Oshkosh JLG 800S Page 89 Operation And Safety Manual Download | Manualshive

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SECTION 4 - MACHINE OPERATION

31215048

4-29

50

1702774

1702774

1702774

1702774

1702774

1702774

- -

1702774

0274518

51

1702773

1702773

1702773

1702773

1702773

1702773

1702773

1702773

0274518

52

1704885

1704885

1704885

1704885

1704885

1704885

- -

1704885

0274518

55

1700818

1700818

1700818

1700818

1700818

1700818

- -

1700818

1700818

57

1001231801

- -

- -

- -

- -

- -

- -

- -

- -

58

0641406

0641406

0641406

0641406

0641406

0641406

0641406

0641406

0641406

59

1705351

1705427

1705430

1705910

1705905

1705429

- -

1705426

- -

61

- -

- -

- -

- -

- -

- -

1001197408

- -

- -

62

1001181145

1001181145

1001181145

1001181145

1001181145

1001181145

1001181145

1001181145

1001181145

63

1001223055

1001224048

1001224050

1001224049

1001224052

1001223971

1001139654

1001224053

- -

64

1001223453

- -

- -

- -

- -

1001223453

- -

- -

- -

66

- -

- -

1001244298

- -

- -

- -

- -

- -

- -

100

1001109029

1001109029

1001109029

1001109029

1001109029

1001109029

1001199949

1001109029

1001199949

101

1701499

1701499

1701499

1701499

1701499

1701499

1701499

1701499

1701499

102

1701509

1701509

1701509

1701509

1701509

1701509

1701509

1701509

1701509

103

1703811

1703811

1703811

1703811

1703811

1703811

1703811

1703811

1703811

104

1703814

1703814

1703814

1703814

1703814

1703814

1703814

1703814

1703814

105

1704277

1704277

1704277

1704277

1704277

1704277

1704277

1704277

1704277

Table 4-1. Decal Location Legend, 800S

Item #

ANSI

1001242459-C

Korean

1001242595-C

Chinese

1001242654-C

Spanish

1001242694-C

Portuguese

1001242700-C

French

1001242753-C

CE

1001257320-A

Japanese

1001242826-C

Australia

1001257322-A

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Summary of Contents for JLG 800S

Page 1: ... Safety Manual ANSI Original Instructions Keep this manual with the machine at all times AS NZS Models 800S 860SJ PVC 2001 31215048 October 2 2019 Rev A T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 2: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 3: ...California to cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle or equipment in a well ventilated area and wear gloves or wash your hands frequently when servicing For more information go to www P65Warnings ca gov T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 4: ...ll 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...

Page 5: ...ATES 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 INDI RECTLY TO THE SAFETY OF PERSONNEL OR PROTECTION OF PROPERTY This is the Safety Alert Symbol It is used to alert you to the potential personal injury ha...

Page 6: ...ACCIDENT INVOLVING BODILY INJURY OR DEATH OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY 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 Phone 240 420 2661 Fax 301 745 3713 E m...

Page 7: ...FOREWORD d 31215048 REVISION LOG Original Issue A October 2 2019 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 8: ...d Inspection 2 6 Function Check 2 8 SkyGuard Function Test 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 Console 3 2 Ground Control Indicator Panel 3 10 Platform Console 3 12 Platform Control Indicator Panel 3 18 SECTION 4 MACHINE OPERATI...

Page 9: ...GENCY 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 MACHINE SAFETY SYSTEM OVERRIDE MSSO CE ONLY 5 3 SECTION 6 ACCESSORIES 6 1 FALL ARREST PLATFORM 6 3 Safety Precautions 6 3 6 2 PIPE RACKS 6 3 Capacity Specifications Australia Only 6 4 Safety Precautions 6 4 Preparation and Inspection 6 4 Operation 6 4 6 3 SKYAIR 6...

Page 10: ...OPERATOR MAINTENANCE 7 1 INTRODUCTION 7 1 7 2 OPERATING SPECIFICATIONS 7 1 Specifications and Performance Data 7 2 Capacities 7 3 Engine Data 7 4 Battery 7 5 Tires 7 6 Major Component Weights 7 6 Hydraulic Oil 7 7 7 3 SERIAL NUMBER LOCATION 7 10 7 4 MAINTENANCE AND LUBRICATION 7 16 7 5 TIRES WHEELS 7 25 Tire Inflation 7 25 Tire Damage 7 25 Tire Replacement 7 26 Wheel Replacement 7 27 Wheel Install...

Page 11: ...tion 4 5 4 2 Position of Least Backward Stability 4 5 4 3 Position of Least Forward Stability 4 6 4 4 Traveling on a Grade 4 9 4 5 Grade and Side Slopes 4 10 4 6 Drive Disconnect Hub 4 15 4 7 Typical 800S 860SJ Transport 4 20 4 8 Lifting and Tie Down Chart 4 21 4 9 Decal Location Sheet 1 of 5 4 22 4 10 Decal Location Sheet 2 of 5 4 23 4 11 Decal Location Sheet 3 of 5 4 24 4 12 Decal Location Sheet...

Page 12: ...formance Data 7 2 7 3 Capacities 7 3 7 4 Deutz D2011L04 Specifications 7 4 7 5 Deutz TD 2 9 Specifications 7 4 7 6 Ford 2 5L 7 5 7 7 Battery Specifications 7 5 7 8 Tire Specifications 7 6 7 9 Component Weights 7 6 7 10 Hydraulic Oil 7 7 7 11 Mobilfluid 424 Specs 7 8 7 12 UCon Hydrolube HP 5046 7 8 7 13 Mobil DTE 10 Excel 32 Specs 7 9 7 14 Mobil EAL 224H Specs 7 9 7 15 Exxon Univis HVI 26 Specs 7 1...

Page 13: ...ion of the machine has been completed under the supervision of an experienced and quali fied operator This section contains the responsibilities of the owner user oper ator lessor and lessee concerning safety training inspection maintenance application and operation If there are any ques tions with regard to safety training inspection maintenance application and operation please contact JLG Indust...

