JLG 800A Use and care manual

Operation and Safety Manual
ANSI
®
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
800A
800AJ
S/N 0300183034 to
Present
3121627
November 5, 2018 - Rev I

NOTE: This manual also applies to machines with the following Serial Num-
bers: 0300174954, 0300180871, and 0300181353.
WARNING
Operating, servicing and maintaining this vehicle or equipment
can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of
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.

FOREWORD
3121627 a
FOREWORD
This manual is a very important tool! Keep it with the machine at all times.
The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions 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.

FOREWORD
b3121627
SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT AVOIDED, WILL
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE A RED BACK-
GROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT AVOIDED, COULD
RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL WILL HAVE AN ORANGE BACK-
GROUND.
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 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
hazards. Obey all safety messages that follow this symbol to avoid possible injury or
death

FOREWORD
3121627 c
THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLETINS. CONTACT JLG
INDUSTRIES, INC. OR THE LOCAL AUTHORIZED JLG REPRESENTATIVE FOR INFORMA-
TION REGARDING SAFETY-RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR
THIS PRODUCT.
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 PER-
SONAL 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:
Phone: [phone]
Fax: [phone]
E-mail: [e-mail]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Special
Product Applications
• Questions Regarding Prod-
uct Modifications

FOREWORD
d3121627
REVISION LOG
Original Issue A - March 20, 2014
Revised B - April 30, 2014
Revised C - June 4, 2014
Revised D - January 5, 2015
Revised E - June 30, 2017
Revised F - March 23, 2018
Revised G - May 30, 2018
Revised H - June 29, 2018 - Revised Covers, Prop 65
Revised I - November 5, 2018

3121627 i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . 1-10
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . 1-11
1.5 MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Maintenance Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3 FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
From the Ground Control Station with No Load in the
Platform:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
From the Platform Control Station: . . . . . . . . . . . . . . . 2-13
SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-17
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 . . . . . . . . . . . . . . . . . . . . 3-8
Platform Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Platform Console Indicator Panel. . . . . . . . . . . . . . . . . 3-18
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 BOOM OPERATING CHARACTERISTICS AND
LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Air Shutoff Valve (ASOV) (If Equipped). . . . . . . . . . . . . . 4-6
Fuel Reserve / Shut-Off System. . . . . . . . . . . . . . . . . . . . . 4-7

ii 3121627
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.4 TRAVELING (DRIVING). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . 4-10
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . 4-11
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-13
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-14
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-14
4.8 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.9 MACHINE SAFETY SYSTEM OVERRIDE (MSSO)
(CE ONLY) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
4.10 SKYGUARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
SkyGuard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
SkyGuard - SkyLine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
SkyGuard - SkyEye. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
SkyGuard Function Table . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.11 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Lifting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Tie Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.12 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-19
4.13 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.14 TOW BAR (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-21
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-22
Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-22
4.16 RE-SYNCHRONIZE UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
Releveling Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22
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 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

3121627 iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3 SKYAIR™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.4 SKYCUTTER™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
6.5 SKYGLAZIER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Capacity Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-10
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
6.6 SKYPOWER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-11
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
6.7 SKYWELDER™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Generator Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Welding Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Accessory Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Preparation and Inspection . . . . . . . . . . . . . . . . . . . . . . 6-14
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.8 SOFT TOUCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
6.9 BOLT-ON EXTERNAL FALL ARREST . . . . . . . . . . . . . . . . . . . 6-15
Inspection Before Use . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
SECTION - 7 - GENERAL SPECIFICATIONS & OPERATOR
MAINTENANCE
7.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 OPERATING SPECIFICATIONS AND PERFORMANCE
DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Operating Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Critical Stability Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7.3 MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . . . 7-14
7.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

iv 3121627
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Tire Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
7.5 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 7-26
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
7.6 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 7-28
7.7 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 7-28
SECTION - 8 - INSPECTION AND REPAIR LOG

