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1. Figure 4 11 Decal Installation Sheet 3 of 5 3121209 JLG Lift 4 23 SECTION 4 MACHINE OPERATION Figure 4 12 Decal Installation Sheet 4 of 5 3121209 JLG Lift 4 24 SECTION 4 MACHINE OPERATION gt GAN y LLL b 1 NJ Figure 4 13 Decal Installation Sheet 5 of 5 3121209 JLG Lift 4 25 SECTION 4 MACHINE OPERATION 4 26 Table 4 1 Decal Legend 800A Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 9 0274464 7 0274470 7 0274466 7 0274468 8 0274472 7 0274474 3 0274462 7 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 17050
2. Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 9 0274464 7 0274471 7 0274467 7 0274469 9 0274473 7 0274475 3 0274462 7 18 1703953 1703945 1703943 1703941 1705903 1703942 1703944 19 20 1702868 1705969 1705968 1704001 1705967 1704000 21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926 22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344 23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950 24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938 25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980 26 3241813 3251813 3251813 3251813 3251813 3251813 27 28 29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 31 1703773 1703773 1703773 1703773 1703773 1703773 1703773 1703773 32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 33 1701645 1707058 1707060 1707056 1703996 1707055 1705978 1707059 34 1707013 1707042 1707044 1707049 1704112 1707047 1705978 1707054 35 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 JLG Lift 4 35 SECTION 4 MACHINE OPERATION 4 36 Table 4 3 Decal Legend 800AJ Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portu
3. 1 Power Emergency Stop Function Speed Control 11 Fuel Select 16 Tower Lift 2 Horn 7 DriveSpeed Torque Select 12 Lights 17 Drive Orientation Override 3 MainLift Swing 8 Platform Rotate 13 Steer Select 18 Soft Touch Override 4 Telescope 9 Platform Level Override 14 Engine Start AuxPower 19 Soft Touch Indicator 5 Drive Steer 10 Articulating Jib 800AJ 15 Tower Telescope Figure 3 4 Platform Control Console w Drive Orientation 3121209 Lift 3 11 SECTION 3 MACHINE CONTROLS AND INDICATORS 5 Drive Steer 7 Proportional single axis joystick is provided to control drive Push forward to drive forward pull back to drive in reverse Steering is accomplished via a thumb activated rocker switch on the end of the handle Push on the left side of the switch to steer left on right side to steer right NOTE Both drive and steer functions work in the opposite direc tion when the main boom is positioned over front of the chassis NOTE When main boom is positioned above horizontal and any 3 12 of the following switches DRIVE SPEED TORQUE SELECT or FUNCTION SPEED are positioned to HIGH high function speeds are automatically set to creep and 8 the machine continues to operate at a lower speed 6 Function Speed Controls the speed of Boom and Swing Functions Rotate CCW for slower speed and CW for faster speed To adjust to creep turn knob fully CCW until it cl
4. 4 8 Swinging the Raising and Lowering the Tower Boom Raising and Lowering the Main Boom Telescoping the Main Boom Function of Tower 4 9 SHUT DOWN AND PARK 4 10 LIFTING AND TIE DOWN 4 11 OSCILLATING AXLE LOCKOUT TEST 4 12 4 13 TOW BAR IF EQUIPPED 4 14 WELDING LEAD IF EQUIPPED 4 15 DUAL FUEL SYSTEM GAS ENGINE ONLY Changing From Gasoline to LP Gas Changing From LP Gas to Gasoline PAGE SECTION PARAGRAPH SUBJECT PAGE 2 4 6 4 16 RE SYNCHRONIZE UPRIGHT 4 20 eel 47 Releveling 4 20 2 4 7 2 4 7 SECTION 5 EMERGENCY PROCEDURES 48 5 1 GENERAL oce ex I ER eqs 5 1 48 5 2 INCIDENT 5 1 5 3 EMERGENCY TOWING PROCEDURES 5 1 48 5 4 EMERGENCY CONTROLS AND THEIR 48 5 2 410 Power Emergency Stop Switches 5 2 410 Ground Control Station 5 2 M nl Auxiliary 5 2 e 411 5 5 EMERGENCY 5 3 411 Use of Ground 5 3 e 412 Operator Unable to Control
5. LBS KG Tire amp Wheel Size 365 65D19 5 565 255 Foam Filled Only 245551195 BTE BE 15X19 5 565 255 18X19 5 675 305 Engine Ford 600 209 Deutz 534 242 Isuzu 463 210 GM w pumps 1030 468 Counterweight Turntable 4805 2180 Wheel Hubs Rear 218 99 Front 2WD 110 99 Front 4WD 218 99 Platform Size 1 83 205 93 8 FT 2 44 M 230 105 3121209 JLG Lift 6 11 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE NO OPERATION ABOVE THIS ali AMBIENT TEMPERATURE 43 C 100 F 38 C 90 F 32 C SUMMER 1 1 1 Lala ae V GRADE al lel fel fs im i fs B 70 F 21 C e T T 1 1 Ed ENGINE Ds amp 8 60 16 SPECIFICATIONS a s 50 F 10 C 40 F 4 C S 30 F 1 C ENGINE WILL START AND OPERATE UNAIDED AT THIS GRADE 0 20 70 TEMPERATURE WITH THE RECOMMENDED FLUIDS AND 10 F 12 C FULLY CHARGED BATTERY fj neces ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WINTER 10 F 23 C WITH THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY GRADE AND THE AID OF ACOMPLETE JLG SPECIFIED COLD WEATHER 20 29 PACKAGE IE ENGINE BLOCK HEATER ETHER INJECTION OR KEROSENE GLOW PLUGS BATTERY WARMER AND HYDRAULIC OIL TANK HEATER AD
6. Pdl NOTE Have a small container ready to collect oil that will drain freely from the regulator at this point 7 Once all of the oil has been drained reinstall the LPG fuel temperature sensor and reconnect the electrical connector 8 Open the fuel tank manual valve 9 Start the engine and verify all connections are secure 10 Dispose of any drained oil per local regulations in a safe and proper fashion 3121209 Lift 6 33 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 6 PROPANE FUEL FILTER REPLACEMENT Removal 1 oon 90 gt 6 34 Relieve the propane fuel system pressure Refer to Pro pane Fuel System Pressure Relief Disconnect the negative battery cable 1 Slowly loosen the Filter housing and remove it 2 Pull the filter housing from the Electric lock off assembly 3 Remove the filter from the housing 4 Locate Filter magnet and remove it 5 Remove and discard the housing seal 6 If equipped remove and discard the retaining bolt seal Remove and discard mounting plate to lock off O ring n seal 8 9 JLG Lift Installation NOTICE BE SURE TO REINSTALL THE FILTER MAGNET INTO THE HOUSING BEFORE INSTALLING NEW SEAL Install the mounting plate to lock off O ring seal If equipped install the retaining bolt seal Install the housing seal Drop the magnet into the bottom of the filter housing Install the filter into the housing If equipped ins
7. ASSURE THAT TURNTABLE LOCK IS DISENGAGED BEFORE STARTING ANY SWING OPERATION Depress footswitch To swing boom position SWING control switch or controller to RIGHT or LEFT for direction desired 3121209 SECTION 4 MACHINE OPERATION Raising and Lowering the Tower Boom Raising and Lowering the Main Boom This machine will have two controls for the tower boom two To raise and lower Main Boom depress footswitch position toggle switches one controls tower lift the other tower tele MAIN LIFT controller to UP OR DOWN and hold until desired scope The switching system will sequence its LIFT and height is reached TELESCOPE functions as follows Telescoping the Main Boom 1 Depress footswitch and sequence while RAISING the ping TOWER BOOM from the fully lowered position s To extend or retract Main Boom depress footswitch position a The TOWER BOOM must be fully elevated up MAIN TELESCOPE control switch to IN or OUT and hold approximately 12 degrees from vertical before the until platform reaches desired position TOWER BOOM can be extended from the fully retracted position b The TOWER TELESCOPE out will only be opera ble when the TOWER BOOM is fully elevated 2 Depress footswitch and sequence while LOWERING the TOWER BOOM from the fully elevated up position a TOWER TELESCOPE in The TOWER BOOM must be fully retracted before the TOWER BOOM can be lowered b TOWER BOOM
8. 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 JLG Lift 3121209 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE SECTION PARAGRAPH SUBJECT PAGE SECTION 1 SAFETY PRECAUTIONS 23 FUNCTION CHECK 2 11 1 1 GENERAL BERE wae 1 1 From the Ground Control Station with No Load in the 1 2 1 1 get en ne 2 11 Operator Training and Knowledge 1 1 From the Platform Control Station 2 15 Workplace 1 2 2 4 OSCILLATING AXLE LOCKOUT TEST Machine Inspection 1 2 IF 2 18 1 3 OPERATION erm bid he eR 1 3 General eat erret E aS 1 8 SECTION 3 MACHINE CONTROLS AND INDICATORS Trip Fall 1 3 3 1 GENERALE n deese Ed 3 1 Electrocution Hazards 1 4 3 2 CONTROLS AND INDICATORS 3 1 Tipping 1 6 Ground Control 3 1 Crushing and Collision Hazards 1 7 Ground Control Indicator Panel 3
9. atidle 6 psi 0 4 Bar 1000 rpm Hot 18 psi 1 2 Bar 2000 rpm Compression Ratio 9 2 1 Firing Order 1 3 4 2 Max RPM 2800 6 6 JLG Lift Hydraulic Oil Table 6 10 Hydraulic Oil T ule System S A E Viscosity perating Grade Temperature Range 0 to 180 18 to 83 C 10W 0 to 210 F 18 to 99 C 10W 20 10W30 50 to 210 F 10 to 99 20W 20 NOTE Hydraulic oils must have anti wear qualities at least to API Service Classification GL 3 and sufficient chemical stabil ity for mobile hydraulic system service JLG Industries recommends Mobilfluid 424 hydraulic oil which has an SAE viscosity index of 152 NOTE When temperatures remain consistently below 20 degrees F 7 degrees C JLG Industries recommends the use of Mobil DTE13 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Aside from JLG recommendations it is not advisable to mix oils Table 6 12 Mobil DTE 13M Specs of different brands or types as they may not contain the same required additives or be of comparable viscosities If use of ISO Viscosity Grade 32 hydraulic oil other than Mobilfluid 424 is desired contact JLG oa Specific Gravity 0 877 Industries for proper recommendations Table 6 11 Mobilfluid 424 Specs Pour Point Max 40 F 40 C Flash Point Min 330
10. JLG recommends a replacement tire be the same size ply and brand as originally installed on the machine Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model If not using a JLG approved replace ment tire we recommend that replacement tires have the follow ing characteristics Equal or greater ply load rating and size of original Tire tread contact width equal or greater than original Wheel diameter width and offset dimensions equal to the original Approved for the application by 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 pneu matic tire When selecting and installing a replacement tire ensure that all tires are inflated to the pressure recommended 6 30 JLG Lift by JLG Due to size variations between tire brands both tires on the same axle should be the same Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width tire pres sure and load capacity Size changes such as rim width center piece location larger or smaller diameter etc without written factory recommendations may result in an unsafe condition regarding stability 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Wheel Instal
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12. 3121209 JLG Lift 3 5 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 6 11 12 Main Lift Control The MAIN LIFT control switch provides raising and low ering of the main boom when positioned to UP or DOWN Main Telescope Control The MAIN TELESCOPE control switch provides exten sion and retraction of the boom when positioned to IN or OUT Ground Control Indicator Panel 12 11 10 9 8 7 1 Battery Charging 7 Glow Plug 2 Low Engine Oil Pressure 8 Boom Malfunction 3 High Engine Water Temp 9 Platform Overload 4 HighEngine Oil Temp 10 Hyd Filter Bypass 5 Engine Malfunction Indicator 11 Transmission Filter By Pass 6 Low Fuel 12 Engine Air Filter By Pass Figure 3 2 Ground Control Indicator Panel JLG Lift 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS Battery Discharging Indicator When illuminated indicates a problem in the battery or charging circuit and service is required Engine Oil Pressure Indicator When illuminated indicates that engine oil pressure is below normal and service is required Engine Coolant Temperature Indicator Ford When illuminated indicates that engine coolant tempera ture is abnormally high and service is required Engine Oil Temperature Indicator Deutz When illuminated indicates that the temperature of the engine oil which also serves as engine coolant is abnormally high and service is required Lift 5 Engine Malf
13. MG An Oshkosh Corporation Company Operation and Safety Manual Original Instructions Keep this manual with the machine at all times Boom Lift Models 800A 800AJ ANSI CC amp 3121209 July 26 2010 FOREWORD 3121209 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 JLG Lift a FOREWORD SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS 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 A DANGER INDICATES AN IMMINENTLY HAZARDOUS SITUATION IF NOT AVOIDED WILL RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE A RED BACKGROUND A WARNING INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED COULD RESULT IN SERIOUS INJURY OR DEATH THIS DECAL WILL HAVE AN ORANGE BACKGROUND b JLG Lift A CAUTION INDICATES A POTENTIALLY HAZARDOUS SITUATION IF NOT AVOIDED MAY RESULT IN MINOR OR MODERATE INJURY IT MAY ALSO ALERT AG
14. Pour Point 76 F 60 C Pour Point lt 20 C lt 4 F Flash Point 217 F 103 C Flash Point 275 C 527 F Viscosity Fire Point 325 C 617 F at 40 C 25 8 cSt Autoignition Temperature 450 C 842 F at 100 C 9 3 cSt Viscosity Viscosity Index 376 at0 C 32 F 360 cSt NOTE Mobil Exxon recommends that this oil be checked at 20 C 68 F 102 cSt on a yearly basis for viscosity 40 C 104 16091 at 100 212 10 Viscosity Index 220 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Critical Stability Weights Table 6 17 Critical Stability Weights 800A DO NOT REPLACE ITEMS CRITICAL TO STABILITY WITH ITEMS OF DIF Foam Filled Only FERENT WEIGHT OR SPECIFICATION FOR EXAMPLE BATTERIES FILLED TIRES COUNTER WEIGHT ENGINE AND PLATFORM DO NOT MODIFY UNIT IN ANY WAY TO EFFECT STABILITY 6 10 LBS KG Tire amp Wheel Size 365 65D19 5 565 255 445 55D19 5 675 305 15X19 5 565 255 18X19 5 675 305 Engine Ford 600 209 Deutz 534 242 Isuzu 463 210 GM w pumps 1030 468 Counterweight Turntable 4805 2180 Wheel Hubs Rear 218 99 Front 2WD 210 99 Front AWD 218 99 Platform 1 83 205 93 8 2 44 M 230 105 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 18 Critical Stability Weights 800AJ
15. Raise the tower boom 6 feet 1 8 m Release the red relevel knob Lower the tower boom fully and continue to hold down the switch to Tower Down for an additional 20 seconds Repeat steps 3 thru 6 as necessary until the upright is 90 vertical relative to the chassis JLG Lift Figure 4 8 Releveling Valve 3121209 SECTION 4 MACHINE OPERATION Figure 4 9 Decal Installation Sheet 1 of 5 3121209 JLG Lift 4 21 SECTION 4 MACHINE OPERATION Figure 4 10 Decal Installation Sheet 2 of 5 4 22 JLG Lift 3121209 SECTION 4 MACHINE OPERATION
16. 1 WOO NIVIA Figure 4 3 Positions of Least Backward Stability Sheet 2 of 2 Lift 3121209 SECTION 4 MACHINE OPERATION Shutdown Procedure A CAUTION IF AN ENGINE MALFUNCTION NECESSITATES UNSCHEDULED SHUT DOWN DETERMINE AND CORRECT CAUSE BEFORE RESUMING ANY OPERATION 1 Remove all load and allow engine to operate at low speed setting for 3 5 minutes this allows for further reduction of internal engine temperature 2 Position POWER EMERGENCY STOP switch to OFF 3 Turn key of MASTER switch to OFF position NOTE Refer to Engine Manufacturer s manual for detailed infor mation 4 4 TRAVELING DRIVING See Figure 4 4 A WARNING DO NOT DRIVE WITH BOOM ABOVE HORIZONTAL EXCEPT ON A SMOOTH FIRM AND LEVEL SURFACE 4 6 JLG Lift TO AVOID LOSS OF TRAVEL CONTROL OR TIP OVER DO NOT DRIVE MACHINE ON GRADES EXCEEDING THOSE SPECIFIED ON THE SERIAL NUMBER PLATE DO NOT DRIVE ON SIDESLOPES WHICH EXCEED 5 DEGREES USE EXTREME CAUTION WHEN DRIVING IN REVERSE AND AT ALL TIMES WHEN THE PLATFORM IS ELEVATED BEFORE DRIVING LOCATE THE BLACK WHITE ORIENTATION ARROWS ON BOTH THE CHASSIS AND THE PLATFORM CONTROLS MOVE THE DRIVE CONTROLS IN A DIRECTION MATCHING THE DIRECTIONAL ARROWS p A 3121209 SECTION 4 MACHINE OPERATION Traveling Forward and Reverse 1 At Platform