Page 14: ...ey all applicable employer local and governmental regulations as they pertain to your utilization and application of the machine WorkplaceInspection Precautions to avoid all hazards in the work area must be taken by the user before and during operation of the machine Do not operate or raise the platform from a position on trucks trailers railway cars floating vessels scaffolds or other equip ment ...

Page 15: ...ery substances from footwear and plat form floor 1 3 OPERATION General Machine operation requires your full attention Bring the machine to a full stop before using any device i e cell phones two way radios etc that will distract your attention from safely operating the machine Do not use the machine for any purpose other than position ing personnel their tools and equipment Before operation the us...

Page 16: ... Do not wear loose fitting clothing or long hair unre strained which may become caught or entangled in equip ment 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 Hydraulic cylinders are subject to thermal expansion and con traction This may result in changes to the platform position while the machine...

Page 17: ... foot or two feet and one hand at all times during entry and exit Keep both feet firmly positioned on the platform floor at all times Never position ladders boxes steps planks or similar items on unit to provide additional reach for any purpose Keep oil mud and slippery substances cleaned from footwear and the platform floor ElectrocutionHazards This machine is not insulated and does not provide p...

Page 18: ...eir equip ment 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 Table 1 1 Minimum Approach Distances M A D Voltage Range Phase to Phase MINIMUM APPROACH DISTANCE in Feet Meters 0to50KV 10 3 Over50KVto200KV 15 5 Over200KVto350KV 20 6 Over350KVto500KV 25 8 Over500KVto750KV 35 11 Over750KVto1000KV 45 ...

Page 19: ...NEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTH ERWISE Tipping Hazards Ensure that the ground conditions are adequate to support the maximum tire load indicated on the tire load decals located on the chassis adjacent to each wheel Do not travel on unsupported surfaces The user must be familiar with the operating surface before driving Do not exc...

Page 20: ...o stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Do not operate the machine when wind conditions exceed specifications shown in Figure 1 2 Beaufort Scale Factors affecting wind speed are platform elevation surrounding structures local weather events and approaching storms Wind speed can be significantly greater at height than at ground level Wi...

Page 21: ...sedskin Leavesrustle 3 8 12 3 4 5 4 Gentlebreeze Leavesandsmallertwigsinconstantmotion 4 13 18 5 5 7 9 Moderatebreeze Dustandloosepaperraised Smallbranchesbegintomove 5 19 24 8 0 10 7 Freshbreeze Smallertreessway 6 25 31 10 8 13 8 Strongbreeze Largebranchesinmotion Flagswavingnearhorizontal Umbrellause becomesdifficult 7 32 38 13 9 17 1 NearGale ModerateGale Wholetreesinmotion Effortneededtowalkag...

Page 22: ...it travel speed according to conditions of ground surface congestion visibility slope location of personnel and other factors Be aware of stopping distances in all drive speeds When driv ing in high speed reduce drive 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 ...

Page 23: ... inserted at the appropriate points in this manual and in the Ser vice and Maintenance Manual It is of utmost importance that maintenance personnel pay strict attention to these precautions to avoid possible injury to personnel or damage to the machine or property A maintenance program must be established by a qualified person and must be followed to ensure that the machine is safe MaintenanceHaza...

Page 24: ...as batteries or solid tires with items of different weight or specification Do not modify the MEWP in any way to affect stability Refer to the Service and Maintenance Manual for the weights of critical stability items MODIFICATION OR ALTERATION OF A MEWP SHALL BE MADE ONLY WITH PRIOR WRIT TEN PERMISSION FROM THE MANUFACTURER Battery Hazards Always disconnect batteries when servicing electrical com...

Page 25: ...e machine to recognize a malfunction or potential malfunc tion 7 The safest means to operate the machine where overhead obstructions other moving equipment and obstacles depressions holes and drop offs exist 8 Means to avoid the hazards of unprotected electrical con ductors 9 Selection of the appropriate MEWP and available options for the work to be performed considering specific job require ments...

Page 26: ...following the manu facturer s operator s manual Prior to users authorization of an operator to use a specific model of MEWP the user shall ensure the operator is familiarized on the follow ing 1 Location of the manual storage compartment and the requirementtoensure the required manual s are present on the MEWP 2 Purpose and function of the machine controls and indicators at the platform and ground...

Page 27: ...hasedused Owner Dealer orUser QualifiedJLGMechanic ServiceandMaintenanceManual andapplicableJLGinspectionform AnnualMachineInspection SeeNote Annually nolaterthan13monthsfromthedateofprior inspection Owner Dealer orUser FactoryTrained ServiceTechnician Recommended ServiceandMaintenanceManual andapplicableJLGinspectionform PreventativeMaintenance AtintervalsasspecifiedintheServiceandMaintenance Man...

Page 28: ... 1 2 15 Figure 2 1 Basic Nomenclature 1 SteerWheels 2 DriveWheels 3 LiftCylinder 4 Tower 5 LevelLink 6 Upright 7 BaseBoomSection 8 MidBoomSection 9 FlyBoomSection 10 BoomAssembly 11 PowerTrack 12 Jib 860SJOnly 13 Platform 14 PlatformControlConsole 15 SkyGuard T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 29: ...tic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container 5 Walk Around Inspection Perform as instructed 6 Battery Charge as required 7 Fuel 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 hydr...

Page 30: ...unloading mate rials 13 Lanyard Attach Points 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 IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDI ATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL...

Page 31: ...LITIES MACHINE PREPARATION AND INSPECTION 31215048 2 7 Walk Around Inspection O AC 01940 1 2 14 15 3 4 5 6 7 8 10 11 6 11 5 5 5 5 15 10 10 12 7 13 10 5 16 9 9 9 9 17 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 32: ...d 1 Platform Assembly and Gate Footswitch works properly not modified disabled or blocked Gate latches and hinges in working condition 2 SkyGuard See Inspection Note 3 Platform Control Console Switches and levers return to neutral when activated and released decals placards secure and legible control markings legible 4 Platform Rotator See Inspection Note 5 All Hydraulic Cylinders No visible damag...

