Manual Operador JLG860

138
Operation and Safety Manual ANSI ® Keep this manual with the machine at all times. Boom Lift Models 800S 860SJ 3121138 July 7, 2006

description

Manual Operadoción Plataforma Elevadora JLG 800S - 860SJ.

Transcript of Manual Operador JLG860

  • Operation and Safety Manual

    ANSI

    Keep this manual with the machine at all times.

    Boom Lift Models800S860SJ

    3121138July 7, 2006

  • FOREWORD

    3121138 a

    FOREWORD

    This manual is a very important tool! Keep it with the machine at all times.

    The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions andoperating pro ose.

    Due to contin ecification changeswithout prior JLG Lift

    cedures essential for the safe and proper machine operation for its intended purp

    uous product improvements, JLG Industries, Inc. reserves the right to make spnotification. Contact JLG Industries, Inc. for updated information.

  • FOREWORD

    b 3121138

    SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

    INDICATES AN IMMINENTLY AVOIDED, WILL RESULT IN SERIOWILL HAVE A RED BACKGROUND

    INDICATES A POTENTIALLY AVOIDED, COULD RESULT IN SDECAL WILL HAVE AN ORANGE B

    S SITUATION. IF NOTERATE INJURY. IT MAY THIS DECAL WILL HAVE

    Thisinjuinju JLG Lift

    HAZARDOUS SITUATION. IF NOTUS INJURY OR DEATH. THIS DECAL.

    HAZARDOUS SITUATION. IF NOTERIOUS INJURY OR DEATH. THISACKGROUND.

    INDICATES A POTENTIALLY HAZARDOUAVOIDED, MAY RESULT IN MINOR OR MODALSO ALERT AGAINST UNSAFE PRACTICES.A YELLOW BACKGROUND.

    is the Safety Alert Symbol. It is used to alert you to the potential personalry hazards. Obey all safety messages that follow this symbol to avoid possiblery or death

  • FOREWORD

    3121138 c

    THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZEDJLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THISPRODUCT.

    IMJLG INDUSTRIES, INC. SENDOWNER OF RECORD OF THIINC. TO ENSURE THAT TUPDATED AND ACCURATE.

    IMJLG INDUSTRIES, INC. MUINSTANCES WHERE JLG PACCIDENT INVOLVING BODOR WHEN SUBSTANTIAL DPROPERTY OR THE JLG PRO

    epartment

    anual cover)

    7-554-7233)

    .com

    For: Accident Reporting

    Product Safety Publica-tions

    Current Owner Updates

    Standards and Regulations Compliance Information

    Questions Regarding Spe-cial Product Applications

    estions Regarding Prod-t Modifications JLG Lift

    PORTANTS SAFETY RELATED BULLETINS TO THE

    S MACHINE. CONTACT JLG INDUSTRIES,HE CURRENT OWNER RECORDS ARE

    PORTANTST BE NOTIFIED IMMEDIATELY IN ALLRODUCTS HAVE BEEN INVOLVED IN ANILY INJURY OR DEATH OF PERSONNEL

    AMAGE HAS OCCURRED TO PERSONALDUCT.

    Contact:

    Product Safety and Reliability DJLG Industries, Inc.1 JLG DriveMcConnellsburg, PA 17233

    or Your Local JLG Office(See addresses on inside of m

    In USA:

    Toll Free: 877-JLG-SAFE (87

    Outside USA:

    Phone: 717-485-5161E-mail: ProductSafety@JLG

    Questions Regarding Product Safety

    Quuc

  • FOREWORD

    d 3121138

    REVISION LOG

    Original Issue - October 9, 2001

    Revised

    Revised

    Revised

    Revised

    Revised

    Revised

    Revised

    Revised JLG Lift

    - October 31, 2001

    - December 4, 2001

    - March 1, 2002

    - January 1, 2003

    - April 24, 2003

    - May 4, 2005

    - March 3, 2006

    - July 7, 2006

  • TABLE OF CONTENTS

    3121138 i

    SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

    SECTION - 1 - SAFETY PRECAUTIONS

    1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

    Operator Training and Knowledge. . . . . . . . . . . 1-1Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2Machine Inspectio

    1.3 OPERATION . . . . . . General . . . . . . . . Trip and Fall HazaElectrocution HazaTipping Hazards . Crushing and Coll

    1.4 TOWING, LIFTING, A1.5 ADDITIONAL HAZAR

    SECTION - 2 - USER RESPON PREPARATION, AND INSP

    2.1 PERSONNEL TRAINOperator TrainingTraining SupervisiOperator Respons

    2.2 PREPARATION, INSP MAINTENANCE . .

    Pre-Start InspectioFunction Check. .

    General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES 2-102.4 OSCILLATING AXLE LOCKOUT TEST

    (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

    S AND INDICATORS

    . . . . . . . . . . . . . . . . . . . 3-1ORS . . . . . . . . . . . . . . . 3-1 . . . . . . . . . . . . . . . . . . . 3-1r Panel . . . . . . . . . . . . . 3-6 . . . . . . . . . . . . . . . . . . . 3-7r Panel . . . . . . . . . . . . 3-12

    N

    . . . . . . . . . . . . . . . . . . . 4-1ISTICS AND . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . . . . 4-1 . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . . . . . . . . . . . . . . 4-2 . . . . . . . . . . . . . . . . . . . 4-3 . . . . . . . . . . . . . . . . . . . 4-5everse . . . . . . . . . . . . . 4-5 . . . . . . . . . . . . . . . . . . . 4-5 JLG Lift

    n . . . . . . . . . . . . . . . . . . . . . . 1-2. . . . . . . . . . . . . . . . . . . . . . . . .1-3. . . . . . . . . . . . . . . . . . . . . . . . 1-3rds . . . . . . . . . . . . . . . . . . . . . 1-3rds . . . . . . . . . . . . . . . . . . . . 1-4

    . . . . . . . . . . . . . . . . . . . . . . . . 1-6ision Hazards. . . . . . . . . . . . . 1-7ND HAULING . . . . . . . . . . . . .1-8DS / SAFETY . . . . . . . . . . . . .1-9

    SIBILITIES, MACHINE ECTION

    ING . . . . . . . . . . . . . . . . . . . . .2-1. . . . . . . . . . . . . . . . . . . . . . . . 2-1on. . . . . . . . . . . . . . . . . . . . . . 2-1ibility . . . . . . . . . . . . . . . . . . . 2-1ECTION, AND

    . . . . . . . . . . . . . . . . . . . . . . . . .2-2n . . . . . . . . . . . . . . . . . . . . . . 2-4. . . . . . . . . . . . . . . . . . . . . . . . 2-5

    SECTION - 3 - MACHINE CONTROL

    3.1 GENERAL . . . . . . . . . . . . .3.2 CONTROLS AND INDICAT

    Ground Control Station .Ground Control IndicatoPlatform Station . . . . . . .Platform Control Indicato

    SECTION - 4 - MACHINE OPERATIO

    4.1 DESCRIPTION. . . . . . . . . .4.2 OPERATING CHARACTER

    LIMITATIONS. . . . . . . . . .Capacities . . . . . . . . . . .Stability . . . . . . . . . . . . .

    4.3 ENGINE OPERATION . . . .Starting Procedure . . . .Shutdown Procedure . .

    4.4 TRAVELING (DRIVING) . . .Traveling Forward and R

    4.5 STEERING. . . . . . . . . . . . .

  • TABLE OF CONTENTS

    ii 3121138

    SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

    4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-7Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-7

    4.7 BOOM . . . . . . . . . . . . . . Swinging the Boom . . Raising and Lowering t

    4.8 FUNCTION SPEED CON4.9 OSCILLATING AXLE LOC

    (IF EQUIPPED). . . . . . . 4.10 EMERGENCY TOWING. 4.11 TOW BAR (IF EQUIPPED4.12 SHUT DOWN AND PARK4.13 LIFTING AND TIE DOWN

    Lifting . . . . . . . . . . . . . Tie Down . . . . . . . . . .

    SECTION - 5 - EMERGENCY PROC

    5.1 GENERAL . . . . . . . . . . . 5.2 INCIDENT NOTIFICATION5.3 EMERGENCY OPERATIO

    Operator Unable to CoPlatform or Boom Caug

    5.4 EMERGENCY TOWING P5.5 MANUAL DESCENT INST

    (IF EQUIPPED). . . . . . .

    To Retract and Lower Boom. . . . . . . . . . . . . . . . 5-3To Lower Boom with Fully Retracted Telescope 5-3

    NS & OPERATOR

    . . . . . . . . . . . . . . . .6-1. . . . . . . . . . . . . . . .6-1ce Data . . . . . . . . 6-2

    . . . . . . . . . . . . . . . 6-3 . . . . . . . . . . . . . . . 6-4 . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-7 . . . . . . . . . . . . . . .6-10 . . . . . . . . . . . . . . .6-20 . . . . . . . . . . . . . . .6-29 . . . . . . . . . . . . . . 6-29 . . . . . . . . . . . . . . 6-29 . . . . . . . . . . . . . . 6-30 . . . . . . . . . . . . . . 6-30 . . . . . . . . . . . . . . 6-31

    THE PROPANE . . . . . . . . . . . . . . .6-32ACEMENT. . . . . . .6-34 JLG Lift

    . . . . . . . . . . . . . . . . . . . . . 4-7

    . . . . . . . . . . . . . . . . . . . . 4-8he Boom . . . . . . . . . . . . 4-8TROL . . . . . . . . . . . . . . . . 4-8KOUT TEST . . . . . . . . . . . . . . . . . . . . . 4-8. . . . . . . . . . . . . . . . . . . . . 4-9) . . . . . . . . . . . . . . . . . . . 4-10 . . . . . . . . . . . . . . . . . . . 4-12

    . . . . . . . . . . . . . . . . . . . . 4-12

    . . . . . . . . . . . . . . . . . . . 4-12

    . . . . . . . . . . . . . . . . . . . 4-13

    EDURES

    . . . . . . . . . . . . . . . . . . . . . 5-1. . . . . . . . . . . . . . . . . . . . 5-1

    N. . . . . . . . . . . . . . . . . . . 5-1ntrol Machine . . . . . . . . 5-1ht Overhead. . . . . . . . . 5-2ROCEDURES . . . . . . . . . 5-2RUCTIONS

    . . . . . . . . . . . . . . . . . . . . . 5-2

    SECTION - 6 - GENERAL SPECIFICATIO MAINTENANCE

    6.1 INTRODUCTION. . . . . . . . . . . .6.2 OPERATING SPECIFICATIONS

    Specifications and PerformanCapacities . . . . . . . . . . . . . . . Engine Data . . . . . . . . . . . . .Battery. . . . . . . . . . . . . . . . . .Tires . . . . . . . . . . . . . . . . . . .Major Component Weights. .Hydraulic Oil . . . . . . . . . . . . .

