JLG 860SJ Operator Manual

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Operation and Safety Manual

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

Boom Lift Models 800S 860SJ

Prior to S/N 0300182742

ANSI

3121138

March 24, 2014

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.

3121138 – 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 – 3121138

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:

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

FOREWORD

REVISION LOG

Original Issue - October 9, 2001

Revised - October 31, 2001

Revised - December 4, 2001

Revised - March 1, 2002

Revised - January 1, 2003

Revised - April 24, 2003

Revised - May 4, 2005

Revised - March 3, 2006

Revised - July 7, 2006

Revised - August 13, 2008

Revised - November 25, 2009

Revised - February 9, 2010

Revised - October 31, 2011

Revised - July 17, 2012

Revised - March 24, 2014

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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

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES 2-10

2.4 OSCILLATING AXLE LOCKOUT TEST

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

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 . . . . . . . . . . . . 3-15

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 . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

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TABLE OF CONTENTS

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

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

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

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

Raising and Lowering the Boom . . . . . . . . . . . . 4-9

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-9

4.9 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.10 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . 4-10

4.11 TOW BAR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 4-11

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

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

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

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

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

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

5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1

Platform or Boom Caught Overhead. . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . 5-2

5.5 MANUAL DESCENT INSTRUCTIONS

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

To Retract and Lower Boom. . . . . . . . . . . . . . . . 5-3

To Lower Boom with Fully Retracted Telescope 5-3

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTENANCE

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

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

Specifications and Performance Data . . . . . . . . 6-3

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Major Component Weights. . . . . . . . . . . . . . . . . 6-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . .6-11

6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-30

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-31

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-31

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.6 DRAINING OIL BUILD UP FROM THE PROPANE

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TABLE OF CONTENTS

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

REGULATOR (PRIOR TO S/N 0300134626) . . . .6-33

6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-35

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-37

6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-37

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . .2-6

2-2. Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 2 . . . . . .2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 2 . . . . . .2-9

2-4. Horizontal and Capacity Limit Switches -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5. Horizontal and Capacity Limit Switches -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-6. Limiting and Cut-Out Switches - Sheet 1 of 2 . . . .2-12

2-7. Limiting and Cut-Out Switches - Sheet 2 of 2 . . . .2-13

3-1. Ground Control Station - 800S . . . . . . . . . . . . . . . .3-3

3-1. Ground Control Station - 860SJ. . . . . . . . . . . . . . . .3-4

3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . .3-7

3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . .3-8

3-4. Platform Control Console. . . . . . . . . . . . . . . . . . . .3-11

3-5. Platform Control Console - w/Drive Orientation . . 3-12

3-6. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-7. Platform Light Panel - w/Drive Orientation . . . . . . 3-19

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

4-2. Position of Least Forward Stability . . . . . . . . . . . . . 4-4

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . 4-7

4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-10

4-5. Typical 800S/860SJ Transport . . . . . . . . . . . . . . . 4-15

4-6. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-16

4-7. Decal Location - Rear Entry Platform -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-8. Decal Location - Rear Entry Platform -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-9. Decal Location - Side Entry Platform -

Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-10. Decal Location - Side Entry Platform -

Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

4-11. Decal Location - Side Entry Platform -

Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4-12. Decal Location - Side Entry Platform -

Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-13. Decal Location - Side Entry Platform -

Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . 6-11

6-2. Engine Operating Temperature Specifications - Deutz

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

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TABLE OF CONTENTS

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

6-3. Engine Operating Temperature Specifications - Deutz

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

6-4. Engine Operating Temperature Specifications - Ford -

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

6-5. Engine Operating Temperature Specifications - Ford -

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

6-6. Engine Operating Temperature Specifications -

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

6-7. Engine Operating Temperature Specifications -

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

6-8. Engine Operating Temperature Specifications - GM -

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

6-9. Engine Operating Temperature Specifications - GM -

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

6-10. Operator Maintenance and Lubrication Diagram . 6-20

6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-36

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 Location Legend - Rear Entry Platform . . . 4-19 4-2 Decal Location Legend - Rear Entry Platform . . . 4-23 4-3 Decal Location Legend - Rear Entry Platform . . . 4-27 4-4 Decal Location Legend, 800S - Side Entry Platform -

Prior to S/N 0300143294 . . . . . . . . . . . . . . . . . . . 4-36

4-5 Decal Location Legend, 800S - Side Entry Platform - S/

N 0300143294 & B30000153 to

S/N 0300182742 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

4-6 Decal Location Legend, 860SJ - Side Entry Platform -

Prior to S/N 0300143294 . . . . . . . . . . . . . . . . . . . 4-44

4-7 Decal Location Legend, 860SJ - Side Entry Platform -

S/N 0300143294 & B300000153 to

S/N 0300182742 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

6-1 Operating Specifications - Prior to

S/N 0300143294 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Operating Specifications - S/N 0300143294 &

B300000153 to S/N 0300182742 . . . . . . . . . . . . . . 6-2

6-3 Specifications and Performance Data . . . . . . . . . . 6-3

6-4 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-5

6-6 Deutz F4M2011 Specifications. . . . . . . . . . . . . . . . 6-5

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TABLE OF CONTENTS

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

6-7 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . 6-6

6-8 Caterpillar 3044C/ Caterpillar 3.4 . . . . . . . . . . . . . . 6-6

6-9 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-10 Battery Specifications. . . . . . . . . . . . . . . . . . . . . . . 6-7

6-11 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-12 Component Weights . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-13 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6-14 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . 6-9

6-15 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . 6-9

6-16 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . 6-10

6-17 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . 6-10

6-18 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . 6-11

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

6-20 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-33

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

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TABLE OF CONTENTS

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

This page left blank intentionally.

vi – JLG Lift – 3121138

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.

