JLG 800AJ HC3 Use and care manual

Copyright ©
ANSI
AS/NZS MOL70 GB
Operation & Safety
Manual
Original Instructions -
Keep this manual with the machine at all times.
Model
800AJ HC
PVC 2307
1222411
July 26, 2023 - Rev B

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 re-
productive harm. To minimi e 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 infor-
mation go to www.P65Warnings.ca.gov.

800AJ HC3 31222411 3
FOREWORD
The Mobile Elevating Work Platform (MEWP) models covered in this manual are
designed and tested to meet or exceed various compliance standards. Please refer to
the manufacturer’s nameplate affixed to the subject MEWP for specific standard
compliance information.
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.
Refer to www. JLG. com for Warranty, Product Registration, and other machine-related
documentation.

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS
This is the Safety Alert Symbol. It is used to alert you to the potential personal injury
ha ards. Obey all safety messages that follow this symbol to avoid possible injury or
death.
DANGER
Indicates an imminently ha ardous situation. If not avoided, will result in serious
injury or death. This decal will have a red background.
WARNING
Indicates a potentially ha ardous situation. If not avoided, could result in serious
injury or death. This decal will have an orange background.
CAUTION
Indicates a potentially ha ardous 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.
NOTICE
Indicates information or a company policy that relates directly or indirectly to the
safety of personnel or protection of property.
Foreword
431222411 800AJ HC3

Foreword
800AJ HC3 31222411 5
WARNING
This product must comply with all safety related bulletins. Contact JLG Industries,
Inc. or the local authori ed JLG representative for information regarding safety
related bulletins which may have been issued for this product.
NOTICE
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.
NOTICE
JLG Industries, Inc. must be notified immediately in all instances where JLG
products have been involved in an accident involving bodily injury or death or
when substantial damage has occurred to personal property or the JLG product.

For
• Accident Reporting
• Product Safety Publications
• Current Owner Updates
• Questions Regarding Product Safety
• Standards and Regulations Compliance Information
• Questions Regarding Special Product Applications
• Questions Regarding Product Modifications
Contact
Product Safety and Reliability Department
JLG Industries, Inc.
13224 Fountainhead Pla a
Hagerstown, MD 21742
USA
or Visit www.jlg.com to find your local JLG office.
In USA
Toll Free: 877-JLG-SAFE (877-554-7233)
Outside USA
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Foreword
631222411 800AJ HC3

800AJ HC3 31222411 7
REVISION LOG
Date Revision Description
July 10, 2023 AOriginal Issue
July 26, 2023 B Revision
Other Publications Available
Publication Publication Number
Service & Maintenance Manual 31222412
Illustrated Parts Manual 31222413

8
This Page is intentionally left blank

800AJ HC3 31222411 9
SECTION CONTENTS
Section Subject Page
FOREWORD ....................................................................................... 3
REVISION LOG .................................................................................. 7
SECTION 1
SAFETY PRECAUTIONS.................................................................. 13
1.1 General.............................................................................13
1.2 Pre-Operation....................................................................13
1.3 Operation .........................................................................15
1.4 Towing, Lifting, and Hauling ............ ...... ...... .................... .... 21
1.5 Maintenance .....................................................................21
SECTION 2
USER RESPONSIBILITIES, MACHINE PREPARATION, AND
INSPECTION .................................................................................... 25
2.1 Personnel Training .............................................................25
2.2 Preparation, Inspection, and Maintenance ............................. 26
2.3 Machine Components.........................................................28
2.4 Pre-Start Inspection . .... .... .... ..... .... .... .... ..... .... .... .... ..... .... .... 29
2.5 Walk-Around Inspection...................................................... 30
2.6 Function Check..................................................................32
2.7 SkyGuard® Function Test . ... ..... .... .... ..... .... .... .... .... .... ..... .... .. 39
2.8 Oscillating Axle Lockout Test (If Equipped) ............................ 39
SECTION 3
MACHINE CONTROLS AND INDICATORS.................................... 41
3.1 General.............................................................................41
3.2 Controls and Indicators . .. .... .. .. .. .. .. .... .. .. ..... .. .... .. .. .. .. .. .... .. .. . 42
3.3 Ground Control Station. ... ... ... ....................... ... ... ... ............. 43
3.4 Ground Control Indicator Panel............................................ 47
3.5 Platform Control Station ..................................................... 50
3.6 Platform Control Indicator Panel .. ... ... ... .................... ... ... ... .. 55
3.7 Beacons............................................................................58

