JLG 800A Use and care manual

ANSI
®
Operation and Safety Manual
Keep this manual with the machine at all times.
Boom Lift Models
800A
800AJ
3121209
July 17, 2006

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 BACKGROUND.
INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT
AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS
DECAL WILL HAVE AN ORANGE BACKGROUND.
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.
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 BULLE-
TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED
JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-
RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS
PRODUCT.
IMPORTANT
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.
IMPORTANT
JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL
INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN
ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL
OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL
PROPERTY OR THE JLG PRODUCT.
Contact:
Product Safety and Reliability Department
JLG Industries, Inc.
1 JLG Drive
McConnellsburg, PA 17233
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]
E-mail: [email protected]
For:
• Accident Reporting
• Product Safety Publica-
tions
• Current Owner Updates
• Questions Regarding
Product Safety
• Standards and Regulations
Compliance Information
• Questions Regarding Spe-
cial 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

TABLE OF CONTENTS
3121209 – JLG Lift – i
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
SECTION - 1 - SAFETY PRECAUTIONS
1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Operator Training and Knowledge . . . . . . . . . . . 1-1
Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2
Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2
1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3
Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4
Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Crushing and Collision Hazards. . . . . . . . . . . . . 1-7
1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8
1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9
SECTION - 2 - USER RESPONSIBILITIES, MACHINE
PREPARATION, AND INSPECTION
2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1
Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1
Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1
2.2 PREPARATION, INSPECTION, AND
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4
Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
2.3 DAILY FUNCTIONAL CHECK . . . . . . . . . . . . . . . . 2-12
2.4 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
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 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Platform Control Indicator Panel . . . . . . . . . . . . 3-13
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
4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

TABLE OF CONTENTS
ii – JLG Lift – 3121209
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
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 . . . . . . . . . . . . . . . . . . . . . 4-12
Raising and Lowering the Tower Boom . . . . . 4-12
Raising and Lowering the Main Boom . . . . . . 4-12
Telescoping the Main Boom . . . . . . . . . . . . . . 4-13
Function of Tower Boom . . . . . . . . . . . . . . . . . 4-13
4.9 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-14
4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-14
4.11 OSCILLATING AXLE LOCKOUT TEST
(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
4.13 WELDING LEAD (IF EQUIPPED). . . . . . . . . . . . . . 4-18
4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-18
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Changing From Gasoline to LP Gas . . . . . . . . 4-19
Changing From LP Gas to Gasoline . . . . . . . . 4-19
4.15 RE-SYNCHRONIZE LOWER LIFT CYLINDER . . . . 4-19
Level Override Valve . . . . . . . . . . . . . . . . . . . . 4-19
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
MAINTENANCE
6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1
6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
Critical Stability Weights . . . . . . . . . . . . . . . . . . . 6-9
6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-20
6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-28

TABLE OF CONTENTS
3121209 – JLG Lift – iii
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28
Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-29
Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-29
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-30
6.5 DRAINING OIL BUILD UP FROM THE PROPANE
REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31
6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-33
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-34
SECTION - 7 - INSPECTION AND REPAIR LOG
LIST OF FIGURES
2-1. Machine Nomenclature - 800A. (Sheet 1 of 2) . . . .2-6
2-2. Machine Nomenclature - 800AJ. (Sheet 2 of 2). . . .2-7
2-3. Daily Walk-Around Inspection. (Sheet 1 of 4) . . . . .2-8
2-4. Daily Walk-Around Inspection. (Sheet 2 of 4) . . . . .2-9
2-5. Daily Walk-Around Inspection. (Sheet 3 of 4) . . . .2-10
2-6. Daily Walk-Around Inspection. (Sheet 4 of 4) . . . .2-11
2-7. Tower Boom Vertical Limit Switch . . . . . . . . . . . . .2-12
2-8. Tower Boom Horizontal Limit Switch. . . . . . . . . . .2-13
3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Ground Control Indicator Panel. . . . . . . . . . . . . . . .3-6
3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-10
3-4. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . 3-15
4-1. Position of Least Forward Stability . . . . . . . . . . . . . 4-3
4-2. Positions of Least Backward Stability
(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4-3. Positions of Least Backward Stability
(Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4-4. Grade and Sideslopes. . . . . . . . . . . . . . . . . . . . . . . 4-9
4-5. Boom Upright Positioning. . . . . . . . . . . . . . . . . . . 4-11
4-6. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . 4-15
4-7. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
4-8. Decal Installation - Sheet 1 of 5 . . . . . . . . . . . . . . 4-20
4-9. Decal Installation - Sheet 2 of 5 . . . . . . . . . . . . . . 4-21
4-10. Decal Installation - Sheet 3 of 5 . . . . . . . . . . . . . . 4-22
4-11. Decal Installation - Sheet 4 of 5 . . . . . . . . . . . . . . 4-23
4-12. Decal Installation - Sheet 5 of 5 . . . . . . . . . . . . . . 4-24
6-1. Engine Operating Temperature Specifications -
Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-11
6-2. Engine Operating Temperature Specifications -
Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-12
6-3. Engine Operating Temperature Specifications -
Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-13
6-4. Engine Operating Temperature Specifications -
Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-14
6-5. Engine Operating Temperature Specifications -
Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . 6-15

TABLE OF CONTENTS
iv – JLG Lift – 3121209
SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE
6-6. Engine Operating Temperature Specifications -
Caterpillar - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . 6-16
6-7. Engine Operating Temperature Specifications -
GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-17
6-8. Engine Operating Temperature Specifications -
GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-18
6-9. Operator Maintenance and Lubrication Diagram . 6-19
6-10. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-33
LIST OF TABLES
1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5
2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3
4-1 Decal Legend - 800A . . . . . . . . . . . . . . . . . . . . . . . 4-25
4-2 Decal Legend - 800AJ . . . . . . . . . . . . . . . . . . . . . . 4-28
6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-1
6-2 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6-4 Ford LRG-425 Specifications. . . . . . . . . . . . . . . . . . 6-3
6-5 Deutz F4M2011F Specifications . . . . . . . . . . . . . . . 6-4
6-6 Caterpillar 3044C . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6-7 Isuzu 4JB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-8 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6-11 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-7
6-12 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . 6-7
6-13 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-8
6-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . 6-8
6-15 Critical Stability Weights - 800A . . . . . . . . . . . . . . . 6-9
6-16 Critical Stability Weights - 800AJ . . . . . . . . . . . . . 6-10
6-17 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-20
6-18 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-31
7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1