Operation and Safety Manual - Inchirieri Nacele · FOREWORD 3121138 – JLG Lift – a FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose

Operation and Safety Manual

ANSI ®

Keep this manual with the machine at all times.

Boom Lift Models800S860SJ

3121138August 13, 2008

FOREWORD

a

l times.

lessors, and lessees with the precautions anderation for its intended purpose.

erves the right to make specification changesformation.

3121138 – JLG Lift –

FOREWORD

This manual is a very important tool! Keep it with the machine at al

The purpose of this manual is to provide owners, users, operators,operating procedures essential for the safe and proper machine op

Due to continuous product improvements, JLG Industries, Inc. reswithout prior notification. Contact JLG Industries, Inc. for updated in

FOREWORD

b 3121138

IGNAL WORDS

INDIAVOWIL

OTENTIALLY HAZARDOUS SITUATION. IF NOTD RESULT IN SERIOUS INJURY OR DEATH. THISE AN ORANGE BACKGROUND.

OTENTIALLY HAZARDOUS SITUATION. IF NOTRESULT IN MINOR OR MODERATE INJURY. IT MAYINST UNSAFE PRACTICES. THIS DECAL WILL HAVE AOUND.

the potential personalmbol to avoid possible

– JLG Lift –

SAFETY ALERT SYMBOLS AND SAFETY S

CATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOTIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECALL HAVE A RED BACKGROUND.

INDICATES A PAVOIDED, COULDECAL WILL HAV

INDICATES A PAVOIDED, MAY ALSO ALERT AGAYELLOW BACKGR

This is the Safety Alert Symbol. It is used to alert you toinjury hazards. Obey all safety messages that follow this syinjury or death

FOREWORD

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act:

duct Safety and Reliability Department Industries, Inc.24 Fountainhead Plazaerstown, MD 21742

our Local JLG Officee addresses on inside of manual cover)

A:

Free: 877-JLG-SAFE (877-554-7233)

ide USA:

ne: 240-420-2661: 301-745-3713ail: [email protected]

ent Reporting

ct Safety Publica-

nt Owner Updates

tions Regarding ct Safety

• Standards and Regulations Compliance Information

• Questions Regarding Spe-cial Product Applications

• Questions Regarding Prod-uct Modifications

3121138 – JLG Lift –

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.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THEOWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,INC. TO ENSURE THAT THE CURRENT OWNER RECORDS AREUPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALLINSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN ANACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL ORWHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-ERTY OR THE JLG PRODUCT.

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FOREWORD

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– JLG Lift –

REVISION LOG

riginal Issue - October 9, 2001

evised - October 31, 2001

evised - December 4, 2001

evised - March 1, 2002

evised - January 1, 2003

evised - April 24, 2003

evised - May 4, 2005

evised - March 3, 2006

evised - July 7, 2006

evised - August 13, 2008

TABLE OF CONTENTS

3121 i

SEC - PARAGRAPH, SUBJECT PAGE

SEC

SEC P

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9HORIZONTAL AND CAPACITY LIMIT SWITCHES 2-10OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

- 3 - MACHINE CONTROLS AND INDICATORS

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1Ground Control Indicator Panel . . . . . . . . . . . . . 3-6Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7Platform Control Indicator Panel . . . . . . . . . . . . 3-12

- 4 - MACHINE OPERATION

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1OPERATING CHARACTERISTICS AND LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-3

TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . 4-5Traveling Forward and Reverse . . . . . . . . . . . . . 4-5

STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

138 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

TION - 1 - SAFETY PRECAUTIONS

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

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

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-81.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

TION - 2 - USER RESPONSIBILITIES, MACHINE REPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

2.32.4

SECTION

3.13.2

SECTION

4.14.2

4.3

4.4

4.5

TABLE OF CONTENTS

ii 3121138

SECTIO RAGRAPH, SUBJECT PAGE

4.6

4.7

4.84.9

4.104.114.124.13

SECTION

5.15.25.3

5.45.5

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

GENERAL SPECIFICATIONS & OPERATOR NCE

ODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1RATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1ecifications and Performance Data . . . . . . . . 6-2

apacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3ngine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4ttery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

res . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6ajor Component Weights. . . . . . . . . . . . . . . . . 6-7ydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7IAL NUMBER LOCATION . . . . . . . . . . . . . . . .6-10RATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21S & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-30

re Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30re Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30re Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-31heel Replacement . . . . . . . . . . . . . . . . . . . . . 6-31heel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-32INING OIL BUILD UP FROM THE PROPANE GULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-33PANE FUEL FILTER REPLACEMENT. . . . . . .6-35

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

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

BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-8Raising and Lowering the Boom . . . . . . . . . . . . 4-8

FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-8OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8EMERGENCY TOWING. . . . . . . . . . . . . . . . . . . . . . 4-9TOW BAR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 4-10SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-12LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-12

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

- 5 - EMERGENCY PROCEDURES

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . 5-1EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1Platform or Boom Caught Overhead . . . . . . . . . 5-2

EMERGENCY TOWING PROCEDURES . . . . . . . . . 5-2MANUAL DESCENT INSTRUCTIONS (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

ToTo

SECTION - 6 - MAINTENA

6.1 INTR6.2 OPE

SpC EBaTiMH

6.3 SER6.4 OPE6.5 TIRE

TiTiTiWW

6.6 DRA RE

6.7 PRO

TABLE OF CONTENTS

3121 iii

SEC - PARAGRAPH, SUBJECT PAGE

SEC

Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . . 4-9Typical 800S/860SJ Transport . . . . . . . . . . . . . . . 4-14Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-15Decal Location - Rear Entry Platform - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16Decal Location - Rear Entry Platform - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17Decal Location - Side Entry Platform - Sheet 1 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30Decal Location - Side Entry Platform - Sheet 2 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31Decal Location - Side Entry Platform - Sheet 3 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32Decal Location - Side Entry Platform - Sheet 4 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33Decal Location - Side Entry Platform - Sheet 5 of 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Serial Number Locations . . . . . . . . . . . . . . . . . . . 6-10Engine Operating Temperature Specifications - Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-12Engine Operating Temperature Specifications - Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-13Engine Operating Temperature Specifications - Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-14Engine Operating Temperature Specifications - Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-15

138 – JLG Lift –

TION - PARAGRAPH, SUBJECT PAGE SECTION

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36

6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-36

TION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . .2-62-2. Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . .2-72-2. Daily Walk-Around Inspection - Sheet 1 of 2 . . . . . .2-82-3. Daily Walk-Around Inspection - Sheet 2 of 2 . . . . . .2-92-4. Horizontal and Capacity Limit Switches -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-102-5. Horizontal and Capacity Limit Switches -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-112-6. Limiting and Cut-Out Switches - Sheet 1 of 2 . . . .2-122-7. Limiting and Cut-Out Switches - Sheet 2 of 2 . . . .2-133-1. Ground Control Station - 800S . . . . . . . . . . . . . . . .3-33-1. Ground Control Station - 860SJ. . . . . . . . . . . . . . . .3-43-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . .3-63-3. Platform Control Console. . . . . . . . . . . . . . . . . . . . .3-93-4. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . .3-144-1. Position of Least Backward Stability . . . . . . . . . . . .4-34-2. Position of Least Forward Stability . . . . . . . . . . . . .4-44-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . .4-6

4-4.4-5.4-6.4-7.

4-8.

4-9.

4-10.

4-11.

4-12.

4-13.

6-1.6-2.

6-3.

6-4.

6-5.

TABLE OF CONTENTS

iv 3121138

SECTIO RAGRAPH, SUBJECT PAGE

6-6.

6-7.

6-8.

6-9.

6-10.6-11.

1-12-14-14-24-34-4

4-5

6-16-26-36-4

tz F4M2011 Specifications. . . . . . . . . . . . . . . . 6-4tz D2011L04 Specifications . . . . . . . . . . . . . . . 6-5rpillar 3044C/ Caterpillar 3.4 . . . . . . . . . . . . . . 6-53.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6ery Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-6Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-6ponent Weights . . . . . . . . . . . . . . . . . . . . . . . 6-7

raulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7ilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-8il DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-8il EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . 6-9n Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-9n Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-10

rication Specifications . . . . . . . . . . . . . . . . . . 6-21el Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-33ection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

– JLG Lift –

N - PARAGRAPH, SUBJECT PAGE SECTION - PA

Engine Operating Temperature Specifications - Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-16Engine Operating Temperature Specifications - Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-17Engine Operating Temperature Specifications - GM - Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-18Engine Operating Temperature Specifications - GM - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . 6-19Operator Maintenance and Lubrication Diagram . 6-20Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-35

LIST OF TABLES

Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5Inspection and Maintenance Table . . . . . . . . . . . . . 2-3Decal Location Legend - Rear Entry Platform. . . . 4-18Decal Location Legend - Rear Entry Platform. . . . 4-22Decal Location Legend - Rear Entry Platform. . . . 4-26Decal Location Legend, 800S - Side Entry Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35Decal Location Legend, 860SJ - Side Entry Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-1Specifications and Performance Data. . . . . . . . . . . 6-2Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3Ford LRG-425 Specifications. . . . . . . . . . . . . . . . . . 6-4

6-5 Deu6-6 Deu6-7 Cate6-8 GM 6-9 Batt6-10 Tire 6-11 Com6-12 Hyd6-13 Mob6-14 Mob6-15 Mob6-16 UCo6-17 Exxo6-18 Lub6-19 Whe7-1 Insp

SECTION 1 - SAFETY PRECAUTIONS

1-1

CAUTIONS

E-OPERATION

Training and Knowledged and understand this manual before operating thehine.

not operate this machine until complete training is per-ed by authorized persons.

y authorized and qualified personnel can operate thehine.

3121138 – JLG Lift –

SECTION 1. SAFETY PRE

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 content of this manual. A maintenanceprogram, using the information provided in this manual andthe Service and Maintenance Manual, must also be estab-lished by a qualified person and followed to ensure themachine is safe to operate.

The owner/user/operator/lessor/lessee of the machineshould not operate the machine until this manual has beenread, training is accomplished, and operation of the machinehas been completed under the supervision of an experi-enced and qualified operator.

If there are any questions with regard to safety, training,inspection, maintenance, application, and operation, pleasecontact JLG Industries, Inc. (“JLG”).

FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED INTHIS MANUAL COULD RESULT IN MACHINE DAMAGE, PROPERTY DAM-AGE, PERSONAL INJURY OR DEATH.

1.2 PR

Operator• Rea

mac

• Do form

• Onlmac


1-2 3121138

Wo

chine can be operated in temperatures of 0o F to-20o C to 40o C). Consult JLG for operation out- range.

pection achine operation, perform inspections and func-

hecks. Refer to Section 2 of this manual for instructions.

perate this machine until it has been serviced anded according to requirements specified in theand Maintenance Manual.

the footswitch and all other safety devices areg properly. Modification of these devices is aolation.

R ALTERATION OF AN AERIAL WORK PLATFORMNLY WITH WRITTEN PERMISSION FROM THE MANU-

perate any machine on which safety or instruction or decals are missing or illegible.

ny buildup of debris on the platform floor. Keep, grease, and other slippery substances from foot-d platform floor.

– JLG Lift –

• 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 personnel must be familiar with the emer-gency controls and emergency operation of the machineas specified in this manual.

• Read, understand, and obey all applicable employer,local, and governmental regulations as they pertain tooperation of the machine.

rkplace Inspection• The operator is to take safety measures to avoid all haz-

ards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trail-ers, railway cars, floating vessels, scaffolds or other equip-ment unless approved in writing by JLG.

• Do not operate the machine in hazardous environmentsunless approved for that purpose by JLG.

• Be sure that the ground conditions are able to support themaximum load shown on the decals located on themachine.

• This ma104o F (side this

Machine Ins• Before m

tional cdetailed

• Do not omaintainService

• Be sureoperatinsafety vi

MODIFICATION OSHALL BE MADE OFACTURER

• Do not oplacards

• Avoid amud, oilwear an


1-3

plies or tools which extend outside the platform arehibited unless approved by JLG.

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

not assist a stuck or disabled machine by pushing,ing, or by using boom functions. Only pull the unit the tie-down lugs on the chassis.

not place boom or platform against any structure tody the platform or to support the structure.

w boom and shut off all power before leaving machine.

Fall Hazards operation, occupants in the platform must wear a fullarness with a lanyard attached to an authorized lan-

nchorage point. Attach only one (1) lanyard per lan-nchorage point.

3121138 – JLG Lift –

1.3 OPERATION

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

tioning personnel, their tools, and equipment.

• Never operate a machine that is not working properly. If amalfunctions occurs, shut down the machine.

• Never slam a control switch or lever through neutral to anopposite direction. Always return switch to neutral andstop before moving the switch to the next function. Oper-ate controls with slow and even pressure.

• Hydraulic cylinders should never be left fully extended orfully retracted before shutdown or for long periods of time.

• Do not allow personnel to tamper with or operate themachine from the ground with personnel in the platform,except in an emergency.

• Do not carry materials directly on platform railing unlessapproved by JLG.

• When two or more persons are in the platform, the opera-tor shall be responsible for all machine operations.

• Always ensure that power tools are properly stowed andnever left hanging by their cord from the platform workarea.

• Suppro

• Whwithfron

• Do pullfrom

• Do stea

• Sto

Trip and Duringbody hyard ayard a


1-4 3121138

reme caution when entering or leaving platform. that the boom is fully lowered. It may be neces-elescope out to position the platform closer to thefor entry/exit. Face the machine, maintain “threentact” with the machine, using two hands and one

o feet and one hand during entry and exit.

n Hazardschine is not insulated and does not provide pro-rom contact or proximity to electrical current.