    6.3 SERIAL NUMBER LOCATION .6.4 OPERATOR MAINTENANCE . .6.5 TIRES & WHEELS . . . . . . . . . .

    Tire Inflation . . . . . . . . . . . . .Tire Damage . . . . . . . . . . . . .Tire Replacement . . . . . . . . .Wheel Replacement . . . . . . .Wheel Installation . . . . . . . . .

    6.6 DRAINING OIL BUILD UP FROM REGULATOR . . . . . . . . . . . . .

    6.7 PROPANE FUEL FILTER REPL

  • TABLE OF CONTENTS

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    SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

    Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

    6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-35

    SECTION - 7 - INSPECTION AND REPAIR LOG

    LIST OF

    2-1. Basic Nomenclature2-2. Basic Nomenclature2-2. Daily Walk-Around In2-3. Daily Walk-Around In2-4. Horizontal and Capa

    Sheet 1 of 2 . . . . . 2-5. Horizontal and Capa

    Sheet 2 of 2 . . . . . 2-6. Limiting and Cut-Ou2-7. Limiting and Cut-Ou3-1. Ground Control Stat3-1. Ground Control Stat3-2. Ground Control Indic3-3. Platform Control Con3-4. Platform Light Panel4-1. Position of Least Bac4-2. Position of Least For4-3. Grade and Side Slop

    4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . 4-94-5. Typical 800S/860SJ Transport . . . . . . . . . . . . . . . 4-144-6. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-154-7. Decal Location - Rear Entry Platform -

    Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16y Platform - . . . . . . . . . . . . . . . . . . 4-17 Platform -

    . . . . . . . . . . . . . . . . . . 4-30y Platform - . . . . . . . . . . . . . . . . . . 4-31y Platform - . . . . . . . . . . . . . . . . . . 4-32y Platform - . . . . . . . . . . . . . . . . . . 4-33y Platform - . . . . . . . . . . . . . . . . . . 4-34 . . . . . . . . . . . . . . . . . . 6-10ture Specifications -

    . . . . . . . . . . . . . . . . . . 6-11ture Specifications -

    . . . . . . . . . . . . . . . . . . 6-12ture Specifications -

    . . . . . . . . . . . . . . . . . . 6-13ture Specifications -

    . . . . . . . . . . . . . . . . . . 6-14 JLG Lift

    FIGURES

    - Sheet 1 of 2 . . . . . . . . . . . . .2-6 - Sheet 2 of 2 . . . . . . . . . . . . .2-7spection - Sheet 1 of 2 . . . . . .2-8spection - Sheet 2 of 2 . . . . . .2-9city Limit Switches - . . . . . . . . . . . . . . . . . . . . . . . .2-10city Limit Switches - . . . . . . . . . . . . . . . . . . . . . . . .2-11t Switches - Sheet 1 of 2 . . . .2-12t Switches - Sheet 2 of 2 . . . .2-13ion - 800S . . . . . . . . . . . . . . . .3-3ion - 860SJ. . . . . . . . . . . . . . . .3-4ator Panel . . . . . . . . . . . . . . . .3-6sole. . . . . . . . . . . . . . . . . . . . .3-9

    . . . . . . . . . . . . . . . . . . . . . . . .3-14kward Stability . . . . . . . . . . . .4-3ward Stability . . . . . . . . . . . . .4-4es . . . . . . . . . . . . . . . . . . . . . .4-6

    4-8. Decal Location - Rear Entr Sheet 2 of 2. . . . . . . . . . .

    4-9. Decal Location - Side Entry Sheet 1 of 5. . . . . . . . . . .

    4-10. Decal Location - Side Entr Sheet 2 of 5. . . . . . . . . . .

    4-11. Decal Location - Side Entr Sheet 3 of 5. . . . . . . . . . .

    4-12. Decal Location - Side Entr Sheet 4 of 5. . . . . . . . . . .

    4-13. Decal Location - Side Entr Sheet 5 of 5. . . . . . . . . . .

    6-1. Serial Number Locations .6-2. Engine Operating Tempera

    Deutz - Sheet 1 of 2 . . . .6-3. Engine Operating Tempera

    Deutz - Sheet 2 of 2 . . . .6-4. Engine Operating Tempera

    Ford - Sheet 1 of 2 . . . . .6-5. Engine Operating Tempera

    Ford - Sheet 2 of 2 . . . . .

  • TABLE OF CONTENTS

    iv 3121138

    SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

    6-6. Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-15

    6-7. Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2

    6-8. Engine Operating Tempe GM - Sheet 1 of 2. . . . .

    6-9. Engine Operating Tempe GM - Sheet 2 of 2. . . . .

    6-10. Operator Maintenance an6-11. Filter Lock Assembly . . .

    LIST OF TAB

    1-1 Minimum Approach Dista2-1 Inspection and Maintenan4-1 Decal Location Legend - 4-2 Decal Location Legend - 4-3 Decal Location Legend - 4-4 Decal Location Legend, 8

    Side Entry Platform . . . 4-5 Decal Location Legend, 8

    Side Entry Platform . . . 6-1 Operating Specifications6-2 Specifications and Perfor6-3 Capacities . . . . . . . . . . . 6-4 Ford LRG-425 Specificati

    6-5 Deutz F4M2011 Specifications. . . . . . . . . . . . . . . . 6-46-6 Caterpillar 3044C . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56-7 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

    . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-6 . . . . . . . . . . . . . . . 6-7 . . . . . . . . . . . . . . . 6-7 . . . . . . . . . . . . . . . 6-8 . . . . . . . . . . . . . . . 6-8 . . . . . . . . . . . . . . . 6-9 . . . . . . . . . . . . . . . 6-9 . . . . . . . . . . . . . . 6-20 . . . . . . . . . . . . . . 6-32 . . . . . . . . . . . . . . . 7-1 JLG Lift

    . . . . . . . . . . . . . . . . . . . 6-16rature Specifications - . . . . . . . . . . . . . . . . . . . . 6-17rature Specifications - . . . . . . . . . . . . . . . . . . . . 6-18d Lubrication Diagram . 6-19. . . . . . . . . . . . . . . . . . . . 6-34

    LES

    nces (M.A.D.) . . . . . . . . . 1-5ce Table . . . . . . . . . . . . . 2-3

    Rear Entry Platform. . . . 4-18Rear Entry Platform. . . . 4-22Rear Entry Platform. . . . 4-2600S - . . . . . . . . . . . . . . . . . . . . 4-3560SJ - . . . . . . . . . . . . . . . . . . . . 4-39. . . . . . . . . . . . . . . . . . . . . 6-1mance Data. . . . . . . . . . . 6-2. . . . . . . . . . . . . . . . . . . . . 6-3ons. . . . . . . . . . . . . . . . . . 6-4

    6-8 Battery Specifications. . . . . . . .6-9 Tire Specifications . . . . . . . . . .6-10 Component Weights . . . . . . . .6-11 Hydraulic Oil . . . . . . . . . . . . . . .6-12 Mobilfluid 424 Specs . . . . . . . .6-13 Mobil DTE 13M Specs . . . . . . .6-14 Mobil EAL 224H Specs. . . . . . .6-15 UCon Hydrolube HP-5046 . . . .6-16 Exxon Univis HVI 26 Specs . . .6-17 Lubrication Specifications . . . .6-18 Wheel Torque Chart . . . . . . . . .7-1 Inspection and Repair Log . . . .

  • SECTION 1 - SAFETY PRECAUTIONS

    3121138 1-1

    SECTION 1. SAFETY PRECAUTIONS

    1.1 GENERALThis section outlines the necessary precautions for properand safe machine operation and maintenance. For propermachine use, it is mandatory that a daily routine is estab-lished based on the program, using the ithe Service and Mailished by a qualifiemachine is safe to op

    The owner/user/opshould not operate tread, training is accohas been completeenced and qualified o

    If there are any queinspection, maintenacontact JLG Industrie

    FAILURE TO COMPLY WITHTHIS MANUAL COULD RESDAMAGE, PERSONAL INJUR

    1.2 PRE-OPERATION

    Operator Training and Knowledge Read and understand this manual before operating the

    til complete training is per-

    personnel can operate the JLG Lift

    content of this manual. A maintenancenformation provided in this manual andntenance Manual, must also be estab-d person and followed to ensure theerate.

    erator/lessor/lessee of the machinehe machine until this manual has beenmplished, and operation of the machined under the supervision of an experi-perator.

    stions with regard to safety, training,nce, application, and operation, pleases, Inc. (JLG).

    THE SAFETY PRECAUTIONS LISTED INULT IN MACHINE DAMAGE, PROPERTY

    Y OR DEATH.

    machine.

    Do not operate this machine unformed by authorized persons.

    Only authorized and qualified machine.

  • SECTION 1 - SAFETY PRECAUTIONS

    1-2 3121138

    Read, understand, and obey all DANGERS, WARNINGS,CAUTIONS, and operating instructions on the machineand in this manual.

    Use the machine in a manner which is within the scope ofits intended application set by JLG.

    All operating personnegency controls and emas specified in this man

    Read, understand, anlocal, and governmenoperation of the machi

    Workplace Inspection The operator is to take

    ards in the work area p

    Do not operate or raiseers, railway cars, floatinment unless approved

    Do not operate the munless approved for th

    Be sure that the groundmaximum load showmachine.

    This machine can be operated in temperatures of 0o F to104o F (-20o C to 40o C). Consult JLG for operation out-side this range.

