JLG 800A-AJ Operator Manual

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Operation and Safety Manual

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models 800A 800AJ

ANSI

3121209

June 21, 2012

FOREWORD

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

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes without prior notification. Contact JLG Industries, Inc. for updated information.

3121209 – JLG Lift – a

FOREWORD

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

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

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD DECAL WILL HAVE AN ORANGE BACKGROUND.

RESULT IN SERIOUS INJURY OR DEATH. THIS

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE A YELLOW BACKGROUND.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY.

b – JLG Lift – 3121209

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETYRELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS PRODUCT.

For:

• Accident Reporting

• Product Safety Publications

• Current Owner Updates

• Questions Regarding Product Safety

FOREWORD

• Standards and Regulations Compliance Information

• Questions Regarding Special Product Applications

• Questions Regarding Product Modifications

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

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROPERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department JLG Industries, Inc. 13224 Fountainhead Plaza Hagerstown, MD 21742 USA

or Your Local JLG Office (See addresses on inside of manual cover)

In USA:

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

Outside USA:

3121209 – JLG Lift – c

Phone: 240-420-2661 Fax: 301-745-3713 E-mail: ProductSafety@JLG.com

FOREWORD

REVISION LOG

Original Issue - May 4, 2005

Revised - September 1, 2005

Revised - March 7, 2006

Revised - July 17, 2006

Revised - March 12, 2007

Revised - March 30, 2007

Revised - January 6, 2009

Revised - November 6, 2009

Revised - December 12, 2009

Revised - July 26, 2010

Revised - June 21, 2012

d – JLG Lift – 3121209

TABLE OF CONTENTS

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

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge. . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

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

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8

2.3 FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . . . . 2-11

From the Ground Control Station with No Load in the

Platform:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

From the Platform Control Station: . . . . . . . . . . 2-15

2.4 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Indicator Panel . . . . . . . . . . . . . 3-6

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Platform Control Indicator Panel . . . . . . . . . . . . 3-16

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATING CHARACTERISTICS AND

LIMITATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

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

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

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-6

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TABLE OF CONTENTS

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

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-6

Traveling Forward and Reverse. . . . . . . . . . . . . 4-7

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-7

4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Loading From Ground Level . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . 4-8

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-10

Raising and Lowering the Tower Boom . . . . . 4-11

Raising and Lowering the Main Boom . . . . . . 4-11

Telescoping the Main Boom . . . . . . . . . . . . . . 4-11

Function of Tower Boom . . . . . . . . . . . . . . . . . 4-12

4.9 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-13

4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-13

4.11 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.13 TOW BAR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 4-17

4.14 WELDING LEAD (IF EQUIPPED). . . . . . . . . . . . . . 4-17

4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-19

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19

Changing From Gasoline to LP Gas . . . . . . . . 4-19

Changing From LP Gas to Gasoline . . . . . . . . 4-19

4.16 RE-SYNCHRONIZE UPRIGHT . . . . . . . . . . . . . . . .4-20

Releveling Valve . . . . . . . . . . . . . . . . . . . . . . . . 4-20

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-1

5.4 EMERGENCY CONTROLS AND THEIR

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

Power/Emergency Stop Switches . . . . . . . . . . . 5-2

Ground Control Station . . . . . . . . . . . . . . . . . . . 5-2

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.5 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-3

Use of Ground Controls . . . . . . . . . . . . . . . . . . . 5-3

Operator Unable to Control Machine . . . . . . . . . 5-4

Platform or Boom Caught Overhead . . . . . . . . . 5-4

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

ii – JLG Lift – 3121209

TABLE OF CONTENTS

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

Critical Stability Weights . . . . . . . . . . . . . . . . . . 6-10

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-29

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-30

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-30

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-31

6.5 DRAINING OIL BUILD UP FROM THE PROPANE REG-

ULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-32

6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-34

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-36

6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-36

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Machine Nomenclature - 800A (Sheet 1 of 2) . . . . .2-5

2-2. Machine Nomenclature - 800AJ (Sheet 2 of 2) . . . .2-6

2-3. Daily Walk-Around Inspection (Sheet 1 of 4). . . . . .2-7

2-4. Daily Walk-Around Inspection (Sheet 2 of 4). . . . . .2-8

2-5. Daily Walk-Around Inspection (Sheet 3 of 4). . . . . .2-9

2-6. Daily Walk-Around Inspection (Sheet 4 of 4). . . . .2-10

2-7. Tower Boom Vertical Limit Switch . . . . . . . . . . . . 2-11

2-8. Tower Boom Horizontal Limit Switch . . . . . . . . . . 2-12

2-9. Boom Upright Positioning - Correct . . . . . . . . . . . 2-13

2-10. Boom Upright Positioning - Incorrect . . . . . . . . . . 2-14

3-1. Ground Control Station. . . . . . . . . . . . . . . . . . . . . . 3-2

3-2. Ground Control Indicator Panel . . . . . . . . . . . . . . . 3-6

3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-10

3-4. Platform Control Console - w/Drive Orientation . . 3-11

3-5. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-6. Platform Light Panel w/Drive Orientation . . . . . . . 3-19

4-1. Position of Least Forward Stability . . . . . . . . . . . . . 4-3

4-2. Positions of Least Backward Stability

(Sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3. Positions of Least Backward Stability

(Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-4. Grade and Sideslopes . . . . . . . . . . . . . . . . . . . . . . 4-9

4-5. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . 4-14

4-6. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-7. Tow Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-8. Releveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20

4-9. Decal Installation - Sheet 1 of 5 . . . . . . . . . . . . . . 4-21

4-10. Decal Installation - Sheet 2 of 5 . . . . . . . . . . . . . . 4-22

4-11. Decal Installation - Sheet 3 of 5 . . . . . . . . . . . . . . 4-23

4-12. Decal Installation - Sheet 4 of 5 . . . . . . . . . . . . . . 4-24

4-13. Decal Installation - Sheet 5 of 5 . . . . . . . . . . . . . . 4-25

6-1. Engine Operating Temperature Specifications - Deutz

3121209 – JLG Lift – iii

TABLE OF CONTENTS

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

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

6-2. Engine Operating Temperature Specifications - Deutz

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-3. Engine Operating Temperature Specifications - Ford -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-4. Engine Operating Temperature Specifications - Ford -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-5. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-16

6-6. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-17

6-7. Engine Operating Temperature Specifications - GM -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-8. Engine Operating Temperature Specifications - GM -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-9. Operator Maintenance and Lubrication Diagram . 6-20

6-10. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-35

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

1-2 Beaufort Scale (For Reference Only) . . . . . . . . . . 1-10

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3

4-1 Decal Legend - 800A . . . . . . . . . . . . . . . . . . . . . . . 4-26

4-2 Decal Legend - 800AJ . . . . . . . . . . . . . . . . . . . . . .4-30

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . .6-1

6-2 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-3

6-5 Deutz F4M2011F Specifications . . . . . . . . . . . . . . 6-4

6-6 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . 6-4

6-7 Caterpillar 3044C/3.4 . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 Isuzu 4JB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-10 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-12 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-7

6-13 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . 6-8

6-14 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-8

6-15 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . 6-9

6-16 Quintolubric 888-46 . . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-17 Critical Stability Weights - 800A . . . . . . . . . . . . . . 6-10

6-18 Critical Stability Weights - 800AJ . . . . . . . . . . . . . 6-11

6-19 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-21

6-20 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-32

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

iv – JLG Lift – 3121209

SECTION 1 - SAFETY PRECAUTIONS

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

This section outlines the necessary precautions for proper and safe machine operation and maintenance. For proper machine use, it is mandatory that a daily routine is established based on the content of this manual. A maintenance program, using the information provided in this manual and the Service and Maintenance Manual, must also be established by a qualified person and followed to ensure the machine is safe to operate.

The owner/user/operator/lessor/lessee of the machine should not operate the machine until this manual has been read, training is accomplished, and operation of the machine has been completed under the supervision of an experienced and qualified operator.

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

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

1.2 PRE-OPERATION

Operator Training and Knowledge

• Read and understand this manual before operating the machine.

• Do not operate this machine until complete training is performed by authorized persons.

• Only authorized and qualified personnel can operate the machine.

3121209 – JLG Lift – 1-1

SECTION 1 - SAFETY PRECAUTIONS

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

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

• All operating personnel must be familiar with the emergency controls and emergency operation of the machine as specified in this manual.

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

Workplace Inspection

• The operator is to take safety measures to avoid all hazards in the work area prior to machine operation.

• Do not operate or raise the platform while on trucks, trailers, railway cars, floating vessels, scaffolds or other equipment unless approved in writing by JLG.

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

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

Machine Inspection

• Before machine operation, perform inspections and functional checks. Refer to Section 2 of this manual for detailed instructions.

• Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual.

• Be sure the footswitch and all other safety devices are operating properly. Modification of these devices is a safety violation.

MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER

• Do not operate any machine on which safety or instruction placards or decals are missing or illegible.

• Avoid any buildup of debris on the platform floor. Keep mud, oil, grease, and other slippery substances from footwear and platform floor.

1-2 – JLG Lift – 3121209

SECTION 1 - SAFETY PRECAUTIONS

1.3 OPERATION

General

• Do not use the machine for any purpose other than positioning personnel, their tools, and equipment.

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

• Never slam a control switch or lever through neutral to an opposite direction. Always return switch to neutral and stop before moving the switch to the next function. Operate controls with slow and even pressure.

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

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

• Do not carry materials directly on platform railing. Contact JLG for approved material handling accessories.

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

• Always ensure that power tools are properly stowed and never left hanging by their cord from the platform work area.

• Supplies or tools which extend outside the platform are prohibited unless approved by JLG.