– JLG Lift –

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

• Keep both feet firmly positioned on the platform floor at alltimes. Never use ladders, boxes, steps, planks, or similaritems on platform to provide additional reach.

• Never use the boom assembly to enter or leave the plat-form.

• Use extBe suresary to tground point cofoot or tw

Electrocutio• This ma

tection f


1-5

in a clearance of at least 10 ft. (3m) between any part machine and its occupants, their tools, and their

ent from any electrical line or apparatus carrying up00 volts. One foot additional clearance is required for

additional 30,000 volts or less.

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

oltage Rangease to Phase)

MINIMUM APPROACH DISTANCEin Feet (Meters)

0 to 50 KV 10 (3)

r 50KV to 200 KV 15 (5)

200 KV to 350 KV 20 (6)

350 KV to 500 KV 25 (8)

500 KV to 750 KV 35 (11)

50 KV to 1000 KV 45 (14)

This requirement shall apply except whereemployer, local or governmental regulationsare more stringent.

3121138 – JLG Lift –

• Maintain distance from electrical lines, apparatus, or anyenergized (exposed or insulated) parts according to theMinimum Approach Distance (MAD) as shown in Table 1-1.

• Allow for machine movement and electrical line swaying.

• Maintaof theequipmto 50,0every

Table

V(Ph

Ove

Over

Over

Over

Over 7

NOTE:


1-6 3121138

•

DO ZONENE

ardsr should be familiar with the surface before driv-not exceed the allowable sideslope and grade

iving.

– JLG Lift –

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 working dimensions of the insulatingbarrier. This determination shall be made by a qualified per-son in accordance with the employer, local, or governmentalrequirements for work practices near energized equipment

NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITEDE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARERGIZED UNLESS KNOWN OTHERWISE.

Tipping Haz• The use

ing. Do while dr


1-7

oom assembly or platform is in a position that one ore wheels are off the ground, all persons must beoved before attempting to stabilize the machine. Usees, forklift trucks, or other appropriate equipment toilize machine and remove personnel.

and Collision Hazardsroved head gear must be worn by all operating and

und personnel.

ck work area for clearances overhead, on sides, andom of platform when lifting or lowering platform, anding.

ing operation, keep all body parts inside platform rail-

3121138 – JLG Lift –

• 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 platform or drive from an elevated posi-tion unless the machine is on firm, level and smooth sur-faces.

• Keep the chassis of the machine at least 2 ft. (0.6m) fromholes, bumps, drop-offs, obstructions, debris, concealedholes, and other potential hazards on the floor/surface.

• Do not push or pull any object with the boom.

• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed28 mph (12.5 m/s).

• Do not increase the surface area of the platform or theload. Increase of the area exposed to the wind willdecrease stability.

• Do not increase the platform size with unauthorized deckextensions or attachments.

• If bmorremcranstab

Crushing• App

gro

• Chebottdriv

• During.


1-8 3121138

G, LIFTING, AND HAULINGllow personnel in platform while towing, lifting, or

chine should not be towed, except in the event ofcy, malfunction, power failure, or loading/unload-

er to the Emergency Procedures section of thisfor emergency towing procedures.

boom is in the stowed position and the turntablerior to towing, lifting or hauling. The platform mustletely empty of tools.

ting machine, lift only at designated areas of the. Lift the unit with equipment of adequate capac-

the Machine Operation section of this manual forormation.

– JLG Lift –

• 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 personnel at least 6 ft. (1.8m) awayfrom machine during all driving and swing operations.

• Limit travel speed according to conditions of ground sur-face, congestion, visibility, slope, location of personnel,and other factors which may cause collision or injury topersonnel.

• Be aware of stopping distances in all drive speeds. Whendriving in high speed, switch to low speed before stop-ping. Travel grades in low speed only.

• Do not use high speed drive in restricted or close quartersor when driving in reverse.

• Exercise extreme caution at all times to prevent obstaclesfrom striking or interfering with operating controls and per-sons in the platform.

• Be sure that operators of other overhead and floor levelmachines are aware of the aerial work platform’s pres-ence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raisedboom or platform. Position barricades on floor if neces-sary.

1.4 TOWIN• Never a

hauling.

• This maemergening. Refmanual

• Ensure locked pbe comp

• When lifmachineity.

• Refer tolifting inf


1-9
3121138 – JLG Lift –
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 machine with the engine running.

• Battery fluid is highly corrosive. Avoid contact with skinand clothing at all times.

• Charge batteries only in a well ventilated area.


1-1 3121138
0 – JLG Lift –
NOTES:

CHINE PREPARATION, AND INSPECTION

2-1

PREPARATION, AND INSPECTION

e safest means to operate the machine where over-ad obstructions, other moving equipment, and obsta-

es, depressions, holes, dropoffs.

eans to avoid the hazards of unprotected electrical nductors.

ecific job requirements or machine application.

Supervisiong must be done under the supervision of a qualified in an open area free of obstructions until the traineeveloped the ability to safely control and operate the

ne.

Responsibilityerator must be instructed that he/she has the respon-

and authority to shut down the machine in case of action or other unsafe condition of either the machinejob site.

SECTION 2 - USER RESPONSIBILITIES, MA

3121138 – JLG Lift –

SECTION 2. USER RESPONSIBILITIES, MACHINE

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 influence of drugs or alcohol or who aresubject to seizures, dizziness or loss of physical control mustnot operate this machine.

Operator TrainingOperator training must cover:

1. Use and limitations of the controls in the platform and at the ground, emergency controls and safety systems.

2. Control labels, instructions, and warnings on the machine.

3. Rules of the employer and government regulations.

4. Use of approved fall protection device.

5. Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal-function.

6. Thhecl

7. Mco

8. Sp

Training Traininpersonhas demachi

OperatorThe opsibilitymalfunor the

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2-2 3121138

2.2, INC. RECOGNIZES A FACTORY-CERTIFIED SERVICEA PERSON WHO HAS SUCCESSFULLY COMPLETED TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT

– JLG Lift –

PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspectionsand maintenance required by JLG Industries, Inc. Consultlocal regulations for further requirements for aerial work plat-forms. The frequency of inspections and maintenance mustbe increased as necessary when the machine is used in aharsh or hostile environment, if the machine is used withincreased frequency, or if the machine is used in a severemanner.

JLG INDUSTRIESTECHNICIAN AS THE JLG SERVICEMODEL.


2-3

ance Table

ryibility

Service Qualification

Reference

tor User or Operator Operator and Safety Manual

, or User Qualified JLG Mechanic

Service and Maintenance Manual and applicable JLG inspection form



, or User Factory Certified Service Technician (Recommended)



Service and Maintenance Manual

nce Manual to perform inspections.


3121138 – JLG Lift –

Table 2-1. Inspection and Mainten

Type FrequencyPrima

Respons

Pre-Start Inspection Before using each day; or whenever there’s an Operator change.

User or Opera

Pre-Delivery Inspection (See Note)

Before each sale, lease, or rental delivery. Owner, Dealer

Frequent Inspection(See Note)

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

Annual Machine Inspection(See Note)

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

Owner, Dealer

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

Owner, Dealer

NOTE: Inspection forms are available from JLG. Use the Service and Maintena


2-4 3121138

Pre stic only) is enclosed in the weather resistant e container.

-Around” Inspection – Refer to Figure 2-2. and 2-3.

y – Charge as required.

ombustion Engine Powered Machines) – Add the fuel as necessary.

e Oil Supply - Ensure the engine oil level is at the ark on the dipstick and the filler cap is secure.

ulic Oil – Check the hydraulic oil level. Ensure lic oil is added as required.

on Check – Once the “Walk-Around” Inspection plete, perform a functional check of all systems in a free of overhead and ground level obstructions. o Section 4 for more specific instructions.

DOES NOT OPERATE PROPERLY, TURN OFF THEIATELY! REPORT THE PROBLEM TO THE PROPERRSONNEL. DO NOT OPERATE THE MACHINE UNTIL ITE FOR OPERATION.

– JLG Lift –

-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 foreign objects. Report any leakage to the proper maintenance personnel.

2. Structure - Inspect the machine structure for dents,damage, weld or parent metal cracks or other discrep-ancies.

3. Decals and Placards – Check all for cleanliness and legibility. Make sure none of the decals and placards are missing. Make sure all illegible decals and placards are cleaned or replaced.

4. Operators and Safety Manuals – Make sure a copy of the Operator and Safety Manual, EMI Safety Manual (Domestic only), and ANSI Manual of Responsibilities

(Domestorag

5. “WalkFigure

6. Batter

7. Fuel (Cproper

8. EnginFull m

9. Hydrahydrau

10. Functiis coman areRefer t

IF THE MACHINEMACHINE IMMEDMAINTENANCE PEIS DECLARED SAF

Parent Metal Crack Weld Crack


2-5

ith the platform in the transport (stowed) position:

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

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


3121138 – JLG Lift –

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 place;

b. Operate all functions and check all limiting and cut-out switches;

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabledwhen the Emergency Stop Button is activated.

2. From the platform control console:

a. Ensure that the control console is firmly secured inthe proper location;

b. Check that all guards protecting the switches orlocks are in place;

c. Operate all functions and check all limiting and cut-out switches;

d. Ensure that all machine functions are disabledwhen the Emergency Stop Button is pushed in.

3. W

a

b


2-6 3121138

t 1 of 2

– JLG Lift –

Figure 2-1. Basic Nomenclature - Shee


2-7

eet 2 of 2


3121138 – 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 - Sh


2-8 3121138

Sheet 1 of 2

– JLG Lift –

Figure 2-2. Daily Walk-Around Inspection -


2-9

wing Drive - No evidence of damage.

heel/Tire Assemblies - No loose or missing lug nuts, roper inflation (pneumatic). Inspect for worn tread, cuts, ars or other discrepancies. Inspect wheels for damage

nd corrosion.

rive Motor, Brake, and Hub - No evidence of leakage.

ood Assemblies - See Inspection Note.

uxiliary Hydraulic Pump - See Inspection Note.

ll Hydraulic Cylinders - No visible damage; pivot pins nd hydraulic hoses undamaged, not leaking.

urntable Bearing - Evidence of proper lubrication. No vidence of loose bolts or looseness between bearing nd machine.

ie Rod Ends and Steering Spindles - See Inspection ote.

orizontal and Capacity Limit Switches - Switches perate properly.

ain Hydraulic Pump - See Inspection Note.

latform Rotator - See Inspection Note.

n - Sheet 2 of 2


3121138 – JLG Lift –

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, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN COR-RECTED.

INSPECTION NOTE: On all components, make sure there areno loose or missing parts, that they are securely fastened, andno visible damage, leaks or excessive wear exists in addition toany other criteria mentioned.

1. Platform Assembly and Gate - Footswitch works prop-erly, not modified, disabled or blocked. Latch, stop, and hinges in working condition.

2. Platform & Ground Control Consoles - Switches and levers return to neutral, decals/placards secure and legi-ble, control markings legible.

3. Boom Sections/Uprights/Turntable - See Inspection Note.

4. S

5. Wptea

6. D

7. H

8. A

9. Aa

10. Tea

11. TN

12. Ho

13. M

14. P

Figure 2-3. Daily Walk-Around Inspectio


2-1 3121138

2.3

es - Sheet 1 of 2

0 – JLG Lift –

HORIZONTAL AND CAPACITY LIMIT SWITCHES

Figure 2-4. Horizontal and Capacity Limit Switch


2-11

s - Sheet 2 of 2

racteristic

m capacity at a designated boom length.

d length.

m capacity at a designated boom height.

zontal.


3121138 – JLG Lift –

Figure 2-5. Horizontal and Capacity Limit Switche

Item Description Operation Cha

1 Boom CapacityLength Switch

Activates platform capacity light to indicate the platfor

2 Boom ExtensionSwitch

Reduces drive speed when boom reaches a designate

3 Boom CapacityAngle Switch

Activates platform capacity light to indicate the platfor

4 Boom ElevationSwitch

Reduces drive speed when boom is raised above hori


2-1 3121138

heet 1 of 2

2 – JLG Lift –

Figure 2-6. Limiting and Cut-Out Switches - S


2-13

hes - Sheet 2 of 2


3121138 – JLG Lift –

Figure 2-7. Limiting and Cut-Out Switc


2-1 3121138

2.4

LOCA SYOPE

NOT

the Drive control lever to the forward position andlly drive machine up ascension ramp until left frontis on top of block.

lly activate Swing control lever and position boomght side of machine.

oom over right side of machine, place Drive con-er to Reverse and drive machine off of block and

n assistant check to see that left front or right rearremains elevated in position off of ground.

lly activate Swing control lever and return boomwed position (centered between drive wheels).boom reaches center, stowed position, lockoutrs should release and allow wheel to rest on, it may be necessary to activate Drive to releasers.

4 – JLG Lift –

OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

KOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIMESTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM

RATION IS SUSPECTED.

E: Ensure boom is fully retracted, lowered, and centeredbetween drive wheels prior to beginning lockout cylindertest.

1. Place a 6 inches (15.2 cm) high block with ascensionramp in front of left front wheel.

2. From platform control station, start engine

3. Place carefuwheel

4. Carefuover ri

5. With btrol levramp.

6. Have awheel

7. Carefuto stoWhen cylindegroundcylinde


2-15

arefully activate Swing control lever and return boom stowed position (centered between drive wheels).hen boom reaches center, stowed position, lockoutlinders should release and allow wheel to rest onound, it may be necessary activate Drive to releaselinders.

lockout cylinders do not function properly, have quali-d personnel correct the malfunction prior to any fur-er operation.