    Machine Inspection inspections and func-2 of this manual for

    has been serviced andents specified in the

    er safety devices aref these devices is a

    IAL WORK PLATFORMSION FROM THE MANU-

    ich safety or instructionlegible.

    e platform floor. Keep substances from foot- JLG Lift

    l must be familiar with the emer-ergency operation of the machineual.

    d obey all applicable employer,tal regulations as they pertain tone.

    safety measures to avoid all haz-rior to machine operation.

    the platform while on trucks, trail-g vessels, scaffolds or other equip-

    in writing by JLG.

    achine in hazardous environmentsat purpose by JLG.

    conditions are able to support then on the decals located on the

    Before machine operation, performtional checks. Refer to Section detailed instructions.

    Do not operate this machine until it maintained according to requiremService and Maintenance Manual.

    Be sure the footswitch and all othoperating properly. Modification osafety violation.

    MODIFICATION OR ALTERATION OF AN AERSHALL BE MADE ONLY WITH WRITTEN PERMISFACTURER

    Do not operate any machine on whplacards or decals are missing or il

    Avoid any buildup of debris on thmud, oil, grease, and other slipperywear and platform floor.

  • SECTION 1 - SAFETY PRECAUTIONS

    3121138 1-3

    1.3 OPERATION

    General Do not use the machine for any purpose other than posi-

    tioning personnel, their tools, and equipment.

    Never operate a mmalfunctions occu

    Never slam a contopposite directionstop before movinate controls with s

    Hydraulic cylinderfully retracted befo

    Do not allow permachine from theexcept in an emer

    Do not carry mateapproved by JLG.

    When two or moretor shall be respon

    Always ensure thanever left hangingarea.

    Supplies or tools which extend outside the platform areprohibited unless approved by JLG.

    When driving, always position boom over rear axle in linewith the direction of travel. Remember, if boom is over thefront axle, steer and drive functions will be reversed.

    Do not assist a stuck or disabled machine by pushing,nctions. Only pull the unithassis.

    m against any structure tort the structure.

    er before leaving machine.

    e platform must wear a fullched to an authorized lan-ly one (1) lanyard per lan- JLG Lift

    achine that is not working properly. If ars, shut down the machine.

    rol switch or lever through neutral to an. Always return switch to neutral andg the switch to the next function. Oper-low and even pressure.

    s should never be left fully extended orre shutdown or for long periods of time.

    sonnel to tamper with or operate the ground with personnel in the platform,gency.

    rials directly on platform railing unless

    persons are in the platform, the opera-sible for all machine operations.

    t power tools are properly stowed and by their cord from the platform work

    pulling, or by using boom fufrom the tie-down lugs on the c

    Do not place boom or platforsteady the platform or to suppo

    Stow boom and shut off all pow

    Trip and Fall Hazards During operation, occupants in thbody harness with a lanyard attayard anchorage point. Attach onyard anchorage point.

  • SECTION 1 - SAFETY PRECAUTIONS

    1-4 3121138

    Before operating the machine, make sure all gates areclosed and fastened in their proper position.

    Keep both feet firmly ptimes. Never use laddeitems on platform to pr

    Never use the boom aform.

    Use extreme caution when entering or leaving platform.Be sure that the boom is fully lowered. It may be neces-sary to telescope out to position the platform closer to theground for entry/exit. Face the machine, maintain threepoint contact with the machine, using two hands and one

    g entry and exit.

    does not provide pro- electrical current. JLG Lift

    ositioned on the platform floor at allrs, boxes, steps, planks, or similar

    ovide additional reach.

    ssembly to enter or leave the plat-

    foot or two feet and one hand durin

    Electrocution Hazards This machine is not insulated and

    tection from contact or proximity to

  • SECTION 1 - SAFETY PRECAUTIONS

    3121138 1-5

    Maintain distance energized (exposeMinimum Approac1.

    Allow for machine

    0 ft. (3m) between any partnts, their tools, and theire or apparatus carrying upal clearance is required forss.

    Table 1-1. Minimum Approach Distances (M.A.D.)

    Voltage Range(Phase to Phase)

    MINIMUM APPROACH DISTANCEin Feet (Meters)

    0 to 50 KV 10 (3)

    Over 50KV to 200 KV 15 (5)

    20 (6)

    25 (8)

    35 (11)

    45 (14)

    apply except wherernmental regulations JLG Lift

    from electrical lines, apparatus, or anyd or insulated) parts according to theh Distance (MAD) as shown in Table 1-

    movement and electrical line swaying.

    Maintain a clearance of at least 1of the machine and its occupaequipment from any electrical linto 50,000 volts. One foot additionevery additional 30,000 volts or le

    Over 200 KV to 350 KV

    Over 350 KV to 500 KV

    Over 500 KV to 750 KV

    Over 750 KV to 1000 KV

    NOTE: This requirement shall employer, local or goveare more stringent.

  • SECTION 1 - SAFETY PRECAUTIONS

    1-6 3121138

    The minimum approach distance may be reduced if insulat-ing barriers are installed to prevent contact, and the barriersare rated for the voltage of the line being guarded. Thesebarriers shall not be part of (or attached to) the machine. Theminimum approach distance shall be reduced to a distancewithin the designed worbarrier. This determinatioson in accordance with threquirements for work pra

    DO NOT MANEUVER MACHINE OZONE (MAD). ASSUME ALL ELEENERGIZED UNLESS KNOWN OT

    Tipping Hazards The user should be familiar with the surface before driv-

    ing. Do not exceed the allowable sideslope and gradewhile driving. JLG Lift

    king dimensions of the insulatingn shall be made by a qualified per-e employer, local, or governmentalctices near energized equipment

    R PERSONNEL INSIDE PROHIBITEDCTRICAL PARTS AND WIRING ARE

    HERWISE.

  • SECTION 1 - SAFETY PRECAUTIONS

    3121138 1-7

    Do not elevate platform or drive with platform elevatedwhile on a sloping, uneven, or soft surface.

    Before driving on floors, bridges, trucks, and other sur-faces, check allowable capacity of the surfaces.

    Never exceed the maximum platform capacity. Distributeloads evenly on platform floor.

    Do not raise the ption unless the mafaces.

    Keep the chassis holes, bumps, droholes, and other p

    Do not push or pu

    Never attempt to uoff machine to any

    Do not operate the28 mph (12.5 m/s)

    Do not increase tload. Increase ofdecrease stability.

    Do not increase thextensions or attac

    If boom assembly or platform is in a position that one ormore wheels are off the ground, all persons must beremoved before attempting to stabilize the machine. Usecranes, forklift trucks, or other appropriate equipment tostabilize machine and remove personnel.

    Crushing and Collision Hazards worn by all operating and

    s overhead, on sides, and or lowering platform, and

    y parts inside platform rail- JLG Lift

    latform or drive from an elevated posi-chine is on firm, level and smooth sur-

    of the machine at least 2 ft. (0.6m) fromp-offs, obstructions, debris, concealedotential hazards on the floor/surface.

    ll any object with the boom.

    se the machine as a crane. Do not tie- adjacent structure.

    machine when wind conditions exceed.

    he surface area of the platform or the the area exposed to the wind will

    e platform size with unauthorized deckhments.

    Approved head gear must beground personnel.

    Check work area for clearancebottom of platform when liftingdriving.

    During operation, keep all boding.

  • SECTION 1 - SAFETY PRECAUTIONS

    1-8 3121138

    Use the boom functions, not the drive function, to positionthe platform close to obstacles.

    Always post a lookout when driving in areas where visionis obstructed.

    Keep non-operating pfrom machine during a

    Limit travel speed accoface, congestion, visiband other factors whicpersonnel.

    Be aware of stopping ddriving in high speed,ping. Travel grades in l

    Do not use high speedor when driving in reve

    Exercise extreme cautifrom striking or interfersons in the platform.

    Be sure that operatorsmachines are aware oence. Disconnect powe

    Warn personnel not to boom or platform. Possary.

    1.4 TOWING, LIFTING, AND HAULING Never allow personnel in platform while towing, lifting, or

    hauling.

    This machine should not be towed, except in the event ofure, or loading/unload-edures section of thisedures.

    ition and the turntableling. The platform must

    esignated areas of thent of adequate capac-

    tion of this manual for JLG Lift

    ersonnel at least 6 ft. (1.8m) awayll driving and swing operations.

    rding to conditions of ground sur-ility, slope, location of personnel,h may cause collision or injury to

    istances in all drive speeds. When switch to low speed before stop-ow speed only.

    drive in restricted or close quartersrse.

    on at all times to prevent obstaclesing with operating controls and per-

    of other overhead and floor levelf the aerial work platforms pres-r to overhead cranes.

    work, stand, or walk under a raisedition barricades on floor if neces-

    emergency, malfunction, power failing. Refer to the Emergency Procmanual for emergency towing proc

    Ensure boom is in the stowed poslocked prior to towing, lifting or haube completely empty of tools.

    When lifting machine, lift only at dmachine. Lift the unit with equipmeity.

    Refer to the Machine Operation seclifting information.

  • SECTION 1 - SAFETY PRECAUTIONS

    3121138 1-9

    1.5 ADDITIONAL HAZARDS / SAFETY Do not use machine as a ground for welding.

    When performing welding or metal cutting operations,precautions must be taken to protect the chassis fromdirect exposure to weld and metal cutting spatter.

    Do not refuel the m

    Battery fluid is higand clothing at all

    Charge batteries o JLG Lift

    achine with the engine running.

    hly corrosive. Avoid contact with skintimes.

    nly in a well ventilated area.

  • SECTION 1 - SAFETY PRECAUTIONS

    1-10 3121138 JLG Lift

    This page left blank intentionally.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-1

    SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2.1 PERSONNEL TRAININGThe aerial platform is a personnel handling device; so it isnecessary that it be operated and maintained only by trainedpersonnel.

    Persons under the insubject to seizures, dnot operate this mac

    Operator TrainingOperator training mu

    1. Use and limitatiothe ground, eme

    2. Control labels, inmachine.

    3. Rules of the emp

    4. Use of approved

    5. Enough knowledmachine to recofunction.

    6. The safest means to operate the machine where over-head obstructions, other moving equipment, and obsta-cles, depressions, holes, dropoffs.

