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

800 series articulating boom lifts
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Download this manual See also: Safety and Operating Manual
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
800A
800AJ
Prior to S/N 0300183033
ANSI
3121209
®
August 1, 2016

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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 Prior to S/N 0300183033 ANSI 3121209 ® August 1, 2016...
  • 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 INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDI- INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY. RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK- GROUND. – JLG Lift – 3121209...
  • 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 Revised - January 6, 2009 Revised - November 6, 2009 Revised - December 12, 2009 Revised - July 26, 2010 Revised - June 21, 2012 Revised - October 1, 2015 Revised - August 1, 2016 – JLG Lift – 3121209...

  • Page 7: Table Of Contents

    FUNCTION CHECK........2-11 3121209 – JLG Lift –...
  • Page 8 Releveling Valve........4-20 – JLG Lift –...
  • Page 9 PROPANE FUEL SYSTEM PRESSURE RELIEF ... 6-36 SUPPLEMENTAL INFORMATION ..... 6-36 SECTION - 7 - INSPECTION AND REPAIR LOG 3121209 – JLG Lift –...
  • Page 10 TABLE OF CONTENTS SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE This Page Left Blank Intentionally. – JLG Lift – 3121209...
  • Page 11 2-1. Machine Nomenclature - 800A (Sheet 1 of 2) ..2-5 4-11. Decal Installation - Sheet 3 of 5 ..... . 4-24 2-2.
  • Page 12 LIST OF FIGURES FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE This Page Left Blank Intentionally. – JLG Lift – 3121209...
  • Page 13 6-17 Critical Stability Weights - 800A..... . 6-11 Beaufort Scale (For Reference Only)....1-10 6-18 Critical Stability Weights - 800AJ.
  • Page 14 LIST OF TABLES TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE This Page Left Blank Intentionally. viii – JLG Lift – 3121209...

  • Page 15: Section 1 - Safety Precautions

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

  • Page 16: Workplace Inspection

    • Do not operate the machine in hazardous environments unless approved for that purpose by JLG. • Be sure that the ground conditions are able to support the maximum load shown on the decals located on the machine.

  • Page 17: Operation

    Attach only one (1) lanyard per lanyard anchor- except in an emergency. age point. • Do not carry materials directly on platform railing. Contact JLG for approved material handling accessories. • When two or more persons are in the platform, the operator shall be responsible for all machine operations.

  • Page 18: Electrocution Hazards

    • Keep both feet firmly positioned on the platform floor at all times. Never use ladders, boxes, steps, planks, or similar items on platform to provide additional reach. • Never use the boom assembly to enter or leave the platform. – JLG Lift – 3121209...
  • Page 19 50,000 volts. • Allow for machine movement and electrical line swaying. One foot additional clearance is required for every additional 30,000 volts or less. 3121209 – JLG Lift –...

  • Page 20: Tipping Hazards

    DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH- ERWISE. • Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface. – JLG Lift – 3121209...

  • Page 21: Crushing And Collision Hazards

    • Keep non-operating personnel at least 6 ft. (1.8m) away from attempting to stabilize the machine. Use cranes, forklift trucks, machine during all driving and swing operations. or other appropriate equipment to stabilize machine. 3121209 – JLG Lift –...

  • Page 22: Towing, Lifting, And Hauling

    • Refer to the Machine Operation section of this manual for lift- ing information. • Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary. – JLG Lift – 3121209...

  • Page 23: Additional Hazards / Safety

    • When performing welding or metal cutting operations, pre- • Charge batteries only in a well ventilated area. cautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter. 3121209 – JLG Lift –...
  • Page 24 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effort needed to walk against the wind. 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road. 47-54 20.8-24.4 Strong Gale Light structure damage. 1-10 – JLG Lift – 3121209...

  • Page 25: Section 2 - User Responsibilities, Machine Preparation, And Inspection

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

  • Page 26: Preparation, Inspection, And Maintenance

    SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION PREPARATION, INSPECTION, AND MAINTENANCE JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A The following table covers the periodic machine inspections and PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL maintenance required by JLG Industries, Inc.
  • Page 27 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. 3121209 – JLG Lift –...

