JLG 800AJ Boom Lift Service Manual
580 pages · Publication 31215046
Fast free USA shippingShips in 1 business daySave 10% on 2 manuals, 15% on 3 or morePay by credit or debit card or with PayPal. No PayPal account needed.
Added to your cart. View cart
- Models
- 800AJ
- Manual type
- Service Manual
- Pages
- 580
- Publication
- 31215046
- Condition
- Brand new
What's inside
From the manual's own table of contents: 556 sections, 648 entries. See sample pages (PDF, 577 KB)
General
Hydraulic System Safety
Maintenance5 topics
- Operating Specifications
- Capacities
- Tires
- Engine Data
- Component Data
Drive System
Swing System
Auxiliary Power Pump3 topics
- Torque Requirements
- Hydraulic Oil
- Major Component Weights
Critical Stability Weights3 topics
- Operator Maintenance
- Threadlocking Compound
- Torque Charts
SAE Fastener Torque Chart
Metric Fastener Torque Chart1 topic
- 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
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Show all 556 sections
Lubrication
Battery
Lubrication and Servicing1 topic
- Lubrication and Information
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift Test
Theory
Cylinder Leakage Test
Cylinder Thermal 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 Damage
Tire Replacement
Wheel Replacement
Wheel Installation10 topics
- Lockout Cylinder Bleeding
- Oscillating Axle Lockout Test
- Chassis Tilt Indicator System
- Drive Orientation System
- Transport Position Sensing System
- Beyond Transport - Drive Speed Cutback System
- Drive/Steer – Boom Function Interlock System
- Oscillating Axle System
- Drive System
- Drive Hub (Torque)
Disassembly
Cleaning and Inspection
Repair
Assembly1 topic
- Drive Brake
Inspection1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Initial Start-up Procedures1 topic
- Swing Drive
Roll, Leak and Brake Testing
Tightening and Torquing Bolts
Motor Control Valve Disassembly
Motor and Brake Disassembly
Main Drive Disassembly
Hub-Shaft Disassembly
Carrier Disassembly
Hub-Shaft Assembly
Carrier Assembly
Main Drive Assembly
Motor and Brake Assembly
Motor Control Valve Assembly1 topic
- Swing Motor
Disassembly and inspection
One Piece Stator Construction1 topic
- Swing Hub Installation
Procedure For Setting Swing Gear Backlash
Swing Drive Lubrication2 topics
- Swing Hub Removal
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Replacement
Swing Bearing Torque Values4 topics
- Tilt Indicator System
- Spark Arrester Cleaning Instructions
- Rotary Coupling
- Generator
Maintenance Schedule
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings
Generator Disassembly and Assembly
Lead Connection List for Generator3 topics
- Auxiliary Power System
- Deutz Engine
- Deutz Engine - TD2.9L4
Check Oil Level
Change Engine Oil
Change Oil Filter
Change Fuel Filters
Replacing the Fuel Pre-Filter
Water in Fuel Sensing System (Optional)
Draining Water
Auxiliary Fuel Filter1 topic
- Deutz Engine - D2011Lo4
Glow Plugs
Replacing Engine Oil
Replacing the Oil Filter
Replacing the Primary Fuel Filter1 topic
- Dual Fuel System
Changing from Gasoline to LP Gas
Changing from LP Gas to Gasoline6 topics
- Deutz EMR 2
- Ford Engine
- Counterweight
- Platform Load Control System
- Machine Safety System Override (MSSO) (CE only)
- Platform
Platform Valve Removal
Platform Valve Installation
Platform Support Removal
Support Installation1 topic
- Rotator and Platform Level Cylinder
Removal
Installation1 topic
- Boom System
Platform Control Enable System
Function Speed Control System
Platform
Main Lift End Stroke Dampening System
QuikStick Lift System
Tower Boom Sequence Valve System
Upright Level System
Ground Control Keyswitch System2 topics
- Main Boom Powertrack