    7. Means to avoid the hazards of unprotected electrical

    machine application.

    supervision of a qualifiedbstructions until the traineely control and operate the

    that he/she has the respon-n the machine in case of aition of either the machine JLG Lift

    fluence of drugs or alcohol or who areizziness or loss of physical control musthine.

    st cover:

    ns of the controls in the platform and at rgency controls and safety systems.

    structions, and warnings on the

    loyer and government regulations.

    fall protection device.

    ge of the mechanical operation of the gnize a malfunction or potential mal-

    conductors.

    8. Specific job requirements or

    Training SupervisionTraining must be done under theperson in an open area free of ohas developed the ability to safemachine.

    Operator ResponsibilityThe operator must be instructed sibility and authority to shut dowmalfunction or other unsafe condor the job site.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-2 3121138

    2.2 PREPARATION, INSPECTION, AND MAINTENANCE

    The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for furtheforms. The frequency of ibe increased as necessaharsh or hostile environincreased frequency, or manner.

    IMPORTANTJLG INDUSTRIES, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICETECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETEDTHE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PROD- JLG Lift

    r requirements for aerial work plat-nspections and maintenance mustry when the machine is used in a

    ment, if the machine is used withif the machine is used in a severe

    UCT MODEL.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-3

    Table 2-1. Inspection and Maintenance Table

    Type FrequencyPrimary

    ResponsibilityService

    QualificationReference

    Pre-Start Inspection Before using each day; or whenever theres an Operator change.

    User or Operator User or Operator Operator and Safety Manual

    Pre-Delivery Inspection (See Note)

    Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG Service and Maintenance Manual and applicable JLG inspection form

    Frequent Inspection(See Note)

    Service and Maintenance Manual and applicable JLG inspection form

    Annual Machine Inspection(See Note)

    Service and Maintenance Manual and applicable JLG inspection form

    Preventative Maintenance Service and Maintenance Manual

    NOTE: Inspection form pections. JLG Lift

    Mechanic

    In service for 3 months or 150 hours, whichever comes first; orOut of service for a period of more than 3 months; orPurchased used.

    Owner, Dealer, or User Qualified JLG Mechanic

    Annually, no later than 13 months from the date of prior inspection.

    Owner, Dealer, or User Factory Certified Service Technician (Recommended)

    At intervals as specified in the Service and Main-tenance Manual.

    Owner, Dealer, or User Qualified JLG Mechanic

    s are available from JLG. Use the Service and Maintenance Manual to perform ins

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-4 3121138

    Pre-Start InspectionThe Pre-Start Inspection should include each of the follow-ing:

    1. Cleanliness Check all surfaces for leakage (oil, fuel, or battery fluid) or forthe proper maintenan

    2. Structure - Inspect damage, weld or paancies.

    3. Decals and Placardlegibility. Make sure nmissing. Make sure acleaned or replaced.

    4. Operators and Safethe Operator and Saf(Domestic only), and

    (Domestic only) is enclosed in the weather resistant storage container.

    5. Walk-Around Inspection Refer to Figure 2-2. and Figure 2-3.

    d Machines) Add the

    ngine oil level is at the filler cap is secure.

    lic oil level. Ensure .

    k-Around Inspection check of all systems in nd level obstructions.

    ic instructions.

    PERLY, TURN OFF THEBLEM TO THE PROPERTE THE MACHINE UNTIL

    Parent Metal Crack JLG Lift

    eign objects. Report any leakage to ce personnel.

    the machine structure for dents,rent metal cracks or other discrep-

    s Check all for cleanliness and one of the decals and placards are ll illegible decals and placards are

    ty Manuals Make sure a copy of ety Manual, EMI Safety Manual ANSI Manual of Responsibilities

    6. Battery Charge as required.

    7. Fuel (Combustion Engine Powereproper fuel as necessary.

    8. Engine Oil Supply - Ensure the eFull mark on the dipstick and the

    9. Hydraulic Oil Check the hydrauhydraulic oil is added as required

    10. Function Check Once the Walis complete, perform a functional an area free of overhead and grouRefer to Section 4 for more specif

    IF THE MACHINE DOES NOT OPERATE PROMACHINE IMMEDIATELY! REPORT THE PROMAINTENANCE PERSONNEL. DO NOT OPERAIT IS DECLARED SAFE FOR OPERATION.

    Weld Crack

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-5

    Function CheckPerform the Function Check as follows:

    1. From the ground control panel with no load in the plat-form:

    a. Check that all guards protecting the switches orlocks are in

    b. Operate all out switches

    c. Check auxil

    d. Ensure thawhen the Em

    2. From the platform

    a. Ensure thatthe proper lo

    b. Check that locks are in

    c. Operate all out switches

    d. Ensure thawhen the Em

    3. With the platform in the transport (stowed) position:

    a. Drive the machine on a grade, not to exceed therated gradeability, and stop to ensure the brakeshold;

    b. Check the tilt sensor alarm to ensure proper opera-tion. JLG Lift

    place;

    functions and check all limiting and cut-;

    iary power (or manual descent);

    t all machine functions are disabledergency Stop Button is activated.

    control console:

    the control console is firmly secured incation;

    all guards protecting the switches orplace;

    functions and check all limiting and cut-;

    t all machine functions are disabledergency Stop Button is pushed in.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-6 3121138 JLG Lift

    Figure 2-1. Basic Nomenclature - Sheet 1 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-7 JLG Lift

    1. Steer Wheels2. Drive Wheels3. Lift Cylinder4. Tower5. Level Link6. Upright7. Base Boom Section8. Mid Boom Section9. Fly Boom Section10. Boom Assembly11. Power Track12. Jib (If Equipped)13. Platform14. Platform Console

    Figure 2-2. Basic Nomenclature - Sheet 2 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-8 3121138 JLG Lift

    Figure 2-2. Daily Walk-Around Inspection - Sheet 1 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-9

    GeneralBegin the "Walk-Around Inspection" at Item 1, as noted on thediagram. Continue to the right (counterclockwise viewed fromtop) checking each item in sequence for the conditions listedin the following checklist.

    TO AVOID POSSIBLE INJURY,

    DO NOT OPERATE MACHINECORRECTED.

    INSPECTION NOTE: no loose or missing pno visible damage, leaany other criteria men

    1. Platform Assemerly, not modifiedhinges in working

    2. Platform & Grolevers return to nble, control mark

    3. Boom SectionsNote.

    4. Swing Drive - No evidence of damage.

    5. Wheel/Tire Assemblies - No loose or missing lug nuts, proper inflation (pneumatic). Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

    b - No evidence of leakage.

    pection Note.

    See Inspection Note.

    o visible damage; pivot pins ed, not leaking.

    e of proper lubrication. No seness between bearing

    Spindles - See Inspection

    mit Switches - Switches

    Inspection Note.

    ection Note. JLG Lift

    BE SURE MACHINE POWER IS OFF.

    UNTIL ALL MALFUNCTIONS HAVE BEEN

    On all components, make sure there arearts, that they are securely fastened, andks or excessive wear exists in addition to

    tioned.

    bly and Gate - Footswitch works prop-, disabled or blocked. Latch, stop, and condition.

    und Control Consoles - Switches and eutral, decals/placards secure and legi-ings legible.

    /Uprights/Turntable - See Inspection

    6. Drive Motor, Brake, and Hu

    7. Hood Assemblies - See Ins

    8. Auxiliary Hydraulic Pump -

    9. All Hydraulic Cylinders - Nand hydraulic hoses undamag

    10. Turntable Bearing - Evidencevidence of loose bolts or looand machine.

    11. Tie Rod Ends and SteeringNote.

    12. Horizontal and Capacity Lioperate properly.

    13. Main Hydraulic Pump - See

    14. Platform Rotator - See Insp

    Figure 2-3. Daily Walk-Around Inspection - Sheet 2 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-10 3121138

    2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES JLG Lift

    Figure 2-4. Horizontal and Capacity Limit Switches - Sheet 1 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-11

    Item Description Operation Characteristic

    1 Boom CapacityLength

    Activates platform capacity light to indicate the platform capacity at a designated boom length.

    2 Boom ESw

    3 Boom Angle

    height.

    4 Boom ESw JLG Lift

    Figure 2-5. Horizontal and Capacity Limit Switches - Sheet 2 of 2

    Switch

    xtensionitch

    Reduces drive speed when boom reaches a designated length.

    Capacity Switch

    Activates platform capacity light to indicate the platform capacity at a designated boom

    levationitch

    Reduces drive speed when boom is raised above horizontal.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-12 3121138 JLG Lift

    Figure 2-6. Limiting and Cut-Out Switches - Sheet 1 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-13 JLG Lift

    Figure 2-7. Limiting and Cut-Out Switches - Sheet 2 of 2

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-14 3121138

    2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

    IMPORTANTLOCKOUT SYSTEM TEST MUSTTIME A SYSTEM COMPONENT ISYSTEM OPERATION IS SUSPECT

    NOTE: Ensure boom is fullybetween drive wheelstest.

    1. Place a 6 inches (15ramp in front of left fr

    2. From platform contro

    3. Place the Drive control lever to the forward position andcarefully drive machine up ascension ramp until left frontwheel is on top of block.

    4. Carefully activate Swing control lever and position boomover right side of machine.

    hine, place Drive con-chine off of block and

    at left front or right rearn off of ground.

    lever and return boometween drive wheels).wed position, lockout

    llow wheel to rest onctivate Drive to release JLG Lift

    BE PERFORMED QUARTERLY, ANYS REPLACED, OR WHEN IMPROPERED.

    retracted, lowered, and centered prior to beginning lockout cylinder

    .2 cm) high block with ascensionont wheel.

    l station, start engine

    5. With boom over right side of mactrol lever to Reverse and drive maramp.

    6. Have an assistant check to see thwheel remains elevated in positio

    7. Carefully activate Swing control to stowed position (centered bWhen boom reaches center, stocylinders should release and aground, it may be necessary to acylinders.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    3121138 2-15

    8. Place the 6 inches (15.2 cm) high block with ascensionramp in front of right front wheel.

    9. Place Drive control lever to Forward and carefully drivemachine up ascension ramp until right front wheel is ontop of block.

