JLG 800A Gebrauchs- und Pflegehandbuch

ANSI

Operation and Safety Manual

Keep this manual with the machine at all times.

Boom Lift Models

800A

800AJ

3121209

July 17, 2006

FOREWORD

3121209 – JLG Lift – a

FOREWORD

This manual is a very important tool! Keep it with the machine at all times.

The purpose of this manual is to provide owners, users, operators, lessors, and lessees with the precautions and

operating procedures essential for the safe and proper machine operation for its intended purpose.

Due to continuous product improvements, JLG Industries, Inc. reserves the right to make specification changes

without prior notification. Contact JLG Industries, Inc. for updated information.

FOREWORD

b– JLG Lift – 3121209

SAFETY ALERT SYMBOLS AND SAFETY SIGNAL WORDS

INDICATES AN IMMINENTLY HAZARDOUS SITUATION. IF NOT

AVOIDED, WILL RESULT IN SERIOUS INJURY OR DEATH. THIS DECAL

WILL HAVE A RED BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, COULD RESULT IN SERIOUS INJURY OR DEATH. THIS

DECAL WILL HAVE AN ORANGE BACKGROUND.

INDICATES A POTENTIALLY HAZARDOUS SITUATION. IF NOT

AVOIDED, MAY RESULT IN MINOR OR MODERATE INJURY. IT MAY

ALSO ALERT AGAINST UNSAFE PRACTICES. THIS DECAL WILL HAVE

A YELLOW BACKGROUND.

This is the Safety Alert Symbol. It is used to alert you to the potential personal

injury hazards. Obey all safety messages that follow this symbol to avoid possible

injury or death

FOREWORD

3121209 – JLG Lift – c

THIS PRODUCT MUST COMPLY WITH ALL SAFETY RELATED BULLE-

TINS. CONTACT JLG INDUSTRIES, INC. OR THE LOCAL AUTHORIZED

JLG REPRESENTATIVE FOR INFORMATION REGARDING SAFETY-

RELATED BULLETINS WHICH MAY HAVE BEEN ISSUED FOR THIS

PRODUCT.

IMPORTANT

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

IMPORTANT

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL

OR WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL

PROPERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

1 JLG Drive

McConnellsburg, PA 17233

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

Toll Free: 877-JLG-SAFE (877-554-7233)

Outside USA:

Phone: 717-485-5161

E-mail: [email protected]

For:

• Accident Reporting

• Product Safety Publica-

tions

• Current Owner Updates

• Questions Regarding

Product Safety

• Standards and Regulations

Compliance Information

• Questions Regarding Spe-

cial Product Applications

• Questions Regarding Prod-

uct Modifications

FOREWORD

d– JLG Lift – 3121209

REVISION LOG

Original Issue - May 4, 2005

Revised - September 1, 2005

Revised - March 7, 2006

Revised - July 17, 2006

TABLE OF CONTENTS

3121209 – JLG Lift – i

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

SECTION - 1 - SAFETY PRECAUTIONS

1.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

1.2 PRE-OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

Operator Training and Knowledge . . . . . . . . . . . 1-1

Workplace Inspection. . . . . . . . . . . . . . . . . . . . . 1-2

Machine Inspection . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Trip and Fall Hazards . . . . . . . . . . . . . . . . . . . . . 1-3

Electrocution Hazards . . . . . . . . . . . . . . . . . . . . 1-4

Tipping Hazards . . . . . . . . . . . . . . . . . . . . . . . . . 1-6

Crushing and Collision Hazards. . . . . . . . . . . . . 1-7

1.4 TOWING, LIFTING, AND HAULING . . . . . . . . . . . . .1-8

1.5 ADDITIONAL HAZARDS / SAFETY . . . . . . . . . . . . .1-9

SECTION - 2 - USER RESPONSIBILITIES, MACHINE

PREPARATION, AND INSPECTION

2.1 PERSONNEL TRAINING . . . . . . . . . . . . . . . . . . . . .2-1

Operator Training . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Training Supervision. . . . . . . . . . . . . . . . . . . . . . 2-1

