JLG 800A, 800AJ Boom Lift Service Manual
494 pages · Publication 3120858
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From the manual's own table of contents: 477 sections, 550 entries. See sample pages (PDF, 615 KB)
General
Hydraulic System Safety
Maintenance1 topic
- Operating specifications
Capacities1 topic
- Component Data
Engine Data
Tires
Swing System
Hydraulic Drive Pump
Variable Displacement Pump
Hydraulic Load Sense Pump
Auxiliary Power Pump
Hydraulic Filter - In-line2 topics
- Torque Requirements
- Lubrication
Hydraulic Oil2 topics
- Cylinder Specifications
- Major Component Weights
Critical Stability Weights2 topics
- Maintenance and Lubrication
- Machine Preparation, Inspection, and Maintenance
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance1 topic
- Service and Guidelines
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Show all 477 sections
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Platform Drift
Cylinder Drift2 topics
- Pins and Composite Bearing Repair Guidelines
- Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment1 topic
- Tires & Wheels
Tire Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation1 topic
- Oscillating Axle Bleeding Procedure And Lockout Test
Lockout Cylinder Bleeding
Oscillating Axle Lockout Test1 topic
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
To Engage Drive Motors and Brakes (Normal Operation)1 topic
- Torque Hub, Drive
Disassembly
Cleaning and Inspection
Repair
Assembly
Inspection
Bleeding
Spare Parts Kits
Replacing the Drive Shaft Seal
Disassembly and Assembly
Assembly Notes
Taper Roller Bearing Initial Tension
Testing and Setup1 topic
- Drive Motor Adjustment Procedure (Prior to S/N 0300083332)
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Initial Start-up Procedures1 topic
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values1 topic
- Procedure for setting swing gear backlash
Hub Shaft Sub-Assembly
Carrier Sub-Assembly
Reassembly
Motor Timing
Main Assembly Procedure
Inspection and Cleaning
Timing Procedure2 topics
- Rotary Coupling
- Tilt Alarm Switch (Prior to S/N 0300065534)
Manual Adjustment2 topics
- Spark Arrester Cleaning Instructions
- Generator
Every 250 hours
Every 500 hours
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline1 topic
- EFI Engine
Performing Diagnostics
EFI Diagnostics (Prior to S/N 0300065534)
ECM and Sensors
Engine Performance Module (EPM)
Fuel System
Regulator
Megajector
Mixer
Lockoff Solenoid
Megajector Diagnostic Code Descriptions1 topic
- Electric Governor Installation And Adjustments - Ford LRG425 Engine (Prior to S/N 0300065534)
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Power Distribution
Check-Out and Initial Start-Up Procedures
Automatic Choke Adjustment Procedure1 topic
- Throttle Checks And Adjustments - Deutz Engine (Prior to S/N 0300065534)
Procedure
Controller Status
Failure Modes1 topic
- Platform
Support Removal
Support Installation
Platform Sections Replacement1 topic
- Rotator and Slave Cylinder
Removal3 topics
- Upper Boom Powertrack
- Boom Cleanliness Guidelines
- Powertrack Maintenance
Flat Bar Removal
Round Bar/Poly Bar Removal
Removing and Installing Links
Installing a New Flat Bar
Installing a New Round Bar/Poly Roller
Replacing a Fixed End Bracket
Replacing a Moving End Bracket
Replacing a One Piece Bracket1 topic
- Upper Boom
Installation2 topics
- Upright
- Tower Boom Assembly
Tower Out of Sync1 topic
- Upright Monitoring System
Re-Synchronizing Upright
Calibration - Pre ADE Machines
Calibration - ADE Equipped Machines
Calibration Faults
Function Check
Service Mode/Tower Boom Retrieval1 topic
- UMS Troubleshooting and Fault Messages - Non-ADE Machines