  • Page 28: Pre-Start Inspection

    4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities (Domestic only) is enclosed in the weather resistant storage container. – JLG Lift – 3121209...
  • Page 29 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION Figure 2-1. Machine Nomenclature - 800A (Sheet 1 of 2) 3121209 – JLG Lift –...
  • Page 30 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION ARTICULATING JIB ARTICULATING JIB LIFT CYLINDER ALL OTHER COMPONENTS ARE SIMILAR TO MODEL 800A ON PRECEDING PAGE Figure 2-2. Machine Nomenclature - 800AJ (Sheet 2 of 2) – JLG Lift – 3121209...
  • Page 31 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 22,23,24 14,15,16,17,18,19,20 9,10 3,4,5 37,38 9,10 24,30,31,32,33 34,35 Figure 2-3. Daily Walk-Around Inspection (Sheet 1 of 4) 3121209 – JLG Lift –...
  • Page 32 Latch, stop, and hinges in working condition. sion. 2. Platform Control Console - Switches and levers return to neutral, decals/placards secure and legible, control markings legible. 3. Rotator - See Inspection Note. Figure 2-4. Daily Walk-Around Inspection (Sheet 2 of 4) – JLG Lift – 3121209...
  • Page 33 20. Hydraulic Oil Breather - Element in place, not clogged, no sign of overflow. 21. Ground Controls - Switches operable, no visible damage, decals secure and legible. Figure 2-5. Daily Walk-Around Inspection (Sheet 3 of 4) 3121209 – JLG Lift –...
  • Page 34 Section 4.16. damage, no missing parts. (If Equipped) 44. SkyGuard (If Equipped) - See Inspection Note 38. Flow Valves - See Inspection Note. Figure 2-6. Daily Walk-Around Inspection (Sheet 4 of 4) 2-10 – JLG Lift – 3121209...

  • Page 35: Function Check

    DO NOT OPERATE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION Figure 2-7. Tower Boom Vertical Limit Switch 2. Test the tower boom assembly sequencing as follows: 3121209 – JLG Lift – 2-11...
  • Page 36 MALFUNCTION LIGHT IS FLASHING OR ON STEADY. DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED d. Raise the tower base boom to full height. Extend the tower fly boom a few feet. Check that the plunger on 2-12 – JLG Lift – 3121209...
  • Page 37 If SkyGuard remains activated after function reversal or cutout, depress and hold the SkyGuard Override Switch to allow normal use of machine functions until the SkyGuard sensor is disen- gaged. 3121209 – JLG Lift – 2-13...
  • Page 38 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 2-14 – JLG Lift – 3121209...
  • Page 39 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION 3121209 – JLG Lift – 2-15...
  • Page 40 7 seconds after depressing the footswitch, reset the neutral position when released. footswitch. DO NOT OPERATE MACHINE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION 2-16 – JLG Lift – 3121209...
  • Page 41 DISCONTINUE OPERATION IF THE CAPACITY INDICATOR SYSTEM DOES NOT OPERATE NOTE: Step 5 is only applicable for 800A ANSI market machines. PROPERLY. 5. If equipped with a dual capacity system, check the limit 6. Drive forward and reverse; check for proper operation.
  • Page 42 Reverse procedure to engage turntable lock. 12. Check that the platform automatically levels properly during raising and lowering of the boom. 2-18 – JLG Lift – 3121209...
  • Page 43 GROUND. Start engine. Platform controls should not oper- 4. Place DRIVE control lever to FORWARD position and carefully ate. drive machine up ascension ramp until left front wheel is on top of block. 3121209 – JLG Lift – 2-19...
  • Page 44 10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block. 2-20 – JLG Lift – 3121209...
  • Page 45 SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION NOTES: 3121209 – JLG Lift – 2-21...