    10. With boom over left side of machine, place Drive controllever to Reverseramp.

    11. Have an assistanwheel remains e

    12. Carefully activate Swing control lever and return boomto stowed position (centered between drive wheels).When boom reaches center, stowed position, lockoutcylinders should release and allow wheel to rest onground, it may be necessary activate Drive to releasecylinders.

    nction properly, have quali-alfunction prior to any fur- JLG Lift

    and drive machine off of block and

    t check to see that right front or left rearlevated in position off of ground.

    13. If lockout cylinders do not fufied personnel correct the mther operation.

  • SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

    2-16 3121138 JLG Lift

    This page left blank intentionally.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-1

    SECTION 3. MACHINE CONTROLS AND INDICATORS

    3.1 GENERAL

    IMPORTANTTHE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERARESPONSIBLE FOR CONFOR

    This section provideunderstand control fu

    3.2 CONTROLS AND

    NOTE: This machines issymbols to indiclocated on the cbox or by the grocorresponding fu

    Ground Control Station

    (See Figure 3-1., Ground Control Station - 800S and Figure 3-1.,Ground Control Station - 860SJ)

    switch is in the ON posi-, an alarm will sound, indi-

    MASTER/EMERGENCY STOPOFF POSITION TO PREVENT

    le switch mustate Telescope,evel Override, JLG Lift

    TION. THE USER AND OPERATOR AREMING WITH GOOD SAFETY PRACTICES.

    s the necessary information needed tonctions.

    INDICATORS

    equipped with control panels that useate control functions. Refer to decal

    ontrol box guard in front of the controlund controls for these symbols and thenctions.

    NOTE: When Power/Emergency Stoption and engine is not runningcating Ignition is ON.

    WHEN THE MACHINE IS SHUT DOWN THESWITCH MUST BE POSITIONED TO THE DRAINING THE BATTERY.

    NOTE: If equipped, the Function Enabbe held down in order to operSwing, Lift, Jib Lift, Platform Land Platform Rotate functions.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-2 3121138

    1. Indicator Panel.

    The LED Indicator Panel contains indicator lights thatsignal problem conditions or functions operating duringmachine operation.

    TO AVOID SERIOUS INJURY, DO NTROL LEVERS OR TOGGLE SWMOVEMENT DO NOT RETURNRELEASED.

    2. Telescope Control.

    Provides extension apositioned to IN or O

    3. Swing Control.

    Provides 360 degree

    4. Lift Control.

    Provides raising and

    5. Platform/Ground Select Switch

    A three position, key operated switch supplies power tothe platform control console when positioned to PLAT-FORM. With the switch key held in the GROUND posi-

    orm and only ground

    T switch in the centertrols at both operating

    machine has been inonnecting into the oilly engine run hours arers up to 9,999.9 hours

    aped switch furnishesSELECT switch when

    (off), power is shut offECT switch. JLG Lift

    OT OPERATE MACHINE IF ANY CON-ITCHES CONTROLLING PLATFORM

    TO THE OFF POSITION WHEN

    nd retraction of the boom, whenUT.

    s continuous turntable rotation.

    lowering of the main boom.

    tion, power is shut off to platfcontrols are operable.

    NOTE: With PLATFORM/GROUND SELECposition, power is shut off to constations.

    6. Hourmeter.

    Registers the amount of time theuse, with engine running. By cpressure circuit of the engine, onrecorded. The hourmeter registeand cannot be reset.

    7. Power/Emergency Stop Switch.

    A two-position red mushroom shpower to PLATFORM/GROUND pulled out (on). When pushed into the PLATFORM/GROUND SEL

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-3

    1. Indicator Panel2. Telescope3. Swing4. Lift5. Platform/Ground S6. Hourmeter7. Power/Emergency8. Engine Start/Auxil or Engine Start/Auxil9. N/A10. Platform Leveling11. Platform Rotate JLG Lift

    elect Switch

    Stopiary Power

    iary Power/Function Enable

    Override

    Figure 3-1. Ground Control Station - 800S

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-4 3121138

    1. Indicator Panel2. Telescope3. Swing4. Lift5. Platform/Ground Se6. Hourmeter7. Power/Emergency S8. Engine Start/Auxiliar or Engine Start/Auxiliar9. Articulating Jib Boom10. Platform Leveling Ov11. Platform Rotate JLG Lift

    Figure 3-1. Ground Control Station - 860SJ

    lect Switch

    topy Power

    y Power/Function Enable

    erride

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-5

    8. Engine Start/Auxiliary Power Switch orEngine Start/ Auxiliary Power Switch /Function Enable.

    To start the engine, the switch must be held"UP" until the engine starts.

    To use auxiliary power, the switch must beheld DOWN fouse. Aux powerengine is not run

    If equipped, the "DOWN" to enabthe engine is run

    NOTE: Auxiliary power osure, and is disab

    NOTE: Functions will obecause of the le

    WHEN USING AUXILIARY POFUNCTION AT A TIME. (SIMUTHE AUXILIARY PUMP.)

    9. Articulating Jib Boom. (If Equipped)

    This switch provides raising and lowering of the jib.

    10. Platform Leveling Override.

    A three position switch allows the operator to compen- automatic self leveling sys-

    its rotation of the platform. JLG Lift

    r duration of auxiliary pump can only be used if thening.

    enable switch must be heldle all boom controls whenning.

    nly works if there is no engine oil pres-led if engine is running.

    perate at a slower than normal ratesser flow of hydraulic fluid delivered.

    WER, DO NOT OPERATE MORE THAN ONELTANEOUS OPERATION CAN OVERLOAD

    sate for any difference in thetem.

    11. Platform Rotate.

    A three position switch perm

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-6 3121138

    Ground Control Indicator Panel

    (See Figure 3-2., Ground Control Indicator Panel)

    1. Battery Charging Indicator

    Indicates a problem in the battery or charging circuit,and service is required.

    2. Low Engine Oil Pressure Indicator.

    e is below normal and

    Indicator (Ford)

    perature is abnormally

    (Deutz).

    engine oil, which alsoormally high and ser-

    full or less. When theroximately four usable

    Figure 3-2. Ground Co

    1. Battery Charging2. Low Engine Oil Pressure3. High Engine Coolant Temp.4. High Engine Oil Temp.5. Low Fuel JLG Lift

    Indicates that engine oil pressurservice is required.

    3. High Engine Coolant Temperature

    Indicates that engine coolant temhigh and service is required.

    4. Engine Oil Temperature Indicator

    Indicates the temperature of the serves as engine coolant, is abnvice is required.

    5. Low Fuel Level Indicator

    Indicates that the fuel level is 1/8light first turns on, there are appgallons of fuel remaining.

    ntrol Indicator Panel

    6. Glow Plug7. Overload8. Hyd. Filter 9. Charge Pump Filter10. Engine Air Filter

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-7

    6. Glow Plug Indicator

    Indicates the glow plugs are operating. After turning onignition, wait until light goes out before cranking engine.

    7. Overload Indicator (If Equipped)

    Indicates the pla

    8. Hydraulic Oil Filt

    Indicates the retbypass mode an

    9. Charge Pump O

    Indicates that chneeds to be repl

    10. Engine Air Filter

    Indicates that thbe replaced.

    Platform Station

    (See Figure 3-3., Platform Control Console)

    1. Power/Emergency Stop

    A two-position red mushroom shaped switch furnishesols when pulled out (on).r is shut off to the platform

    pulling the switch out, thenostic check of the variousrything is OK, the platform this time the lights on the

    once as a bulb check.

    s power to the horn. JLG Lift

    tform has been overloaded.

    er Indicator (Prior to S/N 85332)

    urn oil filter is too restrictive and in thed needs to be replaced.

    il Filter Indicator (Prior to S/N 85332)

    arge pump filter is too restrictive andaced.

    Indicator (Prior to S/N 85332)

    e air filter is too restrictive and needs to

    power to PLATFORM ContrWhen pushed in (off), powefunctions.

    Within about 2 seconds of machine will perform a diagelectrical circuits, and if evealarm will beep once. Duringindicator panel will also blink

    2. Horn

    If pressed, this switch supplie

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-8 3121138

    NOTE: MAIN LIFT, SWING, and DRIVE control levers are spring-loaded and will automatically return to neutral (OFF) posi-tion when released.

    TO AVOID SERIOUS INJURY, DO NTROL LEVERS OR TOGGLE SWMOVEMENT DO NOT RETURN TWHEN RELEASED.

    3. Main Lift/Swing Cont

    An infinitely proportifor main lift and swinward to lift down. Moswing left.

    NOTE: To operate the Main locking ring below the

    4. Main Telescope Cont

    This control allows eboom.

    5. Drive/Steer

    The DRIVE joystick provides for driving either forward orbackward. The controller is ramped to allow variabledrive speed.

    b operated switch on

    up on the locking ring

    orizontal and any of the/TORQUE SELECT or

    to HIGH, high functionnd the machine contin-

    D /TORQUE SELECT OR BOOM IS ABOVE HORI- JLG Lift

    OT OPERATE MACHINE IF ANY CON-ITCHES CONTROLLING PLATFORM

    O THE OFF OR NEUTRAL POSITION

    roller.

    onal dual axis joystick is providedg. Push forward to lift up, pull back-ve right to swing right, move left to

    Lift/Swing Joystick, pull up on the handle.

    rol.

    xtension and retraction of the main

    Steering is controlled by a thumtop of the joystick.

    NOTE: To operate the Drive Joystick, pullbelow the handle.

    NOTE: When boom is positioned above hfollowing switches, DRIVE SPEEDFUNCTION SPEED, are positionedspeeds are automatically cut out aues to operate at a lower speed.

    DO NOT OPERATE MACHINE IF DRIVE SPEEFUNCTION SPEED SWITCHES OPERATE WHENZONTAL.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-9

    1. Power/Em2. Horn3. Main Lift 4. Telescop

    / Aux Power JLG Lift

    ergency Stop

    / Swinge

    5. Drive/Steer6. Function Speed Control7. Drive Speed / Torque Select8. Platform Rotate

    9. Platform Level Override10. Articulating Jib (860SJ)11. Fuel Select12. Lights

    13. Steer Select14. Engine Start15. Light Panel

    Figure 3-3. Platform Control Console

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-10 3121138

    6. Function Speed Control

    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.

