Oshkosh Corporation JLG 800S Gebrauchs- und Pflegehandbuch

Operation and Safety Manual

ANSI

Original Instructions - Keep this manual with the machine at all times.

Boom Lift Models

800S

860SJ

Prior to S/N 0300182742

3121138

March 24, 2014

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FOREWORD

3121138 – 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.

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FOREWORD

b– JLG Lift – 3121138

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.

INDICATES INFORMATION OR A COMPANY POLICY THAT RELATES

DIRECTLY OR INDIRECTLY TO THE SAFETY OF PERSONNEL OR PRO-

TECTION OF PROPERTY.

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

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

injury or death

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FOREWORD

3121138 – 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.

JLG INDUSTRIES, INC. SENDS SAFETY RELATED BULLETINS TO THE

OWNER OF RECORD OF THIS MACHINE. CONTACT JLG INDUSTRIES,

INC. TO ENSURE THAT THE CURRENT OWNER RECORDS ARE

UPDATED AND ACCURATE.

JLG INDUSTRIES, INC. MUST BE NOTIFIED IMMEDIATELY IN ALL

INSTANCES WHERE JLG PRODUCTS HAVE BEEN INVOLVED IN AN

ACCIDENT INVOLVING BODILY INJURY OR DEATH OF PERSONNEL OR

WHEN SUBSTANTIAL DAMAGE HAS OCCURRED TO PERSONAL PROP-

ERTY OR THE JLG PRODUCT.

Contact:

Product Safety and Reliability Department

JLG Industries, Inc.

13224 Fountainhead Plaza

Hagerstown, MD 21742

USA

or Your Local JLG Office

(See addresses on inside of manual cover)

In USA:

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

Outside USA:

Phone: 240-420-2661

Fax: 301-745-3713

E-mail: Pr[email protected]m

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

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FOREWORD

d– JLG Lift – 3121138

REVISION LOG

Original Issue - October 9, 2001

Revised - October 31, 2001

Revised - December 4, 2001

Revised - March 1, 2002

Revised - January 1, 2003

Revised - April 24, 2003

Revised - May 4, 2005

Revised - March 3, 2006

Revised - July 7, 2006

Revised - August 13, 2008

Revised - November 25, 2009

Revised - February 9, 2010

Revised - October 31, 2011

Revised - July 17, 2012

Revised - March 24, 2014

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TABLE OF CONTENTS

3121138 – 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 PREPA-

RATION, 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 HORIZONTAL AND CAPACITY LIMIT SWITCHES 2-10

2.4 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

SECTION - 3 - MACHINE CONTROLS AND INDICATORS

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

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

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

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

Platform Station . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

Platform Control Indicator Panel . . . . . . . . . . . . 3-15

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 . . . . . . . . . . . . . . . . . . . . . 4-3

4.4 TRAVELING (DRIVING) . . . . . . . . . . . . . . . . . . . . . . 4-5

Traveling Forward and Reverse . . . . . . . . . . . . . 4-6

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TABLE OF CONTENTS

ii – JLG Lift – 3121138

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

4.5 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.6 PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

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

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

4.7 BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Swinging the Boom . . . . . . . . . . . . . . . . . . . . . . 4-9

Raising and Lowering the Boom . . . . . . . . . . . . 4-9

4.8 FUNCTION SPEED CONTROL . . . . . . . . . . . . . . . . 4-9

4.9 OSCILLATING AXLE LOCKOUT TEST

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

4.10 EMERGENCY TOWING . . . . . . . . . . . . . . . . . . . . . 4-10

4.11 TOW BAR (IF EQUIPPED) . . . . . . . . . . . . . . . . . . . 4-11

4.12 SHUT DOWN AND PARK . . . . . . . . . . . . . . . . . . . 4-13

4.13 LIFTING AND TIE DOWN. . . . . . . . . . . . . . . . . . . . 4-13

Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13

Tie Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14

SECTION - 5 - EMERGENCY PROCEDURES

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

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

5.3 EMERGENCY OPERATION. . . . . . . . . . . . . . . . . . . 5-1

Operator Unable to Control Machine . . . . . . . . 5-1

Platform or Boom Caught Overhead. . . . . . . . . 5-2

5.4 EMERGENCY TOWING PROCEDURES . . . . . . . . . 5-2

5.5 MANUAL DESCENT INSTRUCTIONS

(IF EQUIPPED) . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

To Retract and Lower Boom. . . . . . . . . . . . . . . . 5-3

To Lower Boom with Fully Retracted Telescope 5-3

SECTION - 6 - GENERAL SPECIFICATIONS &

OPERATOR MAINTENANCE

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

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

Specifications and Performance Data . . . . . . . . 6-3

Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Engine Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7