3121138 – JLG Lift –

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 Reverse and drive machine off of block andramp.

11. Have an assistant check to see that right front or left rearwheel remains elevated in position off of ground.

12. CtoWcygrcy

13. If fieth


2-1 3121138
6 – JLG Lift –
NOTES:

MACHINE CONTROLS AND INDICATORS

3-1

AND INDICATORS

ontrol Station

re 3-1., Ground Control Station - 800S and Figure 3-1.,ontrol Station - 860SJ)

en Power/Emergency Stop switch is in the “ON” posi- and engine is not running, an alarm will sound, indi-

ting Ignition is “ON”.

ACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOPST BE POSITIONED TO THE “OFF” POSITION TO PREVENTE BATTERY.

quipped, the Function Enable switch must held down in order to operate Telescope,ing, Lift, Jib Lift, Platform Level Override,d Platform Rotate functions.

SECTION 3 -

3121138 – JLG Lift –

SECTION 3. MACHINE CONTROLS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINEAPPLICATION AND OPERATION. THE USER AND OPERATOR ARERESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed tounderstand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machines is equipped with control panels that usesymbols to indicate control functions. Refer to decallocated on the control box guard in front of the controlbox or by the ground controls for these symbols and thecorresponding functions.

Ground C

(See FiguGround C

NOTE: Whtionca

WHEN THE MSWITCH MUDRAINING TH

NOTE: If ebeSwan

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3-2 3121138

TO ATROMOV

m/Ground Select Switch

e position, key operated switch supplies power totform control console when positioned to PLAT-

. With the switch key held in the GROUND posi-ower is shut off to platform and only groundls are operable.

ATFORM/GROUND SELECT switch in the center, power is shut off to controls at both operating.

eter.

ers the amount of time the machine has been inith engine running. By connecting into the oilre circuit of the engine, only engine run hours areed. The hourmeter registers up to 9,999.9 hoursnnot be reset.

/Emergency Stop Switch.

position red mushroom shaped switch furnishes to PLATFORM/GROUND SELECT switch when out (on). When pushed in (off), power is shut offPLATFORM/GROUND SELECT switch.

– JLG Lift –

1. Indicator Panel.

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

VOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-L LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

2. Telescope Control.

Provides extension and retraction of the boom, whenpositioned to IN or OUT.

3. Swing Control.

Provides 360 degrees continuous turntable rotation.

4. Lift Control.

Provides raising and lowering of the main boom.

5. Platfor

A threthe plaFORMtion, pcontro

NOTE: With PLpositionstations

6. Hourm

Registuse, wpressurecordand ca

7. Power

A two-powerpulledto the


3-3

800S

SECTION 3 -

3121138 – JLG Lift –

1. Indicator Panel2. Telescope3. Swing4. Lift5. Platform/Ground Select Switch6. Hourmeter7. Power/Emergency Stop8. Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable9. N/A10. Platform Leveling Override11. Platform Rotate

Figure 3-1. Ground Control Station -


3-4 3121138

60SJ

– JLG Lift –

Figure 3-1. Ground Control Station - 8

1. Indicator Panel2. Telescope3. Swing4. Lift5. Platform/Ground Select Switch6. Hourmeter7. Power/Emergency Stop8. Engine Start/Auxiliary Power or Engine Start/Auxiliary Power/Function Enable9. Articulating Jib Boom10. Platform Leveling Override11. Platform Rotate


3-5

ticulating Jib Boom. (If Equipped)

is switch provides raising and lowering of the jib.

atform Leveling Override.

three position switch allows the operator to compen-te for any difference in the automatic self leveling sys-m.

atform Rotate.

three position switch permits rotation of the platform.

SECTION 3 -

3121138 – JLG Lift –

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” for duration of auxiliary pumpuse. Aux power can only be used if theengine is not running.

If equipped, the enable switch must be held"DOWN" to enable all boom controls whenthe engine is running.

NOTE: Auxiliary power only works if there is no engine oil pres-sure, and is disabled if engine is running.

NOTE: Functions will operate at a slower than normal ratebecause of the lesser flow of hydraulic fluid delivered.

WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONEFUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOADTHE AUXILIARY PUMP.)

9. Ar

Th

10. Pl

A sate

11. Pl

A


3-6 3121138

Gro

(S

Charging Indicator

tes a problem in the battery or charging circuit,rvice is required.

ngine Oil Pressure Indicator.

tes that engine oil pressure is below normal and is required.

ngine Coolant Temperature Indicator (Ford)

tes that engine coolant temperature is abnormallynd service is required.

Oil Temperature Indicator (Deutz).

tes the temperature of the engine oil, which also as engine coolant, is abnormally high and ser- required.

uel Level Indicator

tes that the fuel level is 1/8 full or less. When therst turns on, there are approximately four usables of fuel remaining.

– JLG Lift –

und Control Indicator Panel

ee Figure 3-2., Ground Control Indicator Panel)

1. Battery

Indicaand se

2. Low E

Indicaservice

3. High E

Indicahigh a

4. Engine

Indicaservesvice is

5. Low F

Indicalight figallon

Figure 3-2. Ground Control Indicator Panel

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

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


3-7

Station

re 3-3., Platform Control Console)

wer/Emergency Stop

two-position red mushroom shaped switch furnisheswer to PLATFORM Controls when pulled out (on).hen pushed in (off), power is shut off to the platformnctions.

ithin about 2 seconds of pulling the switch out, theachine will perform a diagnostic check of the variousectrical circuits, and if everything is OK, the platformarm will beep once. During this time the lights on thedicator panel will also blink once as a bulb check.

orn

pressed, this switch supplies power to the horn.

SECTION 3 -

3121138 – JLG Lift –

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 platform has been overloaded.

8. Hydraulic Oil Filter Indicator (Prior to S/N 85332)

Indicates the return oil filter is too restrictive and in thebypass mode and needs to be replaced.

9. Charge Pump Oil Filter Indicator (Prior to S/N 85332)

Indicates that charge pump filter is too restrictive andneeds to be replaced.

10. Engine Air Filter Indicator (Prior to S/N 85332)

Indicates that the air filter is too restrictive and needs tobe replaced.

Platform

(See Figu

1. Po

A poWfu

Wmelalin

2. H

If


3-8 3121138

NOT

TO ATROMOVWHE

NOT

teer

RIVE joystick provides for driving either forward orard. The controller is ‘ramped’ to allow variablepeed.

g is controlled by a thumb operated switch onthe joystick.

ate the Drive Joystick, pull up on the locking ringhe handle.

oom is positioned above horizontal and any of theg switches, DRIVE SPEED/TORQUE SELECT orION SPEED, are positioned to HIGH, high function are automatically cut out and the machine contin-perate at a lower speed.

E MACHINE IF DRIVE SPEED /TORQUE SELECT OR SWITCHES OPERATE WHEN BOOM IS ABOVE HORI-

– JLG Lift –

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

VOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON-L LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORMEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITIONN RELEASED.

3. Main Lift/Swing Controller.

An infinitely proportional dual axis joystick is providedfor main lift and swing. Push forward to lift up, pull back-ward to lift down. Move right to swing right, move left toswing left.

E: To operate the Main Lift/Swing Joystick, pull up on thelocking ring below the handle.

4. Main Telescope Control.

This control allows extension and retraction of the mainboom.

5. Drive/S

The Dbackwdrive s

Steerintop of

NOTE: To operbelow t

NOTE: When bfollowinFUNCTspeedsues to o

DO NOT OPERATFUNCTION SPEEDZONTAL.


3-9

Level Overrideng Jib (860SJ)t

13. Steer Select14. Engine Start / Aux Power15. Light Panel

nsole

SECTION 3 -

3121138 – JLG Lift –

1. Power/Emergency Stop2. Horn3. Main Lift / Swing4. Telescope

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

9. Platform 10. Articulati11. Fuel Selec12. Lights

Figure 3-3. Platform Control Co


3-1 3121138

ating Jib Boom. (860SJ)

orward to lift up, pull back to lift down. Variable lift is using the Function Speed Control.

elect (Dual Fuel Engine Only). (If Equipped)

ne or liquid propane fuel may be selected by mov- switch to the appropriate position. It is unneces- purge the fuel system before switching fuels, so

s no waiting period when switching fuels while the is running.

. (If Equipped)

witch operates control console panel lights andights if the machine is so equipped. The ignition does not have to be on to operate the lights, soust be taken to avoid draining the battery if left

nded. The master switch and / or the ignition at the ground control will turn off power to all

0 – JLG Lift –

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 Select.

The forward position gives maximum drive speed byshifting the drive motors to minimum the displacementand giving high engine when drive controller is moved.The back position gives maximum torque for rough ter-rain and climbing grades by shifting the wheel motors tomaximum displacement and giving high engine speedwhen drive controller is moved. The center positionallows the machine to be driven as quietly as possibleby leaving the engine at mid speed and the drive motorsin maximum displacement.

8. Platform Rotate.

This switch allows the operator to rotate the basket tothe left or right.

9. Platform Leveling Override.

This switch allows the operator to adjust the level of theplatform.

10. Articul

Push fspeed

11. Fuel S

Gasoliing thesary tothere iengine

12. Lights

This shead lswitchcare munatteswitchlights.


3-11

art/Auxiliary Power.

hen pushed forward, the switch energizes the starterotor to start the engine.

hen pushed back, it energizes the electrically oper-ed hydraulic pump, when actuated. (Switch must beld ON for duration of auxiliary pump use.)

e auxiliary pump functions to provide sufficient oil flow operate the basic machine functions should the mainmp or engine fail. The auxiliary pump will operate

wer boom lift, tower telescope, main boom lift, mainlescope and swing.

dicator Panel.

e LED Indicator Panel contains indicator lights thatgnal problem conditions or functions operating duringachine operation.

SECTION 3 -

3121138 – JLG Lift –

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 for“crab” steering. When in this mode both front and rearaxles steer in the same direction, which allows the chas-sis to move sideways as it goes forward. This can beused for positioning the machine in aisle ways or againstbuildings. The back switch position is for “coordinated”steering. In this mode the front and rear axles steer inthe opposite directions to produce the tightest turningcircle for maneuvering in confined areas.

To re-synchronize the front and rear axles, position therear drive wheels to the forward drive position by select-ing either crab or compound steer, then select frontsteer (center switch position) to operate the normalsteering function.

14. St

Wm

Wathe

Thtoputote

15. In

Thsim


3-1 3121138

Pla

(S

NOT

ystem Fault Indicator

tes a fault in the electronic leveling system. Thedicator will flash and an alarm sound. All func-ill default to creep if the boom is extended more

0 inches (51 cm) or elevated above horizontal.

YSTEM FAULT INDICATOR IS ILLUMINATED, SHUTINE, RECYCLE THE EMERGENCY STOP, AND RESTART THE FAULT PERSISTS, RETURN THE PLATFORM TOSITION, USING MANUAL LEVELING AS REQUIRED,

ING SYSTEM REPAIRED.

nerator. (Green)

tes the generator is in operation.

ad Indicator. (If equipped)

tes the platform has been overloaded.

2 – JLG Lift –

tform Control Indicator Panel

ee Figure 3-4., Platform Light Panel)

E: The platform control indicator panel uses different shapedsymbols to alert the operator to different types of opera-tional situations that could arise. The meaning of thosesymbols are explained below.

1. Level S

Indicafault intions wthan 2

IF THE LEVEL SDOWN THE MACHTHE MACHINE. IFTHE STOWED POAND HAVE LEVEL

2. AC Ge

Indica

3. Overlo

Indica

Indicates a potentially hazardous situation, whichif not corrected, could result in serious injury ordeath. This indicator will be red.

Indicates an abnormal operating condition,which if not corrected, may result in machineinterruption or damage. This indicator will be yel-low.

Indicates important information regarding theoperating condition, i.e. procedures essential forsafe operation. This indicator will be green withthe exception of the capacity indicator which willbe green or yellow depending upon platformposition.


3-13

low Plug Indicator

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

otswitch/Enable Indicator

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

nction and beginning the next function, the enableht will go out and the footswitch must be released andpressed again to enable the controls.

leasing the footswitch removes power from all con-ls and applies the drive brakes.

ERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLEITCH BY BLOCKING OR ANY OTHER MEANS.

MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHENY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOT-

SECTION 3 -

3121138 – JLG Lift –

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 capacity decals on the machine for restrictedand unrestricted platform capacities.

5. Tilt Alarm Warning Light and Alarm

This orange illuminator indicates that the chassis is on aslope. An alarm will also sound when the chassis is on aslope and the boom is above horizontal. If lit when boomis raised or extended, retract and lower to below hori-zontal then reposition machine so that it is level beforecontinuing operation. If the boom is above horizontaland the machine is on a slope, the tilt alarm warninglight will illuminate and an alarm will sound and CREEPis automatically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OREXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THENREPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDINGBOOM OR RAISING BOOM ABOVE HORIZONTAL.

6. G

Inig

7. Fo

Todeonenonfuligde

Retro

TO AVOID STHE FOOTSW

FOOTSWITCHSWITCH ONLTOM.


3-1 3121138

Indicatorunction Indicatore Indicator

ndicator

4 – JLG Lift –

1. Level System2. AC Generator3. Overload4. Capacity

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

9. Creep Speed10. Engine Malf11. Cable Servic12. Soft Touch I

Figure 3-4. Platform Light Panel


3-15

able Service Indicator. (If Equipped)

hen illuminated, the light indicates the boom cablese loose or broken and must be repaired or adjustedmediately.