    7. Drive Speed/Torque S

    The forward positionshifting the drive moand giving high engiThe back position girain and climbing gramaximum displacemwhen drive controlleallows the machine by leaving the enginein maximum displace

    8. Platform Rotate.

    This switch allows ththe left or right.

    9. Platform Leveling Ov

    This switch allows thplatform.

    10. Articulating Jib Boom. (860SJ)

    Push forward to lift up, pull back to lift down. Variable liftspeed is using the Function Speed Control.

    11. Fuel Select (Dual Fuel Engine Only). (If Equipped)

    ay be selected by mov-position. It is unneces-ore switching fuels, sowitching fuels while the

    sole panel lights andequipped. The ignition operate the lights, soining the battery if leftand / or the ignition

    ll turn off power to all JLG Lift

    elect.

    gives maximum drive speed bytors to minimum the displacementne when drive controller is moved.ves maximum torque for rough ter-des by shifting the wheel motors toent and giving high engine speedr is moved. The center position

    to be driven as quietly as possible at mid speed and the drive motorsment.

    e operator to rotate the basket to

    erride.

    e operator to adjust the level of the

    Gasoline or liquid propane fuel ming the switch to the appropriate sary to purge the fuel system befthere is no waiting period when sengine is running.

    12. Lights. (If Equipped)

    This switch operates control conhead lights if the machine is so switch does not have to be on tocare must be taken to avoid draunattended. The master switch switch at the ground control wilights.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-11

    13. Steer Select. (If Equipped)

    When equipped with four wheel steering, the action ofthe steering system is operator selectable. The centerswitch position gives conventional front wheel steeringwith the rear wheels unaffected. This is for normal driv-ing at maximum speeds. The forward position is forcrab steering. axles steer in thesis to move sideused for positionbuildings. The bsteering. In this the opposite dircircle for maneu

    To re-synchronizrear drive wheelsing either crab steer (center swsteering function

    14. Start/Auxiliary Power.

    When pushed forward, the switch energizes the startermotor to start the engine.

    When pushed back, it energizes the electrically oper-ated hydraulic pump, when actuated. (Switch must be

    ary pump use.)

    to provide sufficient oil flow functions should the mainuxiliary pump will operateope, main boom lift, main

    ntains indicator lights that functions operating during JLG Lift

    When in this mode both front and rear same direction, which allows the chas-ways as it goes forward. This can being the machine in aisle ways or againstack switch position is for coordinatedmode the front and rear axles steer inections to produce the tightest turningvering in confined areas.

    e the front and rear axles, position the to the forward drive position by select-or compound steer, then select frontitch position) to operate the normal

    .

    held ON for duration of auxili

    The auxiliary pump functionsto operate the basic machinepump or engine fail. The atower boom lift, tower telesctelescope and swing.

    15. Indicator Panel.

    The LED Indicator Panel cosignal problem conditions ormachine operation.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-12 3121138

    Platform Control Indicator Panel

    (See Figure 3-4., Platform Light Panel)

    NOTE: The platform control indicator panel uses different shapedsymbols to alert the otional situations that csymbols are explained

    1. Level System Fault Indicator

    Indicates a fault in the electronic leveling system. Thefault indicator will flash and an alarm sound. All func-tions will default to creep if the boom is extended more

    d above horizontal.

    IS ILLUMINATED, SHUTERGENCY STOP, AND

    STS, RETURN THE PLAT-MANUAL LEVELING ASAIRED.

    ation.

    verloaded.

    Indicates a potif not correcteddeath. This ind

    Indicates an which if not cinterruption or low.

    Indicates impoperating condsafe operationthe exception obe green or yposition. JLG Lift

    perator to different types of opera-ould arise. The meaning of those below.

    than 20 inches (51 cm) or elevate

    IF THE LEVEL SYSTEM FAULT INDICATOR DOWN THE MACHINE, RECYCLE THE EMRESTART THE MACHINE. IF THE FAULT PERSIFORM TO THE STOWED POSITION, USING REQUIRED, AND HAVE LEVELING SYSTEM REP

    2. AC Generator. (Green)

    Indicates the generator is in oper

    3. Overload Indicator. (If equipped)

    Indicates the platform has been o

    entially hazardous situation, which, could result in serious injury or

    icator will be red.

    abnormal operating condition,orrected, may result in machinedamage. This indicator will be yel-

    ortant information regarding theition, i.e. procedures essential for

    . This indicator will be green withf the capacity indicator which will

    ellow depending upon platform

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-13

    4. Capacity Indicator.

    Indicates the maximum platform capacity for the currentposition of the platform. Restricted capacities are permit-ted at restricted platform positions (shorter boomlengths and higher boom angles).

    NOTE: Refer to the capaand unrestricted p

    5. Tilt Alarm Warnin

    Indicates that theIf the boom is abslope, an alarm activated.

    IF ILLUMINATED WHEN BOAND LOWER TO BELOW HORTHAT IT IS LEVEL BEFOREABOVE HORIZONTAL.

    6. Glow Plug Indica

    Indicates the gloignition, wait unt

    7. Footswitch/Enable Indicator

    To operate any function, the footswitch must bedepressed and the function selected within seven sec-onds. The enable indicator shows that the controls areenabled. If a function is not selected within seven sec-onds, or if a seven second lapse between ending one

    next function, the enablewitch must be released ande controls.

    oves power from all con-akes.

    MOVE, MODIFY OR DISABLE OTHER MEANS.

    UNCTIONS ACTIVATE WHEN/4" OF TRAVEL, TOP OR BOT- JLG Lift

    city decals on the machine for restrictedlatform capacities.

    g Light. (Red)

    chassis is on a slope (over 5 degrees).ove horizontal and the machine is on awill sound and CREEP is automatically

    OM IS RAISED OR EXTENDED, RETRACTIZONTAL THEN REPOSITION MACHINE SO EXTENDING BOOM OR RAISING BOOM

    tor

    w plugs are operating. After turning onil light goes out before cranking engine.

    function and beginning thelight will go out and the footsdepressed again to enable th

    Releasing the footswitch remtrols and applies the drive br

    TO AVOID SERIOUS INJURY, DO NOT RETHE FOOTSWITCH BY BLOCKING OR ANY

    FOOTSWITCH MUST BE ADJUSTED IF FSWITCH ONLY OPERATES WITHIN LAST 1TOM.

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-14 3121138

    1. L2. A3. O4. C JLG Lift

    evel SystemC Generatorverloadapacity

    5. Tilt Alarm Warning6. Glow Plug7. Enable8. Fuel Level

    9. Creep Speed Indicator10. Engine Malfunction Indicator11. Cable Service Indicator12. Soft Touch Indicator

    Figure 3-4. Platform Light Panel

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3121138 3-15

    8. Fuel Level Indicator.

    Indicates the level of fuel in the fuel tank.

    9. Creep Speed Indicator.

    When the Function Speed Control is turned to the creepposition, the indtions are set to th

    10. Engine Malfunct

    The light indicadetected a malfuhas been set in tManual for instrand trouble code

    The malfunctiononds when the kas a self test.

    11. Cable Service Indicator. (If Equipped)

    When illuminated, the light indicates the boom cablesare loose or broken and must be repaired or adjustedimmediately.

    ILLUMINATED, RETURN THE SHUT DOWN THE MACHINE,D.

    ped)

    per is against an object. All override button is pushed,tive in the Creep mode. JLG Lift

    icator acts as a reminder that all func-e slowest speed.

    ion Indicator.

    tes that the JLG Control System hasnction and a Diagnostic Trouble Code

    he system memory. Refer to the Serviceuctions concerning the trouble codes retrieval.

    indicator light will illuminate for 2-3 sec-ey is positioned to the on position to act

    IF THE CABLE SERVICE INDICATOR IS PLATFORM TO THE STOWED POSITION,AND HAVE THE BOOM CABLES INSPECTE

    12. Soft Touch Indicator. (If Equip

    Indicates the Soft Touch bumcontrols are cut out until theat which time controls are ac

  • SECTION 3 - MACHINE CONTROLS AND INDICATORS

    3-16 3121138 JLG Lift

    This page left blank intentionally.

  • SECTION 4 - MACHINE OPERATION

    3121138 4-1

    SECTION 4. MACHINE OPERATION

    4.1 DESCRIPTIONThis machine is a self-propelled hydraulic lift equipped with awork platform on the end of an elevating and rotating boom.Vibrations emitted by these machines are not hazardous toan operator in the woA-Weighted sound prthan 70dB(A).

    The primary operatothis control station,machine in both forwtor can raise or loweboom to the left or rigcontinuous left and rihas a Ground ControControl Station. GroSwing, and are to beform to the ground unable to do so. ThePre-Start Inspection.

    4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

    Capacities

    rizontal with or without any

    smooth, firm and level sur-

    rated capacity.

    tioning properly.

    ped from JLG.

    o (2) conditions which areD stability. The machines

    lity is shown in (See FigureCKWARD stability is shown JLG Lift

    rk platform. The equivalent continuousessure level at the work platform is less

    r control station is in the platform. From the operator can drive and steer theard and reverse directions. The opera-

    r the upper or lower boom or swing theht. Standard boom swing is 360 degreeght of the stowed position. The machinel Station which will override the Platformund Controls operate Boom Lift and

    used in an emergency to lower the plat-should the operator in the platform be Ground Control is also to be used in

    The boom can be raised above hoload in platform, if:

    1. Machine is positioned on a face.

    2. Load is within manufacturers

    3. All machine systems are func

    4. Proper tire pressure.

    5. Machine is as originally equip

    Stability

    Machine stability is based on twcalled FORWARD and BACKWARposition of least FORWARD stabi4-2.), and its position of least BAin (See Figure 4-1.)

  • SECTION 4 - MACHINE OPERATION

    4-2 3121138

    TO AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOADMACHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SUR-FACE.

    4.3 ENGINE OPERATI

    NOTE: Initial starting shouldGround Control station

    Starting Procedure

    IF ENGINE FAILS TO START PREXTENDED TIME. SHOULD ENGSTARTER TO COOL OFF FOR 2SEVERAL ATTEMPTS, REFER TO

    NOTE: Diesel engines only: must wait until glow pcranking engine.