3121138 – 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 – 3121138

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.

• 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.

3121138 – 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 – 3121138

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)

3121138 – 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 must be familiar with the surface before driving. Do not exceed the allowable sideslope and grade while driving.

1-6 – JLG Lift – 3121138

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.

3121138 – 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 – 3121138

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.

3121138 – 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 – 3121138

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, dropoffs.

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.

3121138 – 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 – 3121138

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 of more than 3 months; 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

3121138 – 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 2-2. and Figure 2-3.

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 an area free of overhead and ground level obstructions. Refer to Section 4 for more specific 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 – 3121138

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

Function Check

Perform the Function Check as follows:

1. From the ground control panel with no load in the platform:

a. Check that all guards protecting the switches or

locks are in place;

b. Operate all functions and check all limiting and cut-

out switches;

c. Check auxiliary power (or manual descent);

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is activated.

2. From the platform control console:

a. Ensure that the control console is firmly secured in

the proper location;

b. Check that all guards protecting the switches or

locks are in place;

c. Operate all functions and check all limiting and cut-

out switches;

d. Ensure that all machine functions are disabled

when the Emergency Stop Button is pushed in.

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

a. Drive the machine on a grade, not to exceed the

rated gradeability, and stop to ensure the brakes hold;

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

tion.

3121138 – JLG Lift – 2-5

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-6 – JLG Lift – 3121138

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

1. Steer Wheels

2. Drive Wheels

3. Lift Cylinder

4. Tower

5. Level Link

6. Upright

7. Base Boom Section

8. Mid Boom Section

9. Fly Boom Section

10. Boom Assembly

11. Power Track

12. Jib (If Equipped)

13. Platform

14. Platform Console

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

3121138 – JLG Lift – 2-7

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

991

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

2-8 – JLG Lift – 3121138

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 and Gate - Footswitch works prop-

erly, not modified, disabled or blocked. Latch, stop, and hinges in working condition.

2. Platform & Ground Control Consoles - Switches and

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

3. Boom Sections/Uprights/Turntable - See Inspection

Note.

4. Swing Drive - No evidence of damage.

5. Wheel/Tire Assemblies - No loose or missing lug nuts,

proper inflation (pneumatic). Inspect for worn tread, cuts, tears or other discrepancies. Inspect wheels for damage and corrosion.

6. Drive Motor, Brake, and Hub - No evidence of leakage.

7. Hood Assemblies - See Inspection Note.

8. Auxiliary Hydraulic Pump - See Inspection Note.

9. All Hydraulic Cylinders - No visible damage; pivot pins

and hydraulic hoses undamaged, not leaking.

10. Turntable Bearing - Evidence of proper lubrication. No

evidence of loose bolts or looseness between bearing and machine.

11. Tie Rod Ends and Steering Spindles - See Inspection

Note.

12. Horizontal and Capacity Limit Switches - Switches

operate properly.

13. Main Hydraulic Pump - See Inspection Note.

14. Platform Rotator - See Inspection Note.

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

3121138 – JLG Lift – 2-9

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES

2-10 – JLG Lift – 3121138

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

Item Description Operation Characteristic

1Boom Capacity

Lengt h Switch

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

2Boom Extension

Switch

Reduces drive speed when boom reaches a designated length.

3Boom Capacity

Angle Switch

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

4Boom Elevation

Switch

Reduces drive speed when boom is raised above horizontal.

3121138 – JLG Lift – 2-11

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

2-12 – JLG Lift – 3121138

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

3121138 – JLG Lift – 2-13

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

2.4 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.

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

between drive wheels prior to beginning lockout cylinder test.

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

2. From platform control station, start engine

3. Place the Drive control lever to the forward position and

carefully drive machine up ascension ramp until left front wheel is on top of block.

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

5. With boom over right side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

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

7. 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.

2-14 – JLG Lift – 3121138

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

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

9. Place Drive control lever to Forward and carefully drive machine up ascension ramp until right front wheel is on top of block.

10. With boom over left side of machine, place Drive control lever to Reverse and drive machine off of block and ramp.

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

12. 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 activate Drive to release cylinders.

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

3121138 – JLG Lift – 2-15

SECTION 2 - USER RESPONSIBILITIES, MACHINE PREPARATION, AND INSPECTION

NOTES:

2-16 – JLG Lift – 3121138

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 machines is equipped with control panels that use

symbols to indicate control functions. Refer to 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

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

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.

NOTE: If equipped, the Function Enable switch must

be held down in order to operate Telescope, Swing, Lift, Jib Lift, Platform Level Override, and Platform Rotate functions.

3121138 – JLG Lift – 3-1

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Indicator Panel.

The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation.

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.

2. Telescope Control.

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

3. Swing Control.

Provides 360 degrees continuous turntable rotation.

4. Lift Control.

Provides raising and lowering of the main boom.

5. Platform/Ground Select Switch

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 PLATFORM/GROUND SELECT switch in the center

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

6. Hourmeter.

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 hourmeter registers up to 9,999.9 hours and cannot be reset.

7. 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.

3-2 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706914 A

12345

1. Indicator Panel

2. Telescope

3. Swing

4. Lift

5. Platform/Ground Select Switch

6. Hourmeter

7. Power/Emergency Stop

8. Engine Star t/Auxiliary 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 b le

9. N/A

10. Platform Leveling Override

11. Platform Rotate

Figure 3-1. Ground Control Station - 800S

3121138 – JLG Lift – 3-3

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1706915 A

123

Figure 3-1. Ground Control Station - 860SJ

1. Indicator Panel

2. Telescope

3. Swing

4. Lift

5. Platform/Ground Select Switch

6. Hourmeter

7. Power/Emergency Stop

8. Engine Star t/Auxiliary Power or E n gi n e S t ar t /A u xi l i ar y Po w er / Fu n ct i o n E n ab l e

9. Ar ticulating Jib Boom

10. Platform Leveling Override

11. Platform Rotate

3-4 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. 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.)