LE SERVICE INDICATOR IS ILLUMINATED, RETURN THEO THE STOWED POSITION, SHUT DOWN THE MACHINE,

HE BOOM CABLES INSPECTED.

ft Touch Indicator. (If Equipped)

dicates the Soft Touch bumper is against an object. Allntrols are cut out until the override button is pushed,

which time controls are active in the Creep mode.

SECTION 3 -

3121138 – JLG Lift –

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 indicator acts as a reminder that all func-tions are set to the slowest speed.

10. Engine Malfunction Indicator.

The light indicates that the JLG Control System hasdetected a malfunction and a Diagnostic Trouble Codehas been set in the system memory. Refer to the ServiceManual for instructions concerning the trouble codesand trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 sec-onds when the key is positioned to the on position to actas a self test.

11. C

Warim

IF THE CABPLATFORM TAND HAVE T

12. So

Incoat


3-1 3121138
6 – JLG Lift –
NOTES:

SECTION 4 - MACHINE OPERATION

4-1

PERATION

ERATING CHARACTERISTICS AND ITATIONS

es

om can be raised above horizontal with or without any platform, if:

achine is positioned on a smooth, firm and level sur-ce.

ad is within manufacturer’s rated capacity.

l machine systems are functioning properly.

oper tire pressure.

achine is as originally equipped from JLG.

ne stability is based on two (2) conditions which are FORWARD and BACKWARD stability. The machine’sn of least FORWARD stability is shown in (See Figurend its position of least BACKWARD stability is shown Figure 4-1.)

3121138 – JLG Lift –

SECTION 4. MACHINE O

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 work platform. The equivalent continuousA-Weighted sound pressure level at the work platform is lessthan 70dB(A).

The primary operator control station is in the platform. Fromthis control station, the operator can drive and steer themachine in both forward and reverse directions. The opera-tor can raise or lower the upper or lower boom or swing theboom to the left or right. Standard boom swing is 360 degreecontinuous left and right of the stowed position. The machinehas a Ground Control Station which will override the PlatformControl Station. Ground Controls operate Boom Lift andSwing, and are to be used in an emergency to lower the plat-form to the ground should the operator in the platform beunable to do so. The Ground Control is also to be used inPre-Start Inspection.

4.2 OPLIM

Capaciti

The boload in

1. Mfa

2. Lo

3. Al

4. Pr

5. M

Stability

Machicalledpositio4-2.), ain (See


4-2 3121138

TO MAC

4.3

NOT

Sta

IF EEXTSTASEV

NOT

O WARM-UP FOR A FEW MINUTES AT LOW SPEEDG ANY LOAD.

ngine has had sufficient time to warm up, shut off.

ELECT switch to PLATFORM.

latform, pull POWER/EMERGENCY STOP switchen push the ENGINE START switch until engine

itch must be in released (up) position beforewill operate. If starter operates with footswitch inressed position, DO NOT OPERATE MACHINE.

– JLG Lift –

AVOID FORWARD OR BACKWARD TIPPING, DO NOT OVERLOADHINE OR OPERATE THE MACHINE ON AN OUT-OF-LEVEL SURFACE.

ENGINE OPERATION

E: Initial starting should always be performed from theGround Control station.

rting Procedure

NGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR ANENDED TIME. SHOULD ENGINE FAIL TO START AGAIN, ALLOWRTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTERERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.

E: Diesel engines only: After turning on ignition, operatormust wait until glow plug indicator light goes out beforecranking engine.

1. Turn key of SELECT switch to GROUND. PositionPOWER/EMERGENCY STOP switch to ON, then pushthe ENGINE START switch until engine starts.

ALLOW ENGINE TBEFORE APPLYIN

2. After eengine

3. Turn S

4. From Pout, thstarts.

NOTE: Footswstarter the dep


4-3

ure 4-1. Position of Least Backward Stability

ROTATE PLATFORM90 DEGREES

BOOM FULLYELEVATED

TURNTABLE ROTATED90 DEGREES FROMSTOWED POSITION

E WILL TIP OVER INTION IF OVERLOADED

R OPERATEDT-OF-LEVEL SURFACE

3121138 – JLG Lift –

Shutdown Procedure

IF AN ENGINE MALFUNCTION CAUSES AN UNSCHEDULED SHUTDOWN,DETERMINE THE CAUSE AND CORRECT IT BEFORE RESTARTING THEENGINE.

1. Remove all load and allow engine to operate at lowspeed for 3-5 minutes; this allows further reduction ofinternal engine temperature.

2. Push POWER/EMERGENCY STOP switch in.

3. Turn MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed informa-tion.

.

Fig

MACHINTHIS DIREC

OON AN OU


4-4 3121138

rd Stability

MACHINE WILL TIP OVER INTHIS DIRECTION IF OVERLOADED

OR OPERATEDON AN OUT-OF-LEVEL SURFACE

– JLG Lift –

Figure 4-2. Position of Least Forwa

TELESCOPEFULLY EXTENDED

TURNTABLE ROTATED90 DEGREES FROMSTOWED POSITION


4-5

ROLS IN A DIRECTION MATCHING THE DIRECTIONAL

Forward and Reverse

Platform Controls, pull out Emergency Stop switch,art engine, and activate footswitch.

sition Drive controller to FORWARD or REVERSE assired.

ERINGn thumb switch on Drive/Steer controller to RIGHT forg right, or to LEFT for steering left.

3121138 – JLG Lift –

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 BOOM ABOVE HORIZONTAL EXCEPT ON ASMOOTH, FIRM AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER” , DO NOT DRIVEMACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIALNUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALLTIMES WHEN THE PLATFORM IS ELEVATED.

BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWSON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE

DRIVE CONTARROWS.

Traveling

1. Atst

2. Pode

4.5 STEPositiosteerin


4-6 3121138

es

– JLG Lift –

Figure 4-3. Grade and Side Slop


4-7

OM

NG OR RAISE BOOM ABOVE HORIZONTAL WHEN MACHINEVEL.

END ON TILT ALARM AS A LEVEL INDICATOR FOR THE

IP OVER, LOWER PLATFORM TO GROUND LEVEL. THENINE TO A LEVEL SURFACE BEFORE RAISING BOOM.

RIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CON- OR TOGGLE SWITCH CONTROLLING PLATFORM MOVE-NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN

FORM DOES NOT STOP WHEN A CONTROL SWITCH ORELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE STOP SWITCH TO STOP THE MACHINE.

3121138 – JLG Lift –

4.6 PLATFORM

Platform Level Adjustment

During normal operation of the machine, the platform willautomatically maintain it’s position. To manually Level Up orDown - Position the Platform/Level control switch Up orDown and hold until the desired platform position isobtained.

Platform Rotation

To rotate the platform to the left or right, use the PlatformRotate control switch to select the direction and hold untildesired position is reached.

4.7 BO

DO NOT SWIIS OUT OF LE

DO NOT DEPCHASSIS.

TO AVOID TDRIVE MACH

TO AVOID SETROL LEVERMENT DOES RELEASED.

IF THE PLATLEVER IS REMERGENCY


4-8 3121138

Sw

WHETHEMEN

Ra

4.8

LATING AXLE LOCKOUT TEST (IF PED)

TEST MUST BE PERFORMED QUARTERLY, ANY TIMEONENT IS REPLACED, OR WHEN IMPROPER SYSTEMSPECTED.

ection 2.4, Oscillating Axle Lockout Test (If for procedure.

– JLG Lift –

inging the Boom

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

N SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIP-T.

ising and Lowering the Boom

To raise or lower the Boom, use Boom Lift control to selectUP or DOWN movement.

FUNCTION SPEED CONTROLThis control affects the speed of all boom functions and Plat-form Rotate. When in the CCW maximum position, Drive isplaced in creep speed.

4.9 OSCILEQUIP

LOCKOUT SYSTEMA SYSTEM COMPOPERATION IS SU

Refer to SEquipped)


4-9

econnect the drive hubs by inverting the disconnectp when towing is complete.

Figure 4-4. Drive Disconnect Hub

3121138 – JLG Lift –

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 CAUSE SERIOUS INJURY OR DEATH.

MAXIMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)

MAXIMUM TOWING GRADE 25%.

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBSENGAGED.

1. Retract, lower and position boom in travel position; lockturntable.

2. Disconnect drive hubs by inverting disconnect cap.

3. Rca


4-1 3121138

4.1

RUNBRAALLLOW

MAX

MAX

DO ENG

nect drive hubs by inverting disconnect cap.o Figure 4-4., Drive Disconnect Hub.

0 – JLG Lift –

1 TOW BAR (IF EQUIPPED)

AWAY VEHICLE/MACHINE HAZARD. MACHINE HAS NO TOWINGKES. TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT TIMES. ON-HIGHWAY TOWING NOT PERMITTED. FAILURE TO FOL- INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH.

IMUM TOWING SPEED 5 M.P.H. (8 K.M.H.)

IMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBSAGED.

1. Retract, lower and position boom in travel position; lockturntable.

2. Lower towbar and connect to towing vehicle

.

3. DisconRefer t


4-11
3121138 – JLG Lift –
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 hubs by inverting disconnect cap.

3. Disconnect towbar from towing vehicle and place it inthe stowed position as shown below. The machine isnow in the driving mode.


4-1 3121138

4.1 G AND TIE DOWN

G Industries or weigh the individual unit to find Gross Vehicle Weight.

the boom in the stowed position with the turntable.

e all loose items from the machine.

rly adjust the rigging to prevent damage to thene and so the machine remains level.

2 – JLG Lift –

2 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 lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Posi-tion Platform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instruc-tion placards, warning decals and operating controlsfrom hostile environment.

4.13 LIFTIN

Lifting

1. Call JLout the

2. Place locked

3. Remov

4. Propemachi


4-13

STEER CONTROLLERS WILL BE REVERSED WHEN THESITIONED OVER THE FRONT WHEELS.

. Drive it onto the trailer with the boom and platformpositioned towards the truck. Refer to Figure 4-5.,Typical 800S/860SJ Transport.

cure the chassis and the platform using straps orains of adequate strength.

3121138 – JLG Lift –

Tie Down

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

1. Remove all loose items from the machine.

2. When transporting an 800S/860SJ a step-deck or sin-gle-drop trailer is required. To avoid damage to the plat-form and to obtain proper weight distribution, load themachine onto the trailer as follows;

a. Position the boom over the front wheels.

DO NOT SWING THE BOOM WHIT THE MACHINE POSITIONED ON ATRAILER. TIPOVER MAY RESULT

b. Place the boom in the stowed position with the turn-table locked.

DRIVE AND BOOM IS PO

c

3. Sech


4-1 3121138

ort

4 – JLG Lift –

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


4-15

art

3121138 – JLG Lift –

Figure 4-6. Lifting and Tie Down Ch


4-1 3121138

rm - Sheet 1 of 2

6 – JLG Lift –

Figure 4-7. Decal Location - Rear Entry Platfo


4-17

rm - Sheet 2 of 2

3121138 – JLG Lift –

Figure 4-8. Decal Location - Rear Entry Platfo


4-1 3121138

ry Platform

-2-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

1 1703924 1704767 1704810

3 1703930 1704820 1704822

- 1703936 - - - -

8 1703948 1701518 1701518

- 1705015 - - - -

- 1703808 - - - -

6)7

J)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

- - - - - - -

- - - - - - -

- - - - - - -

- 1704000 - - - -

7 1704277 1704277 1704277

8 – JLG Lift –

Table 4-1. Decal Location Legend - Rear Ent

Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

French02709190270920

1 1703797 1703992 1703925 1704809 1705053 170481

2 1703798 1704819 1703931 1704821 1705055 170482

3 1703805 - - 1703937 - - - - -

4 1703804 1701518 1703949 1701518 1701518 170151

5 1705015 - - - - - - - - -

6 1703808 - - - - - - - - -

7 1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

170490(800S

170490(860S

8 - - - - - - - - - - -

9 - - - - - - - - - - -

10 - - - - - - - - - - -

11 1702868 - - - - - - - - -

12 1704277 1704277 1704277 1704277 1704277 170427


4-19

- - 1704099 - - - -

- - 1704107 - - - -

05084 3251813 1705084 1705084

01502 1701502 1701502 1701502

01503 1701503 1701503 1701503

01504 1701504 1701504 1701504

- - 1704006 - - - -

02631 1702631 1702631 1702631

00584 1700584 1700584 1700584

- - - - - - - -

01509 1701509 1701509 1701509

02300 1702300 1702300 1702300

Entry Platform

rench70919-270920-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

3121138 – JLG Lift –

13 1705088 1705088(800S)

1704995(860SJ)

1704101 - - - -

14 1705089 1705089(800S)

1704996(860SJ)