- 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 Bracket4 topics
- Boom Cleanliness Guidelines
- Main Boom Assembly
- Upright
- Tower Boom Assembly
Tower Out of Sync1 topic
- Upright Monitoring System (UMS)
Re-Synchronizing Upright
Calibration
Calibration Faults
Function Check
Service Mode/Tower Boom Retrieval1 topic
- Ums Troubleshooting and Diagnostic Trouble Codes (DTC)
Backward Stability Concern DTC (2532)
Forward Stability Concern DTC (2530)
Out of Usable Range DTC (2531)
UMS Sensor Not Calibrated DTC (816)
UMS Sensor Faulted DTC (817)3 topics
- Articulating Jib and Jib Lift Cylinder
- Sequence For Hose Replacement In The Tower Boom
- Limit Switches Adjustment
Main Boom Horizontal Limit Switch
Tower Boom Horizontal Limit Switch1 topic
- Boom Valve Adjustment
Tower Boom
Main Boom1 topic
- Rotator Assembly
Theory of Operation
Required Tools
Installing Counterbalance Valve
Greasing Thrust Washers
Testing the Actuator
Installation and Bleeding2 topics
- Foot Switch Adjustment
- Skyguard®
Operation
Function Test
Diagnostics & Troubleshooting1 topic
- Bolt-On External Fall Arrest
Inspection Before Use1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Hydraulic Connection Assembly and Torque Specification
Tapered Thread Types
Straight Thread Types, Tube and Hose Connections
Straight Thread Types, Port Connections
Flange Connection Types
Tightening Methods
Assembly and Torque Specifications
Assembly Instructions for American Standard Pipe Thread Tapered (NPTF) Connections
Assembly Instructions for British Standard Pipe Thread Tapered (BSPT) Connections
Assembly Instructions for 37° (JIC) Flare Fittings
Assembly Instructions for 45° SAE Flare Fittings
Assembly Instructions for O-Ring Face Seal (ORFS) Fittings
Assembly Instructions for DIN 24° Flare Bite Type Fittings (MBTL and MBTS)
Assembly Instructions for Bulkhead (BH) Fittings
Assembly Instructions for O-Ring Boss (ORB) Fittings
Assembly Instructions for Adjustable Port End Metric (MFF) Fittings
Assembly Instructions for Metric ISO 6149 (MPP) Port Assembly Stud Ends
Assembly Instructions for Adjustable Port End (BSPP) Fittings
Assembly Instructions for Flange Connections: (FL61 and FL62)
Double Wrench Method
FFWR and TFFT Methods
Adjustable Stud End Assembly
O-ring Installation (Replacement)1 topic
- Hydraulic Cylinders
Axle Lockout Cylinder
Platform Level Cylinder
Upright Level Cylinder
Jib Lift Cylinder
Main Boom Lift Cylinder
Tower Boom Lift Cylinder
Master Cylinder
Steer Cylinder
Main Boom Telescope Cylinder
Tower Boom Telescope Cylinder1 topic
- Cylinder Removal and Installation
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 Boom Lift Cylinder Installation
Tower Telescope Cylinder Removal
Tower Telescope Cylinder Installation
Master Cylinder Removal
Master Cylinder Installation2 topics
- Hydraulic Pump W/hayes Pump drive Coupling Lubrication
- Pressure Setting Procedures
Set Up the Function Pump
Adjustments Made at the Main Valve Block
Adjustments Made at the Platform Valve Block3 topics
- Hydraulic Component Start-Up Procedures and Recommendations
- Hydraulic Drive Pump Pre-fill Procedure
- Function Pump
Control Assembly
Plug and Fitting Sizes and Torques1 topic
- Drive Pump
Servo Controlled Piston Pump
Charge Pump Adapter Assembly
Manual Servo Control Basic Assembly
Manual Servo Control Assembly Options
Rotating Kit Assembly
Fault- logic Trouble Shooting
Start-up Procedure2 topics
- Upright Level System Holding Valve Checks
- JLG Control System Analyzer Kit Instructions
Introduction
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 Description3 topics
- Machine Configuration Programming Information
- Machine Personality Settings and Function Speeds