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

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

• Do not place boom or platform against any structure to steady the platform or to support the structure.

• Stow boom and shut off all power before leaving machine.

Trip and Fall Hazards

During operation, occupants in the platform must wear a full body harness with a lanyard attached to an authorized lanyard anchorage point. Attach only one (1) lanyard per lanyard anchorage point.

3121209 – JLG Lift – 1-3

SECTION 1 - SAFETY PRECAUTIONS

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

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

• Never use the boom assembly to enter or leave the platform.

• Use extreme caution when entering or leaving platform. Be sure that the boom is fully lowered. It may be necessary to telescope out to position the platform closer to the ground for entry/exit. Face the machine, maintain “three point contact” with the machine, using two hands and one foot or two feet and one hand during entry and exit.

Electrocution Hazards

• This machine is not insulated and does not provide protection from contact or proximity to electrical current.

1-4 – JLG Lift – 3121209

SECTION 1 - SAFETY PRECAUTIONS

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

• Maintain distance from electrical lines, apparatus, or any energized (exposed or insulated) parts according to the Minimum Approach Distance (MAD) as shown in Table 1-

• Allow for machine movement and electrical line swaying.

Voltage Range

(Phase to Phase)

0 to 50 KV 10 (3)

Over 50KV to 200 KV 15 (5)

Over 200 KV to 350 KV 20 (6)

Over 350 KV to 500 KV 25 (8)

Over 500 KV to 750 KV 35 (11)

Over 750 KV to 1000 KV 45 (14)

NOTE: This requirement shall apply except where

employer, local or governmental regulations are more stringent.

• Maintain a clearance of at least 10 ft. (3m) between any part of the machine and its occupants, their tools, and their equipment from any electrical line or apparatus carrying up to 50,000 volts. One foot additional clearance is required for every additional 30,000 volts or less.

MINIMUM APPROACH DISTANCE

in Feet (Meters)

3121209 – JLG Lift – 1-5

SECTION 1 - SAFETY PRECAUTIONS

• The minimum approach distance may be reduced if insulating barriers are installed to prevent contact, and the barriers are rated for the voltage of the line being guarded. These barriers shall not be part of (or attached to) the machine. The minimum approach distance shall be reduced to a distance within the designed working dimensions of the insulating barrier. This determination shall be made by a qualified person in accordance with the employer, local, or governmental requirements for work practices near energized equipment

DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE (MAD). ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE.

Tipping Hazards

• The user should be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

1-6 – JLG Lift – 3121209

SECTION 1 - SAFETY PRECAUTIONS

• Do not elevate platform or drive with platform elevated while on a sloping, uneven, or soft surface.

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

• Never exceed the maximum platform capacity. Distribute loads evenly on platform floor.

• Do not raise the platform or drive from an elevated position unless the machine is on firm, level and smooth surfaces.

• Keep the chassis of the machine at least 2 ft. (0.6m) from holes, bumps, drop-offs, obstructions, debris, concealed holes, 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 tieoff machine to any adjacent structure.

• Do not operate the machine when wind conditions exceed 28 mph (12.5 m/s). Refer to Table 1-2, Beaufort Scale (For Reference Only).

• Do not increase the surface area of the platform or the load. Increase of the area exposed to the wind will decrease stability.

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

• If boom assembly or platform is in a position that one or more wheels are off the ground, all persons must be removed before attempting to stabilize the machine. Use cranes, forklift trucks, or other appropriate equipment to stabilize machine.

Crushing and Collision Hazards

• Approved head gear must be worn by all operating and ground personnel.

• Check work area for clearances overhead, on sides, and bottom of platform when lifting or lowering platform, and driving.

• During operation, keep all body parts inside platform railing.

3121209 – JLG Lift – 1-7

SECTION 1 - SAFETY PRECAUTIONS

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

• Always post a lookout when driving in areas where vision is obstructed.

• Keep non-operating personnel at least 6 ft. (1.8m) away from machine during all driving and swing operations.

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

• Be aware of stopping distances in all drive speeds. When driving in high speed, switch to low speed before stopping. Travel grades in low speed only.

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

• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.

• Be sure that operators of other overhead and floor level machines are aware of the aerial work platform’s presence. Disconnect power to overhead cranes.

• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.

1.4 TOWING, LIFTING, AND HAULING

• Never allow personnel in platform while towing, lifting, or hauling.

• This machine should not be towed, except in the event of emergency, malfunction, power failure, or loading/unloading. Refer to the Emergency Procedures section of this manual for emergency towing procedures.

• Ensure boom is in the stowed position and the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.

• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

• Refer to the Machine Operation section of this manual for lifting information.

1-8 – JLG Lift – 3121209

SECTION 1 - SAFETY PRECAUTIONS

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 from direct exposure to weld and metal cutting spatter.

• Do not refuel the machine with the engine running.

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

• Charge batteries only in a well ventilated area.

3121209 – JLG Lift – 1-9

SECTION 1 - SAFETY PRECAUTIONS

DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH (12.5 M/S).

Table 1-2. Beaufort Scale (For Reference Only)

Beaufort

Number

0 0 0-0.2 Calm Calm. Smoke rises vertically.

1 1-3 0.3-1.5 Light air Wind motion visible in smoke.

2 4-7 1.6-3.3 Light breeze Wind felt on exposed skin. Leaves r ustle.

3 8-12 3.4-5.4 Gentle breeze Leaves and smaller twigs in constant motion.

4 13-18 5.5-7.9 Moderate breeze Dust and loose paper raised. Small branches begin to move.

5 19-24 8.0-10.7 Fresh breeze Smaller trees sway.

6 25-31 10.8-13.8 Strong breeze Large branches in motion. Whistling heard in overhead wires.

7 32-38 13.9-17.1 Near Gale/Moderate Gale Whole trees in motion. Effor t needed to walk against the wind.

8 39-46 17.2-20.7 Fresh Gale Twigs broken from trees. Cars veer on road.

9 47-54 20.8-24.4 Strong Gale Light structure damage.

Wind Speed

mph m/s

Description Land Conditions

Umbrella use becomes difficult.

1-10 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

The aerial platform is a personnel handling device; so it is necessary that it be operated and maintained only by trained personnel.

Persons under the influence of drugs or alcohol or who are subject to seizures, dizziness or loss of physical control must not operate this machine.

Operator Training

Operator 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 malfunction.

6. The safest means to operate the machine where overhead obstructions, other moving equipment, and obstacles, depressions, holes, drop-offs.

7. Means to avoid the hazards of unprotected electrical conductors.

8. Specific job requirements or machine application.

Training Supervision

Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine.

Operator Responsibility

The operator must be instructed that he/she has the responsibility and authority to shut down the machine in case of a malfunction or other unsafe condition of either the machine or the job site.

3121209 – JLG Lift – 2-1

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

The following table covers the periodic machine inspections and maintenance required by JLG Industries, Inc. Consult local regulations for further requirements for aerial work platforms. The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment, if the machine is used with increased frequency, or if the machine is used in a severe manner.

JLG INDUSTRIES, INC. RECOGNIZES A FACTORY-TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL.

2-2 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Table 2-1. Inspection and Maintenance Table

Type Frequency

Pre-Start Inspection Before using each day; or

whenever there’s an Operator change.

Pre-Delivery Inspection (See Note)

Frequent Inspection (See Note)

Annual Machine Inspection (See Note)

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

NOTE: Inspection forms are available from JLG. Use the Service and Maintenance Manual to perform inspections.

Before each sale, lease, or rental delivery. Owner, Dealer, or User Qualified JLG

In service for 3 months or 150 hours, whichever comes first; o r Out of service for a period o f m or e t h a n 3 m o n t h s ; o r Purchased used.

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

tenance Manual.

Primary

Responsibility

User or Operator User or Operator Operator and Safety Manual

Owner, Dealer, or User Qualified JLG

Owner, Dealer, or User Factory Trained

Owner, Dealer, or User Qualified JLG

Service

Qualification

Mechanic

Service Technician (Recommended)

Mechanic

Service and Maintenance Manual and applicable JLG inspection form

Service and Maintenance Manual

Reference

3121209 – JLG Lift – 2-3

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Parent Metal Crack Weld Crack

Pre-Start Inspection

The Pre-Start Inspection should include each of the following:

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 discrepancies.

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

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

5. “Walk-Around” Inspection – Refer to Figure 2-3. and Figure 2-4.

6. Battery – Charge as required.

7. Fuel (Combustion Engine Powered Machines) – Add the

proper fuel as necessary.

8. Engine Oil Supply - Ensure the engine oil level is at the Full mark on the dipstick and the filler cap is secure.

9. Hydraulic Oil – Check the hydraulic oil level. Ensure hydraulic oil is added as required.

10. Function Check - Once the "Walk-Around" Inspection is complete, perform a functional check of all systems in accordance with Section 2.3 in an area free of overhead and ground level obstructions. Refer to Sections 3 and 4 for more specific machine operating instructions.

IF THE MACHINE DOES NOT OPERATE PROPERLY, TURN OFF THE MACHINE IMMEDIATELY! REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION.

2-4 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-1. Machine Nomenclature - 800A (Sheet 1 of 2)

3121209 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-2. Machine Nomenclature - 800AJ (Sheet 2 of 2)

ARTICULATING JIB

ARTICULATING JIB LIFT CYLINDER

ALL OTHER COMPONENTS ARE SIMILAR TO MODEL 800A ON PRECEDING PAGE

2-6 – JLG Lift – 3121209

3,4,5

9,10

14,15,16,17,18,19,20

22,23,24

11 10

24,30,31,32,33 34,35

37,38

9,10

Figure 2-3. Daily Walk-Around Inspection (Sheet 1 of 4)

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

3121209 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

GENERAL

Begin the "Walk-Around Inspection" at Item 1, as noted on the diagram. Continue to the right (counterclockwise viewed from top) checking each item in sequence for the conditions listed in the following checklist.