  • Page 46: General

    The platform ROTATE control switch provides rotation of the control box guard in front of the control box or by the ground platform when positioned to LEFT or RIGHT. controls for these symbols and the corresponding functions. 3121209 – JLG Lift –...
  • Page 47 5. Engine Start/Auxiliary Power Engine Start/Auxiliary Power/Function Enable 6. Tower Telescope 7. Hourmeter 8. Platform/Ground Select Switch 9. Swing 10. Tower Lift 11. Main Boom Lift 12. Main Boom Telescope 1706912 A Figure 3-1. Ground Control Station – JLG Lift – 3121209...
  • Page 48 3. Jib (If Equipped) out (on). When pushed in (off ), power is shut off to the PLAT- FORM/GROUND SELECT switch. The jib control switch provides raising and lowering of the jib when positioned to UP or DOWN. 3121209 – JLG Lift –...
  • Page 49 The hour meter registers up to the lesser flow of hydraulic fluid delivered. 9,999.9 hours and cannot be reset. WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.) – JLG Lift – 3121209...
  • Page 50 UP or DOWN. This function works only when the tower boom is fully retracted (telescope in). WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM. 3121209 – JLG Lift –...
  • Page 51 3. High Engine Water Temp. 9. Platform Overload 4. High Engine Oil Temp. 10. Hyd. Filter Bypass 5. Engine Malfunction Indicator 11. Transmission Filter By-Pass 6. Low Fuel 12. Engine Air Filter By-Pass Figure 3-2. Ground Control Indicator Panel – JLG Lift – 3121209...
  • Page 52 7. Glow Plug Indicator (If Equipped) When illuminated the glow plugs are operating. After turn- ing on ignition, wait until light goes out before cranking engine. 3121209 – JLG Lift –...
  • Page 53 MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND. THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION. REPORT THE PROB- LEM TO THE PROPER SERVICE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL THE MALFUNCTION IS CORRECTED. – JLG Lift – 3121209...
  • Page 54 MAIN, LIFT, SWING, and DRIVE control levers are spring-loaded tarily. and will automatically return to neutral (OFF) position when released. 2. Travel Warning Horn A push-type HORN switch supplies electrical power to an audible warning device when pressed. 3121209 – JLG Lift –...
  • Page 55 15. Tower Telescope 3. Main Lift / Swing 8. Platform Rotate 12. Lights 16. Tower Lift 4. Telescope 9. Platform Level Override 13. Steer Select 17. Light Panel 5. Drive/Steer Figure 3-3. Platform Control Console 3-10 – JLG Lift – 3121209...
  • Page 56 18. Soft Touch/SkyGuard Override 4. Telescope 9. Platform Level Override 14. Engine Start / Aux Power 19. Soft Touch/SkyGuard Indicator 5. Drive/Steer 10. Articulating Jib (800AJ) 15. Tower Telescope Figure 3-4. Platform Control Console - w/Drive Orientation 3121209 – JLG Lift – 3-11...
  • Page 57 6. Function Speed left or right. Controls the speed of Boom and Swing Functions. Rotate CCW for slower speed and CW for faster speed. To adjust to creep, turn knob fully CCW until it clicks. 3-12 – JLG Lift – 3121209...
  • Page 58 Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position. It is unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is run- ning. 3121209 – JLG Lift – 3-13...
  • Page 59 “UP” or “DOWN”. TOWER LIFT must be fully elevated “UP” of their stroke. This can be done in either crab or coordi- before operating TOWER TELESCOPE. (TOWER LIFT should nated mode. not function when TOWER TELESCOPE is extended). 3-14 – JLG Lift – 3121209...
  • Page 60 SkyGuard sensor has been activated. All controls are cut out intended chassis direction. until the override button is pushed. For Soft Touch, controls are then active in the Creep Mode or for SkyGuard, controls will work normally. 3121209 – JLG Lift – 3-15...
  • Page 61 3-16 – JLG Lift – 3121209...
  • Page 62 On machines from S/N 0300062045 to 0300183033, the light FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY indicates that the JLG Control System has detected a mal- OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM. function and a Diagnostic Trouble Code has been set in the system memory.
  • Page 63 7. Creep Speed 2. Engine Malfunction 8. Glow Plug 3. Soft Touch 9. Tilt Alarm Warning 4. AC Generator 10. Overload 5. Fuel Level 11. Boom Malfunction 6. Capacity Figure 3-5. Platform Light Panel 3-18 – JLG Lift – 3121209...
  • Page 64 9. Tilt Alarm Warning 2. Engine Malfunction 6. Capacity 10. Overload 3. Not Used 7. Creep Speed 11. Boom Malfunction 4. AC Generator 8. Glow Plug 12. Drive Orientation Figure 3-6. Platform Light Panel w/Drive Orientation 3121209 – JLG Lift – 3-19...
  • Page 65 Refer to the capacity decals on the machine for restricted and RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT unrestricted platform capacities. IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL. 3-20 – JLG Lift – 3121209...
  • Page 66 MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND. THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION. REPORT THE PROB- LEM TO THE PROPER SERVICE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL THE CONDITION IS CORRECTED. 3121209 – JLG Lift – 3-21...
  • Page 67 SECTION 3 - MACHINE CONTROLS AND INDICATORS NOTES: 3-22 – JLG Lift – 3121209...