17. 4 23 4 12 Decal Installation Sheet 4 of 5 4 24 4 13 Decal Installation Sheet 5 of 5 4 25 6 1 Engine Operating Temperature Specifications Deutz JLG Lift TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE Sheet1 0f 2 cos cg ee ee 6 12 6 2 Engine Operating Temperature Specifications Deutz Sheet 2 2 6 13 6 3 Engine Operating Temperature Specifications Ford Sheet 1 0 2 1 e ERI RES 6 14 6 4 Engine Operating Temperature Specifications Ford Sheet 2 0F 2 es darent 6 15 6 5 Engine Operating Temperature Specifications Caterpillar Sheet 1 42 6 16 6 6 Engine Operating Temperature Specifications Caterpillar Sheet 2 042 6 17 6 7 Engine Operating Temperature Specifications GM Sheet 6 18 6 8 Engine Operating Temperature Specifications GM Sheet 2 08 2 5 ssa Lee qtue 6 19 6 9 Operator Maintenance and Lubrication Diagram 6 20 6 10 Filter Lock 6 35 LIST OF TABLES 1 4 Minimum Approach Distances M A D 1 5 1 2 Beaufort Scale For Reference Only 1 10 2 1 Inspection and Maintenance Table 2 3 4 1 Decal Legend 800 4 26 4 2 Decal Legend 800 4 30 6 1 Operating 6 1 SECTION PARAGRAPH SUBJE
18. 40 C Figure 6 5 Engine Operating Temperature Specifications Caterpillar Sheet 1 of 2 JLG Lift AMBIENT AIR TEMPERATURE EIN 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 8252 OR ABOVE 180 F 82 C HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC EE OIL COOLER CONSULT JLG SERVICE TEMPERATURE 120 49 NO OPERATION ABOVETHIS PROLONGED OPERATION IN 110 F 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES ee OF 100 F 38 OR ABOVE 90 F 32 C 80 F 27 C 70 F 21 C 3 hb udi HYDRAULIC 5071020 1 SPECIFICATIONS 40 F 4 C Z 30 F 1 C 20 F 7 C 10 F 12 C DO NOT START UP HYDRAULIC SYSTEM 18 C WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE 20 F 29 C DO NOT START UP HYDRAULIC SYSTEM 30 F 84 C WITHOUT HEATING AIDS AND COLD WEATHER HYDRAULIC OIL BELOW THIS TEMPERATURE OPERATION BELOW THI ae 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES CONSISTENTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEALEVEL c 4150548 D Figure 6 6 Engine Operating Temperature Specifications Caterpillar
19. checking each item in sequence for the conditions listed in the following checklist A WARNING TO AVOID POSSIBLE INJURY BE SURE MACHINE POWER IS OFF DO NOT OPERATE MACHINE UNTIL ALL MALFUNCTIONS HAVE BEEN CORRECTED INSPECTION NOTE On all components make sure there are no loose or missing parts that they are securely fastened and no visible damage leaks or excessive wear exists in addition to any other criteria mentioned 1 Platform Assembly Platform Assembly and Gate Footswitch works properly not modified disabled or blocked Latch stop and hinges in working condition 2 Platform Control Console Switches and levers return to neutral decals placards secure and legible control markings legible aap 10 11 12 Rotator See Inspection Note Rotator Motion Control Valve See Inspection Note Articulating Jib Boom See Inspection Note Dual Capacity Limit Switch ANSI Australia if equipped Transport Position Limit Switch CE Properly secured no damage to the switch arm free to move and free from dirt and grease Power Track See Inspection Note Steer Cylinder Assembly See Inspection Note 4 Wheel Steer if equipped Spindle See Inspection Note 4 Wheel Steer if equipped Drive Motor and Brake See Inspection Note Drive Hub See Inspection Note Wheel Tire Assembly No loose or missing lug nuts proper inflation pneumatic Inspect for worn tread cuts tears or othe
20. 425 Specifications Type Water cooled Fuel Gasoline Oil Capacity 4 5 Quarts 4 25 L w Filter Idle RPM 1000 Low RPM 1800 High RPM 2800 Alternator 95 Amp Belt Drive Fuel Consumption Low RPM 3 45 GPH 13 06 Iph High RPM 4 60 GPH 17 41 Iph Battery 1000 Cold Cranking Amps 210 minute reserve Capacity 12 VDC Horsepower 74 3000 RPM full load Cooling System 16 Quarts 15 141 Spark Plug AWSF 52 C Spark Plug Gap 0 044 in 1 117 mm JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 5 Deutz F4M2011F Specifications Table 6 6 Deutz D2011L04 Specifications Type Liquid Cooled Oil Type Liquid Cooled Oil Fuel Diesel Fuel Diesel Oil Capacity Oil Capacity Cooling System 5 Quarts 4 5L Cooling System 5 Quarts 4 5 L Crankcase 11 Quarts 10 5 L w Filter Crankcase 11 Quarts 10 5 L w Filter Total Capacity 16 Quarts 151 Total Capacity 16 Quarts 151 Idle RPM 1000 Idle RPM 1000 Low RPM 1800 Low RPM 1800 High RPM 2800 High RPM 2600 Alternator 55 Amp belt drive Alternator 55 Amp belt drive Fuel Consumption Fuel Consumption Low RPM 1 90 7 19 Iph Low RPM 1 90 7 19 Iph High RPM 2 50 9 46 Iph High RPM 2 50 9 46 Iph Battery 1000 Cold Cranking Amps 210 Battery 1000 Cold Cranking Amps 210 minutes Reserve Capacity 12 minutes Reserve
21. 5 3 EMERGENCY TOWING PROCEDURES Towing this machine is prohibited However provisions for moving the machine in case of a malfunction or power fail ure have been incorporated The following procedures are to be used ONLY for emergency movement to a suitable maintenance area 1 Chock wheels securely 2 Disengage drive hubs by reversing disconnect caps 3 Connect suitable equipment remove chocks and move machine 5 1 SECTION 5 EMERGENCY PROCEDURES After moving machine complete the following procedures 1 2 3 5 4 Position machine on firm and level surface Chock wheels securely Engage drive hubs by reversing disconnect caps on hubs Remove chocks from wheels as needed EMERGENCY CONTROLS AND THEIR LOCATIONS Power Emergency Stop Switches 1 There are red mushroom shaped switches located at the Ground Control box and the platform Control panel The red switch is pulled up for normal machine operation In an emergency push the button down with the palm and the machine will immediately stop A WARNING CHECK MACHINE DAILY TO MAKE SURE EMERGENCY STOP SWITCH IS OPERATIONAL AND THAT GROUND CONTROL INSTRUCTIONS ARE IN PLACE AND LEGIBLE 5 2 JLG Lift Ground Control Station The Ground Control Station is located on the right front side of the turntable The controls on this panel provide the means for overriding the platform controls and for control ling the platform level boo
22. AND INSPECTION 2 1 PERSONNEL TRAINING The aerial platform is a personnel handling device so it is necessary that it be operated and maintained only by trained personnel 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 Operator Training Operator training must cover 1 Use and limitations of the controls in the platform and at the ground emergency controls and safety systems 2 Control labels instructions and warnings on the machine 3 Rules of the employer and government regulations 4 Use of approved fall protection device 5 Enough knowledge of the mechanical operation of the machine to recognize a malfunction or potential mal function 3121209 JLG Lift 6 The safest means to operate the machine where over head obstructions other moving equipment and obsta cles depressions holes drop offs 7 Means to avoid the hazards of unprotected electrical conductors 8 Specific job requirements or machine application Training Supervision Training must be done under the supervision of a qualified person in an open area free of obstructions until the trainee has developed the ability to safely control and operate the machine Operator Responsibility The operator must be instructed that he she has the respon sibility and authority to shut down the machine in case of a malfunction or other unsafe
23. Capacity 12 VDC VDC Horsepower 65 3000 RPM full load Horsepower 64 2600 RPM full load JLG Lift 3121209 6 4 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 7 Caterpillar 3044C 3 4 Table 6 8 Isuzu 4JB1 Type Four Stroke Cycle Type Water cooled Cylinders 4 in line Oil Capacity w filter 8 5 Quarts 8 01 Bore 3 70 inch 94 mm Cooling System Engine Only 5 8 quarts 5 5 L Stroke 4 72 inch 120 mm Idle RPM 1000 Aspiration turbocharged Low RPM 1800 Compression ratio 19 1 High RPM 2800 Displacement 203 in 3 331 Alternator 55 Amp belt drive Firing Order 1 3 4 2 Battery 1000 Cold Cranking Amps 210 Rotation viewed from flywheel Counterclockwise TAVR Oil Capacity w fiter 10 6 quarts 10L Horsepower 66 2800 RPM full load Cooling System Engine Only 5 8 quarts 5 5 L Idle RPM 1000 Low RPM 1800 High RPM 3044C 2600 High RPM 3 4 2500 Alternator 60 Amp belt drive 3121209 JLG Lift 6 5 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 9 GM 3 0L Oil Capacity w filter Fuel Gasoline or Gasoline LP Gas No of Cylinders 4 BHP Gasoline 83 hp 3000 rpm LP 75 hp 3000 rpm Bore 4 0in 101 6 mm Stroke 3 6 in 91 44 mm Displacement 181 cu in 3 0 L 2966 cc 4 5 qts 4 251 Minimum Oil Pressure
24. Indicates the platform has been overloaded 11 Boom Malfunction Indicator When an audible alarm sounds and the Boom Malfunc tion Indicator illuminates when attempting to activate a tower boom function the function is being cutout by tower boom limit switch This function is not permitted at the current boom configuration When an audible alarm sounds and the Boom Malfunc tion Indicator illuminates steady without a boom function attempt the upright is out of alignment A WARNING DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED NOTICE IF THE UPRIGHT IS OUT OF ALIGNMENT WITH THE PLATFORM RAISED LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION REPORT THE PROBLEM TO THE PROPER SER VICE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL THE CONDI TION IS CORRECTED 3121209 Lift 12 Drive Orientation Indicator When the boom is swung beyond the rear drive tires or further in either direction the Drive Orientation indicator will illuminate when the drive function is selected This is a signal for the operator to activate the Drive Orientation Override Switch and verify the drive control direction is correct 3 21 SECTION 3 MACHINE CONTROLS AND INDICATORS 12 NOTES 3 22
25. JLG Lift 3121209 SECTION 4 MACHINE OPERATION SECTION 4 MACHINE OPERATION 4 1 DESCRIPTION 4 2 OPERATING CHARACTERISTICS AND LIMITATIONS This machine is a self propelled hydraulic lift equipped with a work platform on the end of an elevating and rotating boom Ku Capacities The primary operator control station is in the platform From this control station the operator can drive and steer the The boom can be raised above horizontal with or without any machine in both forward and reverse directions The opera load in the platform if tor can raise or lower the upper or lower boom or swing the boom to the left or right Standard boom swing is 360 degree continuous left and right of the stowed position The machine has a Ground Control Station which will override the Platform Control Station Ground Controls operate Boom Lift and Swing and are to be used in an emergency to lower the plat form to the ground should the operator in the platform be unable to do so The Ground Control is also to be used in Pre Start Inspection 1 Machine is positioned on a smooth firm and level sur face Load is within manufacturer s rated design capacity All machine systems are functioning properly Proper tire pressure exists in the tires o RON Machine is as originally equipped from JLG Stability Machine stability is based on two positions which are called FORWARD STABILITY and BACKWARD STABILITY The machine position of le
26. NO OPERATION BELOW THIS diss AMBIENT TEMPERATURE Figure 6 3 Engine Operating Temperature Specifications Ford Sheet 1 of 2 6 14 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT AIR TEMPERATURE 3121209 180 F 82 C HYD OIL TANK TEMP EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 OR ABOVE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE 120 F 49 C 110 F 43 C NO OPERATION ABOVE THIS AMBIENT TEMPERATURE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C ORABOVE 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 C 20 F 7 C 10 F 12 C C 0 F 18 C 10 F 23 C C 20 F 29 C C 30 F 34 C C MOBIL 424 10W 30 MOBIL DTE 13 HYDRAULIC SPECIFICATIONS N gt T gt 2 2 z x 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 40 F 40 NO OPERATION BELOW THIS AMBIENT TEMPERATURE NOTE 1 RECOMMENDATIONS ARE FO
27. Platform position POWER EMERGENCY STOP switch to ON then push the ENGINE START switch to the forward position until engine starts NOTE Footswitch must be in released up position before starter will operate If starter operates with footswitch in the depressed position DO NOT OPERATE MACHINE 3121209 SECTION 4 MACHINE OPERATION BOOM FULLY EXTENDED AT HORIZONTAL 0 DEGREES TOWER BOOM q AT MAX ANGLE AND FULLY RETRACTED LEVEL SURFACE Figure 4 1 Position of Least Forward Stability 3121209 JLG Lift MACHINE WILL UPSET IN THIS DIRECTION IF OVERLOADED OR OPERATED ON AN OUT OF LEVEL SURFACE SECTION 4 MACHINE OPERATION MAIN BOOM FULLY RETRACTED AND FULLY ELEVATED TOWER BOOM FULLY RETRACTED AND LOWERED LEVEL SURFACE A WARNING MACHINE WILL UPSET 5 gt DIRECTION IF OPERATED ON AN OUT OF LEVEL SURFACE Figure 4 2 Positions of Least Backward Stability Sheet 1 of 2 4 4 JLG Lift 3121209 SECTION 4 MACHINE OPERATION Jovduns 1 1 AOVAYNS NV NO GalvuadO d NOLLO3UIG SIH L NI LASdN TIIM 3NIHOVIA SNINHVM Y Q3a1v A313 1 ATINA H3MO L 1
28. 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 prevent obstacles from striking or interfering with operating controls and per sons in the platform Be sure that operators of other overhead and floor level machines are aware of the aerial work platform s pres ence Disconnect power to overhead cranes Warn personnel not to work stand or walk under a raised boom or platform Position barricades on floor if neces sary JLG Lift 1 4 TOWING LIFTING AND HAULING Never allow personnel in platform while towing lifting or hauling This machine should not be towed except in the event of emergency malfunction power failure or loading unload ing Refer to the Emergency Procedures section of this manual for emergency towing procedures Ensure boom is in the stowed position and the turntable locked prior to towing lifting or hauling The platform must be completely empty of tools When lifting machine lift only at designated areas of the machine Lift the unit with equipment of adequate capac ity Refer to the Machine Operation section of this manual for lifting information 3121209 SECTION 1 SAFETY PRECAUTIONS 1 5 ADDITIONAL HAZARDS SAFETY Do not refuel the machine with the engine running Do not use machine as a ground for welding Battery fluid is highly corrosive Avoid contact wi
29. jammed or snagged in overhead structures or equipment do not continue operation of the machine from either the platform or the ground until the operator and all personnel are safely moved to a secure location Only then should an attempt be made to free the platform using any necessary equipment and personnel Do not operate controls to cause one or more wheels to leave the ground JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 1 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE INTRODUCTION This section of the manual provides additional necessary information to the operator for proper operation and mainte nance of this machine The maintenance portion of this section is intended as infor mation to assist the machine operator to perform daily main tenance tasks only and does not replace the more thorough Preventive Maintenance and Inspection Schedule included in the Service and Maintenance Manual Other Publications Available 3121209 Service and Maintenance Manual ANSI CSA Spec3120740 Service and Maintenance Manual CE Spec 3120858 Illustrated Parts Manual ANSI CSA Spec Prior to S N 0300069000 3120741 Illustrated Parts Manual CE Spec Prior to S N 0300069000 3120859 Illustrated Parts Manual ANSI CSA Spec S N 0300069000 to 3121
30. should not lower and the red boom malfunction light should illuminate when pressing the tower down switch A WARNING DISCONTINUE OPERATION IF THE TOWER BASE BOOM LOWERS OR THE BOOM MALFUNCTION LIGHT DOES NOT ILLUMINATE f Check that all machine functions are disabled when the Emergency Stop Button is pushed in g Check for proper operation of the auxiliary power and manual descent system if equipped Operate each function control to ensure proper operation From the Platform Control Station 1 Check that the control console is secure and all guards protecting the function switches or locks are in place Ensure that all function controls and switches return to the off or neutral position when released 3121209 JLG Lift A WARNING DO NOT OPERATE MACHINE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE OFF OR NEUTRAL POSI TION 2 Check the footswitch adjustment and operation as fol lows a With engine power shut down attempt to start engine Engine should not attempt to start when footswitch is activated b Start engine Activate hydraulic system by depress ing footswitch Activate a boom function Continue to activate the function and remove foot from foot switch The motion should stop A WARNING DISCONTINUE OPERATION IF THE FOOTSWITCH DOES NOT OPERATE PROPERLY c Check adjustment of footswitch Footswitch must be adjusted so that functions will operate when pedal is ap