9. Articulating Jib Boom. (If Equipped)

This switch provides raising and lowering of the jib.

10. Platform Leveling Override.

A three position switch allows the operator to compensate for any difference in the automatic self leveling system.

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

11. 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.

3121138 – JLG Lift – 3-5

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Ground Control Indicator Panel

(See Figure 3-2. and Figure 3-3.)

1. Battery Charging Indicator

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

2. Low Engine Oil Pressure Indicator.

Indicates that engine oil pressure is below normal and service is required.

3. High Engine Coolant Temperature Indicator (Ford)

Indicates that engine coolant temperature is abnormally high and service is required.

4. Engine Oil Temperature Indicator (Deutz).

Indicates the temperature of the engine oil, which also serves as engine coolant, is abnormally high and service is required.

5. Malfunction Indicator

Indicates that the JLG Control System has detected a malfunction and a Diagnostic Trouble Code has been set. 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

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

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

3-6 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

64321

811

1. Batter y Charging

2. Low Engine Oil Pressure

3. High Engine Coolant Temp.

4. High Engine Oil Temp.

5. Not Used

6. Low Fuel

7. Glow Plug

8. Platform Overload

9. Hyd. Filter Bypass

10. Charge Pump Filter

11. Engine Air Filter

Figure 3-2. Ground Control Indicator Panel - Sheet 1 of 2

Prior to S/N 0300099882

3121138 – JLG Lift – 3-7

SECTION 3 - MACHINE CONTROLS AND INDICATORS

S/N 0300099882 to S/N 0300182742

1. Battery Charging

2. Engine Oil Pressure

3. Engine Water Temp.

4. Engine Oil Temp.

5. Malfunction Indicator

6. Low Fuel

7. Glow Plug

8. Platform Overload

9. Not Used

10. Not Used

11. Not Used

12. Drive and Steer Disable

Figure 3-3. Ground Control Indicator Panel - Sheet 2 of 2

3-8 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Platform Overload Indicator (If Equipped)

Indicates the platform has been overloaded.

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

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

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

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

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

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

12. Drive and Steer Disable Indicator (If equipped)

Indicates the Drive and Steer Disable function has been activated.

Platform Station

(See Figure 3-4., Platform Control Console)

1. Power/Emergency Stop

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

Within about 2 seconds of pulling the switch out, the machine will perform a diagnostic check of the various electrical circuits, and if everything is OK, the platform alarm will beep once. During this time the lights on the indicator panel will also blink once as a bulb check.

2. Horn

If pressed, this switch supplies power to the horn.

3121138 – JLG Lift – 3-9

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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

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

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.

3. Main Lift/Swing Controller

An infinitely 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: To operate the Main Lift/Swing Joystick, pull up on the

locking ring below the handle.

4. Main Telescope Control

This control allows extension and retraction of the main boom.

5. Drive/Steer

The DRIVE joystick provides for driving either forward or backward. The controller is ‘ramped’ to allow variable drive speed.

Steering is controlled by a thumb operated switch on top of the joystick.

NOTE: To operate the Drive Joystick, pull up on the locking ring

below the handle.

NOTE: When 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 cut out and the machine continues to operate at a lower speed.

DO NOT OPERATE MACHINE IF DRIVE SPEED /TORQUE SELECT OR FUNCTION SPEED SWITCHES OPERATE WHEN BOOM IS ABOVE HORIZONTAL.

3-10 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

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 Override

10. Articulating Jib (860SJ)

11. Fuel Select

12. Lights

13. Steer Select

14. Engine Start / Aux Power

15. Light Panel

Figure 3-4. Platform Control Console

3121138 – JLG Lift – 3-11

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1702567 A

1702676-B

1704997

1705170 A

1702938

13 9

215

10 121781863

14 11 16

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 Override

10. Articulating Jib (860SJ)

11. Fuel Select

12. Lights

13. Steer Select

14. Engine Start / Aux Power

15. Light Panel

16. Drive Orientation Override

17. Soft Touch Override

18. Soft Touch Indicator

Figure 3-5. Platform Control Console - w/Drive Orientation

3-12 – JLG Lift – 3121138

6. Function Speed Control

SECTION 3 - MACHINE CONTROLS AND INDICATORS

Controls the speed of Boom and Swing Functions. Rotate CCW for slower speed and CW for faster speed. To adjust to creep, turn knob fully CCW until it clicks.

7. Drive Speed/Torque Select

The forward position gives maximum drive speed 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 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 maximum displacement.

8. Platform Rotate

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

9. 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.

10. Articulating Jib Boom (860SJ)

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

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.

3121138 – JLG Lift – 3-13

SECTION 3 - MACHINE CONTROLS AND INDICATORS

12. Lights. (If Equipped)

This switch operates control console panel lights and head lights if the machine is so equipped. The 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.

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 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.

To re-synchronize the front and rear axles, position the rear drive wheels to the forward drive position by select-

ing either crab or compound steer, then select front steer (center switch position) to operate the normal steering function.

14. Start/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. Indicator Panel.

The LED Indicator Panel contains indicator lights that signal problem conditions or functions operating during machine operation.

3-14 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

16. 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.

17. 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.

18. 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.

Platform Control Indicator Panel

(See Figure 3-7., Platform Light Panel - w/Drive Orientation)

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.

3121138 – JLG Lift – 3-15

SECTION 3 - MACHINE CONTROLS AND INDICATORS

1. Level System Fault Indicator

Indicates a fault in the electronic leveling system. The fault indicator will flash and an alarm sound. All functions will default to creep if the boom is extended more than 20 inches (51 cm) or elevated above horizontal.