- Machine Orientation When Setting Function Speeds
Test Notes1 topic
- CANbus Communications
Analyzer Diagnostics Menu Structure1 topic
- LSS System
Diagnostic Menu
Calibration Procedure
Testing & Evaluation4 topics
- Resetting The MSSO System
- Diagnostic Trouble Codes (DTC)
- 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
AMP Mate-N-Lok
AMP Faston
AMP Micro-Fit
AMP Mini Fit Jr
Mini Fit Sr
DIN Connectors
Exceptions
Enclosures
Carling Switch Connectors1 topic
- AMP Connector
Applying Silicone Dielectric Compound to AMP Connectors
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 2011 Engine Dipstick
Engine and Hydraulic Operating Temperature Specifications - Deutz
Engine and Hydraulic Operating Temperature Specifications - Ford MSG 425
Axle Installation
Steering Installation
Chassis Component Location
Turntable Component Location
Drive Hub (Torque)
Drive Brake
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
Swashplate 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
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Drive Assembly
Swing Motor and Brake Assembly
Bearing Cone Press Tool (T144566)
Bearing Cone Pressing Tool (T145741)
Bearing Cup Pressing Tool (T149013)
Locknut Wrench Tool (T151047)
Bearing Cup Pressing Tool (T155291)
Seal Press Tool (T175741)
Swing Drive Test Plate (T187845)
Leak Test Adapter Plate (T201476)
Swing Drive Motor
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
Swing Bearing Torque Sequence
Rotary Coupling Seal Installation
Rotary Coupling Cutaway
Rotary Coupling Port Location (7 Port)
Rotary Coupling Port Location (9 Port)
Rotary Coupling Installation
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
Generator Troubleshooting Circuit Diagram (Sheet 1 of 2)
Generator Troubleshooting Circuit Diagram (Sheet 2 of 2)
Generator Electrical Circuit Diagram
Power Board PC1 Electrical Circuit Diagram
Power Board PC2 Electrical Circuit Diagram (Sheet 1 of 2)
Power Board PC2 Electrical Circuit Diagram (Sheet 2 of 2)
Auxiliary Power System
Deutz TD2.9L4 Engine Components - Sheet 1 of 2
Deutz TD2.9L4 Engine Components - Sheet 2 of 2
Deutz TD2.9L4 Engine Installation - Sheet 1 of 8
Deutz TD2.9L4 Engine Installation - Sheet 2 of 8
Deutz TD2.9L4 Engine Installation - Sheet 3 of 8
Deutz TD2.9L4 Engine Installation - Sheet 4 of 8
Deutz TD2.9L4 Engine Installation - Sheet 5 of 8
Deutz TD2.9L4 Engine Installation - Sheet 6 of 8
Deutz TD2.9L4 Engine Installation - Sheet 7 of 8
Deutz TD2.9L4 Engine Installation -Sheet 8 of 8
Deutz TD2.9L4 China III Engine Installation - Sheet 1 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 2 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 3 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 4 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 5 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 6 of 7
Deutz TD2.9L4 China III Engine Installation - Sheet 7 of 7
Deutz D2011L04 Engine Components - Sheet 1 of 2
Deutz D2011L04 Engine Components - Sheet 2 of 2
Deutz T4I (Arctic) Engine Installation - Sheet 1 of 2
Deutz T4I (Arctic) Engine Installation - Sheet 2 of 2
Deutz TD2.9L4 Dipstick Markings
Engine Oil Viscosity
Location of Fuel Pre-Filter
Components of Fuel Pre-Filter
Components of Auxiliary Fuel Filter
Deutz D2011lO4 Engine Dipstick
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
Ford Engine Installation - Sheet 1 of 5
Ford Engine Installation - Sheet 2 of 5
Ford Engine Installation - Sheet 3 of 5
Ford Engine Installation - Sheet 4 of 5
Ford Engine Installation (With Arctic Package) - Sheet 5 Of 5
Counterweight
Location of Components Platform Support
Platform Support Torque Values
Removal/Installation of Components - Rotator and Platform Slave Level Cylinder