31. strapped This prevents the boom from bouncing up causing possible damage 4 13 SECTION 4 MACHINE OPERATION Rig chains so as not to rub NOTE Block rotator and platform Secure platform w o over tightening Figure 4 5 Machine Tie Down 4 14 JLG Lift 3121209 SECTION 4 MACHINE OPERATION MODEL Dimension Steer Axle To Center Of Gravity Tire option Gross Weight Standard Machine 800A 800AJ 52 1320 mm 15 19 5 Pneumatic 34 200 Ibs 15520 kg 800A 800AJ 52 1320 mm 18 19 5 Pneumatic 34 270 Ibs 15550 kg 800A 800AJ 53 1350 mm 15 19 5 Foam Filled 33 100 Ibs 15020 kg 800A 800AJ 53 1350 mm 18X 19 5 Foam Filled 33 550 Ibs 15220 kg LIFT HERE SPREADER BAR REQUIRED AVITY 3121209 ROTATION Figure 4 6 Lifting Chart JLG Lift SECTION 4 MACHINE OPERATION NOTE Crane and lifting devices chains slings etc must be capable of handling the gross machine weight NOTICE ABOVE IS MINIMUM WEIGHT CHECK WEIGHT OF UNIT PRIOR TO LIFT ING NOTE Lifting eyes are provided at the front and rear in the frame slab Each of the four chains or slings used for lifting
32. to the State of California to cause cancer birth defects or other reproductive harm 1702961 PROPOSITION 65 WARNING Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and reproductive harm Batteries also contain other chemicals known to the State of California to cause cancer Wash hands after handling An Oshkosh Corporation Company Corporate Office JLG Industries Inc 1JLG Drive McConnellsburg PA 17233 9533 USA 717 485 5161 El 717 485 6417 JLG Worldwide Locations 3121209 JLG Industries Australia P O Box 5119 11 Bolwarra Road Port Macquarie N S W 2444 Australia c 461265811111 amp 61 265 810122 JLG Latino Americana Ltda Rua Eng Carlos Stevenson 80 Suite 71 13092 310 Campinas SP Brazil 55 19 3295 0407 55 19 3295 1025 JLG Industries UK Ltd Bentley House Bentley Avenue Middleton Greater Manchester M24 2GP England 44 0 161 654 1000 44 0 161 654 1001 JLG France SAS 2 1 de Baulieu 47400 Fauillet France f 33 0 5 53 88 31 70 33 0 5 53 88 31 79 JLG Deutschland GmbH Max Planck Str 21 D 27721 Ritterhude Ihlpohl Germany fc 49 0 421 69 350 20 49 0 421 69 350 45 A JLG Equipment Services Ltd Rm 1107 Landmar
33. using the information provided in this manual and the Service and Maintenance Manual must also be estab lished by a qualified person and followed to ensure the machine is safe to operate The owner user operator lessor lessee of the machine should not operate the machine until this manual has been read training is accomplished and operation of the machine has been completed under the supervision of an experi enced and qualified operator If there are any questions with regard to safety training inspection maintenance application and operation please contact JLG Industries Inc ULG A WARNING FAILURE TO COMPLY WITH THE SAFETY PRECAUTIONS LISTED IN THIS MANUAL COULD RESULT IN MACHINE DAMAGE PROPERTY DAM AGE PERSONAL INJURY OR DEATH 3121209 JLG Lift 1 2 PRE OPERATION Operator Training and Knowledge Read and understand this manual before operating the machine Do not operate this machine until complete training is per formed by authorized persons Only authorized and qualified personnel can operate the machine 1 1 SECTION 1 SAFETY PRECAUTIONS Read understand and obey all DANGERS WARNINGS CAUTIONS and operating instructions on the machine and in this manual Use the machine in a manner which is within the scope of its intended application set by JLG All operating personnel must be familiar with the emer gency controls and emergency operation of the machine as sp
34. 05828 1703980 26 3251813 3251813 3251813 3251813 3251813 3251813 27 28 29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 31 1703772 1703772 1703772 1703772 1703772 1703772 1703772 1703772 32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 33 1001121800 1001122200 1001121809 1001121804 1001121806 1001121802 1705978 1001121807 JLG Lift 4 31 SECTION 4 MACHINE OPERATION 4 32 Table 4 2 Decal Legend 800A S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 10 0274464 8 0274470 8 0274466 8 0274468 9 0274472 8 0274474 3 0274462 8 34 1001121813 1001122201 1001121822 1001121817 1001121819 1001121815 1705978 1001121820 35 1704885 1704885 1704885 1704885 1704885 1704885 1704885 36 1706948 1706948 1706948 1706948 1706948 1706948 1706948 37 1702265 1703987 1703988 1703989 1706439 1703990 1705977 1703986 38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 41 1706941 1706941 1706941 1706941 1706941 1706941 1706941 42 43 44 45 46 47 48 49 50 JLG Lift 3121209 SECTION 4 MAC
35. 1509 1701509 1701509 1701509 1701509 1701509 1701509 6 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 1705084 12 1705514 13 14 15 1705337 1705339 1705342 16 17 1702153 1704007 1705901 1704006 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 3121209 Table 4 4 Decal Legend 800AJ S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 10 0274465 8 0274471 8 0274467 8 0274469 10 0274473 8 0274475 3 0274463 8 18 1703953 1703945 1703943 1703941 1705903 1703942 1703944 19 20 1702868 1705969 1705968 1704001 1705967 1704000 21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926 22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344 23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950 24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938 25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980 26 3241813 3251813 3251813 3251813 3251813 3251813 27 28 29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 31
36. 1703773 1703773 1703773 1703773 1703773 1703773 1703773 1703773 32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 33 1001121801 1001121918 1001121919 1001121805 1001121656 1001121803 1705978 1001121808 34 1001121814 1001121921 1001121922 1001121818 1001121655 1001121816 1705978 1001121821 35 1704885 1704885 1704885 1704885 1704885 1704885 1704885 1704885 JLG Lift 4 39 SECTION 4 MACHINE OPERATION 4 40 Table 4 4 Decal Legend 800AJ S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 10 0274465 8 0274471 8 0274467 8 0274469 10 0274473 8 0274475 3 0274463 8 36 1706948 1706948 1706948 1706948 1706948 1706948 1706948 37 1702265 1703987 1703990 1703989 1706439 1703990 1705977 1703986 38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 41 1706941 1706941 1706941 1706941 1706941 1706941 1706941 42 43 44 45 46 47 48 49 50 51 52 53 JLG Lift SECTION 4 MACHINE OPERATION 3121209 Table 4 4 Decal Legend 800AJ S N 0300141330 to Present Item ANSI Korean Chinese Spanish Por
37. 176 Illustrated Parts Manual CE Spec S N 0300069000 to 3121854 6 2 OPERATING SPECIFICATIONS Table 6 1 Operating Specifications Travel Speed 2WD 3 0 MPH 4 83 Km hr 4WD 3 0 MPH 4 83 Km hr Gradeability 2WD 3096 4WD 45 Turning Radius Outside 2WS 22 ft 6 in 6 86 m 4WS 14ft 6in 4 42 m Turning Radius Inside 2WS 12ft 0 in 3 66 m 4WS 11 ft Oin 2 13 Overall Width 8 ft 0 in 2 44 m Machine Height Stowed 9ft 9 5 in 2 98 Machine Length Stowed 800A 36 ft 9 in 11 25 m 800AJ 36ft 6in 11 13 Wheel base 10ft 0 in 3 05 m JLG Lift 6 1 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 1 Operating Specifications Tires Boom Elevation 800A Table 6 2 Tire Specifications Above Grade 8011 24 38 Below Grade 15ft 7 in 4 75 m Size Type Ply Load Pressure Rating Range Boom Elevation 800AJ Above Grade 80 ft 24 38 m IN385 65D 19 5 pneumatic 16 H 95PSI Below Grade 13ft 1 in 3 99 m 6 5 Bar Max Ground Bearing Pressure 84 psi 5 9 kg cm IN445 55D 19 5 pneumatic 16 H 85PSI 6 0 Bar Max Tire Load 17 755 Ibs 8054 k 9 15X19 5 pneumatic 16 H 95PSI Drive Speed 2WD 6 5 Bar Forward 42 48 Seconds for 200 Ft Reverse 42 48 S
38. 2 7 Daily Walk Around Inspection Sheet 2 of 4 2 8 Daily Walk Around Inspection Sheet 3 of 4 2 9 Daily Walk Around Inspection Sheet 4 of 4 2 10 SECTION PARAGRAPH SUBJECT PAGE 2 7 Tower Boom Vertical Limit Switch 2 11 2 8 Tower Boom Horizontal Limit Switch 2 12 2 9 Upright Positioning Correct 2 13 2 10 Boom Upright Positioning Incorrect 2 14 3 1 Ground Control Station 3 2 3 2 Ground Control Indicator Panel 3 6 3 3 Platform Control 3 10 3 4 Platform Control Console w Drive Orientation 3 11 3 5 Platform Light 3 18 3 6 Platform Light Panel w Drive Orientation 3 19 4 1 Position of Least Forward Stability 4 3 4 2 Positions of Least Backward Stability Sheet 1 2 4 4 4 3 Positions of Least Backward Stability Sheet 2 2 4 5 4 4 Grade and Sideslopes 4 9 4 5 Machine Tie Down 4 14 4 6 Lifting 4 15 4 7 4 18 4 8 Releveling 4 20 4 9 Decal Installation Sheet 1 015 4 21 4 10 Decal Installation Sheet 2 of 5 4 22 4 11 Decal Installation Sheet 3 of 5
39. 6 1 4 TOWING LIFTING AND HAULING 1 8 Platform 3 9 1 5 ADDITIONAL HAZARDS SAFETY 1 9 Platform Control Indicator Panel 3 16 SECTION 2 USER RESPONSIBILITIES MACHINE PREPA SECTION 4 MACHINE OPERATION RATION AND INSPECTION 41 4 1 2 1 PERSONNEL TRAINING 2 1 4 2 OPERATING CHARACTERISTICS AND Operator 0 2 1 LIMITATIONS pl ate we ge ees 4 1 Training 2 1 Capacities eie eei 4 1 Operator Responsibility 2 1 Stability cs jth el Nae Ae eee 4 1 2 2 PREPARATION INSPECTION AND 4 3 ENGINE 4 2 MAINTENANCE 2 2 Starting Procedure 4 2 Pre Start Inspection 2 4 Shutdown Procedure 4 6 GENERAL 3121209 JLG Lift i TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT 4 4 TRAVELING DRIVING Traveling Forward and Reverse 4 5 4 6 PARKING AND STOWING 4 7 Loading From Ground Level Loading From Positions Above Ground Level 4 8 Platform Level Adjustment Platform
40. 84 12 1705514 13 14 15 1705337 1705339 1705342 16 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 3121209 Table 4 1 Decal Legend 800A Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 9 0274464 7 0274470 7 0274466 7 0274468 8 0274472 7 0274474 3 0274462 7 17 1704007 1705901 1704006 18 1703953 1703945 1703943 1703941 1705903 1703942 1703944 19 20 1702868 1705969 1705968 1704001 1705967 1704000 21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926 22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344 23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950 24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938 25 3252347 1703981 1703982 1703983 1705902 1703984 1705828 1703980 26 3251813 3251813 3251813 3251813 3251813 3251813 27 28 29 1703960 1703960 1703960 1703960 1703960 1703960 1703960 1703960 30 1702631 1702631 1702631 1702631 1702631 1702631 1702631 1702631 31 1703772 1703772 1703772 1703772 1703772 1703772 1703772 1703772 32 1701501 1701501 1701501 1701501 1701501 1701501 1701501 1701501 33 1704096 1704103 1704101 1704098 1706380 1704099 1705978 1704102 JLG Lift 4 27 SECTION 4 MACHINE OPERATION 4 28 Table 4 1 Decal L
41. AINST UNSAFE PRACTICES THIS DECAL WILL HAVE A YELLOW BACKGROUND 3121209 FOREWORD A WARNING 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 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 OF PERSONNEL OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP ERTY OR THE JLG PRODUCT 3121209 For Accident Reporting Standards and Regulations Product Safety Publica Compliance Information tions Questions Regarding Spe Current Owner Updates cial Product Applications Questions Regarding Prod Regarding uct Modifications Product Safety Contact Product Safety and Reliability Department JLG Industries Inc 13224 Fountainhead Plaza Hagerstown MD 21742 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 mail ProductSafety JLG com Lift c FOREWORD
42. CT PAGE 6 2 Tire Specifications 6 2 6 3 6 3 6 4 Ford LRG 425 Specifications 6 3 6 5 Deutz FAM2011F Specifications 6 4 6 6 Deutz 02011104 Specifications 6 4 6 7 3044 4 6 5 6 8 1 2 1 6 5 6 9 reete PON 6 6 6 10 Hydraulic 6 6 6 11 Mobilfluid 424 Specs 6 7 6 12 Mobil DTE 13M Specs 6 7 6 13 Mobil EAL 224H 6 8 6 14 UCon Hydrolube 5046 6 8 6 15 Exxon Univis HVI 26 Specs 6 9 6 16 Quintolubric 888 46 6 9 6 17 Critical Stability Weights 800 6 10 6 18 Critical Stability Weights 800 6 11 6 19 Lubrication Specifications 6 21 6 20 Wheel Torque 6 32 7 1 Inspection and 09 7 1 3121209 JLG Lift SECTION 1 SAFETY PRECAUTIONS 1 1 SECTION 1 SAFETY PRECAUTIONS GENERAL This section outlines the necessary precautions for proper and safe machine operation and maintenance For proper machine use it is mandatory that a daily routine is estab lished based on the content of this manual A maintenance program
43. Controls pull out Emergency Stop switch start engine and activate footswitch 2 Position Drive controller to FORWARD or REVERSE as desired This machine is equipped with a Drive Orientation Indicator The yellow light on the platform control console indicates that the boom is swung beyond the rear drive tires and the machine may Drive Steer in the opposite direction from the movement of the controls If the indicator is illuminated operate the Drive function in the following manner 1 Match the black and white direction arrows on both plat form control panel and the chassis to determine the direction the machine will travel 2 Push and release the Drive Orientation Override switch Within 3 seconds slowly move the Drive control toward the arrow matching the intended direction of machine travel The indicator light will flash during the 3 second interval until the drive function is selected 4 5 STEERING Depress the footswitch to steer machine push switch left to steer left to the right to steer right A WARNING BEFORE OPERATING MACHINE MAKE SURE UPPER BOOM IS POSI TIONED OVER REAR AXLE IF BOOM IS OVER FRONT AXLE STEER WHEELS STEER AND DRIVE CONTROLS WILL MOVE IN OPPOSITE DIRECTION THE DIRECTION WILL MATCH THE ARROW DECAL OF THE HAND CONTROLLER WITH THE ARROW DECAL ON THE FRAME 4 6 PARKING AND STOWING Park and stow machine as follows 1 Park machine in travel position boom lowered over rear all access p
44. DED Vy PSOE e s 40 F 40 C NO OPERATION BELOW THIS TS AMBIENT TEMPERATURE Figure 6 1 Engine Operating Temperature Specifications Deutz Sheet 1 of 2 6 12 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 180 F 82 C HYD OIL TANK TEMP AMBIENT AIR TEMPERATURE 120 F 49 C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C 40 F 4 C 30 F 1 20 F 7 C 10 F 12 C 0 F 18 C 10 F 23 C 20 F 29 30 34 40 40 C A EXTENDED DRIVING WITH HYDRAULIC OIL TANK TEMPERATURES OF 180 F 82 C OR ABOVE IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS THE ADDITION OF A HYDRAULIC OIL COOLER CONSULT JLG SERVICE PROLONGED OPERATION IN AMBIENT AIR TEMPERATURES OF 100 F 38 C OR ABOVE NO OPERATION ABOVE THIS AMBIENT TEMPERATURE MOBIL 424 10W 30 MOBIL DTE 13 HYDRAULIC SPECIFICATIONS EXXON UNIVIS HVI 26 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 EET OPERATION BELOW THIS EET TEMPERATURE AMBIENT THVFEFATLFE NOIE 1 FECOMVENDATIONSAFEFORANVBENT IBVFEHAILFES CONSSAN
45. DI TION IS CORRECTED 3121209 SECTION 4 MACHINE OPERATION 4 9 SHUT DOWN AND PARK 3121209 Drive machine to a protected area Assure main boom is fully retracted and lowered over rear Drive axle all access panels and doors closed and secured Remove all load and allow engine to idle 3 5 minutes to permit reduction of engine internal temperatures At Ground Controls turn KEY SELECT switch to center OFF Position POWER EMERGENCY STOP switch down to OFF Remove key Cover Platform Control console to protect instruction placards warning decals and operating controls from hostile environment JLG Lift 4 10 LIFTING AND TIE DOWN When transporting machine boom must be in the stowed position mode booms lowered and retracted with turntable lock pin engaged and machine securely tied down to truck or trailer deck Six tie down eyes are provided in the frame slab one at each corner of the machine and 2 holes at the center of the frame See Figure 4 5 Machine Tie Down If it becomes necessary to lift the machine using an over head or mobile crane it is very important that the turntable lock pin is engaged lifting devices are attached only to the designated lifting eyes and spreader bars are to be used to prevent damage to the machine See Figure 4 6 Lifting Chart for gross machine weights NOTE When transporting machine over rough terrain or long dis tance the boom needs to be chocked and