1704109 - - - -

15 3251813 - - - - 1705084 1705084 17

16 1701502 1701502 1701502 1701502 1701502 17

17 1701503 1701503 1701503 1701503 1701503 17

18 1701504 1701504 1701504 1701504 1701504 17

19 1702153 - - - - - - - -

20 1702631 1702631 1702631 1702631 1702631 17

21 1700584 1700584 1700584 1700584 1700584 17

22 - - - - - - - - - -

23 1701509 1701509 1701509 1701509 1701509 17

24 1702300 1702300 1702300 1702300 1702300 17

Table 4-1. Decal Location Legend - Rear

Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

F0202


4-2 3121138

0 1701500 1701500 1701500

1 1701501 1701501 1701501

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

2 1703984 1693294 1701600

5)2

J)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

- - - - - - -

- - - - - - -

- - - - - - -

- 3252221 - - - -

ry Platform

h-2-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

0 – JLG Lift –

25 1701500 1701500 1701500 1701500 1701500 170150

26 1701501 1701501 1701501 1701501 1701501 170150

27 - - - - - - - - - - -

28 - - - - - - - - - - -

29 - - - - - - - - - - -

30 - - - - - - - - - - -

31 - - - - - - - - - - -

32 - - - - - - - - - - -

33 - - - - - - - - - - -

34 - - - - 1703982 1703518 1701600 169329

35 1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

170347(800S

170348(860S

36 - - - - - - - - - - -

37 - - - - - - - - - - -

38 - - - - - - - - - - -

39 - - - - - - - - - - -


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

Frenc02709190270920


4-21

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

01499 1701499 1701499 1701499

52781 3252781 3252781 3252781

04412 1704412 1704412 1704412

04540 1704540 1704540 1704540

01691 1701691 1701691 1701691

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

Entry Platform

rench70919-270920-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

3121138 – JLG Lift –

40 - - - - - - - - - -

41 - - - - - - - - - -

42 - - - - - - - - - -

43 - - - - - - - - - -

44 1701499 1701499 1701499 1701499 1701499 17

45 3252781 3252781 3252781 3252781 3252781 32

46 1704412 1704412 1704412 1704412 1704412 17

47 1704540 1704540 1704540 1704540 1704540 17

48 1701691 1701691 1701691 1701691 1701691 17

49 - - - - - - - - - -

50 - - - - - - - - - -

51 - - - - - - - - - -

52 - - - - - - - - - -


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

F0202


4-2 3121138

ry Platform

-2-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

1 1703924 1704767 1704810

3 1703930 1704820 1704822

- 1703936 - - - -

8 1703948 1701518 1701518

- 1705015 - - - -

- 1703808 - - - -

6)7

J)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

- - - - - - -

- - - - - - -

- - - - - - -

- 1704000 - - - -

7 1704277 1704277 1704277

2 – JLG Lift –


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

French02709190270920

1 1703797 1703992 1703925 1704809 1705053 170481

2 1703798 1704819 1703931 1704821 1705055 170482

3 1703805 - - 1703937 - - - - -

4 1703804 1701518 1703949 1701518 1701518 170151

5 1705015 - - - - - - - - -

6 1703808 - - - - - - - - -

7 1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

170490(800S

170490(860S

8 - - - - - - - - - - -

9 - - - - - - - - - - -

10 - - - - - - - - - - -

11 1702868 - - - - - - - - -

12 1704277 1704277 1704277 1704277 1704277 170427


4-23

- - 1704099 - - - -

- - 1704107 - - - -

05084 3251813 1705084 1705084

01502 1701502 1701502 1701502

01503 1701503 1701503 1701503

01504 1701504 1701504 1701504

- - 1704006 - - - -

02631 1702631 1702631 1702631

00584 1700584 1700584 1700584

- - - - - - - -

01509 1701509 1701509 1701509

02300 1702300 1702300 1702300

Entry Platform

rench70919-270920-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

3121138 – JLG Lift –

13 1705088 1705088(800S)

1704995(860SJ)

1704101 - - - -

14 1705089 1705089(800S)

1704996(860SJ)

1704109 - - - -

15 3251813 - - - - 1705084 1705084 17

16 1701502 1701502 1701502 1701502 1701502 17

17 1701503 1701503 1701503 1701503 1701503 17

18 1701504 1701504 1701504 1701504 1701504 17

19 1702153 - - - - - - - -

20 1702631 1702631 1702631 1702631 1702631 17

21 1700584 1700584 1700584 1700584 1700584 17

22 - - - - - - - - - -

23 1701509 1701509 1701509 1701509 1701509 17

24 1702300 1702300 1702300 1702300 1702300 17


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

F0202


4-2 3121138

0 1701500 1701500 1701500

1 1701501 1701501 1701501

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

- - - - - - -

2 1703984 1693294 1701600

5)2

J)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

- - - - - - -

- - - - - - -

- - - - - - -

- 3252221 - - - -

ry Platform

h-2-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

4 – JLG Lift –

25 1701500 1701500 1701500 1701500 1701500 170150

26 1701501 1701501 1701501 1701501 1701501 170150

27 - - - - - - - - - - -

28 - - - - - - - - - - -

29 - - - - - - - - - - -

30 - - - - - - - - - - -

31 - - - - - - - - - - -

32 - - - - - - - - - - -

33 - - - - - - - - - - -

34 - - - - 1703982 1703518 1701600 169329

35 1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

170347(800S

170348(860S

36 - - - - - - - - - - -

37 - - - - - - - - - - -

38 - - - - - - - - - - -

39 - - - - - - - - - - -


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

Frenc02709190270920


4-25

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

01499 1701499 1701499 1701499

52781 3252781 3252781 3252781

04412 1704412 1704412 1704412

04540 1704540 1704540 1704540

01691 1701691 1701691 1701691

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

Entry Platform

rench70919-270920-2

French/English

0270929-10270930-1

German0270913-20270914-2

Italian0270917-20270918-2

3121138 – JLG Lift –

40 - - - - - - - - - -

41 - - - - - - - - - -

42 - - - - - - - - - -

43 - - - - - - - - - -

44 1701499 1701499 1701499 1701499 1701499 17

45 3252781 3252781 3252781 3252781 3252781 32

46 1704412 1704412 1704412 1704412 1704412 17

47 1704540 1704540 1704540 1704540 1704540 17

48 1701691 1701691 1701691 1701691 1701691 17

49 - - - - - - - - - -

50 - - - - - - - - - -

51 - - - - - - - - - -

52 - - - - - - - - - -


Item #800S860SJ

ANSI0270907-20270908-2

Australian0270909-20270910-2

China/English

0270931-10270932-1

Dutch0270915-20270916-2

Finnish0271830-20271831-1

F0202


4-2 3121138

ry Platform

Spanish/English

0270927-10270928-1

Swedish0271832-20271833-2

UK0270911-20270912-2

1703923 1705054 1704808

1703929 1705056 1704819

1703935 - - - -

1703947 1701518 1701518

1705015 - - - -

1703808 - - - -

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

- - - - - -

- - - - - -

- - - - - -

1704001 - - - -

1704277 1704277 1704277

1704098 - - - -

1704106 - - - -

3251813 1705084 1705084

6 – JLG Lift –


Item #800S860SJ

Japan0270923-10270924-1

Korean0270925-10270926-1

Portuguese0271392-20271393-2

Portuguese/Spanish

0270933-10270934-1

Spanish0270921-20270922-2

1 1703926 1703927 1704985 1703928 1704812

2 1703932 1703933 1704986 1703934 1704824

3 1703938 1703939 - - 1703940 - -

4 1703950 1703951 1701518 1703952 1701518

5 - - - - - - - - - -

6 - - - - - - - - - -

7 1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

1704906(800S)

1704907(860SJ)

8 - - - - - - - - - -

9 - - - - - - - - - -

10 - - - - - - - - - -

11 - - - - - - 1704002 - -

12 1704277 1704277 - - 1704277 1704277

13 1704102 1704103 - - 1704100 - -

14 1704110 1704111 - - 1704108 - -

15 - - - - 1705084 3251813 1705084


4-27

02 1701502 1701502 1701502

03 1701503 1701503 1701503

04 1701504 1701504 1701504

- - 1704007 - - - -

31 1702631 1702631 1702631

84 1700584 1700584 1700584

- - - - - - - -

09 1701509 1701509 1701509

00 1702300 1702300 1702300

00 1701500 1701500 1701500

01 1701501 1701501 1701501

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

Entry Platform

h1-22-2

Spanish/English

0270927-10270928-1

Swedish0271832-20271833-2

UK0270911-20270912-2

3121138 – JLG Lift –

16 1701502 1701502 1701502 1701502 17015

17 1701503 1701503 1701503 1701503 17015

18 1701504 1701504 1701504 1701504 17015

19 - - - - - - 1704008

20 1702631 1702631 1702631 1702631 17026

21 1700584 1700584 1700584 1700584 17005

22 - - - - - - - -

23 1701509 1701509 1701509 1701509 17015

24 1702300 1702300 1702300 1702300 17023

25 1701500 1701500 1701500 1701500 17015

26 1701501 1701501 1701501 1701501 17015

27 - - - - - - - -

28 - - - - - - - -

29 - - - - - - - -

30 - - - - - - - -

31 - - - - - - - -

32 - - - - - - - -


Item #800S860SJ

Japan0270923-10270924-1

Korean0270925-10270926-1

Portuguese0271392-20271393-2

Portuguese/Spanish

0270933-10270934-1

Spanis027092027092


4-2 3121138

- - - - - -

1703983 1701600 - -

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1701499 1701499 1701499

3252781 3252781 3252781

1704412 1704412 1704412

1704540 1704540 1704540

ry Platform

Spanish/English

0270927-10270928-1

Swedish0271832-20271833-2

UK0270911-20270912-2

8 – JLG Lift –

33 - - - - - - - - - -

34 1703980 1703981 1701600 1703985 1701791

35 1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

1703475(800S)

1703482(860SJ)

36 - - - - - - - - - -

37 - - - - - - - - - -

38 - - - - - - - - - -

39 - - - - - - - - - -

40 - - - - - - - - - -

41 - - - - - - - - - -

42 - - - - - - - - - -

43 - - - - - - - - - -

44 1701499 1701499 1701499 1701499 1701499

45 3252781 3252781 3252781 3252781 3252781

46 1704412 1704412 1704412 1704412 1704412

47 1704540 1704540 1704540 1704540 1704540


Item #800S860SJ

Japan0270923-10270924-1

Korean0270925-10270926-1

Portuguese0271392-20271393-2

Portuguese/Spanish

0270933-10270934-1

Spanish0270921-20270922-2


4-29

91 1701691 1701691 1701691

- - - - - - - -

- - - - - - - -

- - - - - - - -

- - - - - - - -

Entry Platform

h1-22-2

Spanish/English

0270927-10270928-1

Swedish0271832-20271833-2

UK0270911-20270912-2

3121138 – JLG Lift –

48 1701691 1701691 1701691 1701691 17016

49 - - - - - - - -

50 - - - - - - - -

51 - - - - - - - -

52 - - - - - - - -


Item #800S860SJ

Japan0270923-10270924-1

Korean0270925-10270926-1

Portuguese0271392-20271393-2

Portuguese/Spanish

0270933-10270934-1

Spanis027092027092


4-3 3121138

m - Sheet 1 of 5

0 – JLG Lift –

Figure 4-9. Decal Location - Side Entry Platfor


4-31

rm - Sheet 2 of 5

3121138 – JLG Lift –

Figure 4-10. Decal Location - Side Entry Platfo


4-3 3121138

- Sheet 3 of 5

2 – JLG Lift –

Figure 4-11. Decal Location - Side Entry Platform


4-33

rm - Sheet 4 of 5

3121138 – JLG Lift –

Figure 4-12. Decal Location - Side Entry Platfo


4-3 3121138

- Sheet 5 of 5

4 – JLG Lift –

Figure 4-13. Decal Location - Side Entry Platform


4-35

ide Entry Platform

French0274507-3

CE/Aus0274509-3

Japanese0274511-3

- - - - - -

1701499 1701499 1701499

1701502 1701502 1701502

1701503 1701503 1701503

1701509 1701509 1701509

- - - - - -

1703811 1703811 1703811

1703814 1703814 1703814

1704277 1704277 1704277

1704412 1704412 1704412

- - 1705084 - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1704006 - - - -