IF THE LEVEL SYSTEM FAULT INDICATOR IS ILLUMINATED, SHUT DOWN THE MACHINE, RECYCLE THE EMERGENCY STOP, AND RESTART THE MACHINE. IF THE FAULT PERSISTS, RETURN THE PLATFORM TO THE STOWED POSITION, USING MANUAL LEVELING AS REQUIRED, AND HAVE LEVELING SYSTEM REPAIRED.

2. AC Generator (Green)

Indicates the generator is in operation.

3. Overload Indicator. (If equipped)

Indicates the platform has been overloaded.

4. 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.

5. 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.

3-16 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

6. Glow Plug Indicator

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

7. 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 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.

3121138 – JLG Lift – 3-17

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 4*56

91011**

* UNRESTRICTED CAPACITY

** RESTRICTED CAPACITY

1. Level System

2. AC Generator

3. Overload

4. Capacity

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed Indicator

10. Engine Malfunction Indicator

11. Cable Service Indicator

12. Soft Touch Indicator

Figure 3-6. Platform Light Panel

3-18 – JLG Lift – 3121138

SECTION 3 - MACHINE CONTROLS AND INDICATORS

123 4*56

91011**

* UNRESTRICTED CAPACITY

** RESTRICTED CAPACITY

1. Level System

2. AC Generator

3. Overload

4. Capacity

5. Tilt Alarm Warning

6. Glow Plug

7. Enable

8. Fuel Level

9. Creep Speed

10. Engine Malfunction

11. Cable Service

12. Not Used

13. Drive Orientation

Figure 3-7. Platform Light Panel - w/Drive Orientation

3121138 – JLG Lift – 3-19

SECTION 3 - MACHINE CONTROLS AND INDICATORS

8. Fuel Level Indicator

Indicates the level of fuel in the fuel tank.

9. Creep Speed Indicator

When the Function Speed Control is turned to the creep position, the indicator acts as a reminder that all functions are set to the slowest speed.

10. Malfunction Indicator

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.

11. Cable Service Indicator (If Equipped)

When illuminated, the light indicates the boom cables are loose or broken and must be repaired or adjusted immediately.

IF THE CABLE SERVICE INDICATOR IS ILLUMINATED, RETURN THE PLATFORM TO THE STOWED POSITION, SHUT DOWN THE MACHINE, AND HAVE THE BOOM CABLES INSPECTED.

12. 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.

13. 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.

3-20 – JLG Lift – 3121138

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 platform, if:

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

2. Load is within manufacturer’s rated capacity.

3. All machine systems are functioning properly.

4. Proper tire pressure.

5. Machine is as originally equipped from JLG.

Stability

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

3121138 – JLG Lift – 4-1

SECTION 4 - MACHINE OPERATION

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

4.3 ENGINE OPERATION

NOTE: Initial starting should always be performed from the

Ground Control station.

Starting Procedure

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

NOTE: Diesel engines only: After turning on ignition, operator

must wait until glow plug indicator light goes out before cranking engine.

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

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

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

3. Turn SELECT switch to PLATFORM.

4. From Platform, pull POWER/EMERGENCY STOP switch

out, then push the ENGINE START switch 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.

4-2 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Figure 4-1. Position of Least Backward Stability

ROTATE PLATFORM

90 DEGREES

BOOM FULLY

ELEVATED

TU RN TAB LE RO TATE D

90 DEGREES FROM STOWED POSITION

MACHINE WILL TIP OVER IN

THIS DIRECTION IF OVERLOADED

OR OPERATED

ON AN OUT-OF-LEVEL SURFACE

Shutdown Procedure

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

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

2. Push POWER/EMERGENCY STOP switch in.

3. Turn MASTER switch to Off.

Refer to Engine Manufacturer’s manual for detailed information.

3121138 – JLG Lift – 4-3

SECTION 4 - MACHINE OPERATION

Figure 4-2. Position of Least Forward Stability

MACHINE WILL TIP OVER IN

THIS DIRECTION IF OVERLOADED

OR OPERATED

ON AN OUT-OF-LEVEL SURFACE

TELESCOPE

FULLY EXTENDED

TURNTABLE ROTATED

90 DEGREES FROM STOWED POSITION

4-4 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

4.4 TRAVELING (DRIVING)

NOTE: When the upper boom is raised approximately 11 degrees

above horizontal, the high drive function will automatically be in low drive.

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.

3121138 – JLG Lift – 4-5

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

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

4-6 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Figure 4-3. Grade and Side Slopes

3121138 – JLG Lift – 4-7

SECTION 4 - MACHINE OPERATION

4.6 PLATFORM

Platform Level Adjustment

During normal operation of the machine, the platform will automatically maintain it’s position. To manually Level Up or Down - Position the Platform/Level control switch Up or Down and hold until the desired platform position is obtained.

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.

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.

4.7 BOOM

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

DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS.

TO AVOID TIP OVER, LOWER PLATFORM TO GROUND LEVEL. THEN DRIVE MACHINE TO A LEVEL SURFACE BEFORE RAISING BOOM.

TO AVOID SERIOUS INJURY, DO NOT OPERATE MACHINE IF ANY CONTROL LEVER OR TOGGLE SWITCH CONTROLLING PLATFORM MOVEMENT DOES NOT RETURN TO THE ‘OFF’ OR NEUTRAL POSITION WHEN RELEASED.

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

4-8 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Swinging the Boom

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

WHEN SWINGING THE BOOM MAKE SURE THERE IS AMPLE ROOM FOR THE BOOM TO CLEAR SURROUNDING WALLS, PARTITIONS AND EQUIPMENT.