  • Page 68: Description

    Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the oper- 5. Machine is as originally equipped from JLG. ator in the platform be unable to do so. The Ground Control is Stability also to be used in Pre-Start Inspection.
  • Page 69 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTE- tion, DO NOT OPERATE MACHINE. NANCE MANUAL. MACHINES WITH DIESEL ENGINES. AFTER TURNING ON IGNITION, OPERATOR MUST WAIT UNTIL GLOW PLUG INDICATOR LIGHT GOES OUT BEFORE CRANKING ENGINE.(IF EQUIPPED) – JLG Lift – 3121209...
  • Page 70 SECTION 4 - MACHINE OPERATION Figure 4-1. Position of Least Forward Stability 3121209 – JLG Lift –...
  • Page 71 SECTION 4 - MACHINE OPERATION Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2) – JLG Lift – 3121209...
  • Page 72 SECTION 4 - MACHINE OPERATION Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2) 3121209 – JLG Lift –...
  • Page 73 Refer to Engine Manufacturer’s manual for detailed information. BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIREC- TION MATCHING THE DIRECTIONAL ARROWS. – JLG Lift – 3121209...
  • Page 74 2. Check that brakes hold machine in position. The indicator light will flash during the 3 second interval 3. Chock wheels front and rear. until the drive function is selected. 4. Turn off SELECT switch and remove key. 3121209 – JLG Lift –...

  • Page 75: Platform

    To rotate the platform to the left or right, use the Platform Rotate floor. control switch to select the direction and hold until desired posi- tion is reached. – JLG Lift – 3121209...
  • Page 76 SECTION 4 - MACHINE OPERATION LEVEL Figure 4-4. Grade and Sideslopes 3121209 – JLG Lift –...

  • Page 77: Boom

    NEAR GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL ATION. BEFORE EXTENDING OR RAISING MAIN BOOM. Depress footswitch. To swing boom, position SWING control switch or controller to RIGHT or LEFT for direction desired. 4-10 – JLG Lift – 3121209...

  • Page 78: Raising And Lowering The Tower Boom

    TOWER TELESCOPE “in”. The TOWER BOOM must be fully retracted before the TOWER BOOM can be low- ered. b. TOWER BOOM lift “down” will only be operable when the TOWER BOOM is fully retracted. 3121209 – JLG Lift – 4-11...

  • Page 79: Function Of Tower Boom

    MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND. THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION. REPORT THE PROB- LEM TO THE PROPER SERVICE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL THE CONDITION IS CORRECTED. 4-12 – JLG Lift – 3121209...

  • Page 80: Shut Down And Park

    NOTE: When transporting machine over rough terrain or long distance, the boom needs to be chocked and strapped. This prevents the boom from bouncing up causing possible damage. 3121209 – JLG Lift – 4-13...
  • Page 81 SECTION 4 - MACHINE OPERATION NOTE: Rig chains so as not to rub. NOTE: Block rotator and platform. Secure platform w/o over-tight- ening. Figure 4-5. Machine Tie Down 4-14 – JLG Lift – 3121209...
  • Page 82 SECTION 4 - MACHINE OPERATION Figure 4-6. Lifting Chart 3121209 – JLG Lift – 4-15...