1703942 - - 1703944

3121138 – JLG Lift –

Table 4-4. Decal Location Legend, 800S - S

Item #ANSI

0274499-3Korean

0274501-3Chinese

0274503-3Spanish

0274513-3Portuguese0274505-4

1 - - - - - - - - - -

2 1701499 1701499 1701499 1701499 1701499

3 1701502 1701502 1701502 1701502 1701502

4 1701503 1701503 1701503 1701503 1701503

5 1701509 1701509 1701509 1701509 1701509

6 - - - - - - - - - -

7 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412 1704412

11 - - - - - - - - - -

12 - - - - - - - - - -

13 - - - - - - - - - -

14 - - - - - - - - - -

15 - - - - - - - - - -

16 - - - - - - - - - -

17 1702153 - - 1702153 1704007 1705901

18 1703953 1703945 1703943 1703941 1705903


4-3 3121138

- - - - - -

04000 - - - -

03924 1705921 1703926

05347 1705822 1705344

03948 1701518 1703950

03936 1705961 1703938

03984 1705828 1703980

51813 - - 3251813

- - - - - -

- - - - - -

03475 1703475 1703475

02631 1702631 1702631

04906 1704906 1704906

01501 1701501 1701501

04099 1705978 1704102

07046 1705978 1707053

06948 - - 1706948

00584 1700584 1700584

ntry Platform

rench74507-3

CE/Aus0274509-3

Japanese0274511-3

6 – JLG Lift –

19 - - - - - - - - - -

20 1702868 1705969 1702868 1704001 1705967 17

21 1703797 1703927 1703925 1703923 1705895 17

22 1705336 1705345 1705348 1705917 1705896 17

23 1703804 1703951 1703949 1703947 1705898 17

24 1703805 1703939 1703937 1703935 1705897 17

25 - - 1703981 1703982 1703983 1705902 17

26 3251813 - - 3251813 3251813 3251813 32

27 - - - - - - - - - -

28 - - - - - - - - - -

29 1703475 1703475 1703475 1703475 1703475 17

30 1702631 1702631 1702631 1702631 1702631 17

31 1704906 1704906 1704906 1704906 1704906 17

32 1701501 1701501 1701501 1701501 1701501 17

33 1705088 1704103 1704101 1704098 1706380 17

34 1707016 1707043 1707045 1707048 1707051 17

35 1706948 1706948 1706948 1706948 1706948 17

36 1700584 1700584 1700584 1700584 1700584 17

Table 4-4. Decal Location Legend, 800S - Side E

Item #ANSI

0274499-3Korean

0274501-3Chinese

0274503-3Spanish

0274513-3Portuguese0274505-4

F02


4-37

1705015 - - 1705015

1706941 - - 1706941

3252781 3252781 3252781

1701691 1701691 1701691

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

ide Entry Platform

French0274507-3

CE/Aus0274509-3

Japanese0274511-3

3121138 – JLG Lift –

37 1705015 1705015 1705015 1705015 1705015

38 1706941 1706941 1706941 1706941 1706941

39 3252781 3252781 3252781 3252781 3252781

40 1701691 1701691 1701691 1701691 1701691

41 - - - - - - - - - -

42 - - - - - - - - - -

43 - - - - - - - - - -

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 - - - - - - - - - -

48 - - - - - - - - - -

49 - - - - - - - - - -

50 - - - - - - - - - -

51 - - - - - - - - - -

52 - - - - - - - - - -

53 - - - - - - - - - -

54 - - - - - - - - - -

Table 4-4. Decal Location Legend, 800S - S

Item #ANSI

0274499-3Korean

0274501-3Chinese

0274503-3Spanish

0274513-3Portuguese0274505-4


4-3 3121138

- - - - - -

- - - - - -

- - - - - -

- - - - - -

ntry Platform

rench74507-3

CE/Aus0274509-3

Japanese0274511-3

8 – JLG Lift –

55 - - - - - - - - - -

56 - - - - - - - - - -

57 - - - - - - - - - -

58 - - - - - - - - - -

Table 4-4. Decal Location Legend, 800S - Side E

Item #ANSI

0274499-3Korean

0274501-3Chinese

0274503-3Spanish

0274513-3Portuguese0274505-4

F02


4-39

ide Entry Platform

ese6-5

French0274508-4

CE/Aus0274510-3

Japanese0274512-4

- - - - - -

9 1701499 1701499 1701499

2 1701502 1701502 1701502

3 1701503 1701503 1701503

9 1701509 1701509 1701509

- - - - - -

1 1703811 1703811 1703811

4 1703814 1703814 1703814

7 1704277 1704277 1704277

2 1704412 1704412 1704412

- - 1705084 - -

1705514 - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

1 1704006 1704006 - -

3 1703942 1703942 1703944

3121138 – JLG Lift –

Table 4-5. Decal Location Legend, 860SJ - S

Item #ANSI

0274500-3Korean

0274502-4Chinese

0274504-4Spanish

0274514-4Portugu027450

1 - - - - - - - - - -

2 1701499 1701499 1701499 1701499 170149

3 1701502 1701502 1701502 1701502 170150

4 1701503 1701503 1701503 1701503 170150

5 1701509 1701509 1701509 1701509 170150

6 - - - - - - - - - -

7 1703811 1703811 1703811 1703811 170381

8 1703814 1703814 1703814 1703814 170381

9 1704277 1704277 1704277 1704277 170427

10 1704412 1704412 1704412 1704412 170441

11 - - - - - - - - - -

12 - - - - - - - - - -

13 - - - - - - - - - -

14 - - - - - - - - - -

15 - - - - - - - - - -

16 - - - - - - - - - -

17 1702153 - - - - 1704007 170590

18 1703953 1703945 1703943 1703941 170590


4-4 3121138

- - - - - -

1704000 - - - -

1703924 1705921 1703926

1705347 1705822 1705344

1703948 1701518 1703950

1703936 1705961 1703938

1703984 1705828 1703980

3251813 - - 3251813

- - - - - -

- - - - - -

1703482 1703482 1703472

1702631 1702631 1702631

1704907 1704907 1704907

1701501 1701501 1701501

1001094806 1705978 1707059

1001094808 1705978 1707054

1706948 - - 1706948

1700584 1700584 1700584

Entry Platform

French0274508-4

CE/Aus0274510-3

Japanese0274512-4

0 – JLG Lift –

19 - - - - - - - - - -

20 1702868 1705969 1705968 1704001 1705967

21 1703797 1703927 1703925 1703923 1705895

22 1705336 1705345 1705348 1705917 1705896

23 1703804 1703951 1703949 1703947 1705898

24 1703805 1703939 1703937 1703935 1705897

25 - - 1703981 1703982 1703983 1705902

26 3251813 - - 3251813 3251813 3251813

27 - - - - - - - - - -

28 - - - - - - - - - -

29 1703482 1703482 1703482 1703482 1703482

30 1702631 1702631 1702631 1702631 1702631

31 1704907 1704907 1704907 1704906 1704907

32 1701501 1701501 1701501 1701501 1701501

33 1704995 1001094798 1001094800 1001094802 1001094804

34 1707015 1001094799 1001094801 1001094803 1001094805

35 1706948 1706948 1706948 1706948 1706948

36 1700584 1700584 1700584 1700584 1700584

Table 4-5. Decal Location Legend, 860SJ - Side

Item #ANSI

0274500-3Korean

0274502-4Chinese

0274504-4Spanish

0274514-4Portuguese0274506-5


4-41

5 1705015 - - 1705015

1 1706941 - - 1706941

1 3252781 3252781 3252781

1 1701691 1701691 1701691

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

- - - - - -

ide Entry Platform

ese6-5

French0274508-4

CE/Aus0274510-3

Japanese0274512-4

3121138 – JLG Lift –

37 1705015 1705015 1705015 1705015 170501

38 1706941 1706941 1706941 1706941 170694

39 3252781 3252781 3252781 3252781 325278

40 1701691 1701691 1701691 1701691 170169

41 - - - - - - - - - -

42 - - - - - - - - - -

43 - - - - - - - - - -

44 - - - - - - - - - -

45 - - - - - - - - - -

46 - - - - - - - - - -

47 - - - - - - - - - -

48 - - - - - - - - - -

49 - - - - - - - - - -

50 - - - - - - - - - -

51 - - - - - - - - - -

52 - - - - - - - - - -

53 - - - - - - - - - -

54 - - - - - - - - - -

Table 4-5. Decal Location Legend, 860SJ - S

Item #ANSI

0274500-3Korean

0274502-4Chinese

0274504-4Spanish

0274514-4Portugu027450


4-4 3121138

- - - - - -

- - - - - -

- - - - - -

- - - - - -

Entry Platform

French0274508-4

CE/Aus0274510-3

Japanese0274512-4

2 – JLG Lift –

55 - - - - - - - - - -

56 - - - - - - - - - -

57 - - - - - - - - - -

58 - - - - - - - - - -

Table 4-5. Decal Location Legend, 860SJ - Side

Item #ANSI

0274500-3Korean

0274502-4Chinese

0274504-4Spanish

0274514-4Portuguese0274506-5

SECTION 5 - EMERGENCY PROCEDURES

5-1

ROCEDURES

ANY ACCIDENT, THOROUGHLY INSPECT THE MACHINELL FUNCTIONS FIRST FROM THE GROUND CONTROLS,THE PLATFORM CONTROLS. DO NOT LIFT ABOVE 3 M (10OU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED, IFND THAT ALL CONTROLS ARE OPERATING CORRECTLY.

ERGENCY OPERATION

Unable to Control Machine PLATFORM OPERATOR IS PINNED, TRAPPED OR

LE TO OPERATE OR CONTROL MACHINE:

ther personnel should operate the machine from ound controls only as required.

ther qualified personnel on the platform may use the atform controls. DO NOT CONTINUE OPERATION IF ONTROLS DO NOT FUNCTION PROPERLY.

ranes, forklift trucks or other equipment can be used to move platform occupants and stabilize motion of the achine.

3121138 – JLG Lift –

SECTION 5. EMERGENCY P

5.1 GENERALThis section explains the steps to be taken in case of anemergency situation while operating.

5.2 INCIDENT NOTIFICATIONJLG Industries, Inc. must be notified immediately of any inci-dent involving a JLG product. Even if no injury or propertydamage is evident, the factory should be contacted by tele-phone and provided with all necessary details.

In USA:JLG Phone: 877-JLG-SAFE (554-7233) (8am till 4:45pm EST)

Outside USA: 240-420-2661

E-mail:

[email protected]

Failure to notify the manufacturer of an incident involving aJLG Industries product within 48 hours of such an occur-rence may void any warranty consideration on that particularmachine.

FOLLOWINGAND TEST ATHEN FROM FT.) UNTIL YREQUIRED, A

5.3 EM

OperatorIF THEUNAB

1. Ogr

2. OplC

3. Crem


5-2 3121138

Pla

5.4

L DESCENT INSTRUCTIONS (IF ED)

NOT REMAIN LEVEL DURING MANUAL DESCENT

– JLG Lift –

tform or Boom Caught OverheadIf the platform or boom becomes jammed or snagged inoverhead structures or equipment, rescue platform occu-pants prior to freeing the machine.

EMERGENCY TOWING PROCEDURESTowing this machine is prohibited, unless properly equipped.However, provisions for moving the machine have beenincorporated. For specific procedures, refer to Section 4.

5.5 MANUAEQUIPP

PLATFORM WILLOPERATION.


5-3

Boom with Fully Retracted Telescopern knob #1 and #3 clockwise until tight.

rn knob #2 counterclockwise 3 turns.

rn knob #4 counterclockwise until fully open.

mp the hand pump until tight.

en the manual descent operation has been completed,bs #1, #2, and #3 should be open (counterclock-e), knob #4 should be closed (clockwise).

3121138 – JLG Lift –

To Retract and Lower Boom1. Turn knob #1 and #4 clockwise until tight.

2. Turn knobs #2 and #3 counterclockwise 3 turns.

3. Pump the hand pump until tight.

4. After telescope has fully retracted turn knob #4 counter-clockwise until fully open to continue lowering boom.

To Lower1. Tu

2. Tu

3. Tu

4. Pu

NOTE: Whknowis


5-4 3121138
– JLG Lift –
NOTES:

FICATIONS & OPERATOR MAINTENANCE

6-1

OPERATOR MAINTENANCE

ERATING SPECIFICATIONS

Table 6-1. Operating Specifications

ork Load (Capacity)icted:ed

500 lb (230 kg)Refer to Capacity Decals on

machine for restricted platformcapacities

apacity - Dual Rating1000 lb. (450 kg)750 lb. (340 kg)

ravel Grade (Gradeability)* 30%45%

ravel Grade (Side Slope)* 5°

ertical Platform Height: 800S - 80 ft. (24.3 m)860SJ - 86 ft. (26.2 m)

orizontal Platform Reach71 ft. (21.6 m)75 ft. (22.9 m)

ius (outside) 22 ft. 6 in. (6.8 m)

ius (inside) 12 ft. (3.6 m)

SECTION 6 - GENERAL SPECI

3121138 – JLG Lift –

SECTION 6. GENERAL SPECIFICATIONS &

6.1 INTRODUCTIONThis section of the manual provides additional necessaryinformation to the operator for proper operation and mainte-nance of this machine.

The maintenance portion of this section is intended as infor-mation to assist the machine operator to perform daily main-tenance tasks only, and does not replace the more thoroughPreventive Maintenance and Inspection Schedule includedin the Service and Maintenance Manual.

Other Publications Available:

Service and Maintenance Manual ............................ 3121139

Illustrated Parts Manual (ANSI, CSA Spec).............. 3121140

Illustrated Parts Manual (CE Spec)........................... 3121842

6.2 OP

Maximum W Unrestr Restrict

Maximum C 800S 860SJ

Maximum T 2WD 4WD

Maximum T

Maximum V

Maximum H 800S 860SJ

Turning Rad

Turning Rad

SECTION 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6-2 3121138

ns and Performance DataM

M

M

M

El

G

*

2. Specifications and Performance Data

360°

4’8" (1.42 m)

36" x 72" (0.91m x 1.83m)36" x 96" (0.91m x 2.44m)

8’ 2" (2.5 m)

9’ 10.6" (3.01 m)10’ (3.04 m)

37’ 3.25" (11.4 m)40’ (12.2 m)

10’ (3.04 m)

ce 15.625" (0.4 m)

3.0 mph (5.5 kph)3.5 mph (5.6 kph)

0.75 mph (1.2 kph)

– JLG Lift –

Specificatioaximum Drive Speed: 3.5 mph (1.5 m/s)

ax. Hydraulic System Pressure 4500 psi (310 Bar)

aximum Wind Speed 28 mph (12.5 m/s)

aximum Manual Force 400 N

ectrical System Voltage 12 Volts

ross Machine Weight (Platform Empty)

800S 860SJ

34,700 lbs. (15,740 kg)37,900 lbs. (17,191 kg)

With boom in stowed position

Table 6-1. Operating Specifications

Table 6-

Swing

Tail Swing

Platforms

Overall Width

Stowed Height 800S 860SJ

Stowed Length 800S 860SJ

Wheel base

Ground Clearan

Drive Speed Stowed 2WD Stowed 4WD Elevated


6-3

es

Table 6-3. Capacities

Approx. 31 gallons (117 liters)

Tank Approx. 47.8 gallons (181 liters)

l Capacity

ng Systemcase

Capacityllar

4.5 Quarts (4.25 L) w/Filter

5 Quarts (4.5 L)11 Quarts (10.5 L) w/Filter

16 Quarts (15 L)10.6 quarts (10 L)

4.5 Quarts (4.25 L) w/Filter


3121138 – JLG Lift –

CapacitiGround Bearing Pressure - 800S 15-625

15-625FF

41/18LLx22.5

72 psi (5.0 kgm/cm2)79 psi (5.5 kgm/cm2)68 psi (4.8 kgm/cm2)