Page 33: ...t form a Ensure that all machine functions are disabled when the Emergency Stop Button is pushed in b Ensure all functions stop when the function switch is released c Operate all functions and check all limiting and cut out switches to ensure proper operation All boom sections should extend retract together at the same rate of speed Any difference would indicate delayed move ment and loose wire ro...

Page 34: ...DOWN MACHINE AND HAVE WIRE ROPES INSPECTED SERVICED BY A FACTORY TRAINED SERVICE TECHNICIAN LOOSE OR MISADJUSTED WIRE ROPES COULD RESULT IN SERIOUS INJURY OR DEATH 3 With the platform in the transport stowed position a Drive the machine on a grade not beyond the maxi mum operating slope and stop to ensure the brakes hold b Check the tilt indicator is illuminated to ensure proper operation 4 Swing ...

Page 35: ... activated verify the following conditions a Telescope out function stops and telescope in function operates for a short duration b The horn sounds c If equipped with a SkyGuard beacon the beacon illumi nates NOTE If SkyGuard is enabled with the Soft Touch system functions will cut out instead of reversing 4 Disengage the SkyGuard sensor release controls then recy cle the footswitch Ensure normal ...

Page 36: ...CHINE PREPARATION AND INSPECTION 2 12 31215048 2 3 HORIZONTAL AND CAPACITY PROXIMITY SWITCHES 1 2 3 OAC02300 Figure 2 2 Horizontal and Capacity Proximity Sensors Sheet 1 of 2 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 37: ...acteristic 1 LowerAssembly Sensor Communicatesthattheboomisnolongerinthetransportpositionandalsowhenthelimitsofthe capacityzonehasbeenreached 2 BoomTransport ProximitySensor Communicatesthattheboomisnolongerinthetransportposition 3 BoomCapacity ProximitySensor Communicatesthatthelimitofthecapacityzonehasbeenreached T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 38: ...refully 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 8 Place the 6 in 15 2 cm high block with ascension ramp in front of right front wheel 9 Place Drive control lever to Forward and ca...

Page 39: ...s 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 ...

Page 40: ...orPanel 2 Telescope 3 Swing 4 Lift 5 Platform GroundSelectSwitch 6 Hourmeter 7 Power EmergencyStop 8 EngineStart AuxiliaryPower 9 NotUsed 10 PlatformLevelingOverride 11 PlatformRotate 12 NotUsed 13 AirShutoffValve ASOV IfEquipped Figure 3 1 Ground Control Console 800S T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 41: ...e 3 Swing 4 Lift 5 Platform GroundSelectSwitch 6 Hourmeter 7 Power EmergencyStop 8 EngineStart AuxiliaryPower 9 NotUsed 10 PlatformLevelingOverride 11 PlatformRotate 12 MachineSafetySystemOverride MSSO Figure 3 2 Ground Control Console 800S with Machine Safety System Override MSSO CE Only T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 42: ...nd Control Console 860SJ 1 IndicatorPanel 2 Telescope 3 Swing 4 Lift 5 Platform GroundSelectSwitch 6 Hourmeter 7 Power EmergencyStop 8 EngineStart AuxiliaryPower 9 ArticulatingJibBoom 10 PlatformLevelingOverride 11 PlatformRotate 12 NotUsed 13 AirShutoffValve ASOV IfEquipped T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 43: ...e 860SJ with Machine Safety System Override MSSO CE Only 1 IndicatorPanel 2 Telescope 3 Swing 4 Lift 5 Platform GroundSelectSwitch 6 Hourmeter 7 Power EmergencyStop 8 EngineStart AuxiliaryPower 9 ArticulatingJibBoom 10 PlatformLevelingOverride 11 PlatformRotate 12 MachineSafetySystemOverride MSSO T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 44: ... THE MASTER EMERGENCY STOP SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY 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 POSIT...

Page 45: ...9 999 9 hours and cannot be reset NOTE On machines with diesel engines when Glow Plug Indicator is lighted Yellow wait until light goes out before cranking engine 7 Power Emergency Stop Switch A two position red mushroom shaped switch supplies power to Platform Ground Select switch when pulled out On When pushed in Off power is shut off to the Platform Ground Select switch 8 Engine Start Auxiliary...

Page 46: ...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 11 Platform Rotate Provides rotation of the platform 12 Machine Safety System Override MSSO CE Only Provides emergency override of function controls that are locked out in the event of Load Sense System activation 13 Air Sh...

Page 47: ...900 1 BatteryCharge 2 SystemDistress 3 DriveSteerDisable 4 PlatformCapacity 5 Generator 6 GlowPlug 7 FuelLevel 8 PlatformOverload 9 WireRopeService 10 EngineError 11 EmissionsTemperature Figure 3 5 Ground Control Indicator Panel T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 48: ...ice Manual for instructions concerning the trouble codes and trouble code retrieval The system distress indicator light will illuminate for 2 3 seconds when the key is positioned to the On position to act as a self test 3 Drive Steer Disable Indicator Indicates the Drive and Steer Disable function has been activated 4 Platform Capacity Indicator Indicates the platform capacity zone for the current...

Page 49: ... of the fuel in the fuel tank 8 Platform Overload Indicator Indicates the platform has been overloaded 9 Wire Rope Service Indicator When illuminated the light indicates the wire ropes are loose or broken and must be repaired or adjusted prior to use 10 Engine Error Indicator Indicates an engine fault requiring service 11 Emissions Temperature Indicator Indicator illuminates when the engine emissi...

Page 50: ...rSelect 3 PlatformLevelingOverride 4 FuelSelect 5 Horn 6 Power EmergencyStop 7 EngineStart AuxiliaryPower 8 DriveOrientationOverride 9 Drive Steer 10 Telescope 11 Lights 12 Jib IfEquipped 13 SoftTouch SkyGuardOverride 14 SoftTouch SkyGuardIndicator 15 PlatformRotate 16 FunctionSpeedControl 17 MainLift SwingController Figure 3 6 Platform Console T o o r d e r g o t o D i s c o u n t E q u i p m e n...

Page 51: ... 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 coordi nated steering In this mode the front and rear axles steer in the opposite directions to produce the tightest turning cir cle for maneuvering in confined areas To re synchronize the front and rear axles position the rea...

