JLG 800S, 860SJ Boom Lift Parts Manual

Name: JLG 800S, 860SJ Boom Lift Parts Manual
Brand: MidWestTech
SKU: 3121140
Price: 69.83 USD
Availability: InStock

448 pages · Publication 3121140

$69.83

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Models: 800S, 860SJ
Serial coverage: Prior to 0300140000
Manual type: Parts Manual
Pages: 448
Publication: 3121140
Condition: Brand new

JLG 800S, 860SJ Boom Lift Parts Manual, publication 3121140

What's inside

From the manual's own table of contents: 49 sections, 96 entries. See sample pages (PDF, 560 KB)

Search the contents

General47 topics

SECTION 1 - FRAME
FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE
FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE
FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS
FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (4WD) (Prior to SN 0300083331)
FIGURE 1-7. DRIVE MOTOR ASSEMBLY (2WD) (Prior to SN 0300083331)
FIGURE 1-9. DRIVE MOTOR ASSEMBLY (5 BOLT ASSEMBLY)
FIGURE 1-10. FRAME VALVES AND SHIELDS INSTALLATIONS (Prior to SN 0300083331)
FIGURE 1-11. FRAME VALVES AND SHIELDS INSTALLATIONS (SN 0300083331 through 0300140000)
FIGURE 1-12. TOW PACKAGE INSTALLATION
SECTION 2 - TURNTABLE
FIGURE 2-1. CONTROL VALVES INSTALLATIONS
FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY
FIGURE 2-3. TURNTABLE BEARING AND SWING DRIVE INSTALLATION
FIGURE 2-4. SWING HUB ASSEMBLY (Prior to SN 0300066417)
FIGURE 2-5. SWING MOTOR ASSEMBLY (Prior to SN 0300066417)
FIGURE 2-8. CATERPILLAR ENGINE INSTALLATION (Prior to SN 0300139398)
FIGURE 2-9. CATERPILLAR ENGINE INSTALLATION (SN 0300139398 through 0300140000)
FIGURE 2-10. DEUTZ ENGINE INSTALLATION (Prior to SN 0300077586)
FIGURE 2-12. FORD ENGINE INSTALLATION (Prior to SN 0300079612)
FIGURE 2-14. DUAL FUEL INSTALLATIONS
FIGURE 2-15. GM ENGINE INSTALLATION (Prior to SN 0300139210)
FIGURE 2-17. PISTON PUMP ASSEMBLY
FIGURE 2-18. LOAD SENSING PUMP ASSEMBLY
FIGURE 2-19. TANK INSTALLATIONS
FIGURE 2-20. ROTARY COUPLING INSTALLATION (Prior to SN 0300083331)
FIGURE 2-22. GROUND CONTROL BOX ASSEMBLY (WITHOUT UGM)
FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY (WITH UGM)
FIGURE 2-24. LIMIT SWITCHES, LIGHTS AND ALARM INSTALLATIONS
FIGURE 2-25. HOODS INSTALLATION (Prior to SN 0300089982)
FIGURE 2-27. ENGINE TRAY JACK INSTALLATION (OPTIONAL)
FIGURE 2-28. 2500W GENERATOR INSTALLATION - CATERPILLAR MACHINES (OPTIONAL)
FIGURE 2-29. 2500W GENERATOR INSTALLATION - DEUTZ MACHINES (OPTIONAL)
FIGURE 2-30. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL) (Prior to SN 0300079612)
FIGURE 2-32. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)
FIGURE 2-33. 7500W SKYPOWER GENERATOR INSTALLATION - CATERPILLAR AND DEUTZ ENGINES
FIGURE 2-34. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES
FIGURE 2-35. 7500W SKYPOWER GENERATOR INSTALLATION - GM ENGINES
SECTION 3 - BOOM
FIGURE 3-1. TOWER BOOM, UPRIGHT AND CYLINDERS INSTALLATION
FIGURE 3-2. MAIN BOOM INSTALLATION - 800S
FIGURE 3-3. MAIN BOOM INSTALLATION - 860SJ
FIGURE 3-4. MAIN BOOM ASSEMBLY
FIGURE 3-5. ROTATOR ASSEMBLY
FIGURE 3-6. PLATFORM SUPPORT AND CONTROL VALVES INSTALLATIONS
FIGURE 3-7. BOOM CABLE CLAMPS INSTALLATIONS
SECTION 4 - PLATFORM

FIGURE 4-1. PLATFORM ASSEMBLIES (FRONT ENTRY PLATFORM)

FIGURE 4-3. PLATFORM COMPONENTS INSTALLATION (FALL ARREST PLATFORM)

FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY

FIGURE 4-5. CONTROLLER ASSEMBLY (LIFT AND SWING)

FIGURE 4-6. CONTROLLER ASSEMBLY (LIFT AND SWING)