Raising and Lowering the Boom

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

4.8 FUNCTION SPEED CONTROL

This control affects the speed of all boom functions and Platform Rotate. When in the CCW maximum position, Drive is placed in creep speed.

4.9 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.

3121138 – JLG Lift – 4-9

SECTION 4 - MACHINE OPERATION

Figure 4-4. Drive Disconnect Hub

4.10 EMERGENCY TOWING

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%.

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

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

2. Disconnect drive hubs by inverting disconnect cap.

3. Reconnect the drive hubs by inverting the disconnect

cap when towing is complete.

4-10 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

4.11 TOW BAR (IF EQUIPPED)

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 towbar and connect to towing vehicle

3. Disconnect drive hubs by inverting disconnect cap. Refer to Figure 4-4., Drive Disconnect Hub.

3121138 – JLG Lift – 4-11

SECTION 4 - MACHINE OPERATION

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 towbar from towing vehicle and place it in

the stowed position as shown below. The machine is now in the driving mode.

4-12 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

4.12 SHUT DOWN AND PARK

To shut down and park the machine, the procedures are as follows:

1. Drive machine to a reasonably well protected area.

2. Ensure boom is lowered over rear drive axle.

3. Push in the Emergency Stop at Platform Controls.

4. Push in the Emergency Stop at Ground Controls. Posi-

tion Platform/Ground Select switch to center OFF.

5. If necessary, cover Platform Controls to protect instruction placards, warning decals and operating controls from hostile environment.

4.13 LIFTING AND TIE DOWN

Lifting

1. Call JLG Industries or weigh the individual unit to find out the Gross Vehicle Weight.

2. Place the boom in the stowed position with the turntable locked.

3. Remove all loose items from the machine.

4. Properly adjust the rigging to prevent damage to the

machine and so the machine remains level.

3121138 – JLG Lift – 4-13

SECTION 4 - MACHINE OPERATION

Tie Down

WHEN TRANSPORTING THE MACHINE, THE BOOM MUST BE FULLY LOWERED INTO THE BOOM REST.

1. Remove all loose items from the machine.

2. When transporting an 800S/860SJ a step-deck or sin-

gle-drop trailer is required. To avoid damage to the platform and to obtain proper weight distribution, load the machine onto the trailer as follows;

a. Position the boom over the front wheels.

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

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

table locked.

DRIVE AND STEER CONTROLLERS WILL BE REVERSED WHEN THE BOOM IS POSITIONED OVER THE FRONT WHEELS.

c. Drive it onto the trailer with the boom and platform

positioned towards the truck. Refer to Figure 4-5., Typical 800S/860SJ Transport.

3. Secure the chassis and the platform using straps or chains of adequate strength.

4-14 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

3121138 – JLG Lift – 4-15

SECTION 4 - MACHINE OPERATION

Figure 4-6. Lifting and Tie Down Chart

4-16 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

3121138 – JLG Lift – 4-17

SECTION 4 - MACHINE OPERATION

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

4-18 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

1 1703797 1703992 1703925 1704809 1705053 1704811 1703924 1704767 1704810

2 1703798 1704819 1703931 1704821 1705055 1704823 1703930 1704820 1704822

3 1703805 - - 1703937 - - - - - - 1703936 - - - -

4 1703804 1701518 1703949 1701518 1701518 1701518 1703948 1701518 1701518

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

6 1703808 - - - - - - - - - - 1703808 - - - -

7 1704906

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

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

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

11 1702868 - - - - - - - - - - 1704000 - - - -

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

ANSI 0270907-2 0270908-2

(800S)

1704907

(860SJ)

Australian

0270909-2 0270910-2

1704906

(800S)

1704907

(860SJ)

China/

English 0270931-1 0270932-1

1704906

(800S)

1704907

(860SJ)

Dutch 0270915-2 0270916-2

1704906

(800S)

1704907

(860SJ)

Finnish 0271830-2 0271831-1

1704906

(800S)

1704907

(860SJ)

French 0270919-2 0270920-2

1704906

(800S)

1704907

(860SJ)

French/

English 0270929-1 0270930-1

1704906

(800S)

1704907

(860SJ)

German 0270913-2 0270914-2

1704906

(800S)

1704907

(860SJ)

Italian 0270917-2 0270918-2

1704906

(800S)

1704907

(860SJ)

3121138 – JLG Lift – 4-19

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

13 1705088 1705088

14 1705089 1705089

15 3251813 - - - - 1705084 1705084 1705084 3251813 1705084 1705084

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 1702153 - - - - - - - - - - 1704006 - - - -

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- -- -- -- -- -- -- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

ANSI 0270907-2 0270908-2

Australian 0270909-2 0270910-2

(800S)

1704995

(860SJ)

(800S)

1704996

(860SJ)

China/

English 0270931-1 0270932-1

1704101 - - - - - - 1704099 - - - -

1704109 - - - - - - 1704107 - - - -

Dutch 0270915-2 0270916-2

Finnish 0271830-2 0271831-1

French 0270919-2 0270920-2

French/

English 0270929-1 0270930-1

German 0270913-2 0270914-2

Italian 0270917-2 0270918-2

4-20 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

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

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

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

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

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

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

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

34 - - - - 1703982 1703518 1701600 1693292 1703984 1693294 1701600

35 1703475

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

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

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

39 - -- -- -- -- -- -3252221- -- -

ANSI 0270907-2 0270908-2

(800S)

1703482

(860SJ)

Australian

0270909-2 0270910-2

1703475

(800S)

1703482

(860SJ)

China/

English 0270931-1 0270932-1

1703475

(800S)

1703482

(860SJ)

Dutch 0270915-2 0270916-2

1703475

(800S)

1703482

(860SJ)

Finnish 0271830-2 0271831-1

1703475

(800S)

1703482

(860SJ)

French 0270919-2 0270920-2

1703475

(800S)