TO AVOID POSSIBLE INJURY, BE SURE MACHINE POWER IS OFF.

DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED.

INSPECTION NOTE: On all components, make sure there are no loose or missing parts, that they are securely fastened, and no visible damage, leaks or excessive wear exists in addition to any other criteria mentioned.

1. Platform Assembly - Platform Assembly and Gate -

Footswitch works properly, not modified, disabled or blocked. Latch, stop, and hinges in working condition.

2. Platform Control Console -

Switches and levers return to neutral, decals/placards secure and legible, control markings legible.

3. Rotator -

See Inspection Note.

4. Rotator Motion Control Valve -

See Inspection Note.

5. Articulating Jib Boom -

See Inspection Note.

6. Dual Capacity Limit Switch (ANSI, Australia, if equipped); Transport Position Limit Switch (CE) -

Properly secured, no damage to the switch, arm free to move, and free from dirt and grease.

7. Power Track -

See Inspection Note.

8. Steer Cylinder Assembly -

See Inspection Note.

Wheel Steer if equipped)

9. Spindle -

See Inspection Note.

(4 Wheel Steer if

equipped)

10. Drive Motor and Brake -

See Inspection Note.

11. Drive Hub -

See Inspection Note.

12. Wheel/Tire Assembly -

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

Figure 2-4. Daily Walk-Around Inspection (Sheet 2 of 4)

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SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

13. Control Valve (Tank Compartment) -

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

14. Turntable Bearing and Pinion - No loose or missing hardware; no visible damage, evidence of proper lubrication.

15. Hydraulic Oil Medium Pressure Filter Housing -

See

Inspection Note.

16. Hydraulic Oil Return Filter Housing -

See Inspection

Note.

17. Manual Descent -

See Inspection Note.

(if equipped)

18. LP Gas Tank - Brackets, hose and fittings secure; no visible damage, no missing parts. (If Equipped)

19. Hydraulic Oil Supply - Recommended oil level sight gauge. (Check level with cold oil, systems shut down, machine with booms retracted and lowered) Cap in place and secure.

20. Hydraulic Oil Breather - Element in place, not clogged, no sign of overflow.

21. Ground Controls - Switches operable, no visible damage, decals secure and legible.

22. Fuel Supply - Fuel filler cap secure. Tank - no visible damage; no evidence of leaks.

23. Swing Drive Motor and Brake -

See Inspection Note.

24. Door and Latches - Hood door and latches in working condition, properly secured, no loose or missing parts.

25. Oscillating Cam Valve - No visible damage, no evidence of leakage, no unsupported hoses. (If Equipped)

26. Tie Rod and Steering Linkage -

See Inspection Note.

27. Oscillating Axle Cylinder -

See Inspection Note.

(If

Equipped)

28. Dual Capacity and Horizontal Cutout Limit Switches if equipped - Properly secured, no damage to the

switches, arm free to move, and free from dirt and grease.

29. Oscillating Axle -

See Inspection Note.

(If Equipped)

Figure 2-5. Daily Walk-Around Inspection (Sheet 3 of 4)

3121209 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

30. Engine Air Filter - No loose or missing parts; no visible damage; element clean.

31. Battery - Proper electrolyte levels; cables tight, no visible damage or corrosion.

32. Engine Oil Supply - Full mark on dipstick; filler cap secure.

33. Muffler and Exhaust System -

See Inspection Note.

34. Hydraulic Pumps -

See Inspection Note.

35. Engine Tray Pivot -

See Inspection Note.

36. Hydraulic Swivel -

See Inspection Note.

37. LP Gas Tank - Brackets, hose and fittings secure; no visible damage, no missing parts. (If Equipped)

38. Flow Valves -

See Inspection Note.

39. Tower Boom - No visible damage; wear pads secure. All cylinders - rod end pins and barrel-end pins properly secured.

40. Frame -

See Inspection Note.

41. Main Boom Sections - No visible damage; wear pads secure. All cylinders - rod end shafts and barrel-end shafts properly secured.

42. Platform Pivot Pin -

See Inspection Note.

43. Upright - In vertical position, relative to the chassis. Refer to Figure 2-9. and Figure 2-10. If out of alignment, do not use machine until the upright has been synchronized in accordance with Section 4.16.

Figure 2-6. Daily Walk-Around Inspection (Sheet 4 of 4)

2-10 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-7. Tower Boom Vertical Limit Switch

2.3 FUNCTION CHECK

Perform a function check of all systems, once the walkaround inspection is complete, in an area free of overhead and ground level obstructions.

A MACHINE MALFUNCTION COULD CAUSE DEATH OR SERIOUS INJURY. IF ANY MALFUNCTIONS OCCUR DURING THE FUNCTION TEST, DISCONTINUE OPERATION AND CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE.

From the Ground Control Station with No Load in the Platform:

1. Check that all guards protecting the function switches or locks are in place. Ensure that all function controls and switches return to the "off" or neutral position when released.

DO NOT OPERATE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION

a. Place machine on level ground with the tower boom

assembly in the stowed position. Identify the tower boom vertical limit switch adjacent to the tower lift cylinder at the bottom end (rear) of the tower base boom. Open the left side hood and perform a visual check that the plunger on the tower boom vertical limit switch is fully extended. The plunger is shown fully extended in Figure 2-7.

2. Test the tower boom assembly sequencing as follows:

3121209 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Figure 2-8. Tower Boom Horizontal Limit Switch

d. Raise the tower base boom to full height. Extend

the tower fly boom a few feet. Check that the

DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED

b. Attempt to extend the tower fly boom. The tower fly

boom should not extend and the red boom malfunction light in the ground control panel should illuminate when pressing the tower telescope switch.

DISCONTINUE OPERATION IF THE TOWER FLY BOOM EXTENDS OR THE BOOM MALFUNCTION LIGHT DOES NOT ILLUMINATE.

c. Raise the tower base boom to approximately 40

degrees, then lower the tower boom back to the below horizontal position. While raising and lowering the tower boom assembly, observe the position of the upright. Ensure that the upright remains vertical relative to the chassis. Refer to Figure 2-9. and Figure 2-10.

DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY.

DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED

plunger on the tower boom horizontal limit switch at the end of the tower base boom section is fully extended. The plunger is shown fully extended in Figure 2-8.

2-12 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

90°

Figure 2-9. Boom Upright Positioning - Correct

UPRIGHT MUST BE 90° (VERTICAL) RELATIVE

TO THE CHASSIS.

CORRECT

3121209 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

90°

Figure 2-10. Boom Upright Positioning - Incorrect

TO AVOID TIPPING IF THIS OCCURS:

-LOWER PLATFORM TO GROUND USING MAIN

BOOM LIFT AND TELESCOPE FUNCTIONS. HAVE

CONDITION CORRECTED BY A TRAINED JLG

SERVICE TECHNICIAN BEFORE CONTINUING

USE OF MACHINE.

INCORRECT

2-14 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

e. Attempt to lower the tower base boom while the

tower fly boom is extended. The tower base boom should not lower and the red boom malfunction light should illuminate when pressing the tower down switch.

DISCONTINUE OPERATION IF THE TOWER BASE BOOM LOWERS OR THE BOOM MALFUNCTION LIGHT DOES NOT ILLUMINATE.

f. Check that all machine functions are disabled when

the Emergency Stop Button is pushed in.

g. Check for proper operation of the auxiliary power

and manual descent system (if equipped). Operate each function control to ensure proper operation.

From the Platform Control Station:

1. Check that the control console is secure and all guards protecting the function switches or locks are in place. Ensure that all function controls and switches return to the "off" or neutral position when released.

DO NOT OPERATE MACHINE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE "OFF" OR NEUTRAL POSITION

2. Check the footswitch adjustment and operation as follows:

a. With engine power shut down, attempt to start

engine. Engine should not attempt to start when footswitch is activated.

b. Start engine. Activate hydraulic system by depress-

ing footswitch. Activate a boom function. Continue to activate the function and remove foot from footswitch. The motion should stop.

DISCONTINUE OPERATION IF THE FOOTSWITCH DOES NOT OPERATE PROPERLY.

c. Check adjustment of footswitch. Footswitch must

be adjusted so that functions will operate when pedal is approximately at its center of travel. If the footswitch operates within last 1/4" of travel, top or bottom, it should be adjusted.

3121209 – JLG Lift – 2-15

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTE: Footswitch has a 7 second delay timer. If a function is not

activated within 7 seconds after depressing the footswitch, reset the footswitch.

3. Ensure that all machine functions are disabled when the Emergency Stop Button is activated.

4. Check auxiliary power for proper operation. Operate each function control switch to ensure proper operation of the auxiliary power system.

NOTE: Step 5 is only applicable for 800A ANSI market machines.

5. If equipped with a dual capacity system, check the limit switch as follows:

a. On a level surface with less than 500 lb (227 kg) in

the platform, raise tower base boom to maximum angle keeping main boom horizontal.

b. Extend the main fly boom until the capacity indica-

tor lights change from 1000 lb. (454 kg) to 500 lb. (227 kg).

c. With main boom in this position, raise the main

base boom until the capacity indicator lights change back to the 1000 lb. (454 kg) indicator.

DISCONTINUE OPERATION IF THE CAPACITY INDICATOR SYSTEM DOES NOT OPERATE PROPERLY.

