JLG 800S, 860SJ Boom Lift Parts Manual

Name: JLG 800S, 860SJ Boom Lift Parts Manual
Brand: MidWestTech
SKU: 31215050_Rev_B
Price: 99.63 USD
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926 pages · Publication 31215050_Rev_B

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Models: 800S, 860SJ
Manual type: Parts Manual
Pages: 926
Publication: 31215050_Rev_B
Condition: Brand new

JLG 800S, 860SJ Boom Lift Parts Manual, publication 31215050_Rev_B

What's inside

From the manual's own table of contents: 164 sections, 332 entries. See sample pages (PDF, 678 KB)

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General54 topics

SECTION 1 - FRAME
FIGURE 1-1. AXLE INSTALLATION - FIXED (WITHOUT TOW PACKAGE