  • Page 83: Oscillating Axle Lockout Test (If Equipped)

    4.12 TOWING The machine is not equipped with a tow package. Refer to Sec- tion 5 for emergency towing procedures. SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER. 4-16 – JLG Lift – 3121209...

  • Page 84: Tow Bar (If Equipped)

    3. Disconnect drive hubs by inverting disconnect cap. 4. Position steer/tow selector valve for towing; pull valve knob OUT for towing. The machine is now in the towing mode. After towing the machine, complete the following: 3121209 – JLG Lift – 4-17...
  • Page 85 SECTION 4 - MACHINE OPERATION Figure 4-7. Tow Bar 4-18 – JLG Lift – 3121209...

  • Page 86: Dual Fuel System (Gas Engine Only)

    2. Close hand valve on LP gas supply tank by turning clock- wise. IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOP- PING THE ENGINE. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUC- TIONS MUST BE FOLLOWED. 3121209 – JLG Lift – 4-19...

  • Page 87: Re-Synchronize Upright

    6. Lower the tower boom fully and continue to hold down the Figure 4-8. Releveling Valve switch to Tower Down for an additional 20 seconds. 7. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis. 4-20 – JLG Lift – 3121209...

  • Page 88: Skyguard Operation

    C = Indicates Cutout is Activated * Disregard when boom is in line and driving forward with or without steering and no other function active Note: When Soft Touch is enabled with SkyGuard all functions are cut out only. 3121209 – JLG Lift – 4-21...
  • Page 89 SECTION 4 - MACHINE OPERATION Figure 4-9. Decal Installation - Sheet 1 of 5 4-22 – JLG Lift – 3121209...
  • Page 90 SECTION 4 - MACHINE OPERATION Figure 4-10. Decal Installation - Sheet 2 of 5 3121209 – JLG Lift – 4-23...
  • Page 91 SECTION 4 - MACHINE OPERATION Figure 4-11. Decal Installation - Sheet 3 of 5 4-24 – JLG Lift – 3121209...
  • Page 92 SECTION 4 - MACHINE OPERATION Figure 4-12. Decal Installation - Sheet 4 of 5 3121209 – JLG Lift – 4-25...
  • Page 93 SECTION 4 - MACHINE OPERATION Figure 4-13. Decal Installation - Sheet 5 of 5 4-26 – JLG Lift – 3121209...
  • Page 94 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800A - Prior to S/N 0300141330 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-9 0274464-7 0274470-7 0274466-7 0274468-8 0274472-7 0274474-3 0274462-7 1701499 1701499 1701499 1701499 1701499 1701499...
  • Page 95 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800A - Prior to S/N 0300141330 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-9 0274464-7 0274470-7 0274466-7 0274468-8 0274472-7 0274474-3 0274462-7 1704007 1705901 1704006 1703953 1703945 1703943...
  • Page 96 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800A - Prior to S/N 0300141330 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-9 0274464-7 0274470-7 0274466-7 0274468-8 0274472-7 0274474-3 0274462-7 1707014 1707043 1707045 1707048 1707051 1707046...
  • Page 97 SECTION 4 - MACHINE OPERATION Table 4-2. Decal Legend - 800A - Prior to S/N 0300141330 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-9 0274464-7 0274470-7 0274466-7 0274468-8 0274472-7 0274474-3 0274462-7 1705351 1705427 1705430 1705910 1705905 1705429...