6. Drive forward and reverse; check for proper operation.

7. Steer left and right; check for proper operation.

8. Check the high-engine cutout for the tower boom

assembly as follows:

a. Place machine on level surface with booms

retracted and lowered.

b. From the platform control, position DRIVE SPEED/

TORQUE SELECT switch to FAST (Forward Position).

c. Using extreme caution, partially position the DRIVE

control to FORWARD just enough to obtain high engine but not enough to cause the machine to move.

d. Raise the TOWER BASE BOOM until the engine

speed shifts from high speed to mid speed. The bottom of the upright should NOT be above the hood level of the machine.

2-16 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

9. Check the high-engine cutout for the main boom assembly as follows:

a. Place machine on level surface with booms

retracted and lowered.

b. From the platform control, position DRIVE SPEED/

TORQUE SELECT switch to FAST (Forward Position).

c. Raise the main boom above horizontal.

d. Using extreme caution, partially position the DRIVE

control to FORWARD just enough to cause the machine to move. The drive speed should be in slow or creep mode.

10. Swing turntable to LEFT and RIGHT a minimum of 45 degrees. Check for smooth motion.

NOTE: Ensure the turntable lock is disengaged. To disengage

lock, pull snap pin from lock pin, lift lock pin up to unlock turntable. Return snap pin to lock pin to hold lock pin in the disengaged position. Reverse procedure to engage turntable lock.

11. Check the Tilt Alarm and Warning System as follows:

IF THE TILT ALARM AND WARNING SYSTEM DOES NOT OPERATE PROPERLY, DISCONTINUE OPERATION. CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE.

For Machines prior to serial number 0300062045 Have an assistant manually activate the tilt indicator light by compressing any one of the three tilt indicator mounting springs. The tilt indicator light on the platform control console should illuminate.

For Machines from serial number 0300062045 to present - With the platform in the transport position

(tower base boom lowered, main fly boom retracted, and main base boom below horizontal) drive up a suitable ramp of at least 5° slope. The tilt indicator light on the platform control console should illuminate.

12. Check that the platform automatically levels properly during raising and lowering of the boom.

3121209 – JLG Lift – 2-17

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

13. Check that the platform level override operates properly.

14. Check platform rotator for smooth operation and assure

platform will rotate 90 degrees in both directions from centerline of boom.

15. If equipped with 4-wheel steer, check rear steer left and right for proper operation.

16. If equipped, raise and lower the articulating jib boom. Check for smooth operation.

17. If equipped with Auxiliary Power, operate each function control switch to assure that they function in both directions using auxiliary power instead of engine power.

18. Ground Controls - Place GROUND/PLATFORM SELECT switch to GROUND. Start engine. Platform controls should not operate.

2.4 OSCILLATING AXLE LOCKOUT TEST

EQUIPPED

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

NOTE: Ensure boom is fully retracted, lowered, and centered

between drive wheels prior to beginning lockout cylinder test.

1. Place a 6 inch (15.2 cm) high block with ascension ramp in front of left front wheel.

2. From platform control station, start engine.

3. Position DRIVE SPEED/TORQUE SELECT SWITCH to

SLOW.

4. Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block.

5. Carefully activate SWING control lever and position boom over RIGHT side of machine.

)

(IF

2-18 – JLG Lift – 3121209

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

6. With boom over right side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.

7. Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground.

8. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate DRIVE to release cylinders.

9. Place the 6 inch (15.2 cm) high block with ascension ramp in front of right front wheel.

10. Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block.

11. Carefully activate SWING control lever and position boom over left side of machine.

12. With boom over left side of machine, place DRIVE control lever to REVERSE and drive machine off of block and ramp.

13. Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground.

14. Carefully activate SWING control lever and return boom to stowed position (centered between drive wheels). When boom reaches center, stowed position, lockout cylinders should release and allow wheel to rest on ground, it may be necessary to activate DRIVE to release cylinders.

15. If lockout cylinders do not function properly, have qualified personnel correct the malfunction prior to any further operation.

3121209 – JLG Lift – 2-19

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-20 – JLG Lift – 3121209

SECTION 3 - MACHINE CONTROLS AND INDICATORS

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION. THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES.

This section provides the necessary information needed to understand control functions.

3.2 CONTROLS AND INDICATORS

NOTE: This machine is equipped with control panels that use

symbols to indicate control functions. Refer to the decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions.

Ground Control Station

NOTE: Main Lift, Swing, Platform Level, Main Telescope, Platform

Rotator and Auxiliary Power, Towe r Tel e sc o pe , Tow e r L i ft , and jib control switches are spring-loaded and will automatically return to neutral (off) when released.

NOTE: If equipped, the Function Enable switch must

be held down in order to operate Main Boom Tel e sc o pe , Tow e r L i ft , Sw i ng , Ma i n L i ft , J i b Lift, Platform Level Override, and Platform Rotate functions.

1. Platform Rotate

The platform ROTATE control switch provides rotation of the platform when positioned to LEFT or RIGHT.

3121209 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706912 A

Figure 3-1. Ground Control Station

1. Platform Rotate

2. Platform Leveling Override

3. Jib

4. Power/Emergency Stop

5. Engine Star t/Auxiliar y Power or E n gi n e S t ar t / A ux i li a r y P o we r /F u nc t io n En a bl e 6 . To w er Te le sc o pe

7. Hourmeter

8. Platform/Ground Select Switch

9. Swing

10. Tower Lift

11. Main Boom Lift

12. Main Boom Telescope

3-2 – JLG Lift – 3121209

ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM. INCORRECT USE COULD CAUSE THE LOAD/OCCUPANT TO SHIFT OR FALL. FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY.

2. Platform Leveling Override

A three position switch allows the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situations such as ascending/ descending a grade.

3. Jib (If Equipped)

The jib control switch provides raising and lowering of the jib when positioned to UP or DOWN.

SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTE: When Power/Emergency Stop switch is in the “ON” posi-

tion and engine is not running, an alarm will sound, indicating Ignition is “ON”.

WHEN THE MACHINE IS SHUT DOWN THE MASTER/EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE “OFF” POSITION TO PREVENT DRAINING THE BATTERY.

4. Power/Emergency Stop Switch

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

3121209 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Engine Start/Auxiliary Power Switch or Engine 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 be held “DOWN” for duration of auxiliary pump use. Aux power can only be used if the engine is not running.

If equipped, the enable switch must be held "DOWN" to enable all boom controls when the 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 rate

because of the lesser flow of hydraulic fluid delivered.

WHEN USING AUXILIARY POWER, DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME. (SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP.)

6. Tow er Te l e s c op e

The TOWER TELESCOPE control switch provides extending and retracting of the tower boom when positioned to IN or OUT. This function works only when the tower boom is fully elevated (lift up).

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE.

7. Hourmeter

An hour meter, installed in the bottom portion of the Ground Control box, registers the amount of time the machine has been in use, with engine running. By connecting into the oil pressure circuit of the engine, only engine run hours are recorded. The hour meter registers up to 9,999.9 hours and cannot be reset.

3-4 – JLG Lift – 3121209

8. Platform/Ground Select Switch

SECTION 3 - MACHINE CONTROLS AND INDICATORS

A three position, key operated switch supplies power to the platform control console when positioned to PLATFORM. With the switch key held in the GROUND position, power is shut off to platform and only ground controls are operable.

NOTE: With the Platform/Ground Select Switch in the center posi-

tion, power is shut off to controls at both operating stations.

9. Swing Control

The SWING control switch provides 360 degrees continuous turntable rotation when positioned to RIGHT or LEFT.

WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED.

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE.

10. Tow er L i f t

The TOWER LIFT control switch provides raising and lowering of the tower boom when positioned to UP or DOWN. This function works only when the tower boom is fully retracted (telescope in).

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

Figure 3-2. Ground Control Indicator Panel

1. Battery Charging

2. Low Engine Oil Pressure

3. High Engine Water Temp.

4. High Engine Oil Temp.

5. Engine Malfunction Indicator

6. Low Fuel

7. Glow Plug

8. Boom Malfunction

9. Platform Overload

10. Hyd. Filter Bypass

11. Transmission Filter By-Pass

12. Engine Air Filter By-Pass

11. Main Lift Control

The MAIN LIFT control switch provides raising and lowering of the main boom when positioned to UP or DOWN.

12. Main Telescope Control

The MAIN TELESCOPE control switch provides extension and retraction of the boom, when positioned to IN or OUT.

Ground Control Indicator Panel

3-6 – JLG Lift – 3121209

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Battery Discharging Indicator

When illuminated indicates a problem in the battery or charging circuit, and service is required.

2. Engine Oil Pressure Indicator

When illuminated indicates that engine oil pressure is below normal and service is required.

3. Engine Coolant Temperature Indicator (Ford)

When illuminated indicates that engine coolant temperature is abnormally high and service is required.

4. Engine Oil Temperature Indicator (Deutz)

When illuminated indicates that the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. Engine Malfunction Indicator Light (Ford Engines prior to S/N 62045)

Indicates that the Engine Control Module has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

6. Low Fuel Level Indicator (N/A for liquid propane)

When illuminated indicates that the fuel level is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

7. Glow Plug Indicator (If Equipped)

When illuminated the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Boom Malfunction Indicator

If the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. The function is not permitted at the current boom configuration.

If the Boom Malfunction Indicator is flashing or on steady without a boom function attempt, the upright is out of alignment or the monitoring system is in need of calibration.

DISCONTINUE OPERATION IF THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY.

IF THE UPRIGHT IS OUT OF ALIGNMENT WITH THE PLATFORM RAISED, LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND. THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION. REPORT THE PROBLEM TO THE PROPER SERVICE PERSONNEL. DO NOT OPERATE THE MACHINE UNTIL THE MALFUNCTION IS CORRECTED.

9. Platform Overload (If equipped)

Indicates the platform has been overloaded.

10. Hydraulic Oil Filter Indicator (Prior to S/N 85331)

A gauge indicates that the return oil filter is too restrictive and needs to be replaced.