Tower Lift Down Permanently Closed
Backward Stability Concern Message
Forward Stability Concern Message
UMS Out of Usable Range Message
Battery Voltage < 9.0 Volts
Battery Voltage > 16.0 Volts
UMS Sensor Not Calibrated Message
UMS Sensor Faulted
Tower Lift Down Output Short to Ground or Open Circuit
Tower Lift Down Output Short to Battery
Platform Indicator Output Short to Ground or Open Circuit
Platform Indicator Output Short to Battery
Ground Indicator Output Short to Ground
Ground Indicator Output Short to Battery
Turntable Sensor Not Calibrated Message
Turntable Sensor Faulted
EEPROM checksums failure1 topic
- UMS Troubleshooting and Fault Messages - ADE Machines
Auto Detection Input Low Message
UMS Sensor Communications lost
Out of Usable Range Message
UMS Sensor Faulted Message
Incompatible Software Detected Message3 topics
- Articulating Jib
- Sequence For Hose Replacement In The Tower Boom
- Limit Switches Adjustment
Upper Boom Horizontal Limit Switch
Tower Boom Horizontal Limit Switch
Dual Capacity Angle Limit Switch (800A only)
Upper Boom Length Switch (800 A only)2 topics
- Boom Valve Adjustment
- Wear Pads
Tower Boom
Upper Boom
Theory of Operation
Required Tools
Installing Counterbalance Valve
Testing the Actuator
Installation and Bleeding1 topic
- Drive Card Setup Procedures
Lift, Swing, and Drive Cards
Flow Control Card1 topic
- Load Sensing System machines built to S/N 0300062045
Functional Check
Calibration2 topics
- Foot Switch Adjustment
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Valves - Theory Of Operation
Solenoid Control Valve - Rexroth
Relief Valves2 topics
- Holding Valve Checks
- Cylinders - Theory Of Operation
Systems Incorporating Double Acting Cylinders
Systems Incorporating Holding Valves1 topic
- Cylinder Checking Procedure
Cylinders Without Counterbalance Valves - Master Cylinder and Steer Cylinders
Cylinders With Single Counterbalance Valve
Cylinders With Dual Counterbalance Valves1 topic
- Cylinder Repair
Axle Lockout Cylinder
Upright Level Cylinder
Jib Lift Cylinder
Main Boom Lift Cylinder
Tower Lift Cylinder
Master Cylinder - 800A
Master Cylinder - 800 AJ
Slave Cylinder
Steer Cylinder
Main Telescope Cylinder
Tower Telescope Cylinder1 topic
- Cylinder Removal And Installation
Main Boom Telescope Cylinder Removal
Main Boom Telescope Cylinder Installation
Main Lift Cylinder Removal
Main Lift Cylinder Installation
Upright Level Cylinder Removal
Upright Level Cylinder Installation
Tower Boom Lift Cylinder Removal
Tower Lift Cylinder Installation
Tower Telescope Cylinder Removal
Tower Telescope Cylinder Installation
Slave Cylinder Removal
Slave Cylinder Installation2 topics
- Hydraulic Pump W/hayes Pump drive Coupling Lubrication
- Pressure Setting Procedures
FIRST: Set Up the Function Pump
SECOND: Adjustments Made at the Main Valve Block3 topics
- Hydraulic oil change-out procedure
- Hydraulic Component Start-Up Procedures and Recommendations
- Rexroth Variable Displacement Pump (Prior to S/N 0300121643)
Control Assembly
Plug and Fitting Sizes and Torques9 topics
- Introduction
- CANbus Communications
- To Connect the JLG Control System Analyzer
- Using the Analyzer
- Changing the Access Level of the Hand Held Analyzer
- Adjusting Parameters Using the Hand Held Analyzer
- Machine Setup
- Level Vehicle Description
- Machine Personality Settings
Function Speeds
Machine Orientation When Doing Speed Tests
Test Notes
Analyzer Diagnostics Menu Structure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AMP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions
Brad Harrison / Phoenix Contact M12
AMP Junior Timer1 topic
- AMP Connector
