal Legend - 800A
  83
- Decal Legend - 800AJ
  86
Section 5. Emergency Procedures

89
- General
  89
- Incident Notification
  89
- Emergency Towing Procedures
  89
- Emergency Controls and Their Locations
  90
  - Power/Emergency Stop Switches
    90
  - Ground Control Station
    90
  - Auxiliary Power
    90
- Emergency Operation
  91
Section 6. General Specifications & Operator Maintenance

93
- Introduction
  93
- Operating Specifications
  93
  - Tires
    94
  - Capacities
    95
  - Engine Data
    95
- Deutz F4M2011F Specifications
  96
- Isuzu 4JB1
  97
  - Hydraulic Oil
    98
- Mobil DTE 13M Specs
  99
  - Critical Stability Weights
    101
  - Operator Maintenance
    112
  - Tires & Wheels
    120
    
    Tire Replacement
    121
    
    Wheel Installation
    122
    
    Regulator
    123
  - Propane Fuel Filter Replacement
    125
    
    Installation
    126

JLG 800AJ Operation And Safety Manual (156 pages)

800 Series Articulating Boom lifts

Brand: JLG | Category: Lifting Systems | Size: 2.81 MB

Table of Contents
7
Section 1 - Safety Precautions

15
- General
  15
- Pre-Operation
  15
  - Operator Training and Knowledge
    15
  - Workplace Inspection
    16
  - Machine Inspection
    16
- Operation
  17
  - General
    17
  - Trip and Fall Hazards
    17
  - Electrocution Hazards
    18
  - Tipping Hazards
    20
  - Crushing and Collision Hazards
    21
- Towing, Lifting, and Hauling
  22
- Additional Hazards / Safety
  23
Section 2 - User Responsibilities, Machine Preparation, and Inspection

25
- 2.1 Personnel Training
  25
  - Operator Training
    25
  - Training Supervision
    25
  - Operator Responsibility
    25
- Preparation, Inspection, and Maintenance
  26
  - Pre-Start Inspection
    28
- Function Check
  35
- General
  46
- Description
  68
- Platform
  75
- Boom
  77
  - Raising and Lowering the Tower Boom
    78
  - Function of Tower Boom
    79
- Shut down and Park
  80
- Oscillating Axle Lockout Test (if Equipped)
  83
- Tow Bar (if Equipped)
  84
- Dual Fuel System (Gas Engine Only)
  86
- Re-Synchronize Upright
  87
  - Skyguard Operation
    88
- Emergency Controls and Their Locations
  112
- Emergency Operation
  113
  - Operator Unable to Control Machine
    114
- Introduction
  115
- Operating Specifications
  116
  - Tires
    117
  - Engine Data
    118
  - Hydraulic Oil
    121
  - Critical Stability Weights
    124
- Operator Maintenance
  135
  - Tires & Wheels
    143
  - Tire Replacement
    144
  - Wheel Installation
    145
- Propane Fuel Filter Replacement
  148
- Propane Fuel System Pressure Relief
  150

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JLG 800AJ Manuals

JLG 800AJ Operation And Safety Manual (160 pages)

Table of Contents

Section 1 - Safety Precautions

Section 2. User Responsibilities, Machine Preparation, and Inspection

Section 3 - Machine Controls and Indicators

Section 4 - Machine Operation

Section 5 - Emergency Procedures

Section 6 - Accessories

Section 7 - General Specifications & Operator Maintenance

JLG 800AJ Service And Maintenance Manual (172 pages)

Table of Contents

Specifications

General

Chassis & Turntable

JLG 800AJ Operation And Safety Manual (130 pages)

Table of Contents

Section 1. Safety Precautions

Section 2. User Responsibilities, Machine Preparation, and Inspection

Section - 7 - Inspection and Repair Log

Section 3. Machine Controls and Indicators

Section 4. Machine Operation

Section 5. Emergency Procedures

Section 6. General Specifications & Operator Maintenance

JLG 800AJ Operation And Safety Manual (156 pages)

Table of Contents

Section 1 - Safety Precautions

Section 2 - User Responsibilities, Machine Preparation, and Inspection

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