JLG 800A Use and care manual

ANSI
®
Operation and Safety Manual
Original Instructions - Keep this manual with the machine at all times.
Boom Lift Models
800A
800AJ
Prior to S/N 0300183033
3121209
August 1, 2016

FOREWORD
3121209 – JLG Lift – 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
b– JLG Lift – 3121209
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
3121209 – JLG Lift – 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
d– JLG Lift – 3121209
REVISION LOG
Original Issue - May 4, 2005
Revised - September 1, 2005
Revised - March 7, 2006
Revised - July 17, 2006
Revised - March 12, 2007
Revised - March 30, 2007
Revised - January 6, 2009
Revised - November 6, 2009
Revised - December 12, 2009
Revised - July 26, 2010
Revised - June 21, 2012
Revised - October 1, 2015
Revised - August 1, 2016

3121209 – JLG Lift – 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards . . . . . . . . . . . . . . . . . . . . 1-7
1.4 TOWING, LIFTING, AND HAULING. . . . . . . . . . . . . . . . . . . . . 1-8
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . . . . . . . . . . 1-9
SECTION - 2 - USER RESPONSIBILITIES, MACHINE PREPARATION,
AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND MAINTENANCE . . . . . 2-2
Pre-Start Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
2.3 FUNCTION CHECK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
From the Ground Control Station with No Load in the
Platform: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
SkyGuard Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
From the Platform Control Station: . . . . . . . . . . . . . . . 2-16
2.4 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED). . . . 2-19
SECTION - 3 - MACHINE CONTROLS AND INDICATORS
3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ground Control Indicator Panel . . . . . . . . . . . . . . . . . . . . 3-6
Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Platform Control Indicator Panel . . . . . . . . . . . . . . . . . 3-16
SECTION - 4 - MACHINE OPERATION
4.1 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 OPERATING CHARACTERISTICS AND LIMITATIONS . . . . 4-1
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 ENGINE OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Traveling Forward and Reverse . . . . . . . . . . . . . . . . . . . . 4-7

ii – JLG Lift – 3121209
TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Loading From Ground Level . . . . . . . . . . . . . . . . . . . . . . . 4-8
Loading From Positions Above Ground Level. . . . . . . 4-8
Platform Level Adjustment . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Raising and Lowering the Tower Boom. . . . . . . . . . . . 4-11
Raising and Lowering the Main Boom . . . . . . . . . . . . . 4-11
Telescoping the Main Boom . . . . . . . . . . . . . . . . . . . . . . 4-11
Function of Tower Boom . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
4.9 SHUT DOWN AND PARK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
4.11 OSCILLATING AXLE LOCKOUT TEST (IF EQUIPPED) . . . 4-16
4.12 TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4.13 TOW BAR (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.14 WELDING LEAD (IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . 4-17
4.15 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . . . . . . . . . 4-19
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Changing From Gasoline to LP Gas. . . . . . . . . . . . . . . . 4-19
Changing From LP Gas to Gasoline. . . . . . . . . . . . . . . . 4-19
4.16 RE-SYNCHRONIZE UPRIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
Releveling Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
4.17 SKYGUARD OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21
SECTION - 5 - EMERGENCY PROCEDURES
5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 INCIDENT NOTIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.3 EMERGENCY TOWING PROCEDURES. . . . . . . . . . . . . . . . . . 5-1
5.4 EMERGENCY CONTROLS AND THEIR LOCATIONS. . . . . . 5-2
Power/Emergency Stop Switches . . . . . . . . . . . . . . . . . . 5-2
Ground Control Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.5 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Use of Ground Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operator Unable to Control Machine. . . . . . . . . . . . . . . 5-4
Platform or Boom Caught Overhead . . . . . . . . . . . . . . . 5-4
SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR MAINTE-
NANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Critical Stability Weights. . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

3121209 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
TABLE OF CONTENTS
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
6.4 TIRES & WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Tire Inflation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Tire Damage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
6.5 DRAINING OIL BUILD UP FROM THE PROPANE REGULATOR
(PRIOR TO S/N 0300134626) . . . . . . . . . . . . . . . . . . . . . . . . 6-32
6.6 PROPANE FUEL FILTER REPLACEMENT . . . . . . . . . . . . . . . 6-34
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . . . . . . . . . . . 6-36
6.8 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . . . . . . . . . . 6-36
SECTION - 7 - INSPECTION AND REPAIR LOG

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TABLE OF CONTENTS
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
This Page Left Blank Intentionally.