Section Contents
10 31222411 800AJ HC3
SECTION 4
MACHINE OPERATION................................................................... 61
4.1 General.............................................................................61
4.2 Operating Characteristics and Limitations... ... .................... ... . 61
4.3 800AJ HC3 Reach Chart....................................................... 64
4.4 Engine Operation...............................................................65
4.5 Air Shutoff Valve (ASOV) (If Equipped)................. ... ... ... ... ...... 68
4.6 Fuel Reserve / Shut-Off System ............................................ 69
4.7 Diesel Particulate Filter (If Equipped)................... ... ... ... ... ...... 69
4.8 Traveling (Grade and Side Slope).......................................... 70
4.9 Traveling (Driving)..............................................................72
4.10 Steering............................................................................74
4.11 Boom...............................................................................74
4.12 Function Speed Control ...................................................... 77
4.13 USB Charging Port..............................................................77
4.14 ClearSky Smart Fleet™......................................................... 77
4.15 Access Control - ClearSky Smart Fleet™ (If Equipped)........... ... . 78
4.16 Machine Safety System Override (MSSO) (If Equipped) ............ 79
4.17 SkyGuard Operation ........................................................... 79
4.18 Shut Down and Park...........................................................82
4.19 Lifting and Tie Down .......................................................... 82
4.20 Lifting Chart......................................................................83
4.21 Re-Synchroni e Upright ...................................................... 84
4.22 Safety Decals.....................................................................85
SECTION 5
EMERGENCY PROCEDURES .......................................................... 93
5.1 General.............................................................................93
5.2 Incident Notification ... .................... ... ... ... ... .................... ... . 93
5.3 Emergency Operation......................................................... 94
5.4 Emergency Towing Procedures ...................... ... ... ... ............. 94
5.5 ClearSky Smart Fleet™ - Locked Out State ........ ... ... ... ............. 95
5.6 Machine Safety System Override (MSSO) (If Equipped) ............ 96
SECTION 6
ACCESSORIES.................................................................................. 97
6.1 Available Accessories and Relationships ................................ 97
6.2 Bolt-On External Fall Arrest................................................ 101
6.3 Fabric Mesh to Mid or Top Rail ........................................... 103

Section Contents
800AJ HC3 31222411 11
6.4 Fall Arrest Platform.. ... .................... ... ... ... ... .................... .. 103
6.5 Pipe Racks....................................................................... 104
6.6 Platform Mesh to Mid or Top Rail ....................................... 106
6.7 Platform Work Lights ........................................................ 107
6.8 Platform Work Surface ...................................................... 108
6.9 Portable Work Light.......................................................... 109
6.10 SkyAir® ........................................................................... 110
6.11 SkyCutter®....................................................................... 112
6.12 SkyGla ier®...................................................................... 115
6.13 SkyPower® 7.5 kW and Generator 4 kW ............................... 117
6.14 SkySense®....................................................................... 119
6.15 SkySense® Platform Bumper Padding .................................. 123
6.16 SkyWelder® ..................................................................... 124
6.17 Soft Touch ...................................................................... 127
SECTION 7
GENERAL SPECIFICATIONS AND OPERATOR
MAINTENANCE .............................................................................129
7.1 General........................................................................... 129
7.2 Operating Specifications and Performance Data ................... 129
7.3 Hydraulic Oil Operation Chart ............................................ 136
7.4 Engine Operating Temperature Specifications. ... .................. 137
7.5 Operator Maintenance and Lubrication Diagram . ... ... ........... 138
7.6 Operator Maintenance...................................................... 139
7.7 Tires and Wheels.............................................................. 149
7.8 Propane Fuel Filter Replacement .. .. .... .. ... .. .... .. ... .. .. ... .. .. ... .. 151
7.9 Propane Fuel System Pressure Relief ... ..... .. ..... .. .. .. ..... .. .. .. ... 152
7.10 Radio Frequency (RF) Information....................................... 153
7.11 Supplemental Information Only Applicable to CE/UKCA
Machines ........................................................................ 154
7.12 EC Declaration of Conformity........... ... ... ... ... .................... .. 155
7.13 UKCA Declaration of Conformity .. ... ... ... .................... ... ... ... 156