46. EA IS WELL VENTILATED BEFORE DIS CONNECTING ANY FUEL LINE The following information is provided in accordance with the requirements of the European Machinery Directive 2006 42 EC and is only applicable to CE machines For electric powered machines the equivalent continuous A Weighted sound pressure level at the work platform is less than 70dB A For combustion engine powered machines guaranteed Sound 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 Ill Part B Method 1 and 0 of the directive is 104 dB The vibration total value to which the hand arm system is subjected does not exceed 2 5 m s The highest root mean square value of weighted acceleration to which the whole body is subjected does not exceed 0 5 m s 6 36 JLG Lift 3121209 SECTION 7 INSPECTION AND REPAIR LOG Machine Serial Number SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 3121209 JLG Lift 7 1 SECTION 7 INSPECTION AND REPAIR LOG Table 7 1 Inspection and Repair Log Date Comments 7 2 JLG Lift 3121209 amp Ajmou 2 noA ouM 4
47. F 166 C SAE Grade 10W30 Viscosity Gravity API 29 0 at40 C 33cSt Density Lb Gal 60 F 7 35 at100 C 6 6cSt Pour Point Max 46 F 43 C at 100 F 169 SUS Flash Point Min 442 F 228 C at 210 F 48 SUS Viscosity cp at 20 F 6 200 Brookfield cP at 18 C 2700 Viscosity Index 140 at 40 C 55 cSt at 100 C 9 3cSt Viscosity Index 152 3121209 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 13 Mobil EAL 224H Specs Type Synthetic Biodegradable ISO Viscosity Grade 32 46 Specific Gravity 922 Pour Point Max 25 F 32 C Flash Point Min 428 F 220 C Operating Temp 0 to 180 F 17 to 162 C 27 Viscosity at 40 C 37 cSt at 100 C 8 4cSt Viscosity Index 213 NOTE Must be stored above 32 F 14 C 6 8 Table 6 14 UCon Hydrolube HP 5046 JLG Lift Type Synthetic Biodegradable Specific Gravity 1 082 Pour Point Max 58 F 50 C pH 9 1 Viscosity at 0 C 32 F 340 cSt 1600SUS at 40 C 104 46 cSt 215SUS at 65 150 F 22 cSt 106SUS Viscosity Index 170 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Table 6 15 Exxon Univis HVI 26 Specs Table 6 16 Quintolubric 888 46 3121209 Specific Gravity 32 1 Density 0 91 15 C 59 F
48. HINE OPERATION Table 4 2 Decal Legend 800A S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 10 0274464 8 0274470 8 0274466 8 0274468 9 0274472 8 0274474 3 0274462 8 51 52 53 54 55 56 1705351 1705427 1705430 1705910 1705905 1705429 1705426 3121209 JLG Lift 4 33 SECTION 4 MACHINE OPERATION 4 34 Table 4 3 Decal Legend 800AJ Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 9 0274464 7 0274471 7 0274467 7 0274469 9 0274473 7 0274475 3 0274462 7 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 1705084 12 1705514 13 14 15 1705337 1705339 1705342 16 17 1702153 1704007 1705901 1704006 JLG Lift SECTION 4 MACHINE OPERATION 3121209 Table 4 3 Decal Legend 800AJ Prior to S N 0300141330
49. INSIDE TOWER BASE BOOM TOWER LIFT CYLINDER TOWER BOOM ASSEMBLY GROUND CONTROL T aN SWING BEARING r MAIN BOOM ASSEMBLY MAIN FLY BOOM MAIN BASE BOOM ROTATOR PLATFORM CONTROL BOX ae PLATFORM FOOTSWITCH SLAVE CYLINDER INSIDE MASTER CYLINDER 3121209 Figure 2 1 Machine Nomenclature 800A Sheet 1 of 2 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION ARTICULATING JIB ARTICULATING JIB LIFT CYLINDER ALL OTHER COMPONENTS ARE SIMILAR TO MODEL 800A ON PRECEDING PAGE 2 6 Figure 2 2 Machine Nomenclature 800AJ Sheet 2 of 2 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 22 23 24 14 15 16 17 18 19 20 13 12 11 37 38 12 11 24 30 31 32 33 34 35 Figure 2 3 Daily Walk Around Inspection Sheet 1 of 4 3121209 JLG Lift 2 7 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION GENERAL Begin the Walk Around Inspection at Item 1 as noted on the diagram Continue to the right counterclockwise viewed from top
50. Machine 5 4 vo Md Platform or Boom Caught Overhead 5 4 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR 416 MAINTENANCE i pee 6 1 INTRODUCTION irre rev DEL ete es 6 1 22 447 6 2 OPERATING SPECIFICATIONS 6 1 DUM Ui M 6 2 4 19 en 222449 Capacities CR 6 3 2224 19 Data PAM 6 3 2224 19 Hydraulic 6 6 JLG Lift 3121209 TABLE OF CONTENTS SECTION PARAGRAPH SUBJECT PAGE Critical Stability Weights 6 10 6 3 OPERATOR MAINTENANCE 6 21 6 4 TIRES WHEELS 6 29 Tire Inflation 6 29 Tire 6 29 Tire Replacement 6 30 Wheel 6 30 Wheel Installation 6 31 6 5 DRAINING OIL BUILD UP FROM THE PROPANE REG ULATOR enemies RE Ai 6 32 6 6 PROPANE FUEL FILTER REPLACEMENT 6 34 Removal iil aos eget a 6 34 Installation 0 0 eee eee 6 34 6 7 PROPANE FUEL SYSTEM PRESSURE RELIEF 6 36 6 8 SUPPLEMENTAL INFORMATION 6 36 SECTION 7 INSPECTION AND REPAIR LOG 2 1 2 2 2 3 2 4 2 5 2 6 3121209 LIST OF FIGURES Machine Nomenclature 800A Sheet 1 of 2 2 5 Machine Nomenclature 800AJ Sheet 2 of 2 2 6 Daily Walk Around Inspection Sheet 1 of 4
51. NDED DRIVING WITH 82 C OR ABOVE 180 F 82 HYD OIL TANK TEMP IF EITHER OR BOTH CONDITIONS EXIST JLG HIGHLY RECOMMENDS AMBIENT AIR THE ADDITION OF A HYDRAULIC TEMPERATURE OIL COOLER CONSULT JLG SERVICE 120 F 49 C NO OPERATION ABOVE THIS PROLONGED OPERATION IN 110 F 43 C AMBIENT TEMPERATURE AMBIENT AIR TEMPERATURES e OF 100 F 38 C OR ABOVE 100 F 38 C 90 F 32 C 80 F 27 C E 70 F 21 C a t E 60 F 16 C z 2 HYDRAULIC F 10 C d s SPECIFICATIONS 40 F 4 C B B 30 F 1 i d S 20 F 7 C 9 10 F 12 os Fi 18 C DO NOT START UP HYDRAULIC SYSTEM WITHOUT HEATING AIDS WITH MOBILE 424 10 F 23 C HYDRAULIC OIL BELOW THIS TEMPERATURE NOTE 205 E2959 DO NOT START UP HYDRAULIC SYSTEM 1 RECOMMENDATIONS ARE FOR AMBIENT TEMPERATURES 30 F 34 C WITHOUT HEATING AIDS AND COLD WEATHER CONSISTENTLY WITHIN SHOWN LIMITS 40 40 HYDRAULIC OIL BELOW THIS TEMPERATURE OPERATION BELOW THIS 2 ALL VALUES ARE ASSUMED TO BE AT SEALEVEL AMBIENT TEMPERATURE 4150548 D Figure 6 8 Engine Operating Temperature Specifications GM Sheet 2 of 2 3121209 JLG Lift 6 19 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 20 xil 8 thru 20 ENGINE COMPAR
52. NGLY 3121209 JLG Lift 6 21 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 22 2 Wheel Bearings Lube Point s Repack Capacity A R Lube MPG Interval Every 2 years or 1200 hours of operation 3 Wheel Drive Hub JLG Lift Lube Point s Level Fill Plug Capacity 17 oz 0 5 L 1 2 Full Lube EPGL Interval Check level every 3 months or 150 hrs of oper ation 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 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 4 Hydraulic Return Filter 5 Hydraulic Charge Filter Interval Change after first 50 hrs and every 6 months Interval Change after first 50 hrs and every 6 months or 300 hrs thereafter or as indicated by Condition Indi or 300 hrs thereafter or as indicated by Condition Indi cator cator 3121209 Lift 6 23 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 Hydraulic Tank 7 Suction Strainers Lube Point s Fill Cap Capacity 40 gallons 151 L Tank 77 gallons 291 4 L System Lube HO Interval Check Level daily Change every 2 years or 1200 hours of operation Lube Point s 2 Interval Every 2 years or 1200 hours of operation remove and clean a
53. NT WITH THE PLATFORM RAISED LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION REPORT THE PROBLEM TO THE PROPER SER VICE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL THE MAL FUNCTION IS CORRECTED 3 8 JLG Lift Platform Overload If equipped Indicates the platform has been overloaded Hydraulic Oil Filter Indicator Prior to S N 85331 A gauge indicates that the return oil filter is too restrictive and needs to be replaced Transmission Pump Oil Filter Indicator Prior to S N 85331 Indicates that the charge pump filter is too restrictive and needs to be replaced Engine Air Filter Indicator Prior to S N 85331 When illuminated indicates that the air filter is too restric tive and needs to be replaced 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Station A WARNING TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM 3 Main Lift Swing Controller A proportional dual axis joystick is provided for main lift and swing Push forward to lift up pull backward to lift down Move right to swing right move left to swing left MOVEMENT DO NOT RETURN TO THE OFF OR NEUTRAL POSITION NOTE Main boom lift and swing functions may be selected in WHEN RELEASED 1 Power Emergency Stop An ON OFF POWER EMERGENCY STOP switch and a separate ENGINE START AUXILIARY
54. POWER toggle Switch on the platform console supply electrical power to the starter solenoid when the ignition switch is placed combination Maximum speed is reduced when multiple functions are selected Main Telescope Control The MAIN TELESCOPE control switch provides exten sion and retraction of the main boom when positioned to IN or OUT in the ON position and the ENGINE START switch is NOTE MAIN LIFT SWING and DRIVE control levers are spring pushed forward momentarily 2 Travel Warning Horn A push type HORN switch supplies electrical power to an audible warning device when pressed 3121209 JLG Lift loaded and will automatically return to neutral OFF posi tion when released SECTION 3 MACHINE CONTROLS AND INDICATORS 3 10 gt Power Emergency Stop Horn Main Lift Swing Telescope Drive Steer 6 7 8 9 Function Speed Control 10 Articulating Jib 800AJ 14 Engine Start Aux Power Drive Speed Torque Select 11 Fuel Select Platform Rotate 12 Lights Platform Level Override 13 Steer Select Figure 3 3 Platform Control Console JLG Lift 15 Tower Telescope 16 TowerLift 17 Light Panel 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS
55. R AMBIENT TEMPERATURES CONSISTANTLY WITHIN SHOWN LIMITS 2 ALL VALUES ARE ASSUMED TO BE AT SEALEVEL 4150548 D Figure 6 4 Engine Operating Temperature Specifications Ford Sheet 2 of 2 Lift 6 15 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 16 NO OPERATION ABOVE THIS AMBIENT TEMPERATURE ENGINE SPECIFICATIONS ENGINE WILL START AND OPERATE UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY ENGINE WILL START AND OPERATE AT THIS TEMPERATURE WITH AND THE RECOMMENDED FLUIDS A FULLY CHARGED BATTERY HE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER l SAE 5W 30 Lr RE 3 SAE 510 40 gt SAE 10W 30 r m SAE 15W 40 p N SAE 0W 20 M 7 SAE 0W 30 4 9 SAE0W 0 o NO OPERATION BELOW THIS AMBIENT TEMPERATURE 120 F 49 C 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 70 F 21 C 60 F 16 C 50 F 10 C iM 30 F 1 C 20 F 7 C Pn F 18 C 10 F 23 C 20 F 29 C 30 F 34 C 40 F
56. Sheet 2 of 2 3121209 Lift 6 17 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE NO OPERATION BELOW THIS AMBIENT TEMPERATURE 120 F 49 C NO OPERATION ABOVE THIS 1 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C 3 70 F 21 C ENGINE 60 F 16 C SPECIFICATIONS 50 10 o 40 F 4 C ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 30 F 1 C NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 2 12 C WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY F 18 C ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS 8 10 F 23 C A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE 5 20 F 29 C IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 30 F 34 C 40 40 Figure 6 7 Engine Operating Temperature Specifications GM Sheet 1 of 2 6 18 JLG Lift AMBIENT AIR TEMPERATURE SN 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE HYDRAULIC OIL TANK TEMPERATURES OF 180 F EXTE
57. TMENT NEAR SIDE 1 3 5 6 7 TANK COMPARTMENT FAR SIDE Figure 6 9 Operator Maintenance and Lubrication Diagram JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 3 OPERATOR MAINTENANCE NOTE It is recommended as a good practice to replace all filters at the same time NOTE The following numbers correspond to those in Figure 6 9 Operator Maintenance and Lubrication Diagram Swing Bearing Internal Ball Bearing Table 6 19 Lubrication Specifications KEY SPECIFICATIONS MPG Multipurpose Grease having a minimum dripping point of 350 F 177 C Excellent water resistance and adhesive qualities and being of extreme pressure type Timken OK 40 pounds minimum EPGL Extreme Pressure Gear Lube oil meeting API service classifica tion GL 5 or MIL Spec MIL L 2105 HO Hydraulic Oil API service classification GL 3 e g Mobilfluid 424 EO Engine crankcase Oil Gas APISF SH SG class MIL L 2104 Diesel API CC CD class MIL L 2104B MIL L 2104C Lube Point s 2 Grease Fittings Capacity A R NOTICE Lube MPG LUBRICATION INTERVALS ARE BASED ON MACHINE OPERATION Interval Every 3 months or 150 hrs of operation UNDER NORMAL CONDITIONS FOR MACHINES USED IN MULTI SHIFT Comments Remote Access OPERATIONS AND OR EXPOSED TO HOSTILE ENVIRONMENTS OR CON DITIONS LUBRICATION FREQUENCIES MUST BE INCREASED ACCORD I
58. TOWER LIFT is not fully elevated UP A WARNING TO AVOID UPSET AND SERIOUS INJURY DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE DO NOT OPERATE IN THE ORDER DESCRIBED ABOVE 17 3121209 Drive Orientation Override When the boom is swung over the rear tires or further in either direction the Drive Orientation indicator will illumi nate when the drive function is selected Push and release the switch and within 3 seconds move the Drive Steer control to activate drive or steer Before driv ing locate the black white orientation arrows on both the chassis and the platform controls and match the control direction arrow to the intended chassis direction Lift 18 19 Soft Touch Override Switch If equipped This switch enables the functions that were cut out by the Soft Touch system to operate again at creep speed allowing the operator to move the platform away from the obstacle that caused the shutdown situation Soft Touch Indicator If Equipped Indicates the Soft Touch bumper is against an object All controls are cut out until the override button is pushed at which time controls are active in the Creep Mode 3 15 SECTION 3 MACHINE CONTROLS AND INDICATORS Platform Control Indicator Panel NOTE The platform control indicator panel uses different shaped 3 16 gt symbols to alert the operator to different types of opera tional situations that could arise The meaning o
59. TY WIHN SHOWN LIMES 2 ALL VALESAFEASB NED D EEATSEALEVEL RE RE 32 0 23 5 14 10 5 15 4 20 25 22 30 0 10 20 30 40 50 60 oOF ADDED 4150548 D Figure 6 2 Engine Operating Temperature Specifications Deutz Sheet 2 of 2 3121209 JLG Lift SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE AMBIENT TEMPERATURE NS 120 F 49 C NO OPERATION ABOVE THIS A MAMMA AMBIENT TEMPERATURE 110 F 43 C 100 F 38 C 90 F 32 C 80 F 27 C el lel isl 8 S 70 F 21 C amp 181 3 g 3 ENGINE z EZ 8 S8 60 F 16 C SPECIFICATIONS du m B 5 50 5010 40 F 4C ENGINE WILL START AND OPERATE ON LPG UNAIDED AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY 1 NOTE THIS IS THE LOWEST ALLOWABLE OPERATING TEMPERATURE ON LPG ENGINE WILL START AND OPERATE ON GASOLINE UNAIDED AT THIS TEMPERATURE 10 d 12 C WITH THE RECOMMENDED FLUIDS AND A FULLY CHARGED BATTERY y PREG ENGINE WILL START AND OPERATE ON GASOLINE AT THIS TEMPERATURE WITH THE RECOMMENDED FLUIDS 10 F 23 C A FULLY CHARGED BATTERY AND THE AID OF A COMPLETE JLG SPECIFIED COLD WEATHER PACKAGE 20 F 29 C IE ENGINE BLOCK HEATER BATTERY WARMER AND HYDRAULIC OIL TANK HEATER 30 F 34 C 40 F 4
60. UE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT IS FLASHING ON STEADY A WARNING DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED 2 12 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 1984402 woog 6 2 aunbi4 SISSVH JHL OL 1991183 06 38 19 1 4 2 13 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 1984102u Buiuonisog woog 01 2 193u809NI LOAYYOONI INIHOWW 30 ISN SNIANILNOD 380438 NVIJINH231 391AH3 91r GANIWUL V A8 03193990 NOILIGNOD JAVH SNOILONNA 390283131 ANY 1311 008 GNNOYS OL WYOALW1d H3MOT 1580920 SIHL 3I 9NIddlL GIOAV OL ONINYVM VW 3121209 JLG Lift 2 14 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION e Attempt to lower the tower base boom while the tower fly boom is extended The tower base boom