Boom Component Location
Main Boom Powertrack Components
Powertrack Installation Main Boom (Sheet 1 of 2)
Powertrack Installation Main Boom (Sheet 2 of 2)
Powertrack Installation Tower Boom (Sheet 1 of 3)
Powertrack Installation Tower Boom (Sheet 2 of 3)
Powertrack Installation Tower Boom (Sheet 3 of 3)
Removal/Installation of Boom and Cylinder Assembly
Disassembly/Assembly of Main Boom Components
Location of Components - Upright
Disassembly/Assembly of Tower Boom Components
Location of Components - Tower Boom Powertrack
Releveling Valve
Boom Upright Positioning
UMS Sensor Location
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)
Transportation Switch Installation (CE only)
Rotator - Exploded View
Rotator- Assembly Drawing
Rotator Counterbalance Valve
Bolt-On External Fall Arrest Cable Tension
Bolt-On External Fall Arrest System
NPTF Thread
BSPT Thread
JIC Thread
SAE Thread
ORFS Thread
MTBL-MBTS Thread
Bulkhead Thread
ORB-MPP Thread
MFF-BSPP Thread
Torque Wrench Angle
FFWR Method
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
Hydrolock Piston Seal Installation
Piston Seal Kit Installation
Rod Assembly Installation
Spanner Nut Removal
Main Boom Telescopic Cylinder
Tower Boom Telescopic Cylinder
Components Main Boom and Tower Boom
Removal/Installation of Tower Telescope Cylinder
Removal/Installation of Master Cylinder
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
Platform Control Valve Pressure Adjustments
Platform Control Valve Component Torque
Articulating Jib Boom Pressure adjust
Gauge Port Locations
Shaft Seal and Retaining Ring
Plug Locations, Sizes, and Torques
Endcover Inspection
Housing Inspection
Servo Piston Installation
bearing or bushing Inspection
Manual Servo Control Basic Assembly Option
Neutral Lockout Switch Assembly
Gauge Locations
Fault- logic Troubleshooting
Hydraulic Schematic - Sheet 1 of 6
Hydraulic Schematic - Sheet 2 of 6
Hydraulic Schematic - Sheet 3 of 6
Hydraulic Schematic - Sheet 4 of 6
Hydraulic Schematic - Sheet 5 of 6
Hydraulic Schematic - Sheet 6 of 6
Hand Held Analyzer
ADE Block Diagram
Analyzer Flow Chart (Software Version P6.30) -Sheet 1 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 2 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 3 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 4 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 5 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 6 of 7
Analyzer Flow Chart (Software Version P6.30) -Sheet 7 of 7
Fault Code Light Location
Analyzer Connecting Points
Ground Control Module - Sheet 1 of 3
Ground Control Module - Sheet 2 of 3
Ground Control Module - Sheet 3 of 3
Platform Control Module - Sheet 1 of 2
Platform Control Module - Sheet 2 of 2
Voltage Measurement (DC)
Current Measurement (DC)
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
Telematics Gateway Harness - Sheet 1 of 3
Telematics Gateway Harness - Sheet 2 of 3
Telematics Gateway Harness - Sheet 3 of 3
Electrical Schematic - Sheet 1 of 17
Electrical Schematic - Sheet 2 of 17
Electrical Schematic - Sheet 3 of 17
Electrical Schematic - Sheet 4 of 17
Electrical Schematic - Sheet 5 of 17
Electrical Schematic - Sheet 6 of 17
Electrical Schematic - Sheet 7 of 17
Electrical Schematic - Sheet 8 of 17
Electrical Schematic - Sheet 9 of 17
Electrical Schematic - Sheet 10 of 17
Electrical Schematic - Sheet 11 of 17
Electrical Schematic - Sheet 12 of 17
Electrical Schematic - Sheet 13 of 17
Electrical Schematic - Sheet 14 of 17
Electrical Schematic - Sheet 15 of 17
Electrical Schematic - Sheet 16 of 17
Electrical Schematic - Sheet 17 of 17
Machine Specifications
Deutz D2011L04 Specifications
Deutz TD 2.9 Specifications
Deutz TD 2.9 L4 China III Specifications