FIGURE 4-7. CONTROLLER ASSEMBLY (LIFT AND SWING)

FIGURE 4-8. CONTROLLER ASSEMBLY (DRIVE AND STEER)

FIGURE 4-9. CONTROLLER ASSEMBLY (DRIVE AND STEER)

FIGURE 4-10. CONTROLLER ASSEMBLY (DRIVE AND STEER)

FIGURE 4-11. SOFT TOUCH INSTALLATION (FRONT ENTRY PLATFORM) (OPTIONAL)

FIGURE 4-12. SOFT TOUCH SYSTEM INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)

FIGURE 4-13. PLATFORM PADDING INSTALLATION (SIDE ENTRY PLATFORM) (OPTIONAL)

SECTION 5 - CYLINDER

FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 5-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE

FIGURE 5-3. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (800S) (SERVICE REPLACEMENT)

FIGURE 5-4. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (860SJ) (SERVICE REPLACEMENT)

FIGURE 5-5. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) (ORIGINAL EQUIPMENT)

FIGURE 5-6. LIFT CYLINDER ASSEMBLY - JIB (860SJ ONLY) (USAGE MAY VARY) (SERVICE REPLACEMENT)

FIGURE 5-7. LEVEL CYLINDER ASSEMBLY - JIB (860SJ ONLY) (USAGE MAY VARY) (SERVICE REPLACEMENT)

FIGURE 5-8. LIFT CYLINDER ASSEMBLY - MAIN BOOM

FIGURE 5-9. LIFT CYLINDER ASSEMBLY - MAIN BOOM (800S) (SERVICE REPLACEMENT)

FIGURE 5-10. LIFT CYLINDER ASSEMBLY - MAIN BOOM (860SJ) (SERVICE REPLACEMENT)

Show all 50 sections

FIGURE 5-11. STEER CYLINDER ASSEMBLY

FIGURE 5-12. TELESCOPE CYLINDER ASSEMBLY

FIGURE 5-13. TELESCOPE CYLINDER ASSEMBLY (800S) (SERVICE REPLACEMENT)

FIGURE 5-14. TELESCOPE CYLINDER ASSEMBLY (860SJ) (SERVICE REPLACEMENT)

SECTION 6 - HYDRAULIC

FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM

FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (Prior to SN 0300083331)

FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD (Prior to SN 0300083331)

FIGURE 6-6. MANUAL DESCENT HYDRAULIC DIAGRAM (OPTIONAL)

FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM

FIGURE 6-8. HYDRAULIC DIAGRAM LIST

SECTION 7 - ELECTRICAL

FIGURE 7-1. ELECTRICAL DIAGRAM LIST

FIGURE 7-2. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (Prior to SN 0300085332)

FIGURE 7-3. HARNESS COMPONENTS INSTALLATION (WITHOUT UGM) (SN 0300085332 through 0300140000)

FIGURE 7-4. HARNESS COMPONENTS INSTALLATION (WITH UGM)

SECTION 8 - DECALS

FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC) (Prior to SN 0300088933)

FIGURE 8-3. DECAL INSTALLATION (COUNTRY SPEC) (Prior to SN 0300088933)

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 9-1. MODEL 800S/860SJ STANDARD PARTS

FIGURE 9-2. MODEL 800S/860SJ VARIABLE PARTS

SECTION 10 - SPECIAL OPTIONS

FIGURE 10-1. SPECIAL OPTIONS

FIGURE 10-2. SKY WELDER INSTALLATION

PART NUMBER INDEX

Inside this manual

Real pages from this parts manual (448 pages). Open the sample pages (PDF, 560 KB)

Sample pages from the JLG 800S, 860SJ Boom Lift Parts Manual: Parts illustration, Parts illustration, Parts illustration

Parts illustration, page 20: SECTION 1 - FRAME
Parts illustration, page 368: SECTION 7 - ELECTRICAL
Parts illustration, page 428: SECTION 10 - SPECIAL OPTIONS

Other manuals for this machine

Save 10% on 2 manuals, 15% on 3 or more. Other manuals for the 800S, 860SJ are listed below. Editions cover different serial number ranges: check the serial coverage and tick only the ones that match your machine.

This manual: Parts Manual 3121140$69.83

Service manuals

Service Manual 3121139 · 516 pagesCovers 800S, 860SJSerial: Prior to 0300182743, Prior to B300001328$69.51Details

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Service Manual 31215049 · 560 pagesCovers 800S, 860SJ$69.81Details

Service Manual 31217197 · 560 pagesCovers 800S, 860SJ$69.55Details

This is a parts manual

Here's how it compares to the other manual types.

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.

This manual

Parts manual

Illustrated diagrams with factory part numbers for identifying components and ordering parts. Repair procedures are in the service manual.

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, 448 pages

Quantity one is the manual described above.

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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).