3121627 v
LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
2-1. Basic Nomenclature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2-2. Daily Walk-Around Inspection (Sheet 1 of 3) . . . . . . . . . . 2-6
2-3. Daily Walk-Around Inspection (Sheet 2 of 3) . . . . . . . . . . 2-7
2-4. Daily Walk-Around Inspection (Sheet 3 of 3) . . . . . . . . . . 2-8
2-5. Tower Boom Vertical Limit Switch . . . . . . . . . . . . . . . . . . . . 2-9
2-6. Tower Boom Horizontal Limit Switch . . . . . . . . . . . . . . . . 2-10
2-7. Boom Upright Positioning - Correct. . . . . . . . . . . . . . . . . . 2-11
2-8. Boom Upright Positioning - Incorrect . . . . . . . . . . . . . . . . 2-12
3-1. Ground Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3-2. Ground Control Console with Machine Safety System . . .
Override (MSSO) (CE Only). . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3-3. Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . . . 3-9
3-4. Platform Control Console . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
3-5. Platform Console Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-19
4-1. Position of Least Forward Stability . . . . . . . . . . . . . . . . . . . . 4-2
4-2. Positions of Least Backward Stability (Sheet 1 of 2) . . . . 4-3
4-3. Positions of Least Backward Stability (Sheet 2 of 2) . . . . 4-4
4-4. ASOV Reset (Closed to Open Position) . . . . . . . . . . . . . . . . 4-7
4-5. Grade and Sideslopes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
4-6. Lifting Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
4-7. Tow Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4-8. Releveling Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
4-9. Decal Installation - Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . 4-24
4-10. Decal Installation - Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . 4-25
4-11. Decal Installation - Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . 4-26
4-12. Decal Installation - Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . 4-27
4-13. Decal Installation - Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . 4-28
6-1. Bolt-On External Fall Arrest Cable Tension . . . . . . . . . . . 6-16
6-2. Bolt-On External Fall Arrest System . . . . . . . . . . . . . . . . . . 6-18
7-1. Engine Operating Temperature Specifications - Deutz - . .
Sheet 1 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
7-2. Engine Operating Temperature Specifications - Deutz - . .
Sheet 2 of 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
7-3. Engine Operating Temperature Specifications - GM - Sheet
1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
7-4. Engine Operating Temperature Specifications - GM - Sheet
2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
7-5. Maintenance and Lubrication Diagram . . . . . . . . . . . . . . 7-13
7-6. Deutz 2011 Engine Dipstick . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
7-7. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

vi 3121627
LIST OF FIGURES
FIGURE NUMBER - TITLE PAGE FIGURE NUMBER - TITLE PAGE
This Page Left Blank Intentionally

3121627 vii
LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . . . . . . . 1-6
1-2 Beaufort Scale (For Reference Only). . . . . . . . . . . . . . . . . . . 1-9
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . . . . . . . 2-3
4-1 Decal Legend - 800A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-29
4-2 Decal Legend - 800AJ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-33
6-1 Available Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Options/Accessories Relationship Table. . . . . . . . . . . . . . . 6-2
7-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7-2 Tire Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-4 Deutz D2011L04 Specifications . . . . . . . . . . . . . . . . . . . . . . . 7-3
7-5 Deutz TD 2.9 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-6 GM 3.0L. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
7-7 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-8 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7-9 Mobil DTE 10 Excel 32 Specs. . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-10 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
7-11 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-12 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
7-13 Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
7-14 Lubrication Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . .7-14
7-15 Wheel Torque Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-26
8-1 Inspection and Repair Log. . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

viii 3121627
LIST OF TABLES
TABLE NUMBER - TITLE PAGE TABLE NUMBER - TITLE PAGE
This Page Left Blank Intentionally

SECTION 1 - SAFETY PRECAUTIONS
3121627 1-1
SECTION 1. SAFETY PRECAUTIONS
1.1 GENERAL
This section outlines the necessary precautions for proper and
safe machine usage and maintenance. It is mandatory that a daily
routine is established based on the content of this manual to pro-
mote proper machine usage. A maintenance program, using the
information provided in this manual and the Service and Mainte-
nance Manual, must also be established by a qualified person and
must be followed to ensure that the machine is safe to operate.
The owner/user/operator/lessor/lessee of the machine must not
accept operating responsibility until this manual has been read,
training is accomplished, and operation 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 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
• The Operation and Safety Manual must be read and under-
stood in its entirety before operating the machine. For clarifi-
cation, questions, or additional information regarding any
portions of this manual, contact JLG Industries, Inc.