Page 52: ...to start the engine The Auxiliary Power control switch energizes the electrically operated hydraulic pump Switch must be held on for duration of auxil iary 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 Boom Lift Telescope and Swing 8 Drive Orientation Override When the ...

Page 53: ...osition when released 9 Drive Steer Push forward to drive forward pull back to drive in reverse Steering is accomplished via a thumb acti vated rocker switch on the end of the steer handle 10 Main Boom Telescope Provides extension and retraction of the main boom 11 Lights If Equipped This switch operates the accessory lights package if the machine is so equipped NOTE The ignition switch does not h...

Page 54: ...acle that caused the shut down situation 14 Soft Touch SkyGuard Indicator Indicates the Soft Touch bumper is against an object or the SkyGuard sensor has been activated All controls are cut out until the override button is pushed For Soft Touch controls are then active in the Creep Mode or for SkyGuard controls will work normally 15 Platform Rotate Provides rotation of the platform NOTE Main Lift ...

Page 55: ... automatically return to neutral Off position when released 17 Main Lift Swing Controller Provides Main Lift and Swing Push forward to lift up pull back ward to boom down Move right to swing right move left to swing left NOTE Main boom lift and swing functions may be selected in combi nation Maximum speed is reduced when multiple functions are selected T o o r d e r g o t o D i s c o u n t E q u i...

Page 56: ...Orientation 3 CapacityZoneIndicator 4 TiltAlarm Warning 5 Generator 6 Creep 7 Footswitch 8 GlowPlug 9 FuelLevel 10 LevelSystem 11 EmissionsFailure 12 PlatformOverload 13 WireRopeService 14 EngineError 15 EmissionsTemperature Figure 3 7 Platform Control Indicator Panel T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 57: ...ositioned to the ON position to act as a self test 2 Drive Orientation Indicator Indicates the Drive and Steer Disable function has been activated 3 Platform Capacity Indicator Indicates the platform capacity zone 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 capacity decals on...

Page 58: ...tion the indicator acts as a reminder that all functions are set to the slowest speed 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 sec onds or if a seven second lapse between ending one func tion and beginning t...

Page 59: ...st transport mode 24 in 61 cm or elevated more than 15 degrees above horizontal 11 Engine Emissions System Failure Indicator Indicator illuminates when there is a fault with the Emissions After Treatment system 12 Platform Overload Indicator Indicates the platform has been overloaded 13 Wire Rope Service Indicator Indicates the wire ropes are loose or broken and must be repaired or adjusted prior ...

Page 60: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 61: ...ound Control Console which will override the Platform Control Console Ground Controls operate all functions except drive and steer Except for performing inspections and the Function Check the ground controls 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 4 2 OPERATING CHARACTERISTICSAND LIMITATIONS Capacities Raising boom a...

Page 62: ...chine 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 posi tion of least BACKWARD stability is shown in See Figure 4 1 TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPER ATE THE MACHINE BEYOND THE LIMIT OF THE MAXIMUM OPERATING SLOPE O AC 01910 Figure 4 1 Po...

Page 63: ...osition of Least Forward Stability MACHINEWILLTIPOVERINTHISDIRECTION IFOVERLOADEDOROPERATEDBEYONDTHE LIMITSOFTHEMAXIMUMOPERATINGSLOPE TELESCOPE FULLYEXTENDED TURNTABLEROTATED 90DEGREESFROM STOWEDPOSITION T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 64: ...r formed from the Ground Control con sole 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 MIN UTES 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 cr...

Page 65: ...ngine starts NOTE Footswitch must be in released up position before starter will operate If starter operates with footswitch in the depressed posi tion DO NOT OPERATE MACHINE 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...

Page 66: ...located under hood to the left of the ground control panel look for test decal 3 At the ground control panel select any function and activate until valve actuates at test RPM of 1500 Once valve actuates engine will stop 4 Turn ignition to OFF 5 Visually inspect valve to ensure it appears in good condition 6 Reset valve by rotating valve handle to the Open position NOTE The handle cannot be turned ...

Page 67: ...0 times a second and the engine will react accord ing to machine setup Setup options are as follows Engine One Restart When the engine shuts down the operator will be permitted to cycle power and restart the engine once with approximately 2 minutes of run time After the 2 minute run time is complete or if the engine is shut down by the operator prior to the completion of the 2 minute run time it c...

Page 68: ...SECTION 4 MACHINE OPERATION 4 8 31215048 Figure 4 4 Grade and Side Slopes T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 69: ...RT MODE EXCEPT ON A SMOOTH FIRM SURFACE WITHIN THE LIMITS OF THE MAXIMUM OPERATING SLOPE TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED IN THE OPERATING SPECIFICATIONS SECTION OF THIS MANUAL BE SURE THE TURNTABLE LOCK IS ENGAGED BEFORE ANY EXTENDED TRAVELING DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 4 DEGREES USE EXTREME CAUTION WHEN DRIVING IN R...

Page 70: ... the opposite direction from the move ment of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direc tion arrows on both platform control panel and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Over ride switch Within 3 seconds slowly move the Drive control toward th...

Page 71: ...osition thumb switch on Drive Steer controller to Right for steering right or to Left for steering left 4 6 PLATFORM Platform LevelAdjustment 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 To Level Up or Down Position the Platform Level contro...

Page 72: ...REMOVE FOOT FROM FOOTSWITCH OR USE EMERGENCY STOP SWITCH TO STOP THE MACHINE 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 TO AVOID A COLLISION AND INJURY IF PLATFORM DOES NOT STOP WHEN A CONTROL SWITCH OR LEVER IS RELEASED REMOVE FOOT FROM FOOTSWITCH OR USE EMER GENCY ...

Page 73: ...RD OPERATION SkyGuard provides enhanced control panel protection When the SkyGuard sensor is activated functions in use at the time of actu ation will reverse or cutout The SkyGuard Function Table pro vides more details on these functions During activation the horn will sound and if equipped with a SkyGuard beacon the beacon will illuminate until sensor and footswitch are disengaged If the SkyGuar...