  • Page 98 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 800A - S/N 0300141330 to S/N 0300183033 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-10 0274464-8 0274470-8 0274466-8 0274468-9 0274472-8 0274474-3 0274462-8 1701499 1701499 1701499 1701499 1701499...
  • Page 99 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 800A - S/N 0300141330 to S/N 0300183033 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-10 0274464-8 0274470-8 0274466-8 0274468-9 0274472-8 0274474-3 0274462-8 1704007 1705901 1704006 1703953 1703945...
  • Page 100 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 800A - S/N 0300141330 to S/N 0300183033 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-10 0274464-8 0274470-8 0274466-8 0274468-9 0274472-8 0274474-3 0274462-8 1001121813 1001122201 1001121822 1001121817 1001121819...
  • Page 101 SECTION 4 - MACHINE OPERATION Table 4-3. Decal Legend - 800A - S/N 0300141330 to S/N 0300183033 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274460-10 0274464-8 0274470-8 0274466-8 0274468-9 0274472-8 0274474-3 0274462-8 1705351 1705427 1705430 1705910 1705905...
  • Page 102 1703811 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705514 1705337 1705339 1705342 1702153 1704007 1705901 1704006 3121209 – JLG Lift – 4-35...
  • Page 103 1703773 1703773 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701645 1707058 1707060 1707056 1703996 1707055 1705978 1707059 1707013 1707042 1707044 1707049 1704112 1707047 1705978 1707054 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 4-36 – JLG Lift – 3121209...
  • Page 104 1706439 1703990 1705977 1703986 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1706941 1706941 1706941 1706941 1706941 1706941 1706941 3121209 – JLG Lift – 4-37...
  • Page 105 Table 4-4. Decal Legend - 800AJ - Prior to S/N 0300141330 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-9 0274464-7 0274471-7 0274467-7 0274469-9 0274473-7 0274475-3 0274462-7 1705351 1705427 1705430 1705910 1705905 1705429 1705426 4-38 – JLG Lift – 3121209...
  • Page 106 1703811 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1705084 1705514 1705337 1705339 1705342 1702153 1704007 1705901 1704006 3121209 – JLG Lift – 4-39...
  • Page 107 1703773 1703773 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1001121801 1001121918 1001121919 1001121805 1001121656 1001121803 1705978 1001121808 1001121814 1001121921 1001121922 1001121818 1001121655 1001121816 1705978 1001121821 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 4-40 – JLG Lift – 3121209...
  • Page 108 1706439 1703990 1705977 1703986 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1706941 1706941 1706941 1706941 1706941 1706941 1706941 3121209 – JLG Lift – 4-41...
  • Page 109 Table 4-5. Decal Legend - 800AJ - S/N 0300141330 to S/N 0300183033 Item # ANSI Korean Chinese Spanish Portuguese French CE/Aus Japanese 0274461-10 0274465-8 0274471-8 0274467-8 0274469-10 0274473-8 0274475-3 0274463-8 1705351 1705427 1705430 1705910 1705905 1705429 1705426 4-42 – JLG Lift – 3121209...
  • Page 110 SECTION 4 - MACHINE OPERATION NOTES: 3121209 – JLG Lift – 4-43...
  • Page 111 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 TOWING PROCEDURES evident, the factory should be contacted by telephone and pro- Towing this machine is prohibited, However, provisions for mov- vided with all necessary details.