Mobil fluid 424 Specs
Mobil DTE 10 Excel 32 Specs
Mobil EAL 224H Specs
UCon Hydrolube HP-5046
Exxon Univis HVI 26 Specs
Inspection and Maintenance
Cylinder Drift
Inspection and Preventive Maintenance Schedule
Wheel Torque Chart
Drive Mode Speeds
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)
DTC to SPN/FMI Cross Reference Chart
Engine Fault Codes
CAN to DTC Cross Reference (Ford Engine)
SkyGuard Function Table
NPTF Pipe Thread
BSPT Pipe Thread
37° Flare (JIC) Thread - Steel
37° Flare (JIC) Thread - Aluminum/Brass
45° Flare (SAE) - Steel
45° Flare (SAE) - Aluminum/Brass
O-ring Face Seal (ORFS) - Steel
O-ring Face Seal (ORFS) - Aluminum/Brass
DIN 24°Cone (MBTL & MBTS)
Bulkhead Fittings (BH) - INCH
Bulkhead Fittings (BH) - METRIC
O-ring Boss (ORB) - Table 1 of 6
O-ring Boss (ORB) - Table 2 of 6
O-ring Boss (ORB) - Table 3 of 6
O-ring Boss (ORB) - Table 4 of 6
O-ring Boss (ORB) - Table 5 of 6
O-ring Boss (ORB) - Table 6 of 6
Metric Flat Face Port (MFF) - L Series - Table 1 of 3
Metric Flat Face Port (MFF) - L Series - Table 2 of 3
Metric Flat Face Port (MFF) - L Series - Table 3 of 3
Metric Flat Face Port (MFF) - S Series - Table 1 of 3
Metric Flat Face Port (MFF) - S Series - Table 2 of 3
Metric Pipe Parallel O-Ring Boss (MPP)
British Standard Parallel Pipe Port (BSPP) - L Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - L Series - Table 3 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 1 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 2 of 3
British Standard Parallel Pipe Port (BSPP) - S Series - Table 3 of 3
Flange Code (FL61 & FL62) -Inch Fasteners
Flange Code (FL61 & FL62) - Metric Fasteners
Main Control valve Coil Resistance
Platform Control valve Specification
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 (Software Version P6.30)
800AJ Machine Configuration Programming Settings (Software Version P6.30)
Machine Personality Settings
Function Speeds
Adjustments - Personality Descriptions
Diagnostic Menu Descriptions
Accessory Weights
SkyGlazier Capacity Reductions
Pipe Rack Capacity Reductions
LSS Troubleshooting Chart
Diagnostic Trouble Code Chart
Inside this manual
Real pages from this service manual (580 pages). Open the sample pages (PDF, 575 KB)
- Troubleshooting, page 186: Figure 3-102. EMR2 Fault Codes - Sheet 1 of 5
- Specifications, page 522: SECTION 6 - JLG CONTROL SYSTEM
- Diagram, page 562: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page, page 270: SECTION 4 - BOOM & PLATFORM
- Color page, page 349: SECTION 5 - BASIC HYDRAULICS INFORMATION & SCHEMATICS
Other manuals for this machine
Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 800AJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.
This manual: Service Manual 31215046$69.89
Added to your cart. View cart
This is a service manual
Here's how it compares to the other manual types.
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, 580 pages
Quantity one is the manual described above.
Fast free USA shipping
Ships in 1 business day.
60-day returns
Free if the mistake is ours. A manual ordered in error must come back unopened in its shrink-wrap; you pay return shipping and a 20% restocking fee applies. Return policy
Binder not included
Manuals over about 300 pages may need a standard 3-ring binder, which you can buy locally to keep the pages organized for shop use.
Other editions and similar models
Questions about model, serial number, engine coverage or contents? Contact us before purchasing and we'll help confirm it's the right manual. Please verify the manual type, machine model, serial number range and engine coverage before purchasing: manuals ordered in error carry a 20% restocking fee (return policy).