Wedge Lock
Service - Voltage Reading1 topic
- Deutsch Connectors
DT/DTP Series Assembly
DT/DTP Series Disassembly
HD30/HDP20 Series Assembly
HD30/HDP20 Series Disassembly
Maintenance and Lubrication Diagram
Deutz Engine Dipstick
Torque Chart - Sheet 1 of 5 (SAE Fasteners)
Torque Chart - Sheet 2 of 5 (SAE Fasteners)
Torque Chart - Sheet 3 of 5 (SAE Fasteners)
Torque Chart - Sheet 4 of 5 (Metric fasteners)
Torque Chart - Sheet 5 of 5 (METRIC Fasteners)
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Caterpillar
Oscillating Valve Adjustment
Brake Valve Wiring Connection
Torque Hub Drive (Fairfield)
Drive Motor Cutaway
Flow Control Pilot Valves
Drive Motor Adjustment (Prior to S/N 0300083332)
Drive Motor Cross Section
Removing the Shaft Seal
Loop Flushing Spool
Plugs, Fittings, and Speed Sensor
End Cap
Valve Plate & Rear Shaft Bearing
Cylinder Kit
Shaft Seal
Shaft & Front Bearing
Swash Plate & Servo Piston
Cylinder Kit Disassembly
Servo Piston
Cylinder Kit Assembly
Swash Plate and Journal Bearing
Shaft and Front Bearing
Cylinder Kit Installation
Servo Spring and Minimum Angle Stop
Valve Plate and Rear Bearing
Plugs and Fittings Installation
Swing Bearing Tolerance Boom Placement (Sheet 1 of 2)
Swing Bearing Tolerance Boom Placement (Sheet 2 of 2)
Swing Bolt Feeler Gauge Check
Swing Bearing Tolerance Measuring Point
Swing Bearing Removal (800A)
Swing Bearing Removal (800AJ)
Swing Bearing Torque Sequence
Swing Hub
Swing Brake Assembly (Ausco) (Prior to S/N 0300064566)
End Cap Removal
Rotary Coupling Seal Installation
Rotary Coupling Cutaway
Rotary Coupling Port Location (7 Port)
Rotary Coupling Port Location (9 Port)
Rotary Coupling Installation
Tilt Switch Adjustment
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Malfunction Indicator and Test Button
EFI Component Location
Typical Fuel System
Addco Adjustments - Deutz
EMR 2 Engine Side Equipment
Deutz EMR 2 Troubleshooting Flow Chart
Deutz EMR 2 Vehicle Side Connection Diagram
Deutz EMR 2 Engine Side Connection Diagram - Sheet 1 of 2
Deutz EMR 2 Engine Side Connection Diagram - Sheet 2 of 2
EMR 2 Engine Plug Pin Identification
EMR 2 Vehicle Plug Pin Identification
EMR2 Fault Codes - Sheet 1 of 5
EMR2 Fault Codes - Sheet 2 of 5
EMR2 Fault Codes - Sheet 3 of 5
EMR2 Fault Codes - Sheet 4 of 5
EMR2 Fault Codes - Sheet 5 of 5
Location of Components Platform Support
Platform Section Replacement
Platform Support Torque Values
Reassembly of Components-Rotator and Leveling Cylinder
Boom Powertrack Components
Powertrack Installation Upper Boom (Sheet 1 of 2)
Powertrack Installation Upper Boom (Sheet 2 of 2)
Tower Powertrack Installation Upper Boom (Sheet 1 of 2)
Tower Powertrack Installation Upper Boom (Sheet 2 of 2)
Location of Components - Upright
Location of Components - Tower Boom Powertrack
Releveling Valve
Boom Upright Positioning
UMS Sensor Location
UMS Module Location
UMS Module Pin Identification
Location of Components-Articulating Jib
Boom Valve and Limit Switches Location (Sheet 1 of 3)
Boom Valve and Limit Switches Location (Sheet 2 of 3)
Boom Valve and Limit Switches Location (Sheet 3 of 3)
Dual Capacity Switches Installation (800 Only if equipped)
Transportation Switch Installation (CE Only)
Location And Thickness Of Wear Pads
Actuator Timing
Rotator Assembly (Prior to S/N 0300067538)
Rotator Counterbalance Valve
Control Card
Display Unit
Calibration Potentiometers
Load Sensing Transducer
Cylinder Barrel Support
Capscrew Removal
Cylinder Rod Support
Tapered Bushing Removal
Composite Bearing Installation
Rod Seal Installation
Cylinder Head Seal Installation
Wiper Seal Installation
Installation Of Head Seal Kit
Tapered Bushing Installation