  • Page 112: Emergency Controls And Their Locations

    1. Position PLATFORM/GROUND SELECT KEY SWITCH to PLAT- FORM. CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS OPERATIONAL 2. Position POWER/EMERGENCY STOP switch to ON. AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE. 3. Depress and hold footswitch. – JLG Lift – 3121209...

  • Page 113: Emergency Operation

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

  • Page 114: Operator Unable To Control Machine

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

  • Page 115: Introduction

    Prior to S/N 0300183033 ............3120858 Illustrated Parts Manual - ANSI, CSA Spec Prior to S/N 0300069000 ............3120741 Illustrated Parts Manual - CE Spec Prior to S/N 0300069000 ............3120859 Illustrated Parts Manual - ANSI, CSA Spec S/N 0300069000 to 0300140000...........3121176 3121209 – JLG Lift –...

  • Page 116: Operating Specifications

    36 ft.-6 in. (11.13 m) 18 X 19.5 Foam Filled Tires 33,550 lbs. (15,220 kg) Wheel base 10 ft.- 0 in. (3.05 m) Boom Elevation - 800A Above Grade +80 ft.(24.38 m) Below Grade -15 ft.-7 in. (4.75 m) – JLG Lift –...

  • Page 117: Tires

    11 Quarts (10.5 L) w/Filter IN 445/55D 19.5 foam-filled Total Capacity 16 Quarts (15 L) 15 X 19.5 foam-filled Caterpillar 10.6 quarts (10 L) Isuzu 8.5 Quarts (8.0 L) 18 X 19.5 foam-filled 4.5 Quarts (4.25 L) w/Filter 3121209 – JLG Lift –...

  • Page 118: Engine Data

    1000 Cold Cranking Amps, 210 minutes Horsepower 74 @ 3000 RPM, full load Reserve Capacity, 12 VDC Cooling System 16 Quarts (15.14 L) Horsepower 65 @ 3000 RPM, full load Spark Plug AWSF-52-C Spark Plug Gap 0.044 in. (1.117 mm) – JLG Lift – 3121209...
  • Page 119 1000 Battery 1000 Cold Cranking Amps, 210 minutes Idle RPM - 3.4 1200 Reserve Capacity, 12 VDC Low RPM 1800 Horsepower 64 @ 2600 RPM, full load High RPM 2600 Alternator 60 Amp, belt drive 3121209 – JLG Lift –...
  • Page 120 Minimum Oil Pressure Horsepower 66 @ 2800 RPM, full load at idle 6 psi (0.4 Bar) @ 1000 rpm 18 psi (1.2 Bar) @ 2000 rpm Compression Ratio 9.2:1 Firing Order 1-3-4-2 Max. RPM 2800 – JLG Lift – 3121209...

  • Page 121: Hydraulic Oil

    SECTION 6 - 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 6-10.
  • Page 122 100° F 169 SUS Viscosity at 210° F 48 SUS at 40° C 37 cSt cp at -20° F 6,200 at 100° C 8.4 cSt Viscosity Index Viscosity Index NOTE: Must be stored above 32°F (14°C) – JLG Lift – 3121209...
  • Page 123 9.3 cSt at 40° C (104° F) 46 cSt (215SUS) Viscosity Index at 65° C (150° F) 22 cSt (106SUS) NOTE: Mobil/Exxon recommends that this oil be checked on a Viscosity Index yearly basis for viscosity. 3121209 – JLG Lift –...

  • Page 124: Critical Stability Weights

    Fire Point 325°C (617°F) Autoignition Temperature 450°C (842°F) Viscosity at 0° C (32°F) 360 cSt at 20° C (68°F) 102 cSt at 40° C (104°F) 46 cSt at 100° C (212°F) 10 cSt Viscosity Index 6-10 – JLG Lift – 3121209...
  • Page 125 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Table 6-17. Critical Stability Weights - 800A Table 6-18. Critical Stability Weights - 800AJ COMPONENTS LBS. COMPONENTS LBS. Tire & Wheel Size 365/65D19.5 Tire & Wheel Size 365/65D19.5 (Foam Filled Only) (Foam Filled Only) 445/55D19.5...
  • Page 126 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 127 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 128 WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY. 0 F(-18 C) -10 F(-23 C) 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 129 IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR TEMPERATURE THE ADDITION OF A HYDRAULIC OIL COOLER (CONSULT JLG SERVICE 120° F (49° C) PROLONGED OPERATION IN NO OPERATION ABOVE THIS AMBIENT AIR TEMPERATURES 110° F (43° C) AMBIENT TEMPERATURE OF 100°...
  • Page 130 ENGINE WILL START AND OPERATE AT THIS TEMPERATURE -10 F(-23 C) WITH THE RECOMMENDED FLUIDS, A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER -20 F(-29 C) PACKAGE (IE. ENGINE BLOCK HEATER, BATTERY WARMER AND...
  • Page 131 (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 132 -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 133 (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 134 SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE Figure 6-9. Operator Maintenance and Lubrication Diagram 6-20 – JLG Lift – 3121209...