    1. Turn key of SELECPOWER/EMERGENCthe ENGINE START s

    ALLOW ENGINE TO WARM-UP FOR A FEW MINUTES AT LOW SPEEDBEFORE APPLYING ANY LOAD.

    ime to warm up, shut

    M.

    RGENCY STOP switchRT switch until engine

    (up) position beforeates with footswitch inPERATE MACHINE. JLG Lift

    ON

    always be performed from the.

    OMPTLY, DO NOT CRANK FOR ANINE FAIL TO START AGAIN, ALLOW-3 MINUTES. IF ENGINE FAILS AFTERENGINE MAINTENANCE MANUAL.

    After turning on ignition, operatorlug indicator light goes out before

    T switch to GROUND. PositionY STOP switch to ON, then pushwitch until engine starts.

    2. After engine has had sufficient tengine off.

    3. Turn SELECT switch to PLATFOR

    4. From Platform, pull POWER/EMEout, then push the ENGINE STAstarts.

    NOTE: Footswitch must be in releasedstarter will operate. If starter operthe depressed position, DO NOT O

  • SECTION 4 - MACHINE OPERATION

    3121138 4-3

    Shutdown Procedure

    IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUT-DOWN, DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTART-ING THE ENGINE.

    1. Remove all loadspeed for 3-5 minternal engine t

    2. Push POWER/EM

    3. Turn MASTER sw

    Refer to Engine Mantion.

    .

    Backward Stability

    ROTATE PLATFORM90 DEGREES

    OM FULLYLEVATED

    URNTABLE ROTATED90 DEGREES FROMSTOWED POSITION JLG Lift

    and allow engine to operate at lowinutes; this allows further reduction of

    emperature.

    ERGENCY STOP switch in.

    itch to Off.

    ufacturers manual for detailed informa-

    Figure 4-1. Position of Least

    BOE

    T

    MACHINE WILL TIP OVER INTHIS DIRECTION IF OVERLOADED

    OR OPERATEDON AN OUT-OF-LEVEL SURFACE

  • SECTION 4 - MACHINE OPERATION

    4-4 3121138

    TIP OVER IN OVERLOADEDATEDVEL SURFACE JLG Lift

    Figure 4-2. Position of Least Forward Stability

    MACHINE WILLTHIS DIRECTION IF

    OR OPERON AN OUT-OF-LE

    TELESCOPEFULLY EXTENDED

    TURNTABLE ROTATED90 DEGREES FROMSTOWED POSITION

  • SECTION 4 - MACHINE OPERATION

    3121138 4-5

    4.4 TRAVELING (DRIVING)

    NOTE: When the upper boom is raised approximately 11 degreesabove horizontal, the high drive function will automaticallybe in low drive.

    DO NOT DRIVE WITH BOOSMOOTH, FIRM AND LEVEL

    TO AVOID LOSS OF TRAVEL MACHINE ON GRADES EXCENUMBER PLATE.

    DO NOT DRIVE ON SIDESLO

    USE EXTREME CAUTION WTIMES WHEN THE PLATFOR

    BEFORE DRIVING, LOCAARROWS ON BOTH THE CH

    MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIREC-TIONAL ARROWS.

    se

    t Emergency Stop switch,tswitch.

    ORWARD or REVERSE as

    teer controller to RIGHT foring left. JLG Lift

    M ABOVE HORIZONTAL EXCEPT ON ASURFACE.

    CONTROL OR TIP OVER , DO NOT DRIVEEDING THOSE SPECIFIED ON THE SERIAL

    PES WHICH EXCEED 5 DEGREES.

    HEN DRIVING IN REVERSE AND AT ALLM IS ELEVATED.

    TE THE BLACK/WHITE ORIENTATIONASSIS AND THE PLATFORM CONTROLS.

    Traveling Forward and Rever

    1. At Platform Controls, pull oustart engine, and activate foo

    2. Position Drive controller to Fdesired.

    4.5 STEERINGPosition thumb switch on Drive/Ssteering right, or to LEFT for steer

  • SECTION 4 - MACHINE OPERATION

    4-6 3121138 JLG Lift

    Figure 4-3. Grade and Side Slopes

  • SECTION 4 - MACHINE OPERATION

    3121138 4-7

    4.6 PLATFORM

    Platform Level Adjustment

    During normal operation of the machine, the platform willautomatically maintain its position. To manually Level Up orDown - Position theDown and hold unobtained.

    Platform Rotation

    To rotate the platforRotate control switcdesired position is re

    4.7 BOOM

    DO NOT SWING OR RAISE BOOM ABOVE HORIZONTAL WHENMACHINE IS OUT OF LEVEL.

    LEVEL INDICATOR FOR THE

    TO GROUND LEVEL. THENEFORE RAISING BOOM.

    RATE MACHINE IF ANY CON-ROLLING PLATFORM MOVE-R NEUTRAL POSITION WHEN

    EN A CONTROL SWITCH ORROM FOOTSWITCH OR USE MACHINE. JLG Lift

    Platform/Level control switch Up ortil the desired platform position is

    m to the left or right, use the Platformh to select the direction and hold untilached.

    DO NOT DEPEND ON TILT ALARM AS A CHASSIS.

    TO AVOID TIP OVER, LOWER PLATFORMDRIVE MACHINE TO A LEVEL SURFACE B

    TO AVOID SERIOUS INJURY, DO NOT OPETROL LEVER OR TOGGLE SWITCH CONTMENT DOES NOT RETURN TO THE OFF ORELEASED.

    IF THE PLATFORM DOES NOT STOP WHLEVER IS RELEASED, REMOVE FOOT FEMERGENCY STOP SWITCH TO STOP THE

  • SECTION 4 - MACHINE OPERATION

    4-8 3121138

    Swinging the Boom

    To swing boom, use SWING control to select RIGHT or LEFTdirection.

    IMPOWHEN SWINGING THE BOOM MFOR THE BOOM TO CLEAR SUREQUIPMENT.

    Raising and Lowering t

    To raise or lower the BooUP or DOWN movement.

    4.8 FUNCTION SPEEDThis control affects the spform Rotate. When in theplaced in creep speed.

    4.9 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

    IMPORTANTMED QUARTERLY, ANY, OR WHEN IMPROPER

    xle Lockout Test (If JLG Lift

    RTANTAKE SURE THERE IS AMPLE ROOM

    ROUNDING WALLS, PARTITIONS AND

    he Boom

    m, use Boom Lift control to select

    CONTROLeed of all boom functions and Plat- CCW maximum position, Drive is

    LOCKOUT SYSTEM TEST MUST BE PERFORTIME A SYSTEM COMPONENT IS REPLACEDSYSTEM OPERATION IS SUSPECTED.

    Refer to Section 2.4, Oscillating AEquipped) for procedure.

  • SECTION 4 - MACHINE OPERATION

    3121138 4-9

    4.10 EMERGENCY TOWING

    RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE ATALL TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL-LOW INSTRUCTIONS COULD

    MAXIMUM TOWING SPEED 5

    MAXIMUM TOWING GRADE 2

    DO NOT TOW MACHINE WIENGAGED.

    1. Retract, lower anturntable.

    2. Disconnect drive

    y inverting the disconnect.

    nnect Hub JLG Lift

    CAUSE SERIOUS INJURY OR DEATH.

    M.P.H. (8 K.M.H.)

    5%.

    TH ENGINE OPERATING OR DRIVE HUBS

    d position boom in travel position; lock

    hubs by inverting disconnect cap.

    3. Reconnect the drive hubs bcap when towing is complete

    Figure 4-4. Drive Disco

  • SECTION 4 - MACHINE OPERATION

    4-10 3121138

    4.11 TOW BAR (IF EQUIPPED)

    RUNAWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGBRAKES. TOWING VEHICLE MUSALL TIMES. ON-HIGHWAY TOWINLOW INSTRUCTIONS COULD CAU

    MAXIMUM TOWING SPEED 5 M.P.

    MAXIMUM TOWING GRADE 25%.

    Prior to towing the mach

    DO NOT TOW MACHINE WITH EENGAGED.

    1. Retract, lower and poturntable.

    2. Lower towbar and co

    .

    rting disconnect cap.nect Hub. JLG Lift

    T BE ABLE TO CONTROL MACHINE ATG NOT PERMITTED. FAILURE TO FOL-SE SERIOUS INJURY OR DEATH.

    H. (8 K.M.H.)

    ine, complete the following:

    NGINE OPERATING OR DRIVE HUBS

    sition boom in travel position; lock

    nnect to towing vehicle3. Disconnect drive hubs by inve

    Refer to Figure 4-4., Drive Discon

  • SECTION 4 - MACHINE OPERATION

    3121138 4-11

    4. Position steer/tow selector valve for towing; pull valveknob OUT for towing. The machine is now in the towingmode.

    After towing the machine, complete the following:

    1. Actuate steer/tow selector valve for steering; push valveknob IN to the actuated position.

    2. Reconnect drive

    3. Disconnect towbthe stowed posnow in the drivin JLG Lift

    hubs by inverting disconnect cap.

    ar from towing vehicle and place it inition as shown below. The machine isg mode.

  • SECTION 4 - MACHINE OPERATION

    4-12 3121138

    4.12 SHUT DOWN AND PARKTo shut down and park the machine, the procedures are asfollows:

    1. Drive machine to a reasonably well protected area.

    2. Ensure boom is lowe

    3. Push in the Emergen

    4. Push in the Emergention Platform/Ground

    5. If necessary, cover Ption placards, warnifrom hostile environm

    4.13 LIFTING AND TIE DOWN

    Lifting

    1. Call JLG Industries or weigh the individual unit to find

    sition with the turntable

    achine.

    revent damage to theains level. JLG Lift

    red over rear drive axle.

    cy Stop at Platform Controls.

    cy Stop at Ground Controls. Posi- Select switch to center OFF.

    latform Controls to protect instruc-ng decals and operating controlsent.

    out the Gross Vehicle Weight.

    2. Place the boom in the stowed polocked.

    3. Remove all loose items from the m

    4. Properly adjust the rigging to pmachine and so the machine rem

  • SECTION 4 - MACHINE OPERATION

    3121138 4-13

    Tie Down

    IMPORTANTWHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLYLOWERED INTO THE BOOM REST.