Seating the Tapered Bearing
Piston Seal Kit Installation
Rod Assembly Installation
Hydrolock Piston Seal Installation
Jib Lift Cylinder (800AJ Only)
Master Cylinder - 800AJ
Steer Cylinder (Prior to S/N 0300142664)
Piston Seal Kit Installation (Prior to S/N 0300142664)
Components Upper Boom and Tower Boom
Load Sensing Control Adjustment
Pressure Compensation Control Adjustment
Main Control Valve Pressure Adjustments
Main Valve Components - Sheet 1 of 2
Main Valve Components - Sheet 2 of 2
Valve Component Torque - Sheet 1 of 2
Valve Component Torque - Sheet 2 of 2
Articulating Jib Boom Pressure adjust
Variable Displacement Pump (Rexroth)
Gauge Port Locations
Shaft Seal and Retaining Ring
Plug Locations, Sizes, and Torques
Hydraulic Schematic 2 Wheel Drive (Prior to S/N 0300083332)
Hydraulic Schematic 4 Wheel Drive - (Prior to S/N 0300083332) - Sheet 1 of 2
Hydraulic Schematic 4 Wheel Drive (Prior to S/N 0300083332) - Sheet 2 of 2
Hydraulic Schematic (Prior to S/N 0300083332) - Sheet 1 of 2
Hydraulic Schematic (Prior to S/N 0300083332) - Sheet 2 of 2
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Prior to Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 1 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 2 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 3 of 4
Analyzer Flow Chart, Version 5.X Software - Sheet 4 of 4
Analyzer Flow Chart, Version 6.X Software - Sheet 1 of 5
Analyzer Flow Chart, Version 6.X Software - Sheet 2 of 5
Analyzer Flow Chart, Version 6.X Software - Sheet 3 of 5
Analyzer Flow Chart, Version 6.X Software - Sheet 4 of 5
Analyzer Flow Chart, Version 6.X Software - Sheet 5 of 5
Control Module Location
Analyzer Connecting Points
Voltage Measurement (DC)
Current Measurement (DC)
Application to Female Contacts
Use of Seal Plugs
Connector Assembly Figure 1
AMP Connector
Connector Assembly Figure 2
Connector Assembly Figure 3
Connector Assembly Figure 4
Connector Disassembly
Connector Installation
DT/DTP Contact Installation
DT/DTP Contact Removal
HD/HDP Contact Installation
HD/HDP Locking Contacts Into Position
HD/HDP Contact Removal
HD/HDP Unlocking Contacts
Electrical Components Installation (Prior to S/N 0300064432) - Sheet 1 of 2
Electrical Components Installation (Prior to S/N 0300064432) - Sheet 2 of 2
Electrical Schematic - Deutz Engine (Prior to S/N 0300065634) - Sheet 1 of 2
Electrical Schematic - Deutz Engine (Prior to S/N 0300065634) - Sheet 2 of 2
Electrical Schematic Isuzu Engine (Sheet 1 of 2)
Electrical Schematic Isuzu Engine (Sheet 2 of 2)
Electrical Schematic - UL - Sheet 1 of 2
Electrical Schematic - UL - Sheet 2 of 2
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 1 of 6
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 2 of 6
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 3 of 6
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 4 of 6
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 5 of 6
Electrical Schematic - Caterpillar, Deutz, & GM - with UGM - Sheet 6 of 6
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 1 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 2 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 3 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 4 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 5 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 6 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 7 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 8 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 9 of 10
Electrical Schematic - Caterpillar, Deutz - without UGM - Sheet 10 of 10
Operating Specifications
Deutz F4M2011F Specifications
Deutz D2011L04 Specifications