Major Component Weights. . . . . . . . . . . . . . . . . 6-8

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8

6.3 SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . .6-11

6.4 OPERATOR MAINTENANCE . . . . . . . . . . . . . . . . .6-21

6.5 TIRES & WHEELS . . . . . . . . . . . . . . . . . . . . . . . . .6-30

Tire Inflation . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-30

Tire Replacement . . . . . . . . . . . . . . . . . . . . . . . 6-31

Wheel Replacement . . . . . . . . . . . . . . . . . . . . . 6-31

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . . 6-32

6.6 DRAINING OIL BUILD UP FROM THE PROPANE

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TABLE OF CONTENTS

3121138 – JLG Lift – iii

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

REGULATOR (PRIOR TO S/N 0300134626) . . . .6-33

6.7 PROPANE FUEL FILTER REPLACEMENT. . . . . . .6-35

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-35

6.8 PROPANE FUEL SYSTEM PRESSURE RELIEF . .6-37

6.9 SUPPLEMENTAL INFORMATION . . . . . . . . . . . . .6-37

SECTION - 7 - INSPECTION AND REPAIR LOG

LIST OF FIGURES

2-1. Basic Nomenclature - Sheet 1 of 2 . . . . . . . . . . . . .2-6

2-2. Basic Nomenclature - Sheet 2 of 2 . . . . . . . . . . . . .2-7

2-2. Daily Walk-Around Inspection - Sheet 1 of 2 . . . . . .2-8

2-3. Daily Walk-Around Inspection - Sheet 2 of 2 . . . . . .2-9

2-4. Horizontal and Capacity Limit Switches -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

2-5. Horizontal and Capacity Limit Switches -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-11

2-6. Limiting and Cut-Out Switches - Sheet 1 of 2 . . . .2-12

2-7. Limiting and Cut-Out Switches - Sheet 2 of 2 . . . .2-13

3-1. Ground Control Station - 800S . . . . . . . . . . . . . . . .3-3

3-1. Ground Control Station - 860SJ. . . . . . . . . . . . . . . .3-4

3-2. Ground Control Indicator Panel - Sheet 1 of 2 . . . .3-7

3-3. Ground Control Indicator Panel - Sheet 2 of 2 . . . .3-8

3-4. Platform Control Console. . . . . . . . . . . . . . . . . . . .3-11

3-5. Platform Control Console - w/Drive Orientation . . 3-12

3-6. Platform Light Panel . . . . . . . . . . . . . . . . . . . . . . . 3-18

3-7. Platform Light Panel - w/Drive Orientation . . . . . . 3-19

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

4-2. Position of Least Forward Stability . . . . . . . . . . . . . 4-4

4-3. Grade and Side Slopes . . . . . . . . . . . . . . . . . . . . . 4-7

4-4. Drive Disconnect Hub. . . . . . . . . . . . . . . . . . . . . . 4-10

4-5. Typical 800S/860SJ Transport . . . . . . . . . . . . . . . 4-15

4-6. Lifting and Tie Down Chart . . . . . . . . . . . . . . . . . . 4-16

4-7. Decal Location - Rear Entry Platform -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4-8. Decal Location - Rear Entry Platform -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

4-9. Decal Location - Side Entry Platform -

Sheet 1 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

4-10. Decal Location - Side Entry Platform -

Sheet 2 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32

4-11. Decal Location - Side Entry Platform -

Sheet 3 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-33

4-12. Decal Location - Side Entry Platform -

Sheet 4 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34

4-13. Decal Location - Side Entry Platform -

Sheet 5 of 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35

6-1. Serial Number Locations . . . . . . . . . . . . . . . . . . . 6-11

6-2. Engine Operating Temperature Specifications - Deutz

- Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12

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TABLE OF CONTENTS

iv – JLG Lift – 3121138

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

6-3. Engine Operating Temperature Specifications - Deutz

- Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

6-4. Engine Operating Temperature Specifications - Ford -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14

6-5. Engine Operating Temperature Specifications - Ford -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15

6-6. Engine Operating Temperature Specifications -

Caterpillar - Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . 6-16

6-7. Engine Operating Temperature Specifications -

Caterpillar - Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . 6-17

6-8. Engine Operating Temperature Specifications - GM -

Sheet 1 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18

6-9. Engine Operating Temperature Specifications - GM -

Sheet 2 of 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19

6-10. Operator Maintenance and Lubrication Diagram . 6-20

6-11. Filter Lock Assembly . . . . . . . . . . . . . . . . . . . . . . . 6-36

LIST OF TABLES

1-1 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 Location Legend - Rear Entry Platform . . . 4-19

4-2 Decal Location Legend - Rear Entry Platform . . . 4-23

4-3 Decal Location Legend - Rear Entry Platform . . . 4-27

4-4 Decal Location Legend, 800S - Side Entry Platform -

Prior to S/N 0300143294 . . . . . . . . . . . . . . . . . . . 4-36

4-5 Decal Location Legend, 800S - Side Entry Platform - S/

N 0300143294 & B30000153 to

S/N 0300182742 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

4-6 Decal Location Legend, 860SJ - Side Entry Platform -

Prior to S/N 0300143294 . . . . . . . . . . . . . . . . . . . 4-44

4-7 Decal Location Legend, 860SJ - Side Entry Platform -

S/N 0300143294 & B300000153 to

S/N 0300182742 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

6-1 Operating Specifications - Prior to

S/N 0300143294 . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-2 Operating Specifications - S/N 0300143294 &

B300000153 to S/N 0300182742 . . . . . . . . . . . . . . 6-2

6-3 Specifications and Performance Data . . . . . . . . . . 6-3

6-4 Capacities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

6-5 Ford LRG-425 Specifications . . . . . . . . . . . . . . . . . 6-5

6-6 Deutz F4M2011 Specifications. . . . . . . . . . . . . . . . 6-5

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