1703482

(860SJ)

French/

English 0270929-1 0270930-1

1703475

(800S)

1703482

(860SJ)

German 0270913-2 0270914-2

1703475

(800S)

1703482

(860SJ)

Italian 0270917-2 0270918-2

1703475

(800S)

1703482

(860SJ)

3121138 – JLG Lift – 4-21

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

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

41 - -- -- -- -- -- -- -- -- -

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

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

44 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

45 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

46 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

47 1704540 1704540 1704540 1704540 1704540 1704540 1704540 1704540 1704540

48 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

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

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

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

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

ANSI 0270907-2 0270908-2

Australian 0270909-2 0270910-2

China/

English 0270931-1 0270932-1

Dutch 0270915-2 0270916-2

Finnish 0271830-2 0271831-1

French 0270919-2 0270920-2

French/

English 0270929-1 0270930-1

German 0270913-2 0270914-2

Italian 0270917-2 0270918-2

4-22 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

1 1703797 1703992 1703925 1704809 1705053 1704811 1703924 1704767 1704810

2 1703798 1704819 1703931 1704821 1705055 1704823 1703930 1704820 1704822

3 1703805 - - 1703937 - - - - - - 1703936 - - - -

4 1703804 1701518 1703949 1701518 1701518 1701518 1703948 1701518 1701518

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

6 1703808 - - - - - - - - - - 1703808 - - - -

7 1704906

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

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

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

11 1702868 - - - - - - - - - - 1704000 - - - -

12 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277

ANSI 0270907-2 0270908-2

(800S)

1704907

(860SJ)

Australian

0270909-2 0270910-2

1704906

(800S)

1704907

(860SJ)

China/

English 0270931-1 0270932-1

1704906

(800S)

1704907

(860SJ)

Dutch 0270915-2 0270916-2

1704906

(800S)

1704907

(860SJ)

Finnish 0271830-2 0271831-1

1704906

(800S)

1704907

(860SJ)

French 0270919-2 0270920-2

1704906

(800S)

1704907

(860SJ)

French/

English 0270929-1 0270930-1

1704906

(800S)

1704907

(860SJ)

German 0270913-2 0270914-2

1704906

(800S)

1704907

(860SJ)

Italian 0270917-2 0270918-2

1704906

(800S)

1704907

(860SJ)

3121138 – JLG Lift – 4-23

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

13 1705088 1705088

14 1705089 1705089

15 3251813 - - - - 1705084 1705084 1705084 3251813 1705084 1705084

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 1702153 - - - - - - - - - - 1704006 - - - -

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- -- -- -- -- -- -- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

ANSI 0270907-2 0270908-2

Australian 0270909-2 0270910-2

(800S)

1704995

(860SJ)

(800S)

1704996

(860SJ)

China/

English 0270931-1 0270932-1

1704101 - - - - - - 1704099 - - - -

1704109 - - - - - - 1704107 - - - -

Dutch 0270915-2 0270916-2

Finnish 0271830-2 0271831-1

French 0270919-2 0270920-2

French/

English 0270929-1 0270930-1

German 0270913-2 0270914-2

Italian 0270917-2 0270918-2

4-24 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

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

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

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

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

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

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

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

34 - - - - 1703982 1703518 1701600 1693292 1703984 1693294 1701600

35 1703475

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

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

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

39 - -- -- -- -- -- -3252221- -- -

ANSI 0270907-2 0270908-2

(800S)

1703482

(860SJ)

Australian

0270909-2 0270910-2

1703475

(800S)

1703482

(860SJ)

China/

English 0270931-1 0270932-1

1703475

(800S)

1703482

(860SJ)

Dutch 0270915-2 0270916-2

1703475

(800S)

1703482

(860SJ)

Finnish 0271830-2 0271831-1

1703475

(800S)

1703482

(860SJ)

French 0270919-2 0270920-2

1703475

(800S)

1703482

(860SJ)

French/

English 0270929-1 0270930-1

1703475

(800S)

1703482

(860SJ)

German 0270913-2 0270914-2

1703475

(800S)

1703482

(860SJ)

Italian 0270917-2 0270918-2

1703475

(800S)

1703482

(860SJ)

3121138 – JLG Lift – 4-25

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

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

41 - -- -- -- -- -- -- -- -- -

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

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

44 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

45 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

46 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

47 1704540 1704540 1704540 1704540 1704540 1704540 1704540 1704540 1704540

48 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

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

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

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

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

ANSI 0270907-2 0270908-2

Australian 0270909-2 0270910-2

China/

English 0270931-1 0270932-1

Dutch 0270915-2 0270916-2

Finnish 0271830-2 0271831-1

French 0270919-2 0270920-2

French/

English 0270929-1 0270930-1

German 0270913-2 0270914-2

Italian 0270917-2 0270918-2

4-26 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

1 1703926 1703927 1704985 1703928 1704812 1703923 1705054 1704808

2 1703932 1703933 1704986 1703934 1704824 1703929 1705056 1704819

3 1703938 1703939 - - 1703940 - - 1703935 - - - -

4 1703950 1703951 1701518 1703952 1701518 1703947 1701518 1701518

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

6 - - - - - - - - - - 1703808 - - - -

7 1704906

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

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

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

11 - - - - - - 1704002 - - 1704001 - - - -

12 1704277 1704277 - - 1704277 1704277 1704277 1704277 1704277

13 1704102 1704103 - - 1704100 - - 1704098 - - - -

14 1704110 1704111 - - 1704108 - - 1704106 - - - -

15 - - - - 1705084 3251813 1705084 3251813 1705084 1705084

Japan 0270923-1 0270924-1

(800S)

1704907

(860SJ)

Korean 0270925-1 0270926-1

1704906

(800S)

1704907

(860SJ)