Page 74: ...w bar SkyGuard SkyLine Cable is pressed breaking the magnetic connection between the cable and right bracket Reattach magnetic end of cable to bracket if it becomes discon nected SkyGuard SkyEye Operator passes through path of sensor beam 0 0 0 0 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 75: ...Level Basket Rotate R C R C R R R R C C C C R IndicatesReversalisActivated C IndicatesCutoutisActivated DOS DriveOrientationSystem Enabled DOSNotEnabled machineisdrivingstraightwithoutsteering andanyotherhydraulicfunctionisactive Note IfSkyGuardisenabledwiththeSoftTouchsystem functionswillcutoutinsteadofreversing T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 76: ...AKES 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 MPH 8 KM 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...

Page 77: ...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 6 Drive Disconnect Hub 4 Position steer tow selector valve for towing pull valv...

Page 78: ...elector 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 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 79: ...and operating controls from hos tile environment IF PARKING A MEWP WITH THE BOOM ELEVATED IN AN EFFORT TO CONSERVE SPACE BOOMS MAY BE ELEVATED BUT SHALL NOT BE EXTENDED IT IS THE OPERATOR S RESPONSIBILITY TO ENSURE ALL SAFETY PRECAUTIONS IN SECTION 1 OF THIS MAN UAL ARE FOLLOWED FOR EACH UNIQUE SITUATION 4 15 LIFTING AND TIE DOWN Lifting 1 Call JLG Industries or weigh the individual unit to find o...

Page 80: ...lows 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 turnta ble locked DRIVE AND STEER CONTROLLERS WILL BE REVERSED WHEN THE BOOM IS POSI TIONED OVER THE FRONT WHEELS c Drive it onto the trailer with the boom and platform positioned towards the truck Refer to Figure 4 7 Typi...

Page 81: ...SECTION 4 MACHINE OPERATION 31215048 4 21 Figure 4 7 Typical 800S 860SJTransport T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 82: ...SECTION 4 MACHINE OPERATION 4 22 31215048 Figure 4 8 Lifting and Tie Down Chart T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 83: ...NE OPERATION 31215048 4 23 O AC02030 54 101 104 32 30 253 108 36 55 66 31 39 205 204 245 206 49 Figure 4 9 Decal Location 800S Decal Location Sheet 1 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 84: ...5048 OAC02040 104 301 103 55 54 101 104 32 64 301 101 104 61 245 206 53 205 38 245 40 40 31 203 60 AUS 49 203 AUS 34 Figure 4 10 Decal Location 800S Decal Location Sheet 2 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 85: ... 4 MACHINE OPERATION 31215048 4 25 32 32 106 205 203 38 206 204 AUS 61 31 34 O AC 02050 Figure 4 11 Decal Location 800S Decal Location Sheet 3 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 86: ...OPERATION 4 26 31215048 41 AUS 107 26 52 204 AUS 206 205 205 204 204 205 205 204 109 AUS OAC02060 Figure 4 12 Decal Location 800S Decal Location Sheet 4 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 87: ... 41 AUS 25 201 105 56 44 58 48 46 102 105 57 56 59 56 105 201 51 204 204 202 65 33 202 33 ANSI ANSI EXPORT CE AUS O AC 02070 Figure 4 13 Decal Location 800S Decal Location Sheet 5 of 5 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 88: ...1257257 1001257239 1001257257 34 1001257230 1001257234 1001257236 1001257238 1001257242 1001257232 1001257258 1001257240 1001257258 36 1001131269 1001131269 39 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 40 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 41 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051...

Page 89: ...001223971 1001139654 1001224053 64 1001223453 1001223453 66 1001244298 100 1001109029 1001109029 1001109029 1001109029 1001109029 1001109029 1001199949 1001109029 1001199949 101 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 102 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 103 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 170381...

Page 90: ...703949 1703947 1705898 1703948 1705961 1703950 1705961 205 1703805 1703939 1001116851 1703935 1705897 1703936 1705828 1703938 1705828 206 1703953 1703945 1703943 1703941 1705903 1703942 1703944 210 1703981 1703982 1703983 1705902 1703984 1703980 300 2902354 2902354 2902354 2902354 2902354 2902354 2902354 2902354 2902354 301 1703475 1703475 1703475 1703475 1703475 1703475 1703475 1703475 1703475 Ta...

Page 91: ... 1001257254 1001257260 36 1001131269 1001131269 39 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 1001175354 40 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 1701691 41 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 4420051 44 0860520 0860520 0860520 0860520 0860520 0860520 0860520 0860520 0860520 46 3311405 3311405 331140...

Page 92: ...1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 102 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 103 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 104 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 105 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 106 1704412 1704412 1704412 1704...

Page 93: ...97 1703936 1705828 1703938 1705828 206 1703953 1703945 1703943 1703941 1705903 1703942 1703944 210 1703981 1703982 1703983 1705902 1703984 1703980 300 2902429 2902429 2902429 2902429 2902429 2902429 2902429 301 1703482 1703482 1703482 1703482 1703482 1703482 1703482 Item ANSI 1001242586 C Korean 1001242597 C Chinese 1001242655 C Spanish 1001242695 C Portuguese 1001242701 C French 1001242754 C CE 1...

Page 94: ...arranty consideration on that particular machine FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CON TROLS DO NOT LIFT ABOVE 3 M 10 FT UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING COR RECTLY 5 3 EMERGENCYOPERATION Operator Unableto Control Machine IF THE PLATFO...

Page 95: ...rols use the Auxiliary Power System if equipped to carefully free the platform or boom from the object 5 Once clear restart the machine and return the platform to a safe position 6 Inspect the machine for damage If the machine is damaged or does not operate properly turn off the machine immedi ately Report the problem to the proper maintenance per sonnel Do not operate the machine until it is decl...

Page 96: ...r is set with a fault code in the JLG Control System which must be reset by a qualified JLG Service Technician NOTE No functional checks of the MSSO system are necessary The JLG Control system will set a Diagnostic Trouble Code if the control switch is faulty To operate the MSSO 1 From the ground control console place the Platform Ground Select switch in the Ground position 2 Pull out the Power Em...