11. Transmission Pump Oil Filter Indicator (Prior to S/N

85331)

Indicates that the charge pump filter is too restrictive and needs to be replaced.

12. Engine Air Filter Indicator (Prior to S/N 85331)

When illuminated indicates that the air filter is too restrictive and needs to be replaced.

3-8 – JLG Lift – 3121209

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Station

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

1. Power/Emergency Stop

An ON-OFF POWER/EMERGENCY STOP switch and a separate ENGINE START/AUXILIARY POWER toggle switch on the platform console supply electrical power to the starter solenoid, when the ignition switch is placed in the “ON” position and the ENGINE START switch is pushed forward momentarily.

2. Travel Warning Horn

A push-type HORN switch supplies electrical power to an audible warning device when pressed.

3. Main Lift/Swing Controller

A proportional dual axis joystick is provided for main lift and swing. Push forward to lift up, pull backward to lift down. Move right to swing right, move left to swing left.

NOTE: Main boom lift and swing functions may be selected in

combination. Maximum speed is reduced when multiple functions are selected.

4. Main Telescope Control

The MAIN TELESCOPE control switch provides extension and retraction of the main boom when positioned to IN or OUT.

NOTE: MAIN, LIFT, SWING, and DRIVE control levers are spring-

loaded and will automatically return to neutral (OFF) position when released.

3121209 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1702567 A

1702676-B

13 9

217

101581663

1704997

14 11 12

1. Power/Emergency Stop

2. Horn

3. Main Lift / Swing

4. Telescope

5. Drive/Steer

6. Function Speed Control

7. Drive Speed / Torque Select

8. Platform Rotate

9. Platform Level Over ride

10. Articulating Jib (800AJ)

11. Fuel Select

12. Lights

13. Steer Select

14. Engine Start / Aux Power

15. Tower Telescope

16. Tower Lift

17. Light Panel

Figure 3-3. Platform Control Console

3-10 – JLG Lift – 3121209

1702567 A

1702676-B

1704997

1705170 A

1702938

13 9

10 1215 188161963

14 11 17

1. Power/Emergency Stop

2. Horn

3. Main Lift / Swing

4. Telescope

5. Drive/Steer

6. Function Speed Control

7. Drive Speed / Torque Select

8. Platform Rotate

9. Platform Level Over ride

10. Articulating Jib (800AJ)

11. Fuel Select

12. Lights

13. Steer Select

14. Engine Start / Aux Power

15. Tower Telescope

16. Tower Lift

17. Drive Orientation Override

18. Soft Touch Override

19. Soft Touch Indicator

Figure 3-4. Platform Control Console - w/Drive Orientation

SECTION 3 - MACHINE CONTROLS AND INDICATORS

3121209 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

5. Drive/Steer

Proportional single axis joystick is provided to control drive. Push forward to drive forward, pull back to drive in reverse. Steering is accomplished via a thumb-activated rocker switch on the end of the handle. Push on the left side of the switch to steer left, on right side to steer right.

NOTE: Both drive and steer functions work in the opposite direc-

tion when the main boom is positioned over front of the chassis.

NOTE: When main boom is positioned above horizontal and any

of the following switches, DRIVE SPEED/TORQUE SELECT or FUNCTION SPEED, are positioned to HIGH, high function speeds are automatically set to creep and the machine continues to operate at a lower speed.

6. Function Speed

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

Drive Speed/Torque Select is a three position switch The forward position gives maximum drive speed by shifting the drive motors to minimum the displacement and giving high engine when drive controller is moved. The back position gives maximum torque for rough terrain and climbing grades by shifting the wheel motors to maximum displacement and giving high engine speed when the drive controller is moved. The center position allows the machine to be driven as quietly as possible by leaving the engine at mid speed and the drive motors in minimum displacement or fastest speed.

8. Platform Rotate

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

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

12. Work Lights (If Equipped)

9. Platform Leveling Override

A three position switch allow the operator to adjust the automatic self leveling system. This switch is used to adjust platform level in situation such as ascending/ descending a grade.

10. Articulating Jib Boom (If Equipped)

The ARTICULATING control switch provides raising and lowering of the jib when positioned to UP or DOWN.

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

Gasoline or liquid propane fuel may be selected by moving the switch to the appropriate position. It is unnecessary to purge the fuel system before switching fuels, so there is no waiting period when switching fuels while the engine is running.

The switch, on the light, operates work lights if the machine is so equipped. The power/emergency stop switch must be on, (mushroom button out) but ignition switch does not have to be on to operate the lights, so care must be taken to avoid draining the battery if left unattended. The master switch and / or the ignition switch at the ground control will turn off power to all lights.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

13. Steer Select (If Equipped)

When equipped with four wheel steering, the action of the steering system is operator selectable. The center switch position gives conventional front wheel steering with the rear wheels unaffected. This is the best position for normal driving at maximum speeds. The forward position is for “crab” steering. When in this mode both front and rear axles steer in the same direction, which allows the chassis to move sideways as it goes forward. This can be used for positioning the machine in aisle ways or against buildings. The back switch position is for “coordinated” steering. In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneuvering in confined areas. A decal located at top of switch, instructs the desired wheel maneuver with the switch position.

To re-synchronize the front and rear axles, activate the steer switch (thumb rocker) until all steer cylinders are at the end of their stroke. This can be done in either crab or coordinated mode.

14. Auxiliary Power

When pushed forward, the switch energizes the starter motor to start the engine.

When pushed back, it energizes the electrically operated hydraulic pump, when actuated. (Switch must be held ON for duration of auxiliary pump use.)

The auxiliary pump functions to provide sufficient oil flow to operate the basic machine functions should the main pump or engine fail. The auxiliary pump will operate tower boom lift, tower telescope, main boom lift, main telescope and swing.

15. Tow er L i f t

The three position center-off toggle switch provides for raising and lowering of the tower boom when positioned to “UP” or “DOWN”. TOWER LIFT must be fully elevated “UP” before operating TOWER TELESCOPE. (TOWER LIFT should not function when TOWER TELESCOPE is extended).

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

16. Tow er Te l e s c op e

The three position center-off toggle switch provides for extending and retracting of the tower boom when positioned to IN or OUT. TOWER TELESCOPE must be fully RETRACTED before operating TOWER LIFT. (TOWER TELESCOPE should not function when TOWER LIFT is not fully elevated “UP”).

TO AVOID UPSET AND SERIOUS INJURY, DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE.

17. Drive Orientation Override

When the boom is swung over the rear tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. Push and release the switch, and within 3 seconds move the Drive/Steer control to activate drive or steer. Before driving, locate the black/white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction.

18. Soft Touch Override Switch (If equipped)

This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed, allowing the operator to move the platform away from the obstacle that caused the shutdown situation.

19. Soft Touch Indicator (If Equipped)

Indicates the Soft Touch bumper is against an object. All controls are cut out until the override button is pushed, at which time controls are active in the Creep Mode.

3121209 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Platform Control Indicator Panel

NOTE: The platform control indicator panel uses different shaped

symbols to alert the operator to different types of operational situations that could arise. The meaning of those symbols are explained below.

Indicates a potentially hazardous situation, which if not corrected, could result in serious injury or death. This indicator will be red.

Indicates an abnormal operating condition, which if not corrected, may result in machine interruption or damage. This indicator will be yellow.

Indicates important information regarding the operating condition, i.e. procedures essential for safe operation. This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position.

NOTE: For engine starting, the footswitch must be in the released

(up) position. Footswitch must be actuated in order for controls to function.

NOTE: These machines have a 7 second delay timer. If a function

has not been activated within 7 seconds after depressing the footswitch, recycle footswitch.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPERATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL. IF SWITCH OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM, IT SHOULD BE ADJUSTED.

1. Footswitch/Enable Indicator

To operate any function, the footswitch must be depressed and the function selected within seven seconds. The enable indicator shows that the controls are enabled. If a function is not selected within seven seconds, or if a seven second lapse between ending one function and beginning the next function, the enable

3-16 – JLG Lift – 3121209

SECTION 3 - MACHINE CONTROLS AND INDICATORS

light will go out and the footswitch must be released and depressed again to enable the controls.

Releasing the footswitch removes power from all controls and applies the drive brakes.

TO AVOID SERIOUS INJURY, DO NOT REMOVE, MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS.

FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1/4" OF TRAVEL, TOP OR BOTTOM.

2. Engine Malfunction Indicator

On machines prior to S/N 62045, the light turns on and an alarm sounds when machine’s power system requires immediate service. Any of the following conditions will turn on light and alarm: low engine oil pressure, high engine coolant temperature, clogged engine air filter, low alternator output, clogged hydraulic oil return filter, or clogged charge pump filter.

On machines from S/N 62045 to present, the light indicates that the JLG Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory. Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval.

The malfunction indicator light will illuminate for 2-3 seconds when the key is positioned to the on position to act as a self test.

3121209 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

* UNRESTRICTED CAPACITY ** RESTRICTED CAPACITY

87243

10 11

1. Enable

2. Engine Malf unction

3. Sof t Touch

4. AC Generator

5. Fuel Level

6. Capacity

7. Creep Speed

8. Glow Plug

9. Tilt Alarm Warning

10. Overload

11. Boom Malfunction

Figure 3-5. Platform Light Panel

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

* UNRESTRICTED CAPACITY

** RESTRICTED CAPACITY

1001107927 A

872412

10 11

1. Enable

2. Engine Malfunction

3. Not Used

4. AC Generator

5. Fuel Level

6. Capacity

7. Creep Speed

8. Glow Plug

9. Tilt Alarm Warning

10. Overload

11. Boom Malfunction

12. Drive Orientation

Figure 3-6. Platform Light Panel w/Drive Orientation

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

3. Soft Touch Indicator (If Equipped)

When illuminated (Yellow) the Soft Touch bumper is against an object. All controls are disabled until the override button is pushed, at which time controls are active in the Creep mode.