Operator Responsibility . . . . . . . . . . . . . . . . . . . 2-1

2.2 PREPARATION, INSPECTION, AND

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2

Pre-Start Inspection . . . . . . . . . . . . . . . . . . . . . . 2-4

Function Check. . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

2.3 DAILY FUNCTIONAL CHECK . . . . . . . . . . . . . . . . 2-12

2.4 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

3.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.2 CONTROLS AND INDICATORS . . . . . . . . . . . . . . . 3-1

Ground Control Station . . . . . . . . . . . . . . . . . . . . 3-1

Ground Control Indicator Panel . . . . . . . . . . . . . 3-6

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Platform Control Indicator Panel . . . . . . . . . . . . 3-13

SECTION - 4 - MACHINE OPERATION

4.1 DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2 OPERATING CHARACTERISTICS AND

LIMITATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Stability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.3 ENGINE OPERATION . . . . . . . . . . . . . . . . . . . . . . . 4-2

Starting Procedure . . . . . . . . . . . . . . . . . . . . . . . 4-2

Shutdown Procedure . . . . . . . . . . . . . . . . . . . . . 4-6

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-6

Traveling Forward and Reverse . . . . . . . . . . . . . 4-7

4.5 STEERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

TABLE OF CONTENTS

ii – JLG Lift – 3121209

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

4.6 PARKING AND STOWING . . . . . . . . . . . . . . . . . . . . 4-7

4.7 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Loading From Ground Level . . . . . . . . . . . . . . . 4-8

Loading From Positions Above Ground Level . 4-8

Platform Level Adjustment . . . . . . . . . . . . . . . . . 4-8

Platform Rotation . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.8 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . 4-12

Raising and Lowering the Tower Boom . . . . . 4-12

Raising and Lowering the Main Boom . . . . . . 4-12

Telescoping the Main Boom . . . . . . . . . . . . . . 4-13

Function of Tower Boom . . . . . . . . . . . . . . . . . 4-13

4.9 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-14

4.10 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-14

4.11 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED). . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.12 TOWING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.13 WELDING LEAD (IF EQUIPPED). . . . . . . . . . . . . . 4-18

4.14 DUAL FUEL SYSTEM (GAS ENGINE ONLY) . . . . 4-18

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Changing From Gasoline to LP Gas . . . . . . . . 4-19

Changing From LP Gas to Gasoline . . . . . . . . 4-19

4.15 RE-SYNCHRONIZE LOWER LIFT CYLINDER . . . . 4-19

Level Override Valve . . . . . . . . . . . . . . . . . . . . 4-19

SECTION - 5 - EMERGENCY PROCEDURES

5.1 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 INCIDENT NOTIFICATION . . . . . . . . . . . . . . . . . . . .5-1

5.3 EMERGENCY TOWING PROCEDURES . . . . . . . . .5-1

5.4 EMERGENCY CONTROLS AND THEIR

LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

Power/Emergency Stop Switches . . . . . . . . . . . 5-2

Ground Control Station . . . . . . . . . . . . . . . . . . . 5-2

Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

5.5 EMERGENCY OPERATION . . . . . . . . . . . . . . . . . . .5-3

Use of Ground Controls . . . . . . . . . . . . . . . . . . . 5-3

Operator Unable to Control Machine . . . . . . . . . 5-4

Platform or Boom Caught Overhead . . . . . . . . . 5-4

SECTION - 6 - GENERAL SPECIFICATIONS & OPERATOR

MAINTENANCE

6.1 INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.2 OPERATING SPECIFICATIONS. . . . . . . . . . . . . . . .6-1

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

Critical Stability Weights . . . . . . . . . . . . . . . . . . . 6-9

6.3 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-20

6.4 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-28

TABLE OF CONTENTS

3121209 – JLG Lift – iii

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-29

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-29

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-30

6.5 DRAINING OIL BUILD UP FROM THE PROPANE

REGULATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-31

6.6 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-33

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34

6.7 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-34

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Machine Nomenclature - 800A. (Sheet 1 of 2) . . . .2-6