12
This Page is intentionally left blank

800AJ HC3 31222411 13
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 promote proper machine usage. A maintenance program, using the
information provided in this manual and the Service & Maintenance 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
qualified operator.
This section contains the responsibilities of the owner, user, operator, lessor, and lessee
concerning safety, training, inspection, maintenance, application, and operation. If there
are any questions with regard to safety, training, inspection, maintenance, application,
and operation, please contact JLG Industries, Inc. (“JLG”).
WARNING
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
1.2.1 Operator Training and Knowledge
• Read, understand, and study the Operation and Safety Manual in its entirety before
operating the machine. For clarification, questions, or additional information
regarding any portions of this manual, contact JLG Industries, Inc.
• Only personnel who have received proper training regarding the inspection,
application and operation of MEWPs (including recogni ing and avoiding ha ards
associated with their operation) shall be authori ed to operate a MEWP.

Safety Precautions
14 31222411 800AJ HC3
• Only properly trained personnel who have received unit-specific familiari ation shall
operate a MEWP. The user shall determine if personnel are qualified to operate the
MEWP prior to operation.
• Read, understand, and obey all DANGERS, WARNINGS, CAUTIONS, 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 have a thorough understanding of the intended
purpose and function of the MEWP controls, including platform, ground and
emergency descent controls.
• Read, understand, and obey all applicable employer, local, and governmental
regulations as they pertain to your utili ation and application of the machine.
1.2.2 Workplace Inspection
• Precautions to avoid all ha ards 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 equipment unless the application is approved in
writing by JLG.
• Before operation, check work area for overhead ha ards such as electric lines, bridge
cranes, and other potential overhead obstructions.
• Check operating surfaces for holes, bumps, drop-offs, obstructions, debris, concealed
holes, and other potential ha ards.
• Check the work area for ha ardous locations. Do not operate the machine in
ha ardous 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.
1.2.3 Machine Inspection
• Do not operate this machine until the inspections and functional checks as specified
in the User Responsibilities, Machine Preparation, and Inspection Section 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
Manual.
• Ensure all safety devices are operating properly. Modification of these devices is a
safety violation.

Safety Precautions
800AJ HC3 31222411 15
WARNING
Modification or alteration of a MEWP 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 platform floor.
1.3 OPERATION
1.3.1 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 positioning 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 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 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.

Safety Precautions
16 31222411 800AJ HC3
• Do not assist a stuck or disabled machine by pushing or pulling 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 unrestrained which may become caught or entangled in
equipment.
• Persons under the influence of drugs or alcohol or who are subject to sei ures,
di iness or loss of physical control must not operate this machine.
• Hydraulic cylinders are subject to thermal expansion and contraction. This may result
in changes to the platform 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 platform
position.
1.3.2 Trip and Fall Hazards
• Before operating the machine, ensure all gates are closed and fastened in their
proper position.
• During operation, occupants in the platform must wear a full body harness with a
lanyard attached to an authori ed 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 platform 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.