4. AC Generator (Green)

When illuminated (Green), the light indicates the generator is in operation.

5. Low Fuel Indicator (Yellow) N/A for liquid propane

When illuminated (Yellow), the fuel tank is 1/8 full or less. When the light first turns on, there are approximately four usable gallons of fuel remaining.

6. Capacity Indicator

Indicates the maximum platform capacity for the current position of the platform. Restricted capacities are permitted at restricted platform positions (shorter boom lengths and higher boom angles).

NOTE: Refer to the capacity decals on the machine for restricted

and unrestricted platform capacities.

7. Creep Speed Indicator

Illuminated (Green) when the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed.

8. Glow Plug Indicator (If Equipped)

When illuminated the glow plugs are operating. After turning on ignition, wait until light goes out before cranking engine.

9. Tilt Alarm Warning Light and Alarm

This orange illuminator indicates that the chassis is on a slope. An alarm will also sound when the chassis is on a slope and the boom is above horizontal. If lit when boom is raised or extended, retract and lower to below horizontal then reposition machine so that it is level before continuing operation. If the boom is above horizontal and the machine is on a slope, the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated.

IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED, RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

10. Overload Indicator (If equipped)

Indicates the platform has been overloaded.

11. Boom Malfunction Indicator

When an audible alarm sounds and the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function, the function is being cutout by tower boom limit switch. This function is not permitted at the current boom configuration.

When an audible alarm sounds and the Boom Malfunction Indicator illuminates steady without a boom function attempt, the upright is out of alignment.

DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED.

12. Drive Orientation Indicator

When the boom is swung beyond the rear drive tires or further in either direction, the Drive Orientation indicator will illuminate when the drive function is selected. This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct.

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SECTION 3 - MACHINE CONTROLS AND INDICATORS

NOTES:

3-22 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

This machine is a self-propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom.

The primary operator control station is in the platform. From this control station, the operator can drive and steer the machine in both forward and reverse directions. The operator can raise or lower the upper or lower boom or swing the boom to the left or right. Standard boom swing is 360 degree continuous left and right of the stowed position. The machine has a Ground Control Station which will override the Platform Control Station. Ground Controls operate Boom Lift and Swing, and are to be used in an emergency to lower the platform to the ground should the operator in the platform be unable to do so. The Ground Control is also to be used in Pre-Start Inspection.

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

The boom can be raised above horizontal with or without any load in the platform if:

1. Machine is positioned on a smooth, firm and level surface.

2. Load is within manufacturer’s rated design capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure exists in the tires.

5. Machine is as originally equipped from JLG.

Stability

Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY. The machine position of least forward stability is shown in Figure 4-1. and its positions of least backward stability is shown in Figure 4-2.

3121209 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

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

4.3 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

MACHINES WITH DIESEL ENGINES. AFTER TURNING ON IGNITION, OPERATOR MUST WAIT UNTIL GLOW PLUG INDICATOR LIGHT GOES OUT BEFORE CRANKING ENGINE.(IF EQUIPPED)

4. Turn key of SELECT switch to GROUND. Position POWER/EMERGENCY STOP switch to ON, then push the ENGINE START switch to the upward position until engine starts.

Starting Procedure

1. Check engine oil. If necessary, add oil in accordance with the Engine Manufacturer’s manual.

2. Check fuel level. Add fuel if necessary.

3. Check that air cleaner components are in place and

securely fastened.

IF ENGINE FAILS TO START PROMPTLY, DO NOT CRANK FOR AN EXTENDED PERIOD. SHOULD ENGINE FAIL TO START ONCE AGAIN, ALLOW STARTER TO “COOL OFF” FOR 2-3 MINUTES. IF ENGINE FAILS AFTER SEVERAL ATTEMPTS, REFER TO ENGINE MAINTENANCE MANUAL.

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

5. After engine has had sufficient time to warm up, shut engine off.

6. Turn key of SELECT switch to PLATFORM.

7. From Platform position POWER/EMERGENCY STOP

switch to ON, then push the ENGINE START switch to the forward position until engine starts.

NOTE: Footswitch must be in released (up) position before

starter will operate. If starter operates with footswitch in the depressed position, DO NOT OPERATE MACHINE.

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SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Forward Stability

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SECTION 4 - MACHINE OPERATION

Figure 4-2. Positions of Least Backward Stability (Sheet 1 of 2)

4-4 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Figure 4-3. Positions of Least Backward Stability (Sheet 2 of 2)

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SECTION 4 - MACHINE OPERATION

Shutdown Procedure

IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUTDOWN, DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION.

1. Remove all load and allow engine to operate at low speed setting for 3-5 minutes; this allows for further reduction of internal engine temperature.

2. Position POWER/EMERGENCY STOP switch to OFF.

3. Turn key of MASTER switch to OFF position.

NOTE: Refer to Engine Manufacturer’s manual for detailed infor-

mation.

4.4 TRAVELING (DRIVING)

(See Figure 4-4.)

DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH, FIRM AND LEVEL SURFACE.

TO AVOID LOSS OF TRAVEL CONTROL OR “TIP OVER.” DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE.

DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES.

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

BEFORE DRIVING, LOCATE THE BLACK/WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS. MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS.

4-6 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Traveling Forward and Reverse

1. At Platform Controls, pull out Emergency Stop switch, start engine, and activate footswitch.

2. Position Drive controller to FORWARD or REVERSE as desired.

This machine is equipped with a Drive Orientation Indicator. The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive/Steer in the opposite direction from the movement of the controls. If the indicator is illuminated, operate the Drive function in the following manner:

1. Match the black and white direction arrows on both platform control panel and the chassis to determine the direction the machine will travel.

2. Push and release the Drive Orientation Override switch. Within 3 seconds, slowly move the Drive control toward the arrow matching the intended direction of machine travel. The indicator light will flash during the 3 second interval until the drive function is selected.

4.5 STEERING

Depress the footswitch to steer machine, push switch left to steer left, to the right, to steer right.

BEFORE OPERATING MACHINE, MAKE SURE UPPER BOOM IS POSITIONED OVER REAR AXLE. IF BOOM IS OVER FRONT AXLE (STEER WHEELS), STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTION. THE DIRECTION WILL MATCH THE ARROW DECAL OF THE HAND CONTROLLER WITH THE ARROW DECAL ON THE FRAME.

4.6 PARKING AND STOWING

Park and stow machine as follows:

1. Park machine in travel position; boom lowered over rear, all access panels and doors closed and secured, ignition off, turntable locked.

2. Check that brakes hold machine in position.

3. Chock wheels front and rear.

4. Turn off SELECT switch and remove key.

3121209 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

4.7 PLATFORM

Loading From Ground Level

1. Position chassis on a smooth, firm and level surface.

2. If total load (personnel, tools and supplies) is less then

rated capacity, distribute load uniformly on platform floor and proceed to work position.

Loading From Positions Above Ground Level

Before loading weight to platform above ground level:

1. Determine what the total rated capacity weight will be after additional weight is loaded (personnel, tools and supplies).

2. If total weight in platform will be less then rated capacity, proceed with distributing weight uniformly on platform floor.

Platform Level Adjustment

1. Leveling UP. Depress footswitch To raise platform, position PLATFORM LEVEL control switch UP and hold until platform is level.

2. Leveling DOWN. Depress footswitch To lower platform, position PLATFORM LEVEL control switch to DOWN and hold until platform is level.

Platform Rotation

To rotate the platform to the left or right, use the Platform Rotate control switch to select the direction and hold until desired position is reached.

4-8 – JLG Lift – 3121209

LEVEL

Figure 4-4. Grade and Sideslopes

SECTION 4 - MACHINE OPERATION

3121209 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

4.8 BOOM

(See Figure 4-2.)

AN ORANGE TILT ALARM WARNING LIGHT, LOCATED ON THE CONTROL CONSOLE, LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE. DO NOT SWING, EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT.

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS. CHASSIS MUST BE LEVEL BEFORE SWINGING, EXTENDING OR RAISING TOWER BOOM ABOVE HORIZONTAL.

TO AVOID UPSET, IF ORANGE TILT ALARM WARNING LIGHT LIGHTS WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL, RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL. THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTENDING OR RAISING MAIN BOOM.

TRAVELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON THE SERIAL NUMBER PLACARD.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION WHEN RELEASED.

TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED, REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP TO STOP THE MACHINE.

Swinging the Boom

ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTING ANY SWING OPERATION.

Depress footswitch. To swing boom, position SWING control switch or controller to RIGHT or LEFT for direction desired.

4-10 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Raising and Lowering the Tower Boom

This machine will have two controls for the tower boom (two toggle switches), one controls tower lift, the other tower telescope. The switching system will sequence its LIFT and TELESCOPE functions as follows:

1. Depress footswitch and sequence while RAISING the TOWER BOOM from the fully lowered position.

a. The TOWER BOOM must be fully elevated “up”

(approximately 12 degrees from vertical) before the TOWER BOOM can be extended from the fully retracted position.

b. The TOWER TELESCOPE “out” will only be opera-

ble when the TOWER BOOM is fully elevated “up”.

2. Depress footswitch and sequence while LOWERING the TOWER BOOM from the fully elevated “up” position.

a. TOWER TELESCOPE “in”. The TOWER BOOM

must be fully retracted before the TOWER BOOM can be lowered.

b. TOWER BOOM lift “down” will only be operable

when the TOWER BOOM is fully retracted.