SECTION 1 - SAFETY PRECAUTIONS
1-2 3121627
• An operator must not accept operating responsibilities until
adequate training has been given by competent and autho-
rized persons.
• Allow only those authorized and qualified personnel to oper-
ate the machine who have demonstrated that they under-
stand the safe and proper operation and maintenance of the
unit.
• Read, understand, and obey all DANGERS, WARNINGS, CAU-
TIONS, and operating instructions on the machine and in this
manual.
• Ensure that the machine is to be used in a manner which is
within the scope of its intended application as determined 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 your utilization
and application of the machine.
Workplace Inspection
• 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 unless the application is approved in writing by JLG.
• Before operation, check work area for overhead hazards such
as electric lines, bridge cranes, and other potential overhead
obstructions.
• Check operating surfaces for holes, bumps, drop-offs, obstruc-
tions, debris, concealed holes, and other potential hazards.
• Check the work area for hazardous locations. Do not operate
the machine in hazardous environments unless approved for
that purpose by JLG.
• 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.

SECTION 1 - SAFETY PRECAUTIONS
3121627 1-3
Machine Inspection
• Do not operate this machine until the inspections and func-
tional checks as specified in Section 2 of this manual have
been performed.
• Do not operate this machine until it has been serviced and
maintained according to the maintenance and inspection
requirements as specified in the machine’s Service and Main-
tenance Manual.
• Ensure all 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 PRIOR WRITTEN PERMISSION FROM THE MANUFACTURER.
• Do not operate any machine on which the safety or instruction
placards or decals are missing or illegible.
• Check the machine for modifications to original components.
Ensure that any modifications have been approved by JLG.
• Avoid accumulation of debris on platform floor. Keep mud, oil,
grease, and other slippery 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 user must be familiar with the machine
capabilities and operating characteristics of all functions.
• Never operate a malfunctioning machine. If a malfunction
occurs, shut down the machine. Remove the unit from service
and notify the proper authorities.
• Do not remove, modify, or disable any safety devices.
• 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 con-
trols 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.

SECTION 1 - SAFETY PRECAUTIONS
1-4 3121627
• Do not carry materials directly on platform railing unless
approved by JLG.
• 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.
• 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 or pull-
ing except by pulling at the chassis tie-down lugs.
• Fully lower platform and shut off all power before leaving
machine.
• Remove all rings, watches, and jewelry when operating
machine. 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 boom and/or plat-
form position while the machine is stationary. Factors
affecting thermal movement can include the length of time
the machine will remain stationary, hydraulic oil temperature,
ambient air temperature, and boom and platform position.
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.
• Enter and exit only through gate area. Use extreme caution
when entering or leaving platform. Ensure that the platform
assembly is fully lowered. Face the machine when entering or
leaving the platform. Always maintain “three point contact”
with the machine, using two hands and one foot or two feet
and one hand at all times during entry and exit.

SECTION 1 - SAFETY PRECAUTIONS
3121627 1-5
• 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 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.
Electrocution Hazards
• This machine is not insulated and does not provide protection
from contact or proximity to electrical current.

SECTION 1 - SAFETY PRECAUTIONS
1-6 3121627
• Maintain distance from electrical lines, apparatus, or any ener-
gized (exposed or insulated) parts according to the Minimum
Approach Distance (MAD) as shown in Table 1-1.
• Allow for machine movement and electrical line swaying.
• Maintain a clearance of at least 10 ft. (3m) between any part of
the machine and its occupants, their tools, and their 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(14)
NOTE: This requirement shall apply except where
employer, local or governmental regulations are
more stringent.