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
3121138 iii
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
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