2-2. Machine Nomenclature - 800AJ. (Sheet 2 of 2). . . .2-7

2-3. Daily Walk-Around Inspection. (Sheet 1 of 4) . . . . .2-8

2-4. Daily Walk-Around Inspection. (Sheet 2 of 4) . . . . .2-9

2-5. Daily Walk-Around Inspection. (Sheet 3 of 4) . . . .2-10

2-6. Daily Walk-Around Inspection. (Sheet 4 of 4) . . . .2-11

2-7. Tower Boom Vertical Limit Switch . . . . . . . . . . . . .2-12

2-8. Tower Boom Horizontal Limit Switch. . . . . . . . . . .2-13

3-1. Ground Control Station . . . . . . . . . . . . . . . . . . . . . .3-2

3-2. Ground Control Indicator Panel. . . . . . . . . . . . . . . .3-6

3-3. Platform Control Console . . . . . . . . . . . . . . . . . . . 3-10

3-4. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . 3-15

4-1. Position of Least Forward Stability . . . . . . . . . . . . . 4-3

4-2. Positions of Least Backward Stability

(Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4-3. Positions of Least Backward Stability

(Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5

4-4. Grade and Sideslopes. . . . . . . . . . . . . . . . . . . . . . . 4-9

4-5. Boom Upright Positioning. . . . . . . . . . . . . . . . . . . 4-11

4-6. Machine Tie Down . . . . . . . . . . . . . . . . . . . . . . . . 4-15

4-7. Lifting Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4-8. Decal Installation - Sheet 1 of 5 . . . . . . . . . . . . . . 4-20

4-9. Decal Installation - Sheet 2 of 5 . . . . . . . . . . . . . . 4-21

4-10. Decal Installation - Sheet 3 of 5 . . . . . . . . . . . . . . 4-22

4-11. Decal Installation - Sheet 4 of 5 . . . . . . . . . . . . . . 4-23

4-12. Decal Installation - Sheet 5 of 5 . . . . . . . . . . . . . . 4-24

6-1. Engine Operating Temperature Specifications -

Deutz - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-11

6-2. Engine Operating Temperature Specifications -

Deutz - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . 6-12

6-3. Engine Operating Temperature Specifications -

Ford - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-4. Engine Operating Temperature Specifications -

Ford - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-5. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . 6-15

TABLE OF CONTENTS

iv – JLG Lift – 3121209

SECTION - PARAGRAPH, SUBJECT PAGE SECTION - PARAGRAPH, SUBJECT PAGE

6-6. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2. . . . . . . . . . . . . . . . . . . 6-16

6-7. Engine Operating Temperature Specifications -

GM - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-17

6-8. Engine Operating Temperature Specifications -

GM - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-9. Operator Maintenance and Lubrication Diagram . 6-19

6-10. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-33

LIST OF TABLES

1-1 Minimum Approach Distances (M.A.D.) . . . . . . . . . 1-5

2-1 Inspection and Maintenance Table . . . . . . . . . . . . . 2-3

4-1 Decal Legend - 800A . . . . . . . . . . . . . . . . . . . . . . . 4-25

4-2 Decal Legend - 800AJ . . . . . . . . . . . . . . . . . . . . . . 4-28

6-1 Operating Specifications . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Tire Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6-3 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6-4 Ford LRG-425 Specifications. . . . . . . . . . . . . . . . . . 6-3

6-5 Deutz F4M2011F Specifications . . . . . . . . . . . . . . . 6-4

6-6 Caterpillar 3044C . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-7 Isuzu 4JB1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-8 GM 3.0L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

6-9 Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-10 Mobilfluid 424 Specs . . . . . . . . . . . . . . . . . . . . . . . . 6-6

6-11 Mobil DTE 13M Specs . . . . . . . . . . . . . . . . . . . . . . . 6-7

6-12 Mobil EAL 224H Specs. . . . . . . . . . . . . . . . . . . . . . 6-7

6-13 UCon Hydrolube HP-5046 . . . . . . . . . . . . . . . . . . . 6-8

6-14 Exxon Univis HVI 26 Specs . . . . . . . . . . . . . . . . . . 6-8

6-15 Critical Stability Weights - 800A . . . . . . . . . . . . . . . 6-9

6-16 Critical Stability Weights - 800AJ . . . . . . . . . . . . . 6-10

6-17 Lubrication Specifications . . . . . . . . . . . . . . . . . . 6-20

6-18 Wheel Torque Chart . . . . . . . . . . . . . . . . . . . . . . . 6-31

7-1 Inspection and Repair Log . . . . . . . . . . . . . . . . . . . 7-1

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