Raising and Lowering the Main Boom

To raise and lower Main Boom, depress footswitch, position MAIN LIFT controller to UP OR DOWN, and hold until desired height is reached.

Telescoping the Main Boom

To extend or retract Main Boom, depress footswitch, position MAIN TELESCOPE control switch to IN or OUT, and hold until platform reaches desired position.

3121209 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

Function of Tower Boom

1. Sequence while RAISING the TOWER BOOM from the fully lowered position.

a. The TOWER BOOM must be fully elevated “up”

(approximately 12 degrees from vertical) before the TOWER BOOM can be extended from the fully retracted position.

b. The TOWER TELESCOPE “out” or “in” will only be

operable when the TOWER BOOM is fully elevated “up”.

2. Sequence while LOWERING the TOWER BOOM from the fully elevated “up” position.

a. TOWER TELESCOPE “in”. The TOWER BOOM

must be fully retracted before the TOWER BOOM can be lowered.

b. The TOWER BOOM lift “down” will only be operable

when the TOWER BOOM is fully retracted.

DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED.

4-12 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

4.9 SHUT DOWN AND PARK

1. Drive machine to a protected area.

2. Assure main boom is fully retracted and lowered over

rear (Drive) axle; all access panels and doors closed and secured.

3. Remove all load and allow engine to idle 3-5 minutes to permit reduction of engine internal temperatures.

4. At Ground Controls, turn KEY SELECT switch to (center) OFF. Position, POWER/EMERGENCY STOP switch (down) to OFF. Remove key.

5. Cover Platform Control console to protect instruction placards, warning decals and operating controls from hostile environment.

4.10 LIFTING AND TIE DOWN

When transporting machine, boom must be in the stowed position mode, (booms lowered and retracted) with turntable lock pin engaged, and machine securely tied down to truck or trailer deck. Six tie down eyes are provided in the frame slab, one at each corner of the machine and 2 holes at the center of the frame. (See Figure 4-5., Machine Tie Down)

If it becomes necessary to lift the machine using an overhead or mobile crane, it is very important that the turntable lock pin is engaged, lifting devices are attached only to the designated lifting eyes, and spreader bars are to be used to prevent damage to the machine. (See Figure 4-6., Lifting Chart for gross machine weights.)

NOTE: When transporting machine over rough terrain or long dis-

tance, the boom needs to be chocked and strapped. This prevents the boom from bouncing up causing possible damage.

3121209 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Figure 4-5. Machine Tie Down

NOTE: Block rotator and platform.

Secure platform w/o overtightening.

NOTE: Rig chains so

as not to rub.

4-14 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Figure 4-6. Lifting Chart

3121209 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

NOTE: Crane and lifting devices, chains, slings, etc., must be

capable of handling the gross machine weight.

ABOVE IS MINIMUM WEIGHT. CHECK WEIGHT OF UNIT PRIOR TO LIFTING.

NOTE: Lifting eyes are provided at the front and rear in the frame

slab. Each of the four chains or slings used for lifting machine must be adjusted individually so machine remains level when elevated.

SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK/TRAILER.

4.11 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY, ANY TIME A SYSTEM COMPONENT IS REPLACED, OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED.

Refer to Section 2.4, Oscillating Axle Lockout Test (If Equipped) for procedure.

4.12 TOWING

The machine is not equipped with a tow package. Refer to Section 5 for emergency towing procedures.

4-16 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

4.13 TOW BAR (IF EQUIPPED)

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

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

MAXIMUM TOWING GRADE 25%.

Prior to towing the machine, complete the following:

DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED.

1. Retract, lower and position boom in travel position; lock turntable.

2. Lower tow bar and connect to towing vehicle

3. Disconnect drive hubs by inverting disconnect cap.

4. Position steer/tow selector valve for towing; pull valve

knob OUT for towing. The machine is now in the towing mode.

After towing the machine, complete the following:

1. Actuate steer/tow selector valve for steering; push valve

knob IN to the actuated position.

2. Reconnect drive hubs by inverting disconnect cap.

3. Disconnect tow bar from towing vehicle and place it in

the stowed position as shown in Figure 4-7. The machine is now in the driving mode.

4.14 WELDING LEAD (IF EQUIPPED)

This option consists of a single welding cable that is installed in the power track and will allow stick welding from the platform, up to the full elevation of the machine. The single welding cable system differs from the two cable system of previous machines.

DO NOT GROUND WELDER TO THE MACHINE. SERIOUS DAMAGE TO THE MACHINE WILL RESULT. THIS SYSTEM IS INTENDED TO BE GROUNDED TO THE MATERIAL BEING WELDED.

3121209 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

Figure 4-7. Tow Bar

4-18 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Description

The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas. The system includes pressurized cylinders mounted on the frame, and the valves and switches needed to switch the fuel supply from gasoline to LP gas or from LP gas to gasoline.

A two position, FUEL SELECT toggle switch at the platform control station supplies electrical power to open the gasoline shut-off solenoid and close the LP gas shut off solenoid when positioned to the GASOLINE position. This switch also allows electrical power to open the LP gas shut-off solenoid and close the gasoline shut-off solenoid when positioned to the LP position.

IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOPPING THE ENGINE. EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED.

Changing From Gasoline to LP Gas

1. Start engine from Ground Control Station.

2. Open hand valve on LP gas supply tank by turning

counterclockwise.

3. While the engine is operating, place the two position LPG/Gasoline switch at the platform control station to the "LP" position.

Changing From LP Gas to Gasoline

1. With engine operating on LP under a no-load condition, position FUEL SELECT switch at Platform Control Station to GASOLINE position.

2. Close hand valve on LP gas supply tank by turning clockwise.

3121209 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

Figure 4-8. Releveling Valve

4.16 RE-SYNCHRONIZE UPRIGHT

Releveling Valve

A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90° (vertical) relative to the chassis (Refer to Figure 2.9 and Figure 2.10). This valve is located in the tank compartment area.

Perform the following steps with the aid of an assistant:

1. Turn the key switch to the ground control position.

2. Start the engine.

3. Pull and hold the red relevel knob located next to the

main control valve. Refer to Figure 4-8.

4. Raise the tower boom 6 feet (1.8 m).

5. Release the red relevel knob.

6. Lower the tower boom fully and continue to hold down

the switch to Tower Down for an additional 20 seconds.

7. Repeat steps 3 thru 6 as necessary until the upright is 90° (vertical) relative to the chassis.

4-20 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Figure 4-9. Decal Installation - Sheet 1 of 5

3121209 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Installation - Sheet 2 of 5

4-22 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Installation - Sheet 3 of 5

3121209 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Installation - Sheet 4 of 5

4-24 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Figure 4-13. Decal Installation - Sheet 5 of 5

3121209 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 800A - Prior to S/N 0300141330

Item # ANSI

0274460-9

1- -- -- -- -- -- -- -- -

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6- -- -- -- -1701529- -- -- -

7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

11- -- -- -- -- -- -1705084- -

12- -- -- -- -- -1705514- -- -

13- -- -- -- -- -- -- -- -

14- -- -- -- -- -- -- -- -

15 1705 337 1705339 17053 42 - - - - - - - - - -

16- -- -- -- -- -- -- -- -

Korean

0274464-7

Chinese

0274470-7

Spanish

0274466-7

Portuguese

0274468-8

French

0274472-7

CE/Aus

0274474-3

Japanese

0274462-7

4-26 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 800A - Prior to S/N 0300141330

Item # ANSI

0274460-9

17 - - - - - - 1704007 1705901 1704006 - - - -

18 1703 953 1703945 17039 43 1703941 1705903 1703942 - - 1703944

19- -- -- -- -- -- -- -- -

20 1702 868 1705969 17059 68 1704001 1705967 1704000 - - - -

21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926

22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344

23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950

24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938

25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980

26 3251 813 - - 3251813 3251813 3251813 3251813 - - 3251813

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

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

29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960

30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

31 1703772 1703772 1703772 1703772 1703772 1703772 1703772 1703772

32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

33 1704096 1704103 1704101 1704098 1706380 1704099 1705978 1704102

Korean

0274464-7

Chinese

0274470-7

Spanish

0274466-7

Portuguese

0274468-8

French

0274472-7

CE/Aus

0274474-3

Japanese

0274462-7

3121209 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 800A - Prior to S/N 0300141330

Item # ANSI

0274460-9

34 1707014 1707043 1707045 1707048 1707051 1707046 1705978 1707053

35 - - 1704885 1704885 1704885 1704885 1704885 1704885 1704885

36 1706 948 1706948 17069 48 1706948 1706948 1706948 - - 1706948

37 1702265 1703987 1703988 1703989 1706439 1703990 1705977 1703986

38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959

39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 - - 1001108495

41 1706 941 1706941 17069 41 1706941 1706941 1706941 - - 1706941

42- -- -- -- -- -- -- -- -

43- -- -- -- -- -- -- -- -

44- -- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -- -

46- -- -- -- -- -- -- -- -

47- -- -- -- -- -- -- -- -

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50- -- -- -- -- -- -- -- -

Korean

0274464-7

Chinese

0274470-7

Spanish

0274466-7

Portuguese

0274468-8

French

0274472-7

CE/Aus

0274474-3

Japanese

0274462-7

4-28 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-1. Decal Legend - 800A - Prior to S/N 0300141330

Item # ANSI

0274460-9

51- -- -- -- -- -- -- -- -

52- -- -- -- -- -- -- -- -

53- -- -- -- -- -- -- -- -

54- -- -- -- -- -- -- -- -

55- -- -- -- -- -- -- -- -

56 1705 351 1705427 17054 30 1705910 1705905 1705429 - - 1705426

Korean

0274464-7

Chinese

0274470-7

Spanish

0274466-7

Portuguese

0274468-8

French

0274472-7

CE/Aus

0274474-3

Japanese

0274462-7

3121209 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 800A - S/N 0300141330 to Present