Portuguese

0271392-2 0271393-2

1704906(

800S)

1704907(

860SJ)

Portuguese/

Spanish 0270933-1 0270934-1

1704906(8

00S)

1704907(8

60SJ)

Spanish 0270921-2 0270922-2

1704906

(800S)

1704907

(860SJ)

Spanish/

English 0270927-1 0270928-1

1704906

(800S)

1704907

(860SJ)

Swedish 0271832-2 0271833-2

1704906

(800S)

1704907

(860SJ)

UK 0270911-2 0270912-2

1704906

(800S)

1704907

(860SJ)

3121138 – JLG Lift – 4-27

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

16 1701502 1701502 1701502 1701502 1701502 1701502 1701502 1701502

17 1701503 1701503 1701503 1701503 1701503 1701503 1701503 1701503

18 1701504 1701504 1701504 1701504 1701504 1701504 1701504 1701504

19 - - - - - - 1704008 - - 1704007 - - - -

20 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

21 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

22 - -- - - - - -- -- -- -- -

23 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509

24 1702300 1702300 1702300 1702300 1702300 1702300 1702300 1702300

25 1701500 1701500 1701500 1701500 1701500 1701500 1701500 1701500

26 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

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

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

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

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

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

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

Japan 0270923-1 0270924-1

Korean 0270925-1 0270926-1

Portuguese

0271392-2 0271393-2

Portuguese/

Spanish 0270933-1 0270934-1

Spanish 0270921-2 0270922-2

Spanish/

English 0270927-1 0270928-1

Swedish 0271832-2 0271833-2

0270911-2

0270912-2

4-28 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

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

34 1703980 1703981 1701600 1703985 1701791 1703983 1701600 - -

35 1703475

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

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

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

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

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

41 - -- - - - - -- -- -- -- -

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

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

44 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499

45 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

46 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412

47 1704540 1704540 1704540 1704540 1704540 1704540 1704540 1704540

Japan 0270923-1 0270924-1

(800S)

1703482

(860SJ)

Korean 0270925-1 0270926-1

1703475

(800S)

1703482

(860SJ)

Portuguese

0271392-2 0271393-2

1703475(

800S)

1703482

(860SJ)

Portuguese/

Spanish 0270933-1 0270934-1

1703475(8

00S)

1703482

(860SJ)

Spanish 0270921-2 0270922-2

1703475

(800S)

1703482

(860SJ)

Spanish/

English 0270927-1 0270928-1

1703475

(800S)

1703482

(860SJ)

Swedish 0271832-2 0271833-2

1703475

(800S)

1703482

(860SJ)

UK 0270911-2 0270912-2

1703475

(800S)

1703482

(860SJ)

3121138 – JLG Lift – 4-29

SECTION 4 - MACHINE OPERATION

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

Item #

800S

860SJ

48 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

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

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

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

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

Japan 0270923-1 0270924-1

Korean 0270925-1 0270926-1

Portuguese

0271392-2 0271393-2

Portuguese/

Spanish 0270933-1 0270934-1

Spanish 0270921-2 0270922-2

Spanish/

English 0270927-1 0270928-1

Swedish 0271832-2 0271833-2

0270911-2

0270912-2

4-30 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

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

3121138 – JLG Lift – 4-31

SECTION 4 - MACHINE OPERATION

Figure 4-10. Decal Location - Side Entry Platform - Sheet 2 of 5

4-32 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Figure 4-11. Decal Location - Side Entry Platform - Sheet 3 of 5

3121138 – JLG Lift – 4-33

SECTION 4 - MACHINE OPERATION

Figure 4-12. Decal Location - Side Entry Platform - Sheet 4 of 5

4-34 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Figure 4-13. Decal Location - Side Entry Platform - Sheet 5 of 5

3121138 – JLG Lift – 4-35

SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Location Legend, 800S - Side Entry Platform - Prior to S/N 0300143294

Item #

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 - -

1 2 - - - - - - - - - - - - - - - -

1 3 - - - - - - - - - - - - - - - -

1 4 - - - - - - - - - - - - - - - -

1 5 - - - - - - - - - - - - - - - -

1 6 - - - - - - - - - - - - - - - -

17 - - - - 1702153 1704007 1705901 1704006 - - - -

18 1703953 1703945 1703943 1703941 1705903 1703942 - - 1703944

ANSI

0274499-8

Korean

0274501-6

Chinese

0274503-6

Spanish

0274513-6

Portuguese

0274505-7

French

0274507-6

CE/Aus

0274509-3

Japanese 0274511-6

4-36 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Location Legend, 800S - Side Entry Platform - Prior to S/N 0300143294

Item #

1 9 - - - - - - - - - - - - - - - -

20 1702868 1705969 1702868 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 3251813 - - 3251813 3251813 3251813 3251813 - - 3251813

2 7 - - - - - - - - - - - - - - - -

2 8 - - - - - - - - - - - - - - - -

29 1703475 1703475 1703475 1703475 1703475 1703475 1703475 1703475

30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

31 1704906 1704906 1704906 1704906 1704906 1704906 1704906 1704906

32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

33 1705088 1704103 1704101 1704098 1706380 1704099 1705978 1704102

34 1707016 1707043 1707045 1707048 1707051 1707046 1705978 1707053

35 1706948 1706948 1706948 1706948 1706948 1706948 - - 1706948

36 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

ANSI

0274499-8

Korean

0274501-6

Chinese

0274503-6

Spanish

0274513-6

Portuguese

0274505-7

French

0274507-6

CE/Aus

0274509-3

Japanese 0274511-6

3121138 – JLG Lift – 4-37

SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Location Legend, 800S - Side Entry Platform - Prior to S/N 0300143294