61. al 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual 6 26 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE _ 13 Fuel Filter Ford 14 Fuel Filter Deutz Lube Point s Replaceable Element Interval Every Year or 1200 hours of operation Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 15 Fuel Filter Isuzu Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 16 Fuel Filter Caterpillar Lube Point s Replaceable Element Interval Every Year or 600 hours of operation 3121209 Lift 6 27 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 17 Fuel Filter Gasoline GM 19 Electronic Pressure Regulator LP only Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation 18 Air Filter Interval 3 Months or 150 hours of operation Comments Drain oil build up Refer to Section 6 5 DRAINING OIL BUILD UP FROM THE PROPANE REGU LATOR Prior to S N 0300134626 Lube Point s Replaceable Element Interval Every 6 months or 300 hours of operation or as indicated by the condition indicator 6 28 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 20 Fuel Filter Propane GM Engine 6 4 TIRES amp WHEELS Tire Inflation The air pressure for pn
62. anels and doors closed and secured igni tion off turntable locked 2 Check that brakes hold machine in position 3 Chock wheels front and rear 4 Turn off SELECT switch and remove key 3121209 Lift 4 7 SECTION 4 MACHINE OPERATION 4 7 PLATFORM Loading From Ground Level Position chassis on a smooth firm and level surface If total load personnel tools and supplies is less then rated capacity distribute load uniformly on platform floor and proceed to work position Loading From Positions Above Ground Level Before loading weight to platform above ground level 1 4 8 Determine what the total rated capacity weight will be after additional weight is loaded personnel tools and supplies If total weight in platform will be less then rated capacity proceed with distributing weight uniformly on platform floor Platform Level Adjustment 1 Leveling UP Depress footswitch To raise platform posi tion PLATFORM LEVEL control switch UP and hold until platform is level 2 Leveling DOWN Depress footswitch To lower platform position PLATFORM LEVEL control switch to DOWN and hold until platform is level A WARNING ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY Platform Rotation To rotate the platform to the left or right use th
63. ast forward stability is shown in Figure 4 1 its positions of least backward stability is shown in Figure 4 2 3121209 JLG Lift 4 1 SECTION 4 MACHINE OPERATION A WARNING TO AVOID FORWARD OR BACKWARD TIPPING DO NOT OVERLOAD MACHINE OR OPERATE ON AN OUT OF LEVEL SURFACE 4 3 ENGINE OPERATION NOTE Initial starting should always be performed from the Ground Control station Starting Procedure 1 Check engine oil If necessary add in accordance with the Engine Manufacturer s manual 2 Check fuel level Add fuel if necessary 3 Check that air cleaner components are in place and securely fastened A CAUTION IF ENGINE FAILS TO START PROMPTLY DO NOT CRANK FOR AN EXTENDED PERIOD SHOULD ENGINE FAIL TO START ONCE AGAIN ALLOW STARTER TO COOL OFF FOR 2 3 MINUTES IF ENGINE FAILS AFTER SEVERAL ATTEMPTS REFER TO ENGINE MAINTENANCE MAN UAL 4 2 JLG Lift MACHINES WITH DIESEL ENGINES AFTER TURNING ON IGNITION OPERATOR MUST WAIT UNTIL GLOW PLUG INDICATOR LIGHT GOES OUT BEFORE CRANKING ENGINE IF EQUIPPED 4 Turn key of SELECT switch to GROUND Position POWER EMERGENCY STOP switch to ON then push the ENGINE START switch to the upward position until engine starts A CAUTION ALLOW ENGINE TO WARM UP FOR A FEW MINUTES AT LOW SPEED BEFORE APPLYING ANY LOAD 5 After engine has had sufficient time to warm up shut engine off 6 Turn key of SELECT switch to PLATFORM 7 From
64. ckout cylinders should release and allow wheel to rest on ground it may be necessary to activate DRIVE to release cylinders Place the 6 inch 15 2 cm high block with ascension ramp in front of right front wheel Place DRIVE control lever to FORWARD and carefully drive machine up ascension ramp until right front wheel is on top of block JLG Lift 11 12 13 14 15 Carefully activate SWING control lever and position boom over left side of machine With boom over left side of machine place DRIVE con trol lever to REVERSE and drive machine off of block and ramp Have an assistant check to see that right front or left rear wheel remains elevated in position off of ground Carefully 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 If lockout cylinders do not function properly have quali fied personnel correct the malfunction prior to any fur ther operation 2 19 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 12 NOTES 2 20 JLG Lift 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 1 SECTION 3 MACHINE CONTROLS AND INDICATORS Ground Control S
65. condition of either the machine or the job site 2 1 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 2 PREPARATION INSPECTION AND 2 2 MAINTENANCE The following table covers the periodic machine inspections and maintenance required by JLG Industries Inc Consult local regulations for further requirements for aerial work plat forms The frequency of inspections and maintenance must be increased as necessary when the machine is used in a harsh or hostile environment if the machine is used with increased frequency or if the machine is used in a severe manner JLG INDUSTRIES INC RECOGNIZES FACTORY TRAINED SERVICE TECHNICIAN AS A PERSON WHO HAS SUCCESSFULLY COMPLETED THE JLG SERVICE TRAINING SCHOOL FOR THE SPECIFIC JLG PRODUCT MODEL JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Table 2 1 Inspection and Maintenance Table Primary Service Frequency Responsibility Qualification Rererence Pre Start Inspection Before using each day or User or Operator User or Operator Operator and Safety Manual whenever there s an Operator change Pre Delivery Inspection See Before each sale lease or rental delivery Owner Dealer or User Qualified JLG Service and Maintenance Note Mechanic Manual and applicable JLG inspection form Frequent Inspection In service for 3 months or 150 hours whichever Owner Dea
66. cted within seven sec onds or if a seven second lapse between ending one function and beginning the next function the enable 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS light will go out and the footswitch must be released and depressed again to enable the controls Releasing the footswitch removes power from all con trols and applies the drive brakes A WARNING TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS A WARNING FOOTSWITCH MUST BE ADJUSTED IF FUNCTIONS ACTIVATE WHEN SWITCH ONLY OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOT TOM 3121209 Lift 2 Engine Malfunction Indicator On machines prior to S N 62045 the light turns on and an alarm sounds when machine s power system requires immediate service Any of the following condi tions will turn on light and alarm low engine oil pres sure high engine coolant temperature clogged engine air filter low alternator output clogged hydraulic oil return filter or clogged charge pump filter On machines from S N 62045 to present the light indi cates that the Engine Control System has detected a malfunction and a Diagnostic Trouble Code has been set in the system memory Refer to the Service Manual for instructions concerning the trouble codes and trou ble code retrieval The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on pos
67. e Platform Rotate control switch to select the direction and hold until desired position is reached JLG Lift 3121209 SECTION 4 MACHINE OPERATION Figure 4 4 Grade and Sideslopes 3121209 JLG Lift 4 9 SECTION 4 MACHINE OPERATION 4 8 BOOM See Figure 4 2 A WARNING AN ORANGE TILT ALARM WARNING LIGHT LOCATED ON THE CONTROL CONSOLE LIGHTS WHEN THE CHASSIS IS ON A SEVERE SLOPE DO NOT SWING EXTEND OR RAISE MAIN BOOM ABOVE HORIZONTAL WHEN LIT DO NOT DEPEND ON TILT ALARM AS A LEVEL INDICATOR FOR THE CHASSIS CHASSIS MUST BE LEVEL BEFORE SWINGING EXTENDING OR RAISING TOWER BOOM ABOVE HORIZONTAL TO AVOID UPSET IF ORANGE TILT ALARM WARNING LIGHT LIGHTS WHEN MAIN BOOM IS EXTENDED OR RAISED ABOVE HORIZONTAL RETRACT AND LOWER PLATFORM TO NEAR GROUND LEVEL THEN REPOSITION MACHINE SO THAT CHASSIS IS LEVEL BEFORE EXTEND ING OR RAISING MAIN BOOM 4 10 JLG Lift TRAVELING WITH MAIN BOOM RETRACTED AND BELOW HORIZONTAL IS PERMITTED ON GRADES AND SIDE SLOPES SPECIFIED ON THE SERIAL NUMBER PLACARD TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINERY IF ANY CONTROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM MOVEMENT DO 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 EMERGENCY STOP TO STOP THE MACHINE Swinging the Boom
68. ecified in this manual Read understand and obey all applicable employer local and governmental regulations as they pertain to operation of the machine Workplace Inspection The operator is to take safety measures to avoid all haz ards in the work area prior to machine operation Do not operate or raise the platform while on trucks trail ers railway cars floating vessels scaffolds or other equip ment unless approved in writing by JLG Do not operate the machine in hazardous environments unless approved for that purpose by JLG Besure that the ground conditions are able to support the maximum load shown on the decals located on the machine JLG Lift This machine can be operated in temperatures of 0 F to 104 F 20 C to 40 C Consult JLG for operation out side this range Machine Inspection Before machine operation perform inspections and func tional checks Refer to Section 2 of this manual for detailed instructions Do not operate this machine until it has been serviced and maintained according to requirements specified in the Service and Maintenance Manual Be sure the footswitch and all other safety devices are operating properly Modification of these devices is a safety violation A WARNING MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANU FACTURER Do not operate any machine on which safety or instructi
69. econds for 200 Ft LS MINE NE i Drive Speed 4WD Forward 42 48 Seconds for 200 Ft IN385 65D 19 5 foam filled 16 H N A Reverse 42 48 Seconds for 200 Ft IN 445 550 19 5 foam filled 16 H N A Machine Weight approximately 15X19 5 foam filled 16 H N A IN 385 65D 19 5 Pneumatic 34 200 Ibs 15 520 kg 18X19 5 foam tilled 16 H 15X 19 5 Pneumatic 34 200 Ibs 15 520 kg IN 445 55D 19 5 34 270 Ibs 15 550 kg 18X 19 5 Pneumatic Tires 34 270 Ibs 15 550 kg IN 385 65D 19 5 33 100 Ibs 15 020 kg 15X 19 5 Foam Filled Tires 33 100 Ibs 15 020 kg IN 445 55D 19 5 33 550 Ibs 15 220 kg 18X 19 5 Foam Filled Tires 33 550 Ibs 15 220 kg JLG Lift 3121209 6 2 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE Capacities Table 6 3 Capacities Fuel Tank Approx 40 gallons 151 4 liters Hydraulic Tank Approx 40 gallons 151 4 liters Hydraulic System Including Tank 77 Gal 291 41 Drive Hub Priorto S N 83332 17 ounces 0 5L Drive Hub S N 83332 to Present 44 ounces 1 3L Drive Brake S N 8332 to Present 2 7 ounces 80 ml Engine Oil Capacity Ford Deutz Cooling System Crankcase Total Capacity Caterpillar Isuzu GM 4 5 Quarts 4 25 L w Filter 5 Quarts 4 51 11 Quarts 10 5 L w Filter 16 Quarts 151 10 6 quarts 101 8 5 Quarts 8 01 4 5 Quarts 4 25 L w Filter 3121209 Engine Data Table 6 4 Ford LRG
70. egend 800A Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 9 0274464 7 0274470 7 0274466 7 0274468 8 0274472 7 0274474 3 0274462 7 34 1707014 1707043 1707045 1707048 1707051 1707046 1705978 1707053 35 1704885 1704885 1704885 1704885 1704885 1704885 1704885 36 1706948 1706948 1706948 1706948 1706948 1706948 1706948 37 1702265 1703987 1703988 1703989 1706439 1703990 1705977 1703986 38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 41 1706941 1706941 1706941 1706941 1706941 1706941 1706941 42 43 44 45 46 47 48 49 50 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 3121209 Table 4 1 Decal Legend 800A Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 9 0274464 7 0274470 7 0274466 7 0274468 8 0274472 7 0274474 3 0274462 7 51 52 53 54 55 56 1705351 1705427 1705430 1705910 1705905 1705429 1705426 JLG Lift 4 29 SECTION 4 MACHINE OPERATION 4 30 Table 4 2 Decal Legend 800A S N 0300141330 to Present Item ANSI Korean Ch
71. eumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics Tire Damage For pneumatic tires JLG Industries Inc recommends that when any cut rip or tear is discovered that exposes sidewall or tread area cords in the tire measures must be taken to remove the JLG product from service immediately Arrangements must be Interval 3 Months or 150 hours of operation made for replacement of the tire or tire assembly Comments Replace filter Refer to Section 6 6 Propane Fuel Filter Replacement For polyurethane foam filled tires JLG Industries Inc recom mends that when any of the following are discovered measures must be taken to remove the JLG product from service immedi ately and arrangements must be made for replacement of the tire or tire assembly 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 3121209 Lift 6 29 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria Tire Replacement
72. f operation and after each wheel removal Check torque every 3 months or 150 hours of operation 6 32 0300134626 During the course of normal operation oils may build inside the primary and secondary chambers of the propane pres sure regulator These oils may be a result of poor fuel quality contamination of the fuel supply chain or regional variation in the make up of the fuel If the build up of the oil is signifi cant this can effect the operation of the fuel control system Refer to Section 6 3 Operator Maintenance for maintenance intervals More frequent draining may be required if the fuel supply has been contaminated NOTICE FOR BEST RESULTS WARM THE ENGINE TO OPERATING TEMPERA TURE BEFORE DRAINING THIS WILL ALLOW THE OILS TO FLOW FREELY FROM THE REGULATOR 1 Move the equipment to a well ventilated area Ensure there are no external ignition sources 2 Start the engine and bring to operating temperature 3 With the engine running close the manual tank valve and run the engine out of fuel JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 4 Push in the Emergency Switch once the engine stops 6 Remove the retainer clip for the LPG fuel temperature sensor and remove the sensor from the regulator body 5 Disconnect the electrical connection to the LPG fuel temperature sensor in the auxiliary fuel port of the EPR
73. f the platform Restricted capacities are permit ted at restricted platform positions shorter boom lengths and higher boom angles NOTE Refer to the capacity decals on the machine for restricted 3 20 and unrestricted platform capacities 7 Creep Speed Indicator Illuminated Green when the Function Speed Control is turned to the creep position the indicator acts as a reminder that all functions are set to the slowest speed 8 Glow Plug Indicator If Equipped When illuminated the glow plugs are operating After turning on ignition wait until light goes out before crank ing engine 9 Tilt Alarm Warning Light and Alarm This orange illuminator indicates that the chassis is on a slope An alarm will also sound when the chassis is on a slope and the boom is above horizontal If lit when boom is raised or extended retract and lower to below hori zontal then reposition machine so that it is level before continuing operation If the boom is above horizontal and the machine is on a slope the tilt alarm warning light will illuminate and an alarm will sound and CREEP is automatically activated A WARNING IF TILT WARNING LIGHT IS ILLUMINATED WHEN BOOM IS RAISED OR EXTENDED RETRACT AND LOWER TO BELOW HORIZONTAL THEN REPOSITION MACHINE SO THAT IT IS LEVEL BEFORE EXTENDING BOOM OR RAISING BOOM ABOVE HORIZONTAL JLG Lift 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS 10 Overload Indicator If equipped
74. f 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 yel low Indicates important information regarding the operating condition i e procedures essential for safe operation This indicator will be green with the exception of the capacity indicator which will be green or yellow depending upon platform position NOTE NOTE For engine starting the footswitch must be in the released up position Footswitch must be actuated in order for controls to function These machines have a 7 second delay timer If a function has not been activated within 7 seconds after depressing the footswitch recycle footswitch A WARNING TO AVOID SERIOUS INJURY DO NOT REMOVE MODIFY OR DISABLE THE FOOTSWITCH BY BLOCKING OR ANY OTHER MEANS NOTICE FOOTSWITCH MUST BE ADJUSTED SO THAT FUNCTIONS WILL OPER ATE WHEN PEDAL IS APPROXIMATELY AT ITS CENTER OF TRAVEL IF SWITCH OPERATES WITHIN LAST 1 4 OF TRAVEL TOP OR BOTTOM IT SHOULD BE ADJUSTED 1 JLG Lift Footswitch Enable Indicator To operate any function the footswitch must be depressed and the function selected within seven sec onds The enable indicator shows that the controls are enabled If a function is not sele