Page 97: ...ry Market ANSI USA Only ANSI CSA CE AUS Japan China FallArrestPlatform 36 x96 FallArrestPlatform 36 x72 PipeRacks SkyAir SkyCutter SkyGlazier SkyPower SkyWelder SoftTouch Bolt OnExternalFallArrest 36 x96 Bolt OnExternalFallArrest 36 x72 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 98: ...r SkyWelder 4 Platform PipeRacks PlatformMeshtoTopRail SoftTouch SkyGlazier SkyGlazier SkyPower 4 Platform PipeRacks PlatformMeshtoTopRail SoftTouch SkyCutter SkyWelder SkyPower SkyCutter SkyGlazier SkyWelder SkyWelder SkyPower SkyCutter 4 Platform PipeRacks PlatformMeshtoTopRail SoftTouch SkyGlazier SoftTouch PipeRacks SkyCutter SkyGlazier SkyWelder Note1 Anynon Sky accessorynotlistedunder INCOMP...

Page 99: ...body harness is required with lanyard not to exceed 6 ft 1 8 m in length that limits the maximum arrest force to 900 lb 408 kg for the trans fastener type and 1350 lb 612 kg for the shuttle type fall arrest system Safety Precautions DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE THE PLATFORM USE CAUTION WHEN ENTERING EXITING THE PLATFORM AT ELEVATION 6 2 PIPERACKS Pipe Racks provide a way to s...

Page 100: ...e racks are secured to the platform rails Replace torn or frayed tie down straps Operation 1 To prepare racks for loading remove locking pins rotate each rack 90 degrees from stowed to working position then secure with locking pins 2 Loosen and remove tie down straps Place material on racks with weight evenly distributed between both racks 3 Route the tie down straps at each end across loaded mate...

Page 101: ...system CompressorSpecifications Single stage with dual control CFM displacement 9 3 Motor 230 V 2 hp 3 phase Accessory Ratings Safety Precautions DO NOT OVERLOAD PLATFORM Ensure no personnel are beneath platform This factory installed option is available only on specified models Keep lanyard attached at all times CONTROLMODE VOLUME AutomaticStart Stop Control 100 130psi ConstantRunControl 105 120p...

Page 102: ...n the generator then turn on the air com pressor Refer to the J Air Manual PN 3128970 for more information 6 4 SKYCUTTER SkyCutter is capable of cutting up to a thickness of 3 8 metal It can produce 27 A at 92 VDC at 35 duty cycle or 14 A at 92 VDC at 60 duty cycle It receives power from the SkyPower system T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 103: ...ts Check for secure installation of cutter and bracket Spec RatedOutput AmperesInput RatedOutput 60 Hz 1 Phase kVa kW PlasmaGas PlasmaGasFlow Pressure RatedCutting Capacity 10IPM Max OCV 120Volts 10 20A 27A 91VDC 20 DutyCycle 28 8max 0 30 3 4kVa 3 2kW AirorNitrogenOnly 90 120psi 621 827kPa 4 5cfm 129L Min 60psi 414kPa 3 8in 10mm 400VDC 120Volts 10 15A 20A 88VDC 35 DutyCycle 20 6max 0 30 2 5kVa 2 3...

Page 104: ...s Preparation and Inspection Connect ground clamp to metal being cut Ensure there is a good ground connection Operation Start the engine turn on the generator then turn on the plasma cutter Refer to the Miller Plasma Cutter Owner s Manual PN 3128420 for more information 6 5 SKYGLAZIER SkyGlazier allows glaziers to position panels efficiently The gla zier package consists of a tray that attaches th...

Page 105: ...EASE STABILITY LIMIT PANEL AREA TO 32 SQ FT 3 SQ M Ensure no personnel are beneath platform Do not exit platform over rails or stand on rails Remove tray when not in use Use this option only on approved models CapacityZone Max Tray Capacity Max PlatformCapacity With Max WeightinTray 500lb 227kg 150lb 68kg 250lb 113kg 550lb 250kg 150lb 68kg 250lb 113kg 600lb 272kg 150lb 68kg 250lb 113kg 750lb 340kg...

Page 106: ...rn or frayed Operation 1 Load SkyGlazier tray with panel 2 Route the adjustable strap around the panel and tighten until secure 3 Position panel to its desired location 6 6 SKYPOWER The SkyPower system supplies AC power to the platform through an AC receptacle to run tools lights cutting and weld ing equipment T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 107: ...26 A 1 0 pf 1 phase 120 V 6 0 kW 50 A 1 0 pf Peak 3 phase 8 5 kW 1 phase 6 0 kW Accessory Ratings 3000 rpm 50 Hz 3600 rpm 60 Hz Safety Precautions DO NOT OVERLOAD PLATFORM Ensure no personnel are beneath platform This factory installed option is available only on specified models Keep lanyard attached at all times Do not use electrical tools in water Use correct voltage for tool being used Do not ...

Page 108: ...ower from the SkyPower system Generator Output Engine Speed of 1800 rpm 10 ANSI Specifications 3 phase 240 V 60 Hz 7 5 kW 1 phase 240 V 120 V 60 Hz 6 kW CE Specifications 3 phase 400 V 50 Hz 7 5 kW 1 phase 220 V 50 Hz 6 kW Welding Accessories 12 ft welding leads with clamp and stinger stored in the platform Fire extinguisher T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 109: ...ls Use this option only on approved models Keep lanyard attached at all times Ensure correct polarity of leads Wear proper welding apparel Welding Mode Input Power Rated Output Welding Amperage Range MaximumOpen CircuitVoltage Amps InputAt Rated LoadOutput 50 60 Hz 230V 460 V 575V kVa kW Stick SMAW TIG GTAW 3 phase 280Ampat31 2V 35 DutyCycle 5 250A 79VDC 32 17 13 15 7 10 200Ampat28V 100 DutyCycle ...

Page 110: ...oper polarity Operation Start the engine turn on the generator then turn on the welder Refer to the Miller Welder Owner s Manual PN 3128957 for more information 6 8 SOFT TOUCH A padding kit is mounted to the platform rails and to a frame sus pended below the platform Limit switches deactivate platform functions when the padded framework contacts an adjacent structure A button on the platform conso...