Ground Bearing Pressure - 860SJ 15-625

15-625FF

41/18LLx22.5

81 psi (5.7 kgm/cm2)92 psi (6.5 kgm/cm2)79 psi (5.5 kgm/cm2)

Max. Tire Load - 800S 15-625 15-625FF 41/18LLx22.5

16,900 lbs. (7665 kg)17,200 lbs. (7802 kg)17,300 lbs. (7850 kg)

Max. Tire Load - 860SJ 15-625 15-625FF 41/18LLx22.5

19,800 lbs. (8981 kg)20,100 lbs. (9117 kg)20,200 lbs. (9163 kg)

Table 6-2. Specifications and Performance Data

Fuel Tank

Hydraulic

Engine Oi Ford Deutz Cooli Crank Total Caterpi GM


6-4 3121138

En e 6-5. Deutz F4M2011 Specifications

Liquid Cooled (Oil)

Diesel

m 5 Quarts (4.5 L)11 Quarts (10.5 L) w/Filter

16 Quarts (15 L)

1000

1800

2800

55 Amp, belt drive

on1.90 GPH (7.19 lph)2.50 GPH (9.46 lph)

66 @ 3000 RPM, full load

– JLG Lift –

gine Data

Table 6-4. Ford LRG-425 Specifications

Type Water-cooled

Fuel Gasoline

Oil Capacity 4.5 Quarts (4.25 L) w/Filter

Idle RPM 1000

Low RPM 1800

High RPM 2800

Alternator 95 Amp, Belt Drive

Fuel Consumption Low RPM High RPM

3.45 GPH (13.06 lph)4.60 GPH (17.41 lph)

Horsepower 74 @ 3000 RPM, full load

Cooling System 16 Quarts (15.14 L)

Spark Plug AWSF-52-C

Spark Plug Gap 0.044 in. (1.117 mm)

Tabl

Type

Fuel

Oil Capacity Cooling Syste Crankcase Total Capacity

Idle RPM

Low RPM

High RPM

Alternator

Fuel Consumpti Low RPM High RPM

Horsepower


6-5

ble 6-7. Caterpillar 3044C/ Caterpillar 3.4

Four Stroke Cycle

4 in-line

3.70 inch (94 mm)

4.72 inch (120 mm)

turbocharged

ion ratio 19:1

ent 203 in3 (3.33 L)

r 1-3-4-2

iewed from flywheel) Counterclockwise

ty (w/filter) 10.6 quarts (10 L)

stem (Engine Only) 5.8 quarts (5.5 L)

1000

1800

- 3044C 2600

- 3.4 2500

60 Amp, belt drive


3121138 – JLG Lift –

Table 6-6. Deutz D2011L04 Specifications

Type Liquid Cooled (Oil)

Fuel Diesel

Oil Capacity Cooling System Crankcase Total Capacity

5 Quarts (4.5 L)11 Quarts (10.5 L) w/Filter

16 Quarts (15 L)

Idle RPM 1000

Low RPM 1800

High RPM 2600

Alternator 55 Amp, belt drive

Fuel Consumption Low RPM High RPM

1.90 GPH (7.19 lph)2.50 GPH (9.46 lph)

Battery 1000 Cold Cranking Amps, 210minutes Reserve Capacity, 12 VDC

Horsepower 64 @ 2600 RPM, full load

Ta

Type

Cylinders

Bore

Stroke

Aspiration

Compress

Displacem

Firing Orde

Rotation (v

Oil Capaci

Cooling Sy

Idle RPM

Low RPM

High RPM

High RPM

Alternator


6-6 3121138

F

N

B

B

S

D

O

M

C

F

M

Table 6-9. Battery Specifications

12 Volt

31-950

Amps 950 CCA @ 0° F (-18° C)

ity 205 Minutes @ 80° F (27° C)

Table 6-10. Tire Specifications

TypePly

RatingLoad

RangeWeight

(Tire & Wheel)

Pneumatic 95 psi (6.5 Bar)

16 H 269 lbs. (122 kg)

Foam-Filled 16 H 544 lbs. (247 kg)

Pneumatic85 psi (6.5 Bar)

16 H 288 lbs. (131 kg)

Foam-Filled 16 H 601 lbs. (273 kg)

5 Foam-Filled 16 H 724 lbs. (329 kg)

– JLG Lift –

Battery

Tires

Table 6-8. GM 3.0L

uel Gasoline or Gasoline/LP Gas

o. of Cylinders 4

HP Gasoline LP

83 hp @ 3000 rpm75 hp @ 3000 rpm

ore 4.0 in. (101.6 mm)

troke 3.6 in. (91.44 mm)

isplacement 181 cu.in. (3.0 L, 2966 cc)

il Capacity w/filter 4.5 qts. (4.25 L)

inimum Oil Pressure at idle Hot

6 psi (0.4 Bar) @ 1000 rpm18 psi (1.2 Bar) @ 2000 rpm

ompression Ratio 9.2:1

iring Order 1-3-4-2

ax. RPM 2800

Voltage

Type

Cold Cranking

Reserve Capac

Size

15 - 625

15 - 625

18 - 625

18 - 625

41/ 18LL x 22.


6-7

c Oil

draulic oils must have anti-wear qualities at least to APIrvice Classification GL-3, and sufficient chemical stabil-for mobile hydraulic system service. JLG Industriesommends Mobilfluid 424 hydraulic oil, which has anE viscosity index of 152.

en temperatures remain consistently below 20grees F. (-7 degrees C.), JLG Industries recommends use of Mobil DTE13.

Table 6-12. Hydraulic Oil

Hydraulic SystemOperating

Temperature Range

S.A.E. ViscosityGrade

+ 180° F (-18° to +83° C) 10W

+ 210° F (-18° to +99° C) 10W-20, 10W30

+ 210° F (+10° to +99° C 20W-20


3121138 – JLG Lift –

Major Component Weights Hydrauli

NOTE: HySeity recSA

NOTE: Whdethe

Table 6-11. Component Weights

Component Pounds Kilograms

Turntable (bare) 3700 1678

Counterweight (800S) 7000 3175

Counterweight (860SJ) 8750 3969

Upright 1050 476

Tower 685 311

Fly Boom (SJ) 472 214

Fly Boom (S) 490 222

Mid Boom (SJ) 750 340

Mid Boom (S) 740 336

Base Boom (SJ) 1400 635

Base Boom (S) 1410 640

Boom Assembly 3337 1514

Telescope Cylinder (800S) 590 268

Telescope Cylinder (860SJ) 570 259

Slave Cylinder 73 33

Torque Hub (2WD) 218 99

Tire & Wheel (pneu) 269 122

Tire & Wheel (FF) 544 247

+0° to

+0° to

+50° to


6-8 3121138

AofrehyIn

able 6-14. Mobil DTE 13M Specs

osity Grade #32

fic Gravity 0.877

oint, Max -40°F (-40°C)

oint, Min. 330°F (166°C)

Viscosity

40° C 33cSt

100° C 6.6 cSt

100° F 169 SUS

210° F 48 SUS

t -20° F 6,200

sity Index 140

– JLG Lift –

side from JLG recommendations, it is not advisable to mix oils different brands or types, as they may not contain the samequired additives or be of comparable viscosities. If use ofdraulic oil other than Mobilfluid 424 is desired, contact JLGdustries for proper recommendations.

Table 6-13. Mobilfluid 424 Specs

SAE Grade 10W30

Gravity, API 29.0

Density, Lb/Gal. 60°F 7.35

Pour Point, Max -46°F (-43°C)

Flash Point, Min. 442°F (228°C)

Viscosity

Brookfield, cP at -18°C 2700

at 40° C 55 cSt

at 100° C 9.3 cSt

Viscosity Index 152

T

ISO Visc

Speci

Pour P

Flash P

at

at

at

at

cp a

Visco


6-9

Table 6-16. UCon Hydrolube HP-5046

Type Synthetic Biodegradable

pecific Gravity 1.082

our Point, Max -58°F (-50°C)

pH 9.1

Viscosity

at 0° C (32° F) 340 cSt (1600SUS)

t 40° C (104° F) 46 cSt (215SUS)

t 65° C (150° F) 22 cSt (106SUS)

iscosity Index 170


3121138 – JLG Lift –

Table 6-15. Mobil EAL 224H Specs

Type Synthetic Biodegradable

ISO Viscosity Grade 32/46

Specific Gravity .922

Pour Point, Max -25°F (-32°C)

Flash Point, Min. 428°F (220°C)

Operating Temp. 0 to 180°F (-17 to 162°C)

Weight7.64 lb. per gal.(0.9 kg per liter)

Viscosity

at 40° C 37 cSt

at 100° C 8.4 cSt

Viscosity Index 213

NOTE: Must be stored above 32°F (14°C)

S

P

a

a

V


6-1 3121138

L NUMBER LOCATION

er plate is affixed to the left rear side of the frame.mber plate is damaged or missing, the machine

is stamped on the left side of the frame.

N

gure 6-1. Serial Number Locations

0 – JLG Lift –

6.3 SERIA

A serial numbIf the serial nuserial number

Table 6-17. Exxon Univis HVI 26 Specs

Specific Gravity 32.1

Pour Point -76°F (-60°C)

Flash Point 217°F (103°C)

Viscosity

at 40° C 25.8 cSt

at 100° C 9.3 cSt

Viscosity Index 376

OTE: Mobil/Exxon recommends that this oil be checkedon a yearly basis for viscosity.

Fi


6-11

onally


3121138 – JLG Lift –

This page left blank intenti


6-1 3121138

Deutz - Sheet 1 of 2

2 – JLG Lift –

Figure 6-2. Engine Operating Temperature Specifications -


6-13

ions - Deutz - Sheet 2 of 24150548-C


3121138 – JLG Lift –

Figure 6-3. Engine Operating Temperature Specificat


6-1 3121138

- Ford - Sheet 1 of 2

4 – JLG Lift –

Figure 6-4. Engine Operating Temperature Specifications


6-15

tions - Ford - Sheet 2 of 24150548-C


3121138 – JLG Lift –

Figure 6-5. Engine Operating Temperature Specifica


6-1 3121138

aterpillar - Sheet 1 of 2

6 – JLG Lift –

Figure 6-6. Engine Operating Temperature Specifications - C


6-17

ns - Caterpillar - Sheet 2 of 24150548-C


3121138 – JLG Lift –

Figure 6-7. Engine Operating Temperature Specificatio


6-1 3121138

s - GM - Sheet 1 of 2

8 – JLG Lift –

Figure 6-8. Engine Operating Temperature Specification


6-19

tions - GM - Sheet 2 of 24150548-C


3121138 – JLG Lift –

Figure 6-9. Engine Operating Temperature Specifica


6-2 3121138

rication

0 – JLG Lift –

Figure 6-10. Operator Maintenance and Lub


6-21

recommended as a good practice to replace all filtersthe same time.

ing Bearing - Internal Ball Bearing

e Point(s) - 1 Grease Fittingsacity - A/Re - MPGrval - Every 3 months or 150 hrs of operationments - Remote Access


3121138 – JLG Lift –

6.4 OPERATOR MAINTENANCE

NOTE: The following numbers correspond to those in Figure 6-10., Operator Maintenance and Lubrication Diagram.

LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATIONUNDER NORMAL CONDITIONS. FOR MACHINES USED IN MULTI-SHIFTOPERATIONS AND/OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON-DITIONS, LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD-INGLY.

NOTE: It isat

1. Sw

LubCapLubInteCom

Table 6-18. Lubrication Specifications

KEY SPECIFICATIONS

MPG Multipurpose Grease having a minimum dripping point of 350° F (177° C). Excellent water resistance and adhesive qualities, and being of extreme pressure type. (Timken OK 40 pounds minimum.)

EPGL Extreme Pressure Gear Lube (oil) meeting API service classifica-tion GL-5 or MIL-Spec MIL-L-2105

HO Hydraulic Oil. API service classification GL-3, e.g. Mobilfluid 424.

EO Engine (crankcase) Oil. Gas - API SF, SH, SG class, MIL-L-2104. Diesel - API CC/CD class, MIL-L-2104B/MIL-L-2104C.


6-2 3121138

Drive Hub

int(s) - Level/Fill Plug - 17 oz. (0.5 L) - 1/2 FullPGL Check level every 3 months or 150 hrs of opera-nge every 2 years or 1200 hours of operationts - Place Fill port at 12 o’clock position and

ort at 3 o’clock position. Pour lubricant into fill portst starts to flow out of check port.

2 – JLG Lift –

2. Wheel Bearings

Lube Point(s) - RepackCapacity - A/RLube - MPGInterval - Every 2 years or 1200 hours of operation

3. Wheel

Lube PoCapacityLube - EInterval -tion; chaCommenCheck puntil it ju


6-23

ydraulic Charge Filter

rval - Change after first 50 hrs. and every 6 months or hrs. thereafter or as indicated by Condition Indicator.


3121138 – JLG Lift –

4. Hydraulic Return Filter

Interval - Change after first 50 hrs. and every 6 months or300 hrs. thereafter or as indicated by Condition Indicator.

5. H

Inte300


6-2 3121138

m Filter

Change as necessary

4 – JLG Lift –

6. Hydraulic Tank

Lube Point(s) - Fill CapCapacity - 116 liters Tank 124 liters SystemLube - HOInterval - Check Level daily; Change every 2 years or 1200hours of operation.