    1. Remove all loose

    2. When transportigle-drop trailer isform and to obtmachine onto th

    a. Position the

    DO NOT SWING THE BOOMTRAILER. TIPOVER MAY RES

    b. Place the botable locked

    IMPORTANTDRIVE AND STEER CONTROLLERS WILL BE REVERSED WHEN THEBOOM IS POSITIONED OVER THE FRONT WHEELS.

    c. Drive it onto the trailer with the boom and platformpositioned towards the truck. Refer to Figure 4-5.,

    sport.

    platform using straps or JLG Lift

    items from the machine.

    ng an 800S/860SJ a step-deck or sin- required. To avoid damage to the plat-

    ain proper weight distribution, load thee trailer as follows;

    boom over the front wheels.

    WHIT THE MACHINE POSITIONED ON AULT

    om in the stowed position with the turn-.

    Typical 800S/860SJ Tran

    3. Secure the chassis and thechains of adequate strength.

  • SECTION 4 - MACHINE OPERATION

    4-14 3121138 JLG Lift

    Figure 4-5. Typical 800S/860SJ Transport

  • SECTION 4 - MACHINE OPERATION

    3121138 4-15 JLG Lift

    Figure 4-6. Lifting and Tie Down Chart

  • SECTION 4 - MACHINE OPERATION

    4-16 3121138 JLG Lift

    Figure 4-7. Decal Location - Rear Entry Platform - Sheet 1 of 2

  • SECTION 4 - MACHINE OPERATION

    3121138 4-17 JLG Lift

    Figure 4-8. Decal Location - Rear Entry Platform - Sheet 2 of 2

  • SECTION 4 - MACHINE OPERATION

    4-18 3121138

    Table 4-1. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-2027090

    Australian0270909-2

    China/English

    Dutch0270915-2

    Finnish0271830-2

    French0270919-2

    French/English

    German0270913-2

    Italian0270917-2270918-2

    1 170379 704810

    2 170379 704822

    3 170380 - -

    4 170380 701518

    5 170501 - -

    6 170380 - -

    7 170490(800

    170490(860S

    704906(800S)

    704907(860SJ)

    8 - -

    9 - -

    10 - -

    11 170286 - -

    12 170427 704277 JLG Lift

    8-2 0270910-20270931-10270932-1

    0270916-2 0271831-1 0270920-20270929-10270930-1

    0270914-2 0

    7 1703992 1703925 1704809 1705053 1704811 1703924 1704767 1

    8 1704819 1703931 1704821 1705055 1704823 1703930 1704820 1

    5 - - 1703937 - - - - - - 1703936 - -

    4 1701518 1703949 1701518 1701518 1701518 1703948 1701518 1

    5 - - - - - - - - - - 1705015 - -

    8 - - - - - - - - - - 1703808 - -

    6S)7J)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1

    1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    8 - - - - - - - - - - 1704000 - -

    7 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1

  • SECTION 4 - MACHINE OPERATION

    3121138 4-19

    13 1705088 1705088 1704101 - - - - - - 1704099 - - - -

    14 17 - - -

    15 32 1705084

    16 17 1701502

    17 17 1701503

    18 17 1701504

    19 17 - - -

    20 17 1702631

    21 17 1700584

    22 - - -

    23 17 1701509

    24 17 1702300

    Table 4-1. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    (800S)1704995(860SJ)

    05089 1705089(800S)

    1704996(860SJ)

    1704109 - - - - - - 1704107 -

    51813 - - - - 1705084 1705084 1705084 3251813 1705084

    01502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

    01503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

    01504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

    02153 - - - - - - - - - - 1704006 -

    02631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

    00584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

    - - - - - - - - - - - - - - -

    01509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

    02300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

  • SECTION 4 - MACHINE OPERATION

    4-20 3121138

    25 170150 701500

    26 170150 701501

    27 - -

    28 - -

    29 - -

    30 - -

    31 - -

    32 - -

    33 - -

    34 701600

    35 170347(800

    170348(860S

    703475(800S)

    703482(860SJ)

    36 - -

    37 - -

    38 - -

    39 - -

    Table 4-1. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    0 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1

    1 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - 1703982 1703518 1701600 1693292 1703984 1693294 1

    5S)2J)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1

    1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - 3252221 - -

  • SECTION 4 - MACHINE OPERATION

    3121138 4-21

    40 - - - - - - - - - - - - - - - - - -

    41 - - -

    42 - - -

    43 - - -

    44 17 1701499

    45 32 3252781

    46 17 1704412

    47 17 1704540

    48 17 1701691

    49 - - -

    50 - - -

    51 - - -

    52 - - -

    Table 4-1. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    01499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

    52781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

    04412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

    04540 1704540 1704540 1704540 1704540 1704540 1704540 1704540

    01691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

  • SECTION 4 - MACHINE OPERATION

    4-22 3121138

    Table 4-2. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2

    1 170379 704810

    2 170379 704822

    3 170380 - -

    4 170380 701518

    5 170501 - -

    6 170380 - -

    7 170490(800

    170490(860S

    704906(800S)

    704907(860SJ)

    8 - -

    9 - -

    10 - -

    11 170286 - -

    12 170427 704277 JLG Lift

    7 1703992 1703925 1704809 1705053 1704811 1703924 1704767 1

    8 1704819 1703931 1704821 1705055 1704823 1703930 1704820 1

    5 - - 1703937 - - - - - - 1703936 - -

    4 1701518 1703949 1701518 1701518 1701518 1703948 1701518 1

    5 - - - - - - - - - - 1705015 - -

    8 - - - - - - - - - - 1703808 - -

    6S)7J)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1

    1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    8 - - - - - - - - - - 1704000 - -

    7 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1

  • SECTION 4 - MACHINE OPERATION

    3121138 4-23

    13 1705088 1705088 1704101 - - - - - - 1704099 - - - -

    14 17 - - -

    15 32 1705084

    16 17 1701502

    17 17 1701503

    18 17 1701504

    19 17 - - -

    20 17 1702631

    21 17 1700584

    22 - - -

    23 17 1701509

    24 17 1702300

    Table 4-2. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    (800S)1704995(860SJ)

    05089 1705089(800S)

    1704996(860SJ)

    1704109 - - - - - - 1704107 -

    51813 - - - - 1705084 1705084 1705084 3251813 1705084

    01502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

    01503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

    01504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

    02153 - - - - - - - - - - 1704006 -

    02631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

    00584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

    - - - - - - - - - - - - - - -

    01509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

    02300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

  • SECTION 4 - MACHINE OPERATION

    4-24 3121138

    25 170150 701500

    26 170150 701501

    27 - -

    28 - -

    29 - -

    30 - -

    31 - -

    32 - -

    33 - -

    34 701600

    35 170347(800

    170348(860S

    703475(800S)

    703482(860SJ)

    36 - -

    37 - -

    38 - -

    39 - -

    Table 4-2. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    0 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1

    1 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - 1703982 1703518 1701600 1693292 1703984 1693294 1

    5S)2J)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1703475(800S)

    1703482(860SJ)

    1

    1

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - - -

    - - - - - - - - - - - - 3252221 - -

  • SECTION 4 - MACHINE OPERATION

    3121138 4-25

    40 - - - - - - - - - - - - - - - - - -

    41 - - -

    42 - - -

    43 - - -

    44 17 1701499

    45 32 3252781

    46 17 1704412

    47 17 1704540

    48 17 1701691

    49 - - -

    50 - - -

    51 - - -

    52 - - -

    Table 4-2. Decal Location Legend - Rear Entry Platform

    Item #800S

    860SJ

    ANSI0270907-20270908-2

    Australian0270909-20270910-2

    China/English

    0270931-10270932-1

    Dutch0270915-20270916-2

    Finnish0271830-20271831-1

    French0270919-20270920-2

    French/English

    0270929-10270930-1

    German0270913-20270914-2

    Italian0270917-20270918-2 JLG Lift

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    01499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

    52781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

    04412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

    04540 1704540 1704540 1704540 1704540 1704540 1704540 1704540

    01691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

    - - - - - - - - - - - - - - -

  • SECTION 4 - MACHINE OPERATION

    4-26 3121138

    Table 4-3. Decal Location Legend - Rear Entry Platform

    Item #800S860SJ

    Japan0270923-10270924-1

    Korean0270925-10270926-1

    Portuguese0271392-20271393-2

    Portuguese/Spanish

    0270933-10270934-1

    Spanish0270921-20270922-2

    Spanish/English

    0270927-10270928-1

    Swedish0271832-20271833-2

    UK0270911-20270912-2

    1 17 08

    2 17 19

    3 17 - -

    4 17 18

    5 - -

    6 - -

    7 17

    17(8

    060S)07

    SJ)

    8 - -

    9 - -

    10 - -

    11 - -

    12 17 77

    13 17 - -

    14 17 - -

    15 84 JLG Lift

    03926 1703927 1704985 1703928 1704812 1703923 1705054 17048

    03932 1703933 1704986 1703934 1704824 1703929 1705056 17048

    03938 1703939 - - 1703940 - - 1703935 - -

    03950 1703951 1701518 1703952 1701518 1703947 1701518 17015

    - - - - - - - - - - 1705015 - -

    - - - - - - - - - - 1703808 - -

    04906(800S)0490760SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    1704906(800S)

    1704907(860SJ)

    17049(80

    17049(860

    - - - - - - - - - - - - - -

    - - - - - - - - - - - - - -

    - - - - - - - - - - - - - -

    - - - - - - 1704002 - - 1704001 - -

    04277 1704277 - - 1704277 1704277 1704277 1704277 17042

    04102 1704103 - - 1704100 - - 1704098 - -

    04110 1704111 - - 1704108 - - 1704106 - -

    - - - - 1705084 3251813 1705084 3251813 1705084 17050

  • SECTION 4 - MACHINE OPERATION

    3121138 4-27

    16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

    17 701503

    18 701504

    19 - -

    20 702631

    21 700584

    22 - -

    23 701509

    24 702300

    25 701500

    26 701501

    27 - -

    28 - -

    29 - -

    30 - -

    31 - -

    32 - -

    Table 4-3. Decal Location Legend - Rear Entry Platform

    Item #800S860SJ

    Ja