Page 111: ... capacity is 310 lb 140 kg one 1 person maximum Do not move platform during use of the external fall arrest system DO NOT OPERATE ANY MACHINE FUNCTIONS WHILE OUTSIDE OF PLATFORM BE CAREFUL WHEN ENTERING EXITING THE PLATFORM AT ELEVATION IF THE EXTERNAL FALL ARREST SYSTEM IS USED TO ARREST A FALL OR IS OTHERWISE DAMAGED THE ENTIRE SYSTEM MUST BE REPLACED AND THE PLATFORM FULLY INSPECTED BEFORE RETU...

Page 112: ...gs Brackets Ensure all fittings are tight and there are no signs of fractures Inspect brackets for any damage Attachment Ring No cracks or signs of wear are acceptable Any signs of corrosion requires replacement Attaching Hardware Inspect all attaching hardware to ensure there are no missing components and hardware is properly tight ened Platform Rails No visible damage is acceptable NO GAP CORREC...

Page 113: ...17 I 8 7 1 2 3 4 6 9 5 Figure 6 2 Bolt On External Fall Arrest System 1 BellevilleWasher 2 Washer 3 HexNut 4 JamNut 5 LHBracket 6 AttachmentRing 7 Cable 8 RHBracket 9 Decal T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 114: ...ded in the Service and Maintenance Manual Other Publications Available Service and Maintenance Manual 31215049 Illustrated Parts Manual 31215050 7 2 OPERATING SPECIFICATIONS Table 7 1 Operating Specifications MaximumWorkLoad Capacity AllMarkets Unrestricted Restricted 500lb 227kg RefertoCapacityDecalsonmachinefor restrictedplatformcapacities MaximumCapacity DualRating AllMarkets 800S 860SJ 1000lb ...

Page 115: ...33 030lb 14 982kg 36 230lb 16 433kg Withboominstowedposition Table 7 1 Operating Specifications Table 7 2 Specifications and Performance Data Swing 360 TailSwing 4 8 1 42m Platforms 36 x72 0 91mx1 83m 36 x96 0 91mx2 44m OverallWidth 8 2 2 48m StowedHeight 800S 860SJ 9 11 3 02m 10 3 04m StowedLength 800S 860SJ 37 3 25 11 4m 40 12 2m Wheelbase 800S 860SJ 10 3 06m GroundClearance 800S 860SJ 11 0 28m ...

Page 116: ...em Crankcase TotalCapacity DeutzTD2 9L Ford2 5L 5Quarts 4 5L 11Quarts 10 5L w Filter 16Quarts 15L 2 4Gallon 8 9L w Filter 7Quarts 6 6L w Filter Table 7 2 Specifications and Performance Data Table 7 4 Deutz D2011L04 Specifications Type LiquidCooled Oil Fuel Diesel OilCapacity CoolingSystem Crankcase TotalCapacity 5Quarts 4 5L 11Quarts 10 5L w Filter 16Quarts 15L IdleRPM 1000 LowRPM 1800 HighRPM 260...

Page 117: ...PH 4 0LPH Table 7 6 Ford 2 5L DF Specifications Fuel GasolineorGasoline LPGas BHP Gasoline LP 84hp 3200rpm 80hp 3200rpm Bore 4 0in 101 6mm Stroke 3 6in 91 44mm Displacement 181cu in 3 0L 2966cc OilCapacityw filter 7Quarts 6 6L MinimumOilPressure atidle Hot 6psi 0 4Bar 1000rpm 18psi 1 2Bar 2000rpm CoolantCapacity 0 63Gal 2 4L StarterRating 12V64 4A 3574RPM AlternatorRating 12V 150Amp FanRatio 1 3 M...

Page 118: ...16 H N A 18 625 foam filled 16 H N A Table 7 9 Component Weights Component Pounds Kilograms Turntable bare 3700 1678 Counterweight S 7000 3175 Counterweight SJ 8750 3969 Upright 1050 476 Tower 685 311 FlyBoom SJ 472 214 FlyBoom S 490 222 MidBoom SJ 750 340 MidBoom S 740 336 BaseBoom SJ 1400 635 BaseBoom S 1410 640 BoomAssembly 3337 1514 TelescopeCylinder 800S 590 268 TelescopeCylinder 860SJ 579 26...

Page 119: ...able to mix oils of differ ent brands or types as they may not contain the same required addi tives or be of comparable viscosities If use of hydraulic oil other than standard UTTO is desired contact JLG Industries for proper recommen dations Table 7 10 Hydraulic Oil Hydraulic System Operating TemperatureRange S A E Viscosity Grade 0 to 180 F 18 to 83 C 10W 0 to 210 F 18 to 99 C 10W 20 10W30 50 to...

Page 120: ...at0 C 32 F 340cSt 1600SUS at40 C 104 F 46cSt 215SUS at65 C 150 F 22cSt 106SUS ViscosityIndex 170 Table 7 13 Mobil DTE 10 Excel 32 Specs ISOViscosityGrade 32 SpecificGravity 0 877 PourPoint Max 40 F 40 C FlashPoint Min 330 F 166 C Viscosity at40 C 33cSt at100 C 6 6cSt at100 F 169SUS at210 F 48SUS cpat 20 F 6 200 ViscosityIndex 140 T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 121: ... 17to162 C Weight 7 64lb pergal 0 9kgperliter Viscosity at40 C 37cSt at100 C 8 4cSt ViscosityIndex 213 NOTE Must be stored above 32 F 14 C Table 7 15 Exxon Univis HVI 26 Specs SpecificGravity 32 1 PourPoint 76 F 60 C FlashPoint 217 F 103 C Viscosity at40 C 25 8cSt at100 C 9 3cSt ViscosityIndex 376 NOTE Mobil Exxon recommends that this oil be checked on a yearly basis for viscosity T o o r d e r g ...

Page 122: ...CATION A serial number plate is affixed to the left rear side of the frame If the serial number plate is damaged or missing the machine serial num ber is stamped on the left side of the frame Figure 7 1 Serial Number Locations T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 123: ...GED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY AMBIENT AIR TEMPERATURE SUMMER GRADE FUEL WINTER GRADE FUEL WINTER GRADE FUEL WITH KEROSENE ADDED NO OPERATION BELOW THIS AMBIENT TEMPERATURE NO OPERATION ABOVE THIS AMBIE...