7. Platfor

Interval -


6-25

il Change w/Filter - Ford

e Point(s) - Fill Cap/Spin-on Element (JLG P/N014501)acity - 4.5 Quartse - EOrval - 3 Months or 150 hours of operationments - Check level daily/Change in accordance with

ine manual.


3121138 – JLG Lift –

8. Suction Strainers

Lube Point(s) - 2Interval - Every 2 years or 1200 hours of operation, removeand clean at time of hydraulic oil change.

9. O

Lub 7CapLubInteComeng


6-2 3121138

ange w/Filter - Caterpillar

int(s) - Fill Cap/Spin-on Element (JLG P/N855) - 10.6 QuartsO 3 Months or 150 hours of operationnts - Check level daily/Change in accordance with

anual.

6 – JLG Lift –

10. Oil Change w/Filter - Deutz

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7016331)Capacity - 11 Quarts(10.5 L) Crankcase; Lube - EOInterval - Every Year or 1200 hours of operationComments - Check level daily/Change in accordance withengine manual.

11. Oil Ch

Lube Po 7026CapacityLube - EInterval -Commeengine m


6-27

el Filter - Ford

e Point(s) - Replaceable Elementrval - Every Year or 1200 hours of operation


3121138 – JLG Lift –

12. Oil Change w/Filter - GM

Lube Point(s) - Fill Cap/Spin-on Element (JLG P/N 7027965)Capacity - 4.5 qt. (4.25 L) w/filterLube - EOInterval - 3 Months or 150 hours of operationComments - Check level daily/Change in accordancewith engine manual.

13. Fu

LubInte


6-2 3121138

ilter - Caterpillar

int(s) - Replaceable Element Every Year or 600 hours of operation

ilter (Gasoline) - GM

oint(s) - Replaceable Elementl - Every 6 months or 300 hours of operation

er

int(s) - Replaceable Element- Every 6 months or 300 hours of operation or as by the condition indicator

8 – JLG Lift –

14. Fuel Filter - Deutz

Lube Point(s) - Replaceable ElementInterval - Every Year or 600 hours of operation

15. Fuel F

Lube PoInterval -

16. Fuel F

Lube PInterva

17. Air Filt

Lube PoInterval indicated


6-29

el Filter (Propane) - GM Engine

terval - 3 Months or 150 hours of operationomments - Replace filter. Refer to Section 6.7, Propaneel Filter Replacement


3121138 – JLG Lift –

18. Electronic Pressure Regulator (LP only)

Interval - 3 Months or 150 hours of operationComments - Drain oil build up. Refer to Section 6.6,Draining Oil Build Up From The Propane Regulator

19. Fu

InCFu


6-3 3121138

6.5

Tir

Tir

FanarJLm

ane foam filled tires, JLG Industries, Inc. recom-en any of the following are discovered, measures to remove the JLG product from service immedi-ngements must be made for replacement of thembly.

ooth, even cut through the cord plies whicheds 3 inches (7.5 cm) in total length

tears or rips (ragged edges) in the cord pliesh exceeds 1 inch (2.5 cm) in any direction

punctures which exceed 1 inch in diameter

damage to the bead area cords of the tire

aged but is within the above noted criteria, the tirected on a daily basis to insure the damage hasd beyond the allowable criteria.

0 – JLG Lift –

TIRES & WHEELS

e InflationThe air pressure for pneumatic tires must be equal to the airpressure that is stenciled on the side of the JLG product orrim decal for safe and proper operational characteristics.

e Damage

or pneumatic tires, JLG Industries, Inc. recommends that wheny cut, rip, or tear is discovered that exposes sidewall or treadea cords in the tire, measures must be taken to remove theG product from service immediately. Arrangements must beade for replacement of the tire or tire assembly.

For polyurethmends that whmust be takenately and arratire or tire asse

• a smexce

• any whic

• any

• any

If a tire is dammust be inspenot propagate


6-31

placement

installed on each product model have been designedy requirements which consist of track width, tire pres- load capacity. Size changes such as rim width, centeration, larger or smaller diameter, etc., without writtencommendations, may result in an unsafe condition stability.


3121138 – JLG Lift –

Tire Replacement

JLG recommends a replacement tire be the same size, ply andbrand as originally installed on the machine. Please refer to theJLG Parts Manual for the part number of the approved tires for aparticular machine model. If not using a JLG approved replace-ment tire, we recommend that replacement tires have the follow-ing characteristics:

• Equal or greater ply/load rating and size of original

• Tire tread contact width equal or greater than original

• Wheel diameter, width, and offset dimensions equal tothe original

• Approved for the application by the tire manufacturer(including inflation pressure and maximum tire load)

Unless specifically approved by JLG Industries Inc. do notreplace a foam filled or ballast filled tire assembly with a pneu-matic tire. When selecting and installing a replacement tire,ensure that all tires are inflated to the pressure recommendedby JLG. Due to size variations between tire brands, both tireson the same axle should be the same.

Wheel Re

The rims for stabilitsure, andpiece locfactory reregarding


6-3 3121138

WhIt m

WHETORBLETO WHE

Ticoyolutigremat

n nuts in the following sequence:

2 – JLG Lift –

eel Installationis extremely important to apply and maintain proper wheelounting torque.

EL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPERQUE TO PREVENT LOOSE WHEELS, BROKEN STUDS, AND POSSI- DANGEROUS SEPARATION OF WHEEL FROM THE AXLE. BE SUREUSE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THEEL.

ghten the lug nuts to the proper torque to prevent wheels fromming loose. Use a torque wrench to tighten the fasteners. Ifu do not have a torque wrench, tighten the fasteners with a

g wrench, then immediately have a service garage or dealerhten the lug nuts to the proper torque. Over-tightening willsult in breaking the studs or permanently deforming theounting stud holes in the wheels. The proper procedure fortaching wheels is as follows:

1. Start all nuts by hand to prevent cross threading. DO NOT use a lubricant on threads or nuts.

2. Tighte


6-33

AINING OIL BUILD UP FROM THE OPANE REGULATOR the course of normal operation oils may build inside

imary and secondary chambers of the propane pres-gulator. These oils may be a result of poor fuel quality,ination of the fuel supply chain, or regional variation

make up of the fuel. If the build up of the oil is signifi-is can effect the operation of the fuel control system.o Section 6.4, Operator Maintenance for maintenancels. More frequent draining may be required if the fuel has been contaminated.

ESULTS WARM THE ENGINE TO OPERATING TEMPERA-RE DRAINING. THIS WILL ALLOW THE OILS TO FLOWM THE REGULATOR.

ove the equipment to a well ventilated area. Ensureere are no external ignition sources.

art the engine and bring to operating temperature.

ith the engine running, close the manual tank valved run the engine out of fuel.


3121138 – JLG Lift –

3. The tightening of the nuts should be done in stages. Fol-lowing the recommended sequence, tighten nuts per wheel torque chart.

4. Wheel nuts should be torqued after first 50 hours of operation and after each wheel removal. Check torque every 3 months or 150 hours of operation.

6.6 DRPR

Duringthe prsure recontamin the cant thRefer tintervasupply

FOR BEST RTURE BEFOFREELY FRO

1. Mth

2. St

3. Wan

Table 6-19. Wheel Torque Chart

TORQUE SEQUENCE

1st Stage 2nd Stage 3rd Stage

70 ft. lbs.(95 Nm)

170 ft. lbs.(225 Nm)

300 ft. lbs.(405 Nm)


6-3 3121138

e the retainer clip for the LPG fuel temperaturer and remove the sensor from the regulator body.

small container ready to collect oil that will drainom the regulator at this point.

all of the oil has been drained, reinstall the LPGmperature sensor and reconnect the electricalctor.

the fuel tank manual valve.

e engine and verify all connections are secure.

e of any drained oil per local regulations in a safeoper fashion.

4 – JLG Lift –

4. Push in the Emergency Switch once the engine stops.

5. Disconnect the electrical connection to the LPG fueltemperature sensor in the auxiliary fuel port of the EPR.

6. Removsenso

NOTE: Have afreely fr

7. Once fuel teconne

8. Open

9. Start th

10. Disposand pr


6-35

lieve the propane fuel system pressure. Refer to Pro-ne Fuel System Pressure Relief.

isconnect the negative battery cable.

owly loosen the Filter housing retaining bolt andmove it.

ll the filter housing from the Electric lock off assembly.

cate Filter magnet and remove it.

move the filter from the housing.

emove and discard the housing seal.

emove and discard the retaining bolt seal.

emove and discard mounting plate to lock off O-ringal.


3121138 – JLG Lift –

6.7 PROPANE FUEL FILTER REPLACEMENT Removal1. Re

pa

2. D

3. Slre

4. Pu

5. Lo

6. Re

7. R

8. R

9. Rse

1. Electric Lock Off Solenoid2. Mounting Plate3. Housing Seal4. Filter Magnet5. Filter Housing6. Seal

7. Electrical Connector8. Fuel Outlet9. O-ring10. Filter11. Fuel Inlet12. Retaining Bolt

Figure 6-11. Filter Lock Assembly


6-3 3121138

Ins

BE SBEF

NE FUEL SYSTEM PRESSURE RELIEF

EL SYSTEM OPERATES AT PRESSURES UP TO 312 TO MINIMIZE THE RISK OF FIRE AND PERSONAL THE PROPANE FUEL SYSTEM PRESSURE (WHEREORE SERVICING THE PROPANE FUEL SYSTEM COM-

ane fuel system pressure:

the manual shut-off valve on the propane fuel

nd run the vehicle until the engine stalls.

e ignition switch OFF.

R PRESSURE WILL BE PRESENT IN THE FUEL SYS-E WORK AREA IS WELL VENTILATED BEFORE DIS- FUEL LINE.

6 – JLG Lift –

tallation

URE TO REINSTALL THE FILTER MAGNET INTO THE HOUSINGORE INSTALLING NEW SEAL

1. Install the mounting plate to lock off O-ring seal.

2. Install the retaining bolt seal.

3. Install the housing seal.

4. Drop the magnet into the bottom of the filter housing.

5. Install the filter into the housing.

6. Install the retaining bolt into the filter housing.

7. Install the filter up to the bottom of the electric lock off.

8. Tighten the filter retaining bolt to 106 in lbs (12 Nm).

9. Open manual shut-off valve. Start the vehicle and leakcheck the propane fuel system at each serviced fitting.Refer to Propane Fuel System Leak Test.

6.8 PROPA

THE PROPANE FUPSI (21.5 BAR).INJURY, RELIEVEAPPLICABLE) BEFPONENTS.

To relieve prop

1. Close tank.

2. Start a

3. Turn th

RESIDUAL VAPOTEM. ENSURE THCONNECTING ANY

TION 7 - INSPECTION AND REPAIR LOG

7-1

D REPAIR LOG

ir Log

nts

SEC

3121138 – JLG Lift –

SECTION 7. INSPECTION ANMachine Serial Number _______________________________________

Table 7-1. Inspection and Repa

Date Comme

SECTION 7 - INSPECTION AND REPAIR LOG

7-2 3121138

og

– JLG Lift –

Table 7-1. Inspection and Repair L

Date Comments

JLG Worldwide LocationsJLG Industries (UK)

Unit 12, Southside

Bredbury Park Industrial Estate

Bredbury

Stockport

SK6 2sP

England

Phone: (44) 870 200 7700

Fax: (44) 870 200 7711

JLG Industries (Europe)

Kilmartin Place,

Tannochside Park

Uddingston G71 5PH

Scotland

Phone: (44) 1 698 811005

Fax: (44) 1 698 811055

JLG Industries (Australia)

P.O. Box 5119

11 Bolwarra Road

Port Macquarie

N.S.W. 2444

Australia

Phone: (61) 2 65 811111

Fax: (61) 2 65 810122

JLG Industries (Pty) Ltd.

Unit 1, 24 Industrial Complex

Herman Street

Meadowdale

Germiston

South Africa

Phone: (27) 11 453 1334

Fax: (27) 11 453 1342

JLG Europe B.V.

Jupiterstraat 234

2132 HJ Foofddorp

The Netherlands

Phone: (31) 23 565 5665

Fax: (31) 23 557 2493

JLG Latino Americana Ltda.

Rua Eng. Carlos Stevenson,

80-Suite 71

13092-310 Campinas-SP

Brazil

Phone: (55) 19 3295 0407

Fax: (55) 19 3295 1025

JLG Polska

UI. Krolewska

00-060 Warsawa

Poland

Phone: (48) 91 4320 245

Fax: (48) 91 4358 200

JLG Industries (Sweden)

Enkopingsvagen 150

Box 704

SE - 175 27 Jarfalla

Sweden

Phone: (46) 8 506 59500

Fax: (46) 8 506 59534

JLG Deutschland GmbH

Max Planck Strasse 21

D-27721 Ritterhude/lhlpohl

Bei Bremen

Germany

Phone: (49) 421 693 500

Fax: (49) 421 693 5035

JLG Industries (Italia)

Via Po. 22

20010 Pregnana Milanese - MI

Italy

Phone: (39) 02 9359 5210

Fax: (39) 02 9359 5845

Plataformas Elevadoras

JLG Iberica, S.L.

Trapadella, 2

P.I. Castellbisbal Sur

08755Castellbisbal

Spain

Phone: (34) 93 77 24700

Fax: (34) 93 77 11762

www.jlg.com

Corporate Office

JLG Industries, Inc.

1 JLG Drive

McConnellsburg PA. 17233-9533

USA

Phone: (717) 485-5161

Fax: (717) 485-6417 3121138

Documents

Operation and Safety Manual - Inchirieri Nacele · FOREWORD 3121138 – JLG Lift – a FOREWORD This manual is a very important tool! Keep it with the machine at all times. The purpose