Item #

37 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 - - 1001108496

38 1706941 1706941 1706941 1706941 1706941 1706941 - - 1706941

39 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

40 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

4 1 - - - - - - - - - - - - - - - -

4 2 - - - - - - - - - - - - - - - -

4 3 - - - - - - - - - - - - - - - -

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

4 5 - - - - - - - - - - - - - - - -

4 6 - - - - - - - - - - - - - - - -

4 7 - - - - - - - - - - - - - - - -

4 8 - - - - - - - - - - - - - - - -

4 9 - - - - - - - - - - - - - - - -

5 0 - - - - - - - - - - - - - - - -

5 1 - - - - - - - - - - - - - - - -

5 2 - - - - - - - - - - - - - - - -

5 3 - - - - - - - - - - - - - - - -

5 4 - - - - - - - - - - - - - - - -

ANSI

0274499-8

Korean

0274501-6

Chinese

0274503-6

Spanish

0274513-6

Portuguese

0274505-7

French

0274507-6

CE/Aus

0274509-3

Japanese 0274511-6

4-38 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Table 4-4. Decal Location Legend, 800S - Side Entry Platform - Prior to S/N 0300143294

Item #

5 5 - - - - - - - - - - - - - - - -

5 6 - - - - - - - - - - - - - - - -

5 7 - - - - - - - - - - - - - - - -

5 8 - - - - - - - - - - - - - - - -

59 1705351 1705427 1705430 1705910 1705905 1705429 - - 1705426

ANSI

0274499-8

Korean

0274501-6

Chinese

0274503-6

Spanish

0274513-6

Portuguese

0274505-7

French

0274507-6

CE/Aus

0274509-3

Japanese 0274511-6

3121138 – JLG Lift – 4-39

SECTION 4 - MACHINE OPERATION

Table 4-5. Decal Location Legend, 800S - Side Entry Platform - S/N 0300143294 & B30000153 to S/N 0300182742

Item #

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 - -

1 2 - - - - - - - - - - - - - - - -

1 3 - - - - - - - - - - - - - - - -

1 4 - - - - - - - - - - - - - - - -

1 5 - - - - - - - - - - - - - - - -

1 6 - - - - - - - - - - - - - - - -

17 - - - - 1702153 1704007 1705901 1704006 - - - -

18 1703953 1703945 1703943 1703941 1705903 1703942 - - 1703944

ANSI

0274499-9

Korean

0274501-7

Chinese

0274503-7

Spanish

0274513-7

Portuguese

0274505-8

French

0274507-7

CE/Aus

0274509-3

Japanese 0274511-7

4-40 – JLG Lift – 3121138

SECTION 4 - MACHINE OPERATION

Table 4-5. Decal Location Legend, 800S - Side Entry Platform - S/N 0300143294 & B30000153 to S/N 0300182742

Item #

1 9 - - - - - - - - - - - - - - - -

20 1702868 1705969 1702868 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 3251813 - - 3251813 3251813 3251813 3251813 - - 3251813

2 7 - - - - - - - - - - - - - - - -

2 8 - - - - - - - - - - - - - - - -

29 1703475 1703475 1703475 1703475 1703475 1703475 1703475 1703475

30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631

31 1704906 1704906 1704906 1704906 1704906 1704906 1704906 1704906

32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501

33 1001122507 1001122200 1001121809 1001121804 1001121806 1001121802 1705978 1001121807

34 1001122515 1001122201 1001121822 1001121817 1001121819 1001121815 1705978 1001121820

35 1706948 1706948 1706948 1706948 1706948 1706948 - - 1706948

36 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584

ANSI

0274499-9

Korean

0274501-7

Chinese

0274503-7

Spanish

0274513-7

Portuguese

0274505-8

French

0274507-7

CE/Aus

0274509-3

Japanese 0274511-7

3121138 – JLG Lift – 4-41

SECTION 4 - MACHINE OPERATION

Table 4-5. Decal Location Legend, 800S - Side Entry Platform - S/N 0300143294 & B30000153 to S/N 0300182742

Item #

37 1001108496 1001108496 1001108496 1001108496 1001108496 1001108496 - - 1001108496

38 1706941 1706941 1706941 1706941 1706941 1706941 - - 1706941

39 3252781 3252781 3252781 3252781 3252781 3252781 3252781 3252781

40 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691

4 1 - - - - - - - - - - - - - - - -

4 2 - - - - - - - - - - - - - - - -

4 3 - - - - - - - - - - - - - - - -

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

4 5 - - - - - - - - - - - - - - - -

4 6 - - - - - - - - - - - - - - - -

4 7 - - - - - - - - - - - - - - - -

4 8 - - - - - - - - - - - - - - - -

4 9 - - - - - - - - - - - - - - - -

5 0 - - - - - - - - - - - - - - - -

5 1 - - - - - - - - - - - - - - - -

5 2 - - - - - - - - - - - - - - - -

5 3 - - - - - - - - - - - - - - - -

5 4 - - - - - - - - - - - - - - - -

ANSI

0274499-9

Korean

0274501-7

Chinese

0274503-7

Spanish

0274513-7

Portuguese

0274505-8

French

0274507-7

CE/Aus

0274509-3

Japanese 0274511-7

4-42 – JLG Lift – 3121138

JLG 860SJ 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

Function Check

2.3 HORIZONTAL AND CAPACITY LIMIT SWITCHES

2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

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 PLATFORM

Platform Level Adjustment

Platform Rotation

4.7 BOOM

Swinging the Boom

Raising and Lowering the Boom

4.8 FUNCTION SPEED CONTROL

4.9 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED)

4.10 EMERGENCY TOWING

4.11 TOW BAR (IF EQUIPPED)

4.12 SHUT DOWN AND PARK

4.13 LIFTING AND TIE DOWN

Lifting

Tie Down