75. guese French CE Aus Japanese 0274461 9 0274464 7 0274471 7 0274467 7 0274469 9 0274473 7 0274475 3 0274462 7 36 1706948 1706948 1706948 1706948 1706948 1706948 1706948 37 1702265 1703987 1703990 1703989 1706439 1703990 1705977 1703986 38 1703959 1703959 1703959 1703959 1703959 1703959 1703959 1703959 39 1700584 1700584 1700584 1700584 1700584 1700584 1700584 1700584 40 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 1001108495 41 1706941 1706941 1706941 1706941 1706941 1706941 1706941 42 43 44 45 46 47 48 49 50 51 52 53 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 3121209 Table 4 3 Decal Legend 800AJ Prior to S N 0300141330 Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 9 0274464 7 0274471 7 0274467 7 0274469 9 0274473 7 0274475 3 0274462 7 54 55 56 1705351 1705427 1705430 1705910 1705905 1705429 1705426 JLG Lift 4 37 SECTION 4 MACHINE OPERATION 4 38 Table 4 4 Decal Legend 800AJ S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274461 10 0274465 8 0274471 8 0274467 8 0274469 10 0274473 8 0274475 3 0274463 8 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 170
76. h provides raising and lowering of the jib when positioned to UP or DOWN 3121209 JLG Lift 3 3 SECTION 3 MACHINE CONTROLS AND INDICATORS 5 Engine Start Auxiliary Power Switch NOTE NOTE or Engine Start Auxiliary Power Switch Function Enable 9 Auxiliary power only works if there is no engine oil pres sure and is disabled if engine is running To start the engine the switch must be held UP until the engine starts To use auxiliary power the switch must be held DOWN for duration of auxiliary pump use Aux power can only be used if the engine is not running If equipped the enable switch must be held DOWN to enable all boom controls when the engine is running Functions will operate at a slower than normal rate because of the lesser flow of hydraulic fluid delivered A CAUTION WHEN USING AUXILIARY POWER DO NOT OPERATE MORE THAN ONE FUNCTION AT A TIME SIMULTANEOUS OPERATION CAN OVERLOAD THE AUXILIARY PUMP 3 4 6 Tower Telescope The TOWER TELESCOPE control switch provides extending and retracting of the tower boom when posi tioned to IN or OUT This function works only when the tower boom is fully elevated lift up A WARNING TO AVOID UPSET AND SERIOUS INJURY DO NOT OPERATE MACHINE IF TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE ABOVE SEQUENCE 7 JLG Lift Hourmeter An hour meter installed in the bottom portion of the Ground Control b
77. he machine at least 2 ft 0 6m from bottom of platform when lifting or lowering platform and holes bumps drop offs obstructions debris concealed driving holes and other potential hazards on the floor surface 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 Do not operate the machine when wind conditions exceed 28 mph 12 5 m s Refer to Table 1 2 Beaufort Scale For Reference Only Do not increase the surface area of the platform or the load Increase of the area exposed to the wind will decrease stability Do not increase the platform size with unauthorized deck or attachments During operation keep all body parts inside platform rail ing 3121209 JLG Lift 1 7 SECTION 1 SAFETY PRECAUTIONS 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 8m away from machine during all driving and swing operations Limit travel speed according to conditions of ground sur face congestion visibility slope location of personnel and other factors which may cause collision or injury to personnel Be aware of stopping distances in all drive speeds When driving in high speed switch to low speed before stop ping Travel
78. icks JLG Lift Drive Speed Torque Select Drive Speed Torque Select is a three position switch The forward position gives maximum drive speed by shifting the drive motors to minimum the displacement and giv ing high engine when drive controller is moved The back position gives maximum torque for rough terrain and climbing grades by shifting the wheel motors to maximum displacement and giving high engine speed when the drive controller is moved The center position allows the machine to be driven as quietly as possible by leaving the engine at mid speed and the drive motors in minimum displacement or fastest speed Platform Rotate This switch allows the operator to rotate the basket to the left or right 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS A WARNING ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY 9 Platform Leveling Override A three position switch allow the operator to adjust the automatic self leveling system This switch is used to adjust platform level in situation such as ascending descending a grade 10 Articulating Jib Boom Equipped The ARTICULATING control switch provides raising and lowering of the jib when positioned to UP or DOWN 11 Fuel Select Dual Fuel Engine Only If Equipped Gasoline or liquid propane fuel ma
79. inese Spanish Portuguese French CE Aus Japanese 0274460 10 0274464 8 0274470 8 0274466 8 0274468 9 0274472 8 0274474 3 0274462 8 1 2 1701499 1701499 1701499 1701499 1701499 1701499 1701499 1701499 3 4 5 1701509 1701509 1701509 1701509 1701509 1701509 1701509 1701509 6 1701529 7 1703811 1703811 1703811 1703811 1703811 1703811 1703811 1703811 8 1703814 1703814 1703814 1703814 1703814 1703814 1703814 1703814 9 1704277 1704277 1704277 1704277 1704277 1704277 1704277 1704277 10 1704412 1704412 1704412 1704412 1704412 1704412 1704412 1704412 11 1705084 12 1705514 13 14 15 1705337 1705339 1705342 16 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 3121209 Table 4 2 Decal Legend 800A S N 0300141330 to Present Item ANSI Korean Chinese Spanish Portuguese French CE Aus Japanese 0274460 10 0274464 8 0274470 8 0274466 8 0274468 9 0274472 8 0274474 3 0274462 8 17 1704007 1705901 1704006 18 1703953 1703945 1703943 1703941 1705903 1703942 1703944 19 20 1702868 1705969 1705968 1704001 1705967 1704000 21 1703797 1703927 1703925 1703923 1705895 1703924 1705921 1703926 22 1705336 1705345 1705348 1705917 1705896 1705347 1705822 1705344 23 1703804 1703951 1703949 1703947 1705898 1703948 1701518 1703950 24 1703805 1703939 1703937 1703935 1705897 1703936 1705961 1703938 25 3252347 1703981 1703982 1703983 1705902 1703984 17
80. ition This switch also allows electrical power to open the LP gas shut off solenoid and close the gasoline shut off solenoid when positioned to the LP position A CAUTION IT IS POSSIBLE TO SWITCH FROM ONE FUEL SOURCE TO THE OTHER WITHOUT STOPPING THE ENGINE EXTREME CARE MUST BE TAKEN AND THE FOLLOWING INSTRUCTIONS MUST BE FOLLOWED Changing From Gasoline to LP Gas 1 2 Start engine from Ground Control Station Open hand valve on LP gas supply tank by turning counterclockwise While the engine is operating place the two position LPG Gasoline switch at the platform control station to the LP position Changing From LP Gas to Gasoline 1 Lift With engine operating on LP under a no load condition position FUEL SELECT switch at Platform Control Sta tion to GASOLINE position Close hand valve on LP gas supply tank by turning clockwise 4 19 SECTION 4 MACHINE OPERATION 4 16 RE SYNCHRONIZE UPRIGHT Releveling Valve A pull type control valve allows the operator to adjust the upright level cylinder if the upright is not 90 vertical relative to the chassis Refer to Figure 2 9 and Figure 2 10 This valve is located in the tank compartment area 4 20 Perform the following steps with the aid of an assistant 1 2 3 Turn the key switch to the ground control position Start the engine Pull and hold the red relevel knob located next to the main control valve Refer to Figure 4 8
81. ition to act as a self test 3 17 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 18 UNRESTRICTED CAPACITY RESTRICTED CAPACITY Enable 7 Creep Speed Engine Malfunction 8 Glow Plug Soft Touch 9 Tilt Alarm Warning AC Generator 10 Overload Fuel Level 11 Boom Malfunction Capacity Figure 3 5 Platform Light Panel JLG Lift 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS UNRESTRICTED CAPACITY RESTRICTED CAPACITY 1 Enable 5 FuelLevel 9 Tilt Alarm Warning 2 Engine Malfunction 6 Capacity 10 Overload 3 NotUsed 7 CreepSpeed 11 BoomMalfunction 4 AC Generator 8 Glow Plug 12 Drive Orientation Figure 3 6 Platform Light Panel w Drive Orientation 3121209 Lift 3 19 SECTION 3 MACHINE CONTROLS AND INDICATORS 3 Soft Touch Indicator If Equipped When illuminated Yellow the Soft Touch bumper is against an object All controls are disabled until the override button is pushed at which time controls are active in the Creep mode AC Generator Green When illuminated Green the light indicates the genera tor is in operation Low Fuel Indicator Yellow N A for liquid propane When illuminated Yellow the fuel tank is 1 8 full or less When the light first turns on there are approximately four usable gallons of fuel remaining Capacity Indicator Indicates the maximum platform capacity for the current position o
82. k North 39 Lung Sum Avenue Sheung Shui N T Hong Kong 852 2639 5783 852 2639 5797 JLG Industries Italia s r l Via Po 22 20010 Pregnana Milanese MI Italy FF 39 029 359 5210 39 029 359 5845 Oshkosh JLG Singapore Technology Equipment Pte Ltd 29 Tuas Ave 4 Jurong Industrial Estate Singapore 639379 Z 465 6591 9030 JLG Polska UI Krolewska 00 060 Warsawa Poland Z 48 0 914 320 245 48 0 914 358 200 A JLG Industries Scotland Wright Business Centre 1 Lonmay Road Queenslie Glasgow G33 4EL Scotland 44 0 141 781 6700 44 0 141 773 1907 e Plataformas Elevadoras JLG Iberica S L Trapadella 2 Castellbisbal Sur 08755 Castellbisbal Barcelona Spain Sg 34 93 772 4700 34 93 771 1762 A JLG Sverige AB Enkopingsvagen 150 Box 704 SE 176 27 Jarfalla Sweden 46 0 850 659 500 46 0 850 659 534 www jlg com
83. lation 2 Tighten nuts in the following sequence It is extremely important to apply and maintain proper wheel mounting torque A WARNING WHEEL NUTS MUST BE INSTALLED AND MAINTAINED AT THE PROPER TORQUE TO PREVENT LOOSE WHEELS BROKEN STUDS AND POSSI BLE DANGEROUS SEPARATION OF WHEEL FROM THE AXLE BE SURE TO USE ONLY THE NUTS MATCHED TO THE CONE ANGLE OF THE WHEEL Tighten the lug nuts to the proper torque to prevent wheels from coming loose Use a torque wrench to tighten the fasteners If you do not have a torque wrench tighten the fasteners with a lug wrench then immediately 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 3121209 Lift 6 31 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 3 The tightening of the nuts should be done in stages Fol 6 5 DRAINING OIL BUILD UP FROM THE lowing the recommended sequence tighten nuts per PROPANE REGULATOR PRIOR TO S N wheel torque chart Table 6 20 Wheel Torque Chart TORQUE SEQUENCE 151 Stage 2nd Stage 3rd Stage 70 ft Ibs 170 ft Ibs 300 ft Ibs 95 Nm 225 Nm 405 Nm 4 Wheel nuts should be torqued after first 50 hours o
84. ler or User Qualified JLG Service and Maintenance See Note comes first Mechanic Manual and applicable JLG or inspection form Outof service for a period of more than 3 months or Purchased used Annual Machine Inspection Annually nolaterthan 13 months fromthe date of Owner Dealer or User Factory Trained Service and Maintenance See Note prior inspection Service Technician Manual and applicable JLG Recommended inspection form Preventative Maintenance Atintervals as specified in the Service and Main Owner Dealer or User Qualified JLG Service and Maintenance tenance Manual Mechanic Manual NOTE Inspection forms are available from JLG Use the Service and Maintenance Manual to perform inspections 3121209 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION Pre Start Inspection The Pre Start Inspection should include each of the follow ing 1 Cleanliness Check all surfaces for leakage oil fuel or battery fluid or foreign objects Report any leakage to the proper maintenance personnel Structure Inspect the machine structure for dents damage weld or parent metal cracks or other discrep ancies SN 492 Parent Metal Crack Weld Crack 3 Decals and Placards Check all for cleanliness and legibility Make sure none of the decals and placards are missing Make sure all illegible decals and placards are cleaned o
85. lift down will only be operable when the TOWER BOOM is fully retracted 3121209 JLG Lift 4 11 SECTION 4 MACHINE OPERATION Function of Tower Boom This machine will have two controls for the tower boom two toggle switches one controls tower lift the other tower tele scope The switching system will sequence its LIFT and TELESCOPE functions as follows 1 Sequence while RAISING the TOWER BOOM from the fully lowered position a The TOWER BOOM must be fully elevated up approximately 12 degrees from vertical before the TOWER BOOM can be extended from the fully retracted position b The TOWER TELESCOPE out or in will only be operable when the TOWER BOOM is fully elevated up JLG Lift 2 Sequence while LOWERING the TOWER BOOM from the fully elevated up position a TOWER TELESCOPE in The TOWER BOOM must be fully retracted before the TOWER BOOM can be lowered b The TOWER BOOM lift down will only be operable when the TOWER BOOM is fully retracted A WARNING DISCONTINUE OPERATION IF THE UPRIGHT IS OUT OF ALIGNMENT OR THE BOOM MALFUNCTION LIGHT REMAINS ILLUMINATED NOTICE IF THE UPRIGHT IS OUT OF ALIGNMENT WITH THE PLATFORM RAISED LOWER THE MAIN BOOM AND TELESCOPE OUT UNTIL THE PLATFORM REACHES THE GROUND THE TOWER BOOM DOWN FUNCTION IS CUT OUT IN THIS CONDITION REPORT THE PROBLEM TO THE PROPER SER VICE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL THE CON
86. llows a Place machine on level surface with booms retracted and lowered b From the platform control position DRIVE SPEED TORQUE SELECT switch to FAST Forward Posi tion c Using extreme caution partially position the DRIVE control to FORWARD just enough to obtain high engine but not enough to cause the machine to move d Raise the TOWER BASE BOOM until the engine speed shifts from high speed to mid speed The bottom of the upright should NOT be above the hood level of the machine 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 3121209 9 Check the high engine cutout for the main boom assem bly as follows a Place machine on level surface with booms retracted and lowered b From the platform control position DRIVE SPEED TORQUE SELECT switch to FAST Forward Posi tion c Raise the main boom above horizontal d Using extreme caution partially position the DRIVE control to FORWARD just enough to cause the machine to move The drive speed should be in slow or creep mode 10 Swing turntable to LEFT and RIGHT a minimum of 45 degrees Check for smooth motion NOTE Ensure the turntable lock is disengaged To disengage lock pull snap pin from lock pin lift lock pin up to unlock turntable Return snap pin to lock pin to hold lock pin in the disengaged position Reverse procedure to engage turntable lock 11 Check the Tilt Alarm and Warning System as follo
87. m and swing functions from the ground Place the KEY SELECT switch to GROUND position and operate the proper switch to lift swing or telescope the boom or level the platform Auxiliary Power A toggle type auxiliary power control switch is located on the platform control station and another is located on the ground control station Operation of either switch turns on the electri cally driven auxiliary hydraulic pump This should be used in case of failure of the main power plant The auxiliary pump will operate all functions from the platform control station To activate auxiliary power 1 Position PLATFORM GROUND SELECT KEY SWITCH to PLATFORM 2 Position POWER EMERGENCY STOP switch to ON 3 Depress and hold footswitch 4 Operate appropriate control switch lever or controller for desired function and hold 3121209 SECTION 5 EMERGENCY PROCEDURES 7 Position AUXILIARY POWER switch to ON and hold 5 5 Release AUXILIARY POWER switch selected control switch lever or controller and footswitch Position POWER EMERGENCY STOP switch to OFF To activate auxiliary power from the ground control sta tion 1 3121209 Position PLATFORM GROUND SELECT KEY SWITCH to GROUND Position POWER EMERGENCY STOP switch to ON Operate appropriate control switch or controller for desired function and hold Position AUXILIARY POWER switch to ON and hold Release AUXILIARY POWER switch followed by the selected cont