Item # ANSI

0274460-10

1- -- -- -- -- -- -- -- -

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6- -- -- -- -1701529- -- -- -

7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

11- -- -- -- -- -- -1705084- -

12- -- -- -- -- -1705514- -- -

13- -- -- -- -- -- -- -- -

14- -- -- -- -- -- -- -- -

15 1705 337 1705339 17053 42 - - - - - - - - - -

16- -- -- -- -- -- -- -- -

Korean

0274464-8

Chinese

0274470-8

Spanish

0274466-8

Portuguese

0274468-9

French

0274472-8

CE/Aus

0274474-3

Japanese

0274462-8

4-30 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 800A - S/N 0300141330 to Present

Item # ANSI

0274460-10

17 - - - - - - 1704007 1705901 1704006 - - - -

18 1703 953 1703945 17039 43 1703941 1705903 1703942 - - 1703944

19- -- -- -- -- -- -- -- -

20 1702 868 1705969 17059 68 1704001 1705967 1704000 - - - -

21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926

22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344

23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950

24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938

25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980

26 3251 813 - - 3251813 3251813 3251813 3251813 - - 3251813

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

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

29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960

30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

31 1703772 1703772 1703772 1703772 1703772 1703772 1703772 1703772

32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

33 1001121800 1001122200 1001121809 1001121804 1001121806 1001121802 1705978 1001121807

Korean

0274464-8

Chinese

0274470-8

Spanish

0274466-8

Portuguese

0274468-9

French

0274472-8

CE/Aus

0274474-3

Japanese

0274462-8

3121209 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 800A - S/N 0300141330 to Present

Item # ANSI

0274460-10

34 1001121813 1001122201 1001121822 1001121817 1001121819 1001121815 1705978 1001121820

35 - - 1704885 1704885 1704885 1704885 1704885 1704885 1704885

36 1706 948 1706948 17069 48 1706948 1706948 1706948 - - 1706948

37 1702265 1703987 1703988 1703989 1706439 1703990 1705977 1703986

38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959

39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 - - 1001108495

41 1706 941 1706941 17069 41 1706941 1706941 1706941 - - 1706941

42- -- -- -- -- -- -- -- -

43- -- -- -- -- -- -- -- -

44- -- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -- -

46- -- -- -- -- -- -- -- -

47- -- -- -- -- -- -- -- -

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50- -- -- -- -- -- -- -- -

Korean

0274464-8

Chinese

0274470-8

Spanish

0274466-8

Portuguese

0274468-9

French

0274472-8

CE/Aus

0274474-3

Japanese

0274462-8

4-32 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-2. Decal Legend - 800A - S/N 0300141330 to Present

Item # ANSI

0274460-10

51- -- -- -- -- -- -- -- -

52- -- -- -- -- -- -- -- -

53- -- -- -- -- -- -- -- -

54- -- -- -- -- -- -- -- -

55- -- -- -- -- -- -- -- -

56 1705 351 1705427 17054 30 1705910 1705905 1705429 - - 1705426

Korean

0274464-8

Chinese

0274470-8

Spanish

0274466-8

Portuguese

0274468-9

French

0274472-8

CE/Aus

0274474-3

Japanese

0274462-8

3121209 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 800AJ - Prior to S/N 0300141330

Item # ANSI

0274461-9

1- -- -- -- -- -- -- -- -

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6- -- -- -- -- -- -- -- -

7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

11- -- -- -- -- -- -1705084- -

12- -- -- -- -- -1705514- -- -

13- -- -- -- -- -- -- -- -

14- -- -- -- -- -- -- -- -

15 1705 337 1705339 17053 42 - - - - - - - - - -

16- -- -- -- -- -- -- -- -

17 1702 153 - - - - 1704007 1705901 1704006 - - - -

Korean

0274464-7

Chinese

0274471-7

Spanish

0274467-7

Portuguese

0274469-9

French

0274473-7

CE/Aus

0274475-3

Japanese

0274462-7

4-34 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 800AJ - Prior to S/N 0300141330

Item # ANSI

0274461-9

18 1703 953 1703945 17039 43 1703941 1705903 1703942 - - 1703944

19- -- -- -- -- -- -- -- -

20 1702 868 1705969 17059 68 1704001 1705967 1704000 - - - -

21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926

22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344

23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950

24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938

25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980

26 3241 813 - - 3251813 3251813 3251813 3251813 - - 3251813

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

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

29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960

30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

31 1703773 1703773 1703773 1703773 1703773 1703773 1703773 1703773

32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

33 1701645 1707058 1707060 1707056 1703996 1707055 1705978 1707059

34 1707013 1707042 1707044 1707049 1704112 1707047 1705978 1707054

35 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885

Korean

0274464-7

Chinese

0274471-7

Spanish

0274467-7

Portuguese

0274469-9

French

0274473-7

CE/Aus

0274475-3

Japanese

0274462-7

3121209 – JLG Lift – 4-35

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 800AJ - Prior to S/N 0300141330

Item # ANSI

0274461-9

36 1706 948 1706948 17069 48 1706948 1706948 1706948 - - 1706948

37 1702265 1703987 1703990 1703989 1706439 1703990 1705977 1703986

38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959

39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 - - 1001108495

41 1706 941 1706941 17069 41 1706941 1706941 1706941 - - 1706941

42- -- -- -- -- -- -- -- -

43- -- -- -- -- -- -- -- -

44- -- -- -- -- -- -- -- -

45- -- -- -- -- -- -- -- -

46- -- -- -- -- -- -- -- -

47- -- -- -- -- -- -- -- -

48- -- -- -- -- -- -- -- -

49- -- -- -- -- -- -- -- -

50- -- -- -- -- -- -- -- -

51- -- -- -- -- -- -- -- -

52- -- -- -- -- -- -- -- -

53- -- -- -- -- -- -- -- -

Korean

0274464-7

Chinese

0274471-7

Spanish

0274467-7

Portuguese

0274469-9

French

0274473-7

CE/Aus

0274475-3

Japanese

0274462-7

4-36 – JLG Lift – 3121209

SECTION 4 - MACHINE OPERATION

Table 4-3. Decal Legend - 800AJ - Prior to S/N 0300141330

Item # ANSI

0274461-9

54- -- -- -- -- -- -- -- -

55- -- -- -- -- -- -- -- -

56 1705 351 1705427 17054 30 1705910 1705905 1705429 - - 1705426

Korean

0274464-7

Chinese

0274471-7

Spanish

0274467-7

Portuguese

0274469-9

French

0274473-7

CE/Aus

0274475-3

Japanese

0274462-7

3121209 – JLG Lift – 4-37

SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Legend - 800AJ - S/N 0300141330 to Present

Item # ANSI

0274461-10

1- -- -- -- -- -- -- -- -

2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

3- -- -- -- -- -- -- -- -

4- -- -- -- -- -- -- -- -

5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

6- -- -- -- -- -- -- -- -

7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811

8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814

9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

11- -- -- -- -- -- -1705084- -

12- -- -- -- -- -1705514- -- -

13- -- -- -- -- -- -- -- -

14- -- -- -- -- -- -- -- -

15 1705 337 1705339 17053 42 - - - - - - - - - -

16- -- -- -- -- -- -- -- -

17 1702 153 - - - - 1704007 1705901 1704006 - - - -

Korean

0274465-8

Chinese

0274471-8

Spanish

0274467-8

Portuguese 0274469-10

French

0274473-8

CE/Aus

0274475-3

Japanese

0274463-8

4-38 – JLG Lift – 3121209

JLG 800A-AJ Operator Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

SECTION 1. SAFETY PRECAUTIONS

1.1 GENERAL

1.2 PRE-OPERATION

Operator Training and Knowledge

Workplace Inspection

Machine Inspection

1.3 OPERATION

General

Trip and Fall Hazards

Electrocution Hazards

Tipping Hazards

Crushing and Collision Hazards

1.4 TOWING, LIFTING, AND HAULING

1.5 ADDITIONAL HAZARDS / SAFETY

SECTION 2. USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING

Operator Training

Training Supervision

Operator Responsibility

2.2 PREPARATION, INSPECTION, AND MAINTENANCE

Pre-Start Inspection

2.3 FUNCTION CHECK

From the Ground Control Station with No Load in the Platform:

From the Platform Control Station:

SECTION 3. MACHINE CONTROLS AND INDICATORS

3.1 GENERAL

3.2 CONTROLS AND INDICATORS

Ground Control Station

Ground Control Indicator Panel

Platform Station

Platform Control Indicator Panel

SECTION 4. MACHINE OPERATION

4.1 DESCRIPTION

4.2 OPERATING CHARACTERISTICS AND LIMITATIONS

Capacities

Stability

4.3 ENGINE OPERATION

Starting Procedure

Shutdown Procedure

4.4 TRAVELING (DRIVING)

Traveling Forward and Reverse

4.5 STEERING

4.6 PARKING AND STOWING

4.7 PLATFORM

Loading From Ground Level

Loading From Positions Above Ground Level

Platform Level Adjustment

Platform Rotation

4.8 BOOM

Swinging the Boom

Raising and Lowering the Tower Boom

Raising and Lowering the Main Boom

Telescoping the Main Boom

Function of Tower Boom

4.9 SHUT DOWN AND PARK

4.10 LIFTING AND TIE DOWN

4.11 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

4.12 TOWING

4.13 TOW BAR (IF EQUIPPED)

4.14 WELDING LEAD (IF EQUIPPED)

4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY)

Description

Changing From Gasoline to LP Gas

Changing From LP Gas to Gasoline

4.16 RE-SYNCHRONIZE UPRIGHT

Releveling Valve