Page 124: ...ULIC SPECIFICATIONS NO OPERATION ABOVE THIS AMBIENT TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 HYDRAULIC OIL BELOW THIS TEMPERATURE DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE EXXON UNIVIS HVI 26 MOBIL DTE 13 N OT E 1 R E COM M E N D A T ION SA R EF ORA M B IE N TT E M P E R A T U R E S CON S IS ...

Page 125: ...SECTION 7 GENERAL SPECIFICATIONS OPERATOR MAINTENANCE 7 12 31215048 Figure 7 4 Maintenance and Lubrication Diagram T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 126: ...wing Bearing Internal Ball Bearing Lube Point s 1 Grease Fittings Capacity A R Lube MPG Interval Every 3 months or 150 hrs of operation Comments Remote Access Table 7 16 Lubrication Specifications KEY SPECIFICATIONS MPG MultipurposeGreasehavingaminimumdrippingpointof350 F 177 C Excel lentwaterresistanceandadhesivequalities andbeingofextremepressuretype TimkenOK40poundsminimum EPGL ExtremePressureG...

Page 127: ...e Point s Level Fill Plug Capacity 44 oz 1 3 L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hours of opera tion change every 2 years or 1200 hours of operation Comments Place Fill port at 12 o clock position and Check port at 3 o clock position Pour lubricant into fill port until it just starts to flow out of check port T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m...

Page 128: ... first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator 5 Hydraulic Charge Filter Interval Change after first 50 hours and every 6 months or 300 hours thereafter or as indicated by Condition Indicator if equipped T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 129: ...Cap Capacity Tank to Full mark on sight gauge Approx 21 gallons 79 5 liters System Capacity 59 gallons 223 liters Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation 7 Platform Filter Interval Change as necessary T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 130: ...l Every Year or 1200 hours of operation Comments Check level daily Change in accordance with engine manual B Oil Change w Filter Deutz TD2 9 Lube Point s Fill Cap Spin on Element Capacity 9 6 Quarts 9 0 L Lube EO Interval Every Year or 600 hours of operation Comments Check level daily Change in accordance with engine manual T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 131: ...Deutz 2011 Engine Dipstick MAXIMUMOIL LEVEL NOTE Hotoilchecksshouldbemadeaperiodof5minutesaftertheenginehasbeenshutdown MINIMUMLEVELOIL HOT MAXIMUMLEVELOIL HOT MINIMUMLEVELOIL COLD MAXIMUMLEVELOIL COLD MINIMUMOIL LEVEL T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 132: ...on Element Capacity 4 5 qt 4 25 L w filter Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 10 Fuel Filter Deutz D2011 Lube Point s Replaceable Element Interval Every Year or 600 hours of operation T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 133: ...ent Interval Change in accordance with engine manual C Fuel Filter Deutz TD2 9 On Engine Lube Point s Replaceable Element Interval Change in accordance with engine manual 11 Fuel Filter Gasoline GM Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 134: ...ment Interval Every 6 months or 300 hours of operation or as indi cated by the condition indicator B Air Filter Deutz TD 2 9 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

Page 135: ...ct from service immediately and arrange ments must be made for replacement of the tire or tire assembly a smooth even cut through the cord plies which exceeds 3 inches 7 5 cm in total length any tears or rips ragged edges in the cord plies which exceeds 1 inch 2 5 cm in any direction any punctures which exceed 1 inch in diameter any damage to the bead area cords of the tire If a tire is damaged bu...

Page 136: ... the tire manufacturer including inflation pressure and maximum tire load Unless specifically approved by JLG Industries Inc do not replace a foam filled or ballast filled tire assembly with a pneumatic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recommended by JLG Due to size variations between tire brands both tires on the same axle sh...

Page 137: ...y have a service garage or dealer tighten the lug nuts to the proper torque Over tightening will result in breaking the studs or permanently deforming the mounting stud holes in the wheels The proper procedure for attaching wheels is as follows 1 Start all nuts by hand to prevent cross threading DO NOT use a lubricant on threads or nuts 2 Tighten nuts in the following sequence 3 The tightening of ...

Page 138: ...nting plate to lock off O ring seal Installation BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL 1 Install the mounting plate to lock off O ring seal 2 If equipped install the retaining bolt seal 3 Install the housing seal 4 Drop the magnet into the bottom of the filter housing 5 Install the filter into the housing 6 If equipped install the retaining bolt into th...

Page 139: ...ve propane fuel system pressure 1 Close the manual shut off valve on the propane fuel tank 2 Start and run the vehicle until the engine stalls 3 Turn the ignition switch Off RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYSTEM ENSURE THE WORK AREA IS WELL VENTILATED BEFORE DISCONNECTING ANY FUEL LINE 1 ElectricLockOffSolenoid 2 HousingSeal 3 FilterMagnet 4 FilterHousing 5 ElectricalConnector...

Page 140: ...ound Power Level LWA per European Directive 2000 14 EC Noise Emission in the Environment by Equipment for Use Outdoors based on test methods in accordance with Annex III Part B Method 1 and 0 of the directive is 106 dB for Tier4i engines 113 dB for machines equipped with T4F engines and steel hoods and 112 dB for machines equipped T4F engines and ABS hoods The vibration total value to which the ha...

Page 141: ...S Curtis Gehl Pavers Heli Honda ICS PowerGrit IHI Partner Imer Clipper MMD Koshin Rice CH E General Equip ment Amida Coleman NAC Gradall Square Shooter Kent Stanley Tamco Toku Hatz Kohler Robin Wisconsin Northrock Oztec Toker TK Rol Air APT Wylie Ingersoll Rand Doosan Innovatech Con X Ammann Mecalac Makinex Smith Surface Prep Small Line Wanco Yanmar Discount Equipment com is your online resource f...

Page 142: ...T o o r d e r g o t o D i s c o u n t E q u i p m e n t c o m ...

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