88. machine must be adjusted individually so machine remains level when elevated NOTICE SECURE TURNTABLE WITH TURNTABLE LOCK BEFORE TRAVELING LONG DISTANCES OR HAULING MACHINE ON TRUCK TRAILER 4 11 OSCILLATING AXLE LOCKOUT TEST IF EQUIPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED Refer to Section 2 4 Oscillating Axle Lockout Test If Equipped for procedure 4 12 TOWING The machine is not equipped with a tow package Refer to Section 5 for emergency towing procedures 4 16 JLG Lift 3121209 SECTION 4 MACHINE OPERATION 4 13 TOW BAR IF EQUIPPED 4 Position steer tow selector valve for towing pull valve knob OUT for towing The machine is now in the towing de WARNING RUNAWAY VEHICLE MACHINE HAZARD MACHINE HAS NO TOWING After towing the machine complete the following BRAKES TOWING VEHICLE MUST BE ABLE TO CONTROL MACHINE AT 1 Actuate steer tow selector valve for steering push valve ALL TIMES ON HIGHWAY TOWING NOT PERMITTED FAILURE TO FOL knob IN to the actuated position LOW INSTRUCTIONS COULD CAUSE SERIOUS INJURY OR DEATH 2 Reconnect drive hubs by inverting disconnect cap MAXIMUM TOWING SPEED 5 M PH 8 K M H 3 Disconnect towbar from towing vehicle and place it in the stowed position as shown in Figure 4 7 The MAXIMUM TOWING GRADE 25 machine is now in the driving mode Prior to t
89. o the machine The ing Do not exceed the allowable sideslope and grade minimum approach distance shall be reduced to a distance while driving within the designed working dimensions of the insulating barrier This determination shall be made by a qualified per son in accordance with the employer local or governmental requirements for work practices near energized equipment DO NOT MANEUVER MACHINE OR PERSONNEL INSIDE PROHIBITED ZONE MAD ASSUME ALL ELECTRICAL PARTS AND WIRING ARE ENERGIZED UNLESS KNOWN OTHERWISE 1 6 JLG Lift 3121209 SECTION 1 SAFETY PRECAUTIONS Do not elevate platform or drive with platform elevated f boom assembly or platform is in a position that one or while on a sloping uneven or soft surface more wheels are off the ground all persons must be removed before attempting to stabilize the machine Use cranes forklift trucks or other appropriate equipment to stabilize machine Before driving on floors bridges trucks and other sur faces check allowable capacity of the surfaces Never exceed the maximum platform capacity Distribute loads evenly on platform floor Crushing and Collision Hazards Do not raise the platform or drive from an elevated posi Approved head gear must be worn by all operating and tion unless the machine is on firm level and smooth sur ground personnel faces Check work area for clearances overhead on sides and Keep the chassis of t
90. om Sections No visible damage wear pads secure All cylinders rod end shafts and barrel end shafts properly secured Platform Pivot Pin See Inspection Note Upright In vertical position relative to the chassis Refer to Figure 2 9 and Figure 2 10 If out of align ment do not use machine until the upright has been synchronized in accordance with Section 4 16 Figure 2 6 Daily Walk Around Inspection Sheet 4 of 4 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 3 FUNCTION CHECK Perform a function check of all systems once the walk around inspection is complete in an area free of overhead and ground level obstructions A WARNING A MACHINE MALFUNCTION COULD CAUSE DEATH OR SERIOUS INJURY IF ANY MALFUNCTIONS OCCUR DURING THE FUNCTION TEST DISCONTINUE OPERATION AND CONTACT A QUALIFIED SERVICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERATING THE MACHINE From the Ground Control Station with No Load in the Platform 1 Check that all guards protecting the function switches or locks are in place Ensure that all function controls and switches return to the off or neutral position when released A WARNING DO NOT OPERATE IF GUARDS OR LOCKS ARE MISSING OR THE SWITCHES DO NOT RETURN TO THE OFF OR NEUTRAL POSITION 2 Test the tower boom assembly sequencing as follows 3121209 JLG Lift a Place machine on level ground with the tower boom as
91. on placards or decals are missing or illegible Avoid any buildup of debris on the platform floor Keep mud oil grease and other slippery substances from foot wear and platform floor 3121209 SECTION 1 SAFETY PRECAUTIONS 1 3 OPERATION General 3121209 Do not use the machine for any purpose other than posi tioning personnel their tools and equipment Never operate a machine that is not working properly If a malfunctions occurs shut down the machine 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 Oper ate controls with slow and even pressure Hydraulic cylinders should never be left fully extended or fully retracted before shutdown or for long periods of time 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 Contact JLG for approved material handling accessories When two or more persons are in the platform the opera tor 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 Supplies or tools which extend outside the platform are prohibited unless approved by JLG When driving always position boom over rear axle in line with the di
92. onal reach Never use the boom assembly to enter or leave the plat form JLG Lift 3121209 SECTION 1 SAFETY PRECAUTIONS Table 1 1 Minimum Approach Distances M A D Voltage Range MINIMUM APPROACH DISTANCE Phase to Phase in Feet Meters Oto 50 KV 10 3 Over 50KV 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 Over 750 KV to 1000 KV 45 14 NOTE This requirement shall apply except where employer local or governmental regulations are more stringent Maintain distance from electrical lines apparatus or any energized exposed or insulated parts according to the Maintain a clearance of at least 10 ft 3m between any part Minimum Approach Distance MAD as shown in Table 1 of the machine and its occupants their tools and their 1 equipment from any electrical line or apparatus carrying up Allow for machine movement and electrical line swaying to 50 000 volts One foot additional clearance is required for every additional 30 000 volts or less 3121209 JLG Lift 1 5 SECTION 1 SAFETY PRECAUTIONS The minimum approach distance may be reduced if insulat Tipping Hazards ing barriers are installed to prevent contact and the barriers are rated for the voltage of the line being guarded These The user should be familiar with the surface before driv barriers shall not be part of or attached t
93. owing the machine complete the following 4 14 WELDING LEAD IF EQUIPPED A CAUTION This option consists of a single welding cable that is installed in the power track and will allow stick welding from the plat form up to the full elevation of the machine The single weld ing cable system differs from the two cable system of previous machines DO NOT TOW MACHINE WITH ENGINE OPERATING OR DRIVE HUBS ENGAGED 1 Retract lower and position boom in travel position lock turntable NOTICE 2 Lower towbar and connect to towing vehicle DO NOT GROUND WELDER TO THE MACHINE SERIOUS DAMAGE TO THE MACHINE WILL RESULT THIS SYSTEM IS INTENDED TO BE 3 Disconnect drive hubs by inverting disconnect cap GROUNDED THE MATERIAL BEING WELDED 3121209 JLG Lift 4 17 SECTION 4 MACHINE OPERATION Figure 4 7 Tow Bar 3121209 JLG Lift 4 18 SECTION 4 MACHINE OPERATION 4 15 DUAL FUEL SYSTEM GAS ENGINE ONLY Description 3121209 The dual fuel system enables the standard gasoline engine to run on either gasoline or LP gas The system includes pressurized cylinders mounted on the frame and the valves and switches needed to switch the fuel supply from gasoline to LP gas or from LP gas to gasoline A two position FUEL SELECT toggle switch at the platform control station supplies electrical power to open the gasoline shut off solenoid and close the LP gas shut off solenoid when positioned to the GASOLINE pos
94. ox registers the amount of time the machine has been in use with engine running By con necting into the oil pressure circuit of the engine only engine run hours are recorded The hour meter registers up to 9 999 9 hours and cannot be reset 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS 8 Platform Ground Select Switch CAUTION A three position key operated switch supplies power to TO AVOID SERIOUS INJURY DO NOT OPERATE MACHINE IF ANY CON the platform control console when positioned to PLAT TROL LEVERS OR TOGGLE SWITCHES CONTROLLING PLATFORM FORM With the switch key held in the GROUND posi MOVEMENT DO NOT RETURN TO THE OFF POSITION WHEN RELEASED tion power is shut off to platform and only ground controls are operable A WARNING NOTE With the Platform Ground Select Switch in the center posi TO AVOID UPSET AND SERIOUS INJURY DO NOT OPERATE MACHINE IF tion power is shut off to controls at both operating sta TOWER LIFT AND TELESCOPE FUNCTIONS DO NOT OPERATE IN THE tions ABOVE SEQUENCE 9 Swing Control 10 Tower Lift The SWING control switch provides 360 degrees contin uous turntable rotation when positioned to RIGHT or LEFT CAUTION WHEN OPERATING THE BOOM ENSURE THERE ARE NO PERSONNEL AROUND OR UNDER PLATFORM The TOWER LIFT control switch provides raising and lowering of the tower boom when positioned to UP or DOWN This function works only when the tower boom is fully retracted telescope in
95. proximately at its center of travel If the footswitch operates within last 1 4 of travel top or bottom it should be adjusted 2 15 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION NOTE NOTE 5 2 16 Footswitch has a 7 second delay timer If a function is not activated within 7 seconds after depressing the foot switch reset the footswitch Ensure that all machine functions are disabled when the Emergency Stop Button is activated Check auxiliary power for proper operation Operate each function control switch to ensure proper operation of the auxiliary power system Step 5 is only applicable for 800A ANSI market machines If equipped with a dual capacity system check the limit switch as follows level surface with less than 500 Ib 227 kg in the platform raise tower base boom to maximum angle keeping main boom horizontal b Extend the main fly boom until the capacity indica tor lights change from 1000 Ib 454 kg to 500 Ib 227 kg c With main boom in this position raise the main base boom until the capacity indicator lights change back to the 1000 Ib 454 kg indicator A WARNING DISCONTINUE OPERATION IF THE CAPACITY INDICATOR SYSTEM DOES NOT OPERATE PROPERLY 6 7 JLG Lift Drive forward and reverse check for proper operation Steer left and right check for proper operation Check the high engine cutout for the tower boom assembly as fo
96. r discrepancies Inspect wheels for damage and corrosion Figure 2 4 Daily Walk Around Inspection Sheet 2 of 4 2 8 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 13 14 15 16 17 18 19 20 3121209 Control Valve Tank Compartment No loose or miss ing lug nuts proper inflation pneumatic Inspect for worn tread cuts tears or other discrepancies Inspect wheels for damage and corrosion Turntable Bearing and Pinion No loose or missing hardware no visible damage evidence of proper lubri cation Hydraulic Oil Medium Pressure Filter Housing See Inspection Note Hydraulic Oil Return Filter Housing See Inspection Note Manual Descent See Inspection Note if equipped LP Gas Tank Brackets hose and fittings secure no visible damage no missing parts If Equipped Hydraulic Oil Supply Recommended oil level sight gauge Check level with cold oil systems shut down machine with booms retracted and lowered Cap in place and secure Hydraulic Oil Breather Element in place not clogged no sign of overflow 21 22 23 24 25 26 27 28 29 Ground Controls Switches operable no visible dam age decals secure and legible Fuel Supply Fuel filler cap secure Tank no visible damage no evidence of leaks Swing Drive Motor and Brake See Inspection Note Door and Latches Hood door and la
97. r replaced 4 Operators and Safety Manuals Make sure copy of 2 4 the Operator and Safety Manual EMI Safety Manual Domestic only and ANSI Manual of Responsibilities Domestic only is enclosed in the weather resistant storage container 5 Walk Around Inspection Refer to Figure 2 3 and Figure 2 4 6 Battery Charge as required 7 Fuel Combustion Engine Powered Machines 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 hydraulic oil is added as required 10 Function Check Once the Walk Around Inspection is complete perform a functional check of all systems in accordance with Section 2 3 in an area free of overhead and ground level obstructions Refer to Sections 3 and 4 for more specific machine operating instructions A WARNING IF THE MACHINE DOES NOT OPERATE PROPERLY TURN OFF THE MACHINE IMMEDIATELY REPORT THE PROBLEM TO THE PROPER MAINTENANCE PERSONNEL DO NOT OPERATE THE MACHINE UNTIL IT IS DECLARED SAFE FOR OPERATION JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION MASTER CYLINDER MAIN LIFT BOX FAR SIDE CYLINDER UPRIGHT 2 AN UPRIGHT LEVEL LS CYLINDER TOWER Bi TELESCOPE TOWER FLY BOOM
98. rection 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 pulling or by using boom functions Only pull the unit from the tie down lugs on the chassis Do not place boom or platform against any structure to steady the platform or to support the structure Stow boom and shut off all power before leaving machine Trip and Fall Hazards During operation occupants in the platform must wear a full body harness with a lanyard attached to an authorized lan yard anchorage point Attach only one 1 lanyard per lan yard anchorage point Lift SECTION 1 SAFETY PRECAUTIONS Before operating the machine make sure all gates Use extreme caution when entering or leaving platform closed and fastened in their proper position Be sure that the boom is fully lowered It may be neces sary to telescope out to position the platform closer to the ground for entry exit Face the machine maintain three point contact with the machine using two hands and one foot or two feet and one hand during entry and exit Electrocution Hazards This machine is not insulated and does not provide pro tection from contact or proximity to electrical current d Keep both feet firmly positioned on the platform floor at all W times Never use ladders boxes steps planks or similar items on platform to provide additi
99. rol switch or controller Position POWER EMERGENCY STOP switch to OFF JLG Lift EMERGENCY OPERATION Use of Ground Controls KNOW HOW TO USE THE GROUND CONTROLS IN AN EMERGENCY SITUATION Ground personnel must be thoroughly familiar with the machine operating characteristics and the ground control functions Training should include operation of the machine review and understanding of this section and hands on oper ation of the controls in simulated emergencies SECTION 5 EMERGENCY PROCEDURES Operator Unable to Control Machine IF THE PLATFORM OPERATOR IS PINNED TRAPPED OR UNABLE TO OPERATE OR CONTROL THE MACHINE A WARNING DO NOT OPERATE WITH PRIMARY POWER SOURCE ENGINE OR ELEC TRIC MOTOR IF PERSONS ARE PINNED OR TRAPPED USE AUXILIARY POWER INSTEAD 1 5 4 Operate the machine from ground controls ONLY with the assistance of other personnel and equipment cranes overhead hoists etc as may be required to safely remove the danger or emergency condition Other qualified personnel on the platform may use the platform controls with regular or auxiliary power DO NOT CONTINUE OPERATION IF CONTROLS DO NOT FUNCTION NORMALLY Cranes forklift trucks or other equipment which may be available are to be used to remove platform occupants and stabilize motion of the machine in case machine controls are inadequate or malfunction when used Platform or Boom Caught Overhead If the platform or boom becomes