  • Page 135: Operator Maintenance

    CONDITIONS. FOR MACHINES USED IN MULTI-SHIFT OPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CONDITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORDINGLY. NOTE: It is recommended as a good practice to replace all filters at the same time. 3121209 – JLG Lift – 6-21...
  • Page 136 2 years or 1200 hours of operation Comments - Place Fill port at 12 o’clock position and Check port at 3 o’clock position. Pour lubricant into fill port until it just starts to flow out of check port. 6-22 – JLG Lift – 3121209...
  • Page 137 Interval - Change after first 50 hrs. and every 6 months or Interval - Change after first 50 hrs. and every 6 months or 300 hrs. thereafter or as indicated by Condition Indicator. 300 hrs. thereafter or as indicated by Condition Indicator. 3121209 – JLG Lift – 6-23...
  • Page 138 Interval - Check Level daily; Change every 2 years or 1200 hours of operation. Lube Point(s) - 2 Interval - Every 2 years or 1200 hours of operation, remove and clean at time of hydraulic oil change. 6-24 – JLG Lift – 3121209...
  • Page 139 Interval - 3 Months or 150 hours of operation Interval - Every Year or 1200 hours of operation Comments - Check level daily/Change in accordance with Comments - Check level daily/Change in accordance with engine manual. engine manual. 3121209 – JLG Lift – 6-25...
  • Page 140 Comments - Check level daily/Change in accordance with Capacity - 4.5 qt. (4.25 L) w/filter engine manual. Lube - EO Interval - 3 Months or 150 hours of operation Comments - Check level daily/Change in accordance with engine manual. 6-26 – JLG Lift – 3121209...
  • Page 141 15. Fuel Filter - Isuzu Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 16. Fuel Filter - Caterpillar Lube Point(s) - Replaceable Element Interval - Every Year or 600 hours of operation 3121209 – JLG Lift – 6-27...
  • Page 142 ING OIL BUILD UP FROM THE PROPANE REGULATOR (Prior to S/N 0300134626) Lube Point(s) - Replaceable Element Interval - Every 6 months or 300 hours of operation or as indi- cated by the condition indicator 6-28 – JLG Lift – 3121209...

  • Page 143: 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 144: 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 145: Wheel Installation

    The proper procedure for attaching wheels is as follows: 1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts. 3121209 – JLG Lift – 6-31...
  • Page 146 1. Move the equipment to a well ventilated area. Ensure there are no external ignition sources. 2. Start the engine and bring to operating temperature. 3. With the engine running, close the manual tank valve and run the engine out of fuel. 6-32 – JLG Lift – 3121209...
  • Page 147 8. Open the fuel tank manual valve. 9. Start the engine and verify all connections are secure. 10. Dispose of any drained oil per local regulations in a safe and proper fashion. 3121209 – JLG Lift – 6-33...

  • Page 148: Propane Fuel Filter Replacement

    9. Remove and discard mounting plate to lock off O-ring seal. 9. Open manual shut-off valve. Start the vehicle and leak check the propane fuel system at each serviced fitting. Refer to Propane Fuel System Leak Test. 6-34 – JLG Lift – 3121209...
  • Page 149 10. Filter 2. Mounting Plate 7. Electrical Connector 11. Fuel Inlet 3. Housing Seal 8. Fuel Outlet 12. Retaining Bolt 4. Filter Magnet 9. O-ring 13. Ring 5. Filter Housing Figure 6-10. Filter Lock Assembly 3121209 – JLG Lift – 6-35...

  • Page 150: Propane Fuel System Pressure Relief

    RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM. ENSURE THE jected does not exceed 0,5 m/s WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE. 6-36 – JLG Lift – 3121209...
  • Page 151 SECTION 7 - INSPECTION AND REPAIR LOG SECTION 7. INSPECTION AND REPAIR LOG Machine Serial Number _______________________________________ Table 7-1. Inspection and Repair Log Date Comments 3121209 – JLG Lift –...
  • Page 152 SECTION 7 - INSPECTION AND REPAIR LOG Table 7-1. Inspection and Repair Log Date Comments – JLG Lift – 3121209...
  • Page 156 +33 (0) 553 84 85 74 +(852) 2639 5797 Email:german-parts@jlg.com Email: emeaservice@jlg.com Email: pieces@jlg.com JLG Industries (Italia) S.R.L. JLG EMEA B.V. JLG NZ Access Equipment & Services JLG Industries Via Po. 22 Polaris Avenue 63 2B Fisher Cresent Vahutinskoe shosse 24b. 20010 Pregnana Milanese (MI)

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800aj

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