Safety Precautions
800AJ HC3 31222411 17
• 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.
1.3.3 Electrocution Hazards
• This machine is not insulated and does not provide protection from contact with or
proximity to electrical current.
• It is not recommended to use the machine during lightning. To prevent injury or
machine damage if lightning occurs during operation, lower the boom and shut
down the machine in a safe and secure location.
• Maintain distance from electrical lines, apparatus, or any energi ed (exposed or
insulated) parts according to the Minimum Approach Distance (MAD) as shown in
Table — Minimum Approach Distances (MAD), page 1 .
• Allow for machine movement and electrical line swaying.
Table 1. Minimum Approach Distances (MAD)
Voltage Range (Phase to Phase) Minimum Approach Distance in Feet (Meters)
0 to 50 KV 10 (3)
Over 50K V 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)

Safety Precautions
18 31222411 800AJ HC3
Table 1. Minimum Approach Distances (MAD) (continued)
Voltage Range (Phase to Phase) Minimum Approach Distance in Feet (Meters)
Over 750 KV to 1000 KV 45 (14)
Note: This requirement shall apply e cept 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.
• The MAD 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 MAD shall be reduced to a distance within the designed working dimensions of
the insulating barrier. This determination shall be made by a qualified person with
respect to electrical transmission and distribution in accordance with the employer,
local, or governmental requirements for work practices near energi ed equipment.
DANGER
Do not maneuver machine or personnel inside prohibited one (MAD). Assume all
electrical parts and wiring are energi ed unless known otherwise.
1.3.4 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 exceed
the allowable side slope and grade while driving.
• Do not elevate platform or drive with platform elevated while on or near a sloping,
uneven, or soft surface.

Safety Precautions
800AJ HC3 31222411 19
• Ensure machine is positioned on a smooth, firm surface within the limits of the
maximum operating slope before elevating platform or driving with the platform in
the elevated position.
• Before driving on floors, bridges, trucks, and other surfaces, check allowable capacity
of the surfaces.
• Never exceed the maximum platform capacity as specified on the platform. Keep all
loads within the confines of the platform, unless authori ed by JLG.
• Keep the chassis of the machine a minimum of 2 ft (0.6m) from holes, bumps, drop-
offs, obstructions, debris, concealed holes, and other potential ha ards at the ground
level.
• Do not push or pull any object with the boom.
• Never attempt to use the machine as a crane. Do not tie-off machine to any adjacent
structure. Never attach wire, cable, or any similar items to platform.
• 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 stabili e the machine.
Use cranes, forklift trucks, or other appropriate equipment to stabili e machine.
• Do not operate the machine when wind conditions, including gusts, exceed 28 mph
(12.5 m/s). Refer to Table — Beaufort Scale (For Reference Only), page 20. 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.
• Wind speed can change rapidly. Always consider approaching weather events, the
time required to lower the platform, and methods to monitor current and potential
wind conditions.
• Do not cover or increase surface area of the platform or the load. Do not carry large
surface area items in the platform when operating outdoors. The addition of such
items increases the exposed wind area of the machine. Increased areas exposed to
wind will decrease stability.
• Do not increase the platform si e with unauthori ed modifications or attachments.
WARNING
Do not operate the machine when wind conditions exceed specifications shown in
the General Specifications section of this manual or as shown on the capacity
placard on the platform billboard.

Safety Precautions
20 31222411 800AJ HC3
Table 2. Beaufort Scale (For Reference Only)
Beaufort
Number
Wind peed
Description Land Conditions
mph m/s
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 e posed skin. Leaves rustle
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 be-
gin 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. Flags waving near
horizontal. Umbrella use becomes difficult.
7 32-38 13.9-17.1 Near Gale/Mod-
erate Gale
Whole trees in motion. Effort 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.
1.3.5 Crushing and Collision Hazards
• Approved head gear must be worn by all operating and ground personnel.
• Watch for obstructions around machine and overhead when driving. Check
clearances above, on sides, and bottom of platform during all operations.
• During operation, keep all body parts inside platform railing.
• 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 (1.8 m) away from machine during all
operations.