100. sembly in the stowed position Identify the tower boom vertical limit switch adjacent to the tower lift cylinder at the bottom end rear of the tower base boom Open the left side hood and perform a visual check that the plunger on the tower boom vertical limit switch is fully extended The plunger is shown fully extended in Figure 2 7 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION d A WARNING DISCONTINUE OPERATION IF PLUNGER IS NOT FULLY EXTENDED b Attempt to extend the tower fly boom The tower fly boom should not extend and the red boom mal function light in the ground control panel should illuminate when pressing the tower telescope switch A WARNING DISCONTINUE OPERATION IF THE TOWER FLY BOOM EXTENDS OR THE BOOM MALFUNCTION LIGHT DOES NOT ILLUMINATE c Raise the tower base boom to approximately 40 degrees then lower the tower boom back to the below horizontal position While raising and lower ing the tower boom assembly observe the position of the upright Ensure that the upright remains verti cal relative to the chassis Refer to Figure 2 9 and Figure 2 10 Raise the tower base boom to full height Extend the tower fly boom a few feet Check that the plunger on the tower boom horizontal limit switch at the end of the tower base boom section is fully extended The plunger is shown fully extended in Figure 2 8 A WARNING Figure 2 8 Tower Boom Horizontal Limit Switch DISCONTIN
101. ssure that they function in both direc tions using auxiliary power instead of engine power Ground Controls Place GROUND PLATFORM SELECT switch to GROUND Start engine Platform controls should not operate 2 4 OSCILLATING AXLE LOCKOUT TEST iF EQUIPPED NOTICE LOCKOUT SYSTEM TEST MUST BE PERFORMED QUARTERLY ANY TIME A SYSTEM COMPONENT IS REPLACED OR WHEN IMPROPER SYSTEM OPERATION IS SUSPECTED NOTE Ensure boom is fully retracted lowered and centered between drive wheels prior to beginning lockout cylinder test 1 Place a 6 inch 15 2 cm high block with ascension ramp in front of left front wheel 2 From platform control station start engine 3 Position DRIVE SPEED TORQUE SELECT SWITCH to SLOW 4 Place DRIVE control lever to FORWARD position and carefully drive machine up ascension ramp until left front wheel is on top of block 5 Carefully activate SWING control lever and position boom over RIGHT side of machine JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 10 3121209 With boom over right side of machine place DRIVE con trol lever to REVERSE and drive machine off of block and ramp Have an assistant check to see that left front or right rear wheel remains elevated in position off of ground Carefully activate SWING control lever and return boom to stowed position centered between drive wheels When boom reaches center stowed position lo
102. t time of hydraulic oil change 6 24 JLG Lift 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 3121209 2 8 Oil Change w Filter Ford es fe Lube Point s Fill Cap Spin on Element Capacity 4 5 Quarts Lube EO Interval 3 Months or 150 hours of operation Comments Check level daily Change in accordance with engine manual Lift 9 Oil Change w Filter Deutz Lube Point s Fill Cap Spin on Element Capacity 11 Quarts 10 5 L Crankcase Lube EO Interval Every Year or 1200 hours of operation Comments Check level daily Change in accordance with engine manual 6 25 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 10 Oil Change w Filter Isuzu 12 Oil hange w Filter GM Lube Point s Fill Cap Spin on Element Capacity 8 5 qt 8 0L engine 5 3 qt 5 L cooler Lube EO Interval Change oil after first 50 and every 200 hrs there after Change oil filter after 50hrs and every 400 hrs there after Comments Check level daily Change in accordance with engine manual 11 Oil Change w Filter Caterpillar Lube Point s Fill Cap Spin on Element Capacity 10 6 Quarts Lube EO Interval 3 Months or 150 hours of operation Lube Point s Fill Cap Spin on Element Comments Check level daily Change in accordance with JLG P N 7027965 engine manual Capacity 4 5 qt 4 25 L w filter Lube EO Interv
103. tall the retaining bolt into the filter hous ing Install the filter up to the bottom of the electric lock off Tighten the filter bowl retainer to 106 in lbs 12 Nm Open manual shut off valve Start the vehicle and leak check the propane fuel system at each serviced fitting Refer to Propane Fuel System Leak Test 3121209 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 1 ElectricLockOffSolenoid 6 Seal 10 Filter 2 Mounting Plate 7 Electrical Connector 11 Fuellnlet 3 Housing Seal 8 Fuel Outlet 12 Retaining Bolt 4 Filter Magnet 9 O ring 13 Ring 5 Filter Housing Figure 6 10 Filter Lock Assembly 3121209 JLG Lift 6 35 SECTION 6 GENERAL SPECIFICATIONS amp OPERATOR MAINTENANCE 6 7 PROPANE FUEL SYSTEM PRESSURE RELIEF 6 8 SUPPLEMENTAL INFORMATION A CAUTION THE PROPANE FUEL SYSTEM OPERATES AT PRESSURES UP TO 312 PSI 21 5 BAR TO MINIMIZE THE RISK OF FIRE AND PERSONAL INJURY RELIEVE THE PROPANE FUEL SYSTEM PRESSURE WHERE APPLICABLE BEFORE SERVICING THE PROPANE FUEL SYSTEM COM PONENTS To relieve 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 A CAUTION RESIDUAL VAPOR PRESSURE WILL BE PRESENT IN THE FUEL SYS TEM ENSURE THE WORK AR
104. tation GENERAL NOTICE THE MANUFACTURER HAS NO DIRECT CONTROL OVER MACHINE APPLICATION AND OPERATION THE USER AND OPERATOR ARE RESPONSIBLE FOR CONFORMING WITH GOOD SAFETY PRACTICES This section provides the necessary information needed to understand control functions 3 2 CONTROLS AND INDICATORS NOTE 3121209 This machine is equipped with control panels that use symbols to indicate control functions Refer to the decal located on the control box guard in front of the control box or by the ground controls for these symbols and the corresponding functions NOTE NOTE 1 Lift Main Lift Swing Platform Level Main Telescope Platform Rotator and Auxiliary Power Tower Telescope Tower Lift and jib control switches are spring loaded and will auto matically return to neutral off when released be held down in order to operate Main Boom Telescope Tower Lift Swing Main Lift Jib Lift Platform Level Override and Platform Rotate func tions If equipped the Function Enable switch must Platform Rotate The platform ROTATE control switch provides rotation of the platform when positioned to LEFT or RIGHT 3 1 SECTION 3 MACHINE CONTROLS AND INDICATORS 1 1 Platform Rota
105. tches in working condition properly secured no loose or missing parts Oscillating Cam Valve No visible damage no evi dence of leakage no unsupported hoses lf Equipped Tie Rod and Steering Linkage See Inspection Note Oscillating Axle Cylinder See Inspection Note If Equipped Dual Capacity and Horizontal Cutout Limit Switches if equipped Properly secured no damage to the switches arm free to move and free from dirt and grease Oscillating Axle See Inspection Note If Equipped Figure 2 5 Daily Walk Around Inspection Sheet 3 of 4 JLG Lift SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 2 10 30 31 32 33 34 35 36 37 38 Engine Air Filter No loose or missing parts no visi ble damage element clean Battery Proper electrolyte levels cables tight no visi ble damage or corrosion Engine Oil Supply Full mark on dipstick filler cap secure Muffler and Exhaust System See Inspection Note Hydraulic Pumps See Inspection Note Engine Tray Pivot See Inspection Note Hydraulic Swivel See Inspection Note LP Gas Tank Brackets hose and fittings secure no visible damage no missing parts If Equipped Flow Valves See Inspection Note 39 40 41 42 43 Tower Boom No visible damage wear pads secure All cylinders rod end pins and barrel end pins prop erly secured Frame See Inspection Note Main Bo
106. te 2 Platform Leveling Override 3 Jib 2 4 Power Emergency Stop 4 8 12 5 Engine Start Auxiliary Power 3 or Engine Start Auxiliary Power Function Enable OR 4 6 Tower Telescope MI 11 7 Hourmeter 8 Platform Ground Select Switch 9 Swing 5 10 10 Tower Lift 11 Main Boom Lift 6 12 Main Boom Telescope rm 9 8 Figure 3 1 Ground Control Station 3 2 JLG Lift 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS NOTE When Power Emergency Stop switch is in the ON posi A WARNING tion and engine is not running an alarm will sound indi ONLY USE THE PLATFORM LEVELING OVERRIDE FUNCTION FOR cating Ignition is ON SLIGHT LEVELING OF THE PLATFORM INCORRECT USE COULD CAUSE THE LOAD OCCUPANT TO SHIFT OR FALL FAILURE TO DO SO COULD RESULT IN DEATH OR SERIOUS INJURY A CAUTION WHEN THE MACHINE IS SHUT DOWN THE MASTER EMERGENCY STOP 2 Platform Leveling Override SWITCH MUST BE POSITIONED TO THE OFF POSITION TO PREVENT DRAINING THE BATTERY A three position switch allows the operator to adjust the automatic self leveling system This switch is used 4 Power Emergency Stop Switch to adjust platform level in situations such as ascending descending a grade A two position red mushroom shaped switch furnishes power to PLATFORM GROUND SELECT switch when pulled out on When pushed in off power is shut off to the PLATFORM GROUND SELECT switch 3 Jib If Equipped The jib control switc
107. th skin and clothing at all times When performing welding or metal cutting operations Charge batteries only in a well ventilated area precautions must be taken to protect the chassis from direct exposure to weld and metal cutting spatter 3121209 JLG Lift 1 9 SECTION 1 SAFETY PRECAUTIONS NOTICE DO NOT OPERATE THE MACHINE WHEN WIND CONDITIONS EXCEED 28 MPH 12 5 M S Table 1 2 Beaufort Scale For Reference Only 1 X Description Land Conditions 0 0 0 0 2 Calm Calm Smoke rises vertically 1 1 3 0 3 1 5 Lightair Wind motion visible in smoke 2 4 7 1 6 3 3 Light breeze Wind felt on exposed 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 begin 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 Whistling heard in overhead wires Umbrella use becomes difficult 7 32 38 13 9 17 1 NearGale Moderate Gale Whole trees in motion Effort needed to walk againstthe 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 10 JLG Lift 3121209 SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION
108. tuguese French CE Aus Japanese 0274461 10 0274465 8 0274471 8 0274467 8 0274469 10 0274473 8 0274475 3 0274463 8 54 55 56 1705351 1705427 1705430 1705910 1705905 1705429 1705426 JLG Lift 4 41 SECTION 4 MACHINE OPERATION 12 NOTES 4 42 JLG Lift 3121209 SECTION 5 EMERGENCY PROCEDURES SECTION 5 EMERGENCY PROCEDURES 5 1 GENERAL This section explains the steps to be taken in case of an emergency situation while operating 5 2 INCIDENT NOTIFICATION JLG Industries Inc must be notified immediately of any inci dent involving a JLG product Even if no injury or property damage is evident the factory should be contacted by tele phone and provided with all necessary details In USA JLG Phone 877 JLG SAFE 554 7233 8am till 4 45pm EST Outside USA 240 420 2661 E mail ProductSafety JLG com Failure to notify the manufacturer of an incident involving a JLG Industries product within 48 hours of such an occur rence may void any warranty consideration on that particular machine 3121209 Lift NOTICE FOLLOWING ANY ACCIDENT THOROUGHLY INSPECT THE MACHINE AND TEST ALL FUNCTIONS FIRST FROM THE GROUND CONTROLS THEN FROM THE PLATFORM CONTROLS DO NOT LIFT ABOVE 10 FT 3 M UNTIL YOU ARE SURE THAT ALL DAMAGE HAS BEEN REPAIRED IF REQUIRED AND THAT ALL CONTROLS ARE OPERATING CORRECTLY
109. unction Indicator Light Ford Engines prior to S N 62045 Indicates that the Engine Control Module has detected a malfunction in the Electronic Fuel Injection System and a Diagnostic Trouble Code has been set in the ECM Refer to the Service Manual for instructions concerning the trouble codes and trouble code retrieval The malfunction indicator light will illuminate for 2 3 sec onds when the key is positioned to the on position to act as a self test Low Fuel Level Indicator N A for liquid propane When illuminated indicates that the fuel level is 1 8 full or less When the light first turns on there are approxi mately four usable gallons of fuel remaining Glow Plug Indicator If Equipped When illuminated the glow plugs are operating After turning on ignition wait until light goes out before crank ing engine SECTION 3 MACHINE CONTROLS AND INDICATORS 8 Boom Malfunction Indicator 9 If the Boom Malfunction Indicator illuminates when attempting to activate a tower boom function the func 10 tion is being cutout by tower boom limit switch The i function is not permitted at the current boom configura tion If the Boom Malfunction Indicator is flashing or on 11 steady without a boom function attempt the upright is out of alignment or the monitoring system is in need of calibration A WARNING 12 DISCONTINUE OPERATION IF THE BOOM MALFUNCTION LIGHT IS FLASHING OR ON STEADY NOTICE IF THE UPRIGHT IS OUT OF ALIGNME
110. vering in confined areas A decal located at top of switch instructs the desired wheel maneuver with the switch position To re synchronize the front and rear axles activate the steer switch thumb rocker until all steer cylinders are at the end of their stroke This can be done in either crab or coordinated mode 14 15 JLG Lift Auxiliary Power When pushed forward the switch energizes the starter motor to start the engine When pushed back it energizes the electrically oper ated hydraulic pump when actuated Switch must be held ON for duration of auxiliary 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 tower boom lift tower telescope main boom lift main telescope and swing Tower Lift The three position center off toggle switch provides for raising and lowering of the tower boom when positioned to UP or DOWN TOWER LIFT must be fully elevated UP before operating TOWER TELESCOPE TOWER LIFT should not function when TOWER TELESCOPE is extended 3121209 SECTION 3 MACHINE CONTROLS AND INDICATORS 16 Tower Telescope The three position center off toggle switch provides for extending and retracting of the tower boom when posi tioned to IN or OUT TOWER TELESCOPE must be fully RETRACTED before operating TOWER LIFT TOWER TELESCOPE should not function when
111. ws A WARNING IF THE TILT ALARM AND WARNING SYSTEM DOES NOT OPERATE PROPERLY DISCONTINUE OPERATION CONTACT A QUALIFIED SER VICE TECHNICIAN TO CORRECT THE MALFUNCTION BEFORE OPERAT ING THE MACHINE 12 Lift For Machines prior to serial number 0300062045 Have an assistant manually activate the tilt indicator light by compressing any one of the three tilt indicator mount ing springs The tilt indicator light on the platform control console should illuminate For Machines from serial number 0300062045 to present With the platform in the transport position tower base boom lowered main fly boom retracted and main base boom below horizontal drive up a suit able ramp of at least 5 slope The tilt indicator light on the platform control console should illuminate Check that the platform automatically levels properly during raising and lowering of the boom SECTION 2 USER RESPONSIBILITIES MACHINE PREPARATION AND INSPECTION 13 14 15 16 17 18 2 18 Check that the platform level override operates properly Check platform rotator for smooth operation and assure platform will rotate 90 degrees in both directions from centerline of boom If equipped with 4 wheel steer check rear steer left and right for proper operation If equipped raise and lower the articulating jib boom Check for smooth operation If equipped with Auxiliary Power operate each function control switch to a
112. y be selected by mov ing the switch to the appropriate position It is unneces sary to purge the fuel system before switching fuels so there is no waiting period when switching fuels while the engine is running 3121209 JLG Lift 12 Work Lights If Equipped The switch on the light operates work lights if the machine is so equipped The power emergency stop switch must be on mushroom button out but ignition switch does not have to be on to operate the lights so care must be taken to avoid draining the battery if left unattended The master switch and or the ignition switch at the ground control will turn off power to all lights 3 13 SECTION 3 MACHINE CONTROLS AND INDICATORS 13 Steer Select If Equipped 3 14 When equipped with four wheel steering the action of the steering system is operator selectable The center switch position gives conventional front wheel steering with the rear wheels unaffected This is the best position for normal driving at maximum speeds The forward position is for crab steering When in this mode both front and rear axles steer in the same direction 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 coordinated steering In this mode the front and rear axles steer in the opposite directions to produce the tightest turning circle for maneu

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