Caterpillar 3044C/3.4
Isuzu 4JB1
Tire Specifications
Drive System Specifications
Swing System Specifications
Hydraulic Drive Pump Specifications
Variable Displacement Pump Specifications
Hydraulic Load Sense Pump Specifications
Auxiliary Power Pump Specifications
Hydraulic FIlter Specifications
Torque Requirements
Mobilfluid 424 Specs
Mobil DTE 13M Specs
Mobil EAL 224H Specs
UCon Hydrolube HP-5046
Exxon Univis HVI 26 Specs
Cylinder Specifications - 800A
Cylinder Specifications - 800AJ
Major Component Weights - 800A
Major Component Weights - 800AJ
Critical Stability Weights - 800A
Critical Stability Weights - 800AJ
Inspection and Maintenance
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Excessive Noise and/or Vibration
System Operating Hot
Won’t Shift or Slow to Start
Displacement Identifiers
Slipper Foot Thickness & End Play
Cylinder Block Measurements
Coupling Port Information Table (7 port)
Coupling Port Information Table (9 port)
ECM Diagnostic Trouble Codes
Diagnostics Fault Codes
Position Controller Truth Table
Ramp Current Setting Range
Ramp time Setting
Symbols Used
Gauge and Port Information
Excessive Noise and/ or Vibration
Actuator Response Is Sluggish
Low Pump Output Flow
Pressure or Flow Instability
System Pressure Not Reaching Pressure Compensator Setting
High Inlet Vacuum
Analyzer Abbreviations
Machine Configuration Programming Information Prior to Software Version P5.3
Machine Configuration Programming Information Software Version P5.3 to P6.1
800A Machine Configuration Programming Settings
800AJ Machine Configuration Programming Settings
Machine Configuration Parameters
Personality Ranges/Defaults
Help Fault Codes, Displayed Faults, and Descriptions - (Prior to S/N 0300066931)
Help Fault Codes, Displayed Faults, and Descriptions - (S/N 0300066931 to S/N 0300183033)
Analyzer Fault Code Listing
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions
Inside this manual
Real pages from this service manual (494 pages). Open the sample pages (PDF, 613 KB)
- Specifications, page 22: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 176: Figure 3-67. EMR2 Fault Codes - Sheet 1 of 5
- Diagram, page 470: SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 195: SECTION 4 - BOOM & PLATFORM
- Color page, page 452: SECTION 7 - ELECTRICAL INFORMATION & SCHEMATICS
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This is a service manual
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This manual
Service manual
Factory repair procedures and technical information such as specifications, troubleshooting, and wiring and hydraulic diagrams, for the models and systems the manual covers. See What's inside for its topics.
Operator's manual
Safe operation, controls, maintenance schedules, lubrication points, inspections, and basic checks. Repair procedures are in the service manual.
Parts manual
Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.
Engine service manuals are sometimes sold separately, since certain machine models were offered with more than one engine option.
What it's used for
Factory manual for in-house farm and construction shop use. Straightforward, complete, and easy to follow. It contains the OEM information dealership service departments and parts counters use to diagnose problems, identify components, and perform maintenance or repairs correctly.
Service shops and owner/operators who repair their own equipment
Identifying correct parts and seeing how assemblies come apart and go back together
Keeping equipment running with less downtime
Factory manual, 494 pages
Quantity one is the manual described above.
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