Service and Maintenance Manual - Model 800A - 800AJ - Introduction, Maintenance Safety Precautions

Oct 23, 2026

Uploaded by jayni

Aerial platform service and maintenance manual for models 800A and 800AJ, including identification details such as model numbers, prior serial number guidance, part number 3120858, and the revision date January 15, 2016. Section A establishes maintenance safety precautions covering general warning requirements, hydraulic system hazards at extremely high pressures, and mandatory practices. It specifies replacing parts with identical or equivalent items, anti-fire and electrical storm fueling rules, personal protective behavior, safe support procedures, and controls shutdown before adjustments or maintenance.

LanguageEnglish

CategoryHealthcare

FormatPDF

Pages494

Reading Time20 h 45 min

AccessFree to download

SECTION A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS

A GENERAL

B HYDRAULIC SYSTEM SAFETY

C MAINTENANCE

SECTION 1 - SPECIFICATIONS

1.1 Operating specifications

1.2 Component Data

1.3 Torque Requirements

1.4 Lubrication

1.5 Cylinder Specifications

1.6 Major Component Weights

Service and Maintenance Manual Model 800A 800AJ Prior to S/N 0300183033 P/N-3120858 January 15, 2016 SECTION A. INTRODUCTION-MAINTENANCE SAFETY PRECAUTIONS A GENERAL This section contains the general safety precautions which must be observed during maintenance of the aerial platform. It is of utmost importance that maintenance personnel pay strict attention to these warnings and precautions to avoid possible injury to themselves or others, or damage to the equipment. A maintenance program must be followed to ensure that the machine is safe to operate. MODIFICATION OR ALTERATION OF AN AERIAL WORK PLATFORM SHALL BE MADE ONLY WITH WRITTEN PERMISSION FROM THE MANUFACTURER. The specific precautions to be observed during maintenance are inserted at the appropriate point in the manual. These precautions are, for the most part, those that apply when servicing hydraulic and larger machine component parts. Your safety, and that of others, is the first consideration when engaging in the maintenance of equipment. Always be conscious of weight. Never attempt to move heavy parts without the aid of a mechanical device. Do not allow heavy objects to rest in an unstable position. When raising a portion of the equipment, ensure that adequate support is provided. SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CONTROL OVER THE FIELD INSPECTION AND MAINTENANCE, SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPERATOR. B HYDRAULIC SYSTEM SAFETY It should be noted that the machines hydraulic systems operate at extremely high potentially dangerous pressures. Every effort should be made to relieve any system pressure prior to disconnecting or removing any portion of the system. Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. Wear gloves to help protect hands from spraying fluid. C MAINTENANCE FAILURE TO COMPLY WITH SAFETY PRECAUTIONS LISTED IN THIS SECTION COULD RESULT IN MACHINE DAMAGE, PERSONNEL INJURY OR DEATH AND IS A SAFETY VIOLATION. • ENSURE REPLACEMENT PARTS OR COMPONENTS ARE IDENTICAL OR EQUIVALENT TO ORIGINAL PARTS OR COMPONENTS. • NO SMOKING IS MANDATORY. NEVER REFUEL DURING ELECTRICAL STORMS. ENSURE THAT FUEL CAP IS CLOSED AND SECURE AT ALL OTHER TIMES. • REMOVE ALL RINGS, WATCHES AND JEWELRY WHEN PERFORMING ANY MAINTENANCE. • DO NOT WEAR LONG HAIR UNRESTRAINED, OR LOOSE-FITTING CLOTHING AND NECKTIES WHICH ARE APT TO BECOME CAUGHT ON OR ENTANGLED IN EQUIPMENT. • OBSERVE AND OBEY ALL WARNINGS AND CAUTIONS ON MACHINE AND IN SERVICE MANUAL. • KEEP OIL, GREASE, WATER, ETC. WIPED FROM STANDING SURFACES AND HAND HOLDS. • USE CAUTION WHEN CHECKING A HOT, PRESSURIZED COOLANT SYSTEM. • NEVER WORK UNDER AN ELEVATED BOOM UNTIL BOOM HAS BEEN SAFELY RESTRAINED FROM ANY MOVEMENT BY BLOCKING OR OVERHEAD SLING, OR BOOM SAFETY PROP HAS BEEN ENGAGED. • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR PERFORMING ANY OTHER MAINTENANCE, SHUT OFF ALL POWER CONTROLS. • BATTERY SHOULD ALWAYS BE DISCONNECTEDDURING REPLACEMENT OF ELECTRICAL COMPONENTS. • KEEP ALL SUPPORT EQUIPMENT AND ATTACHMENTS STOWED IN THEIR PROPER PLACE. • USE ONLY APPROVED, NONFLAMMABLE CLEANING SOLVENTS. 3120858 –JLG Lift – A-1 REVISON LOG Original Issue Revised Revised Revised Revised Revised Revised Revised Revised Revised -August, 1998 -September 15, 1999 -August 29, 2001 -January 14, 2003 -October 19, 2004 -July 11, 2005 -June 12, 2007 -May 23, 2008 -December 12, 2012 -January 15, 2016 A-2 –JLG Lift – 3120858 SECTION NO. TITLE PAGE NO. SECTION A -INTRODUCTION-MAINTENANCE SAFETY PRECAUTIONS A General ............................................................................................ A-1 B Hydraulic System Safety ............................................................................ A-1 C Maintenance ....................................................................................... A-1 SECTION 1 -SPECIFICATIONS 1.1

FAQs

What is the core safety requirement before starting maintenance?

Follow the maintenance program and pay strict attention to the warnings and precautions to prevent injury or equipment damage. Safety of maintenance personnel and others is the first consideration.

How should hydraulic system pressure be handled during maintenance?

Relieve any system pressure before disconnecting or removing any portion of the hydraulic system, since the hydraulic systems operate at extremely high and dangerous pressures.

Which maintenance actions are prohibited or required for safe work?

Do not use your hand to check for leaks; use paper or cardboard and wear gloves. Never work under an elevated boom until it is safely restrained, and shut off all power controls before adjustments, lubrication, or other maintenance.

Oct 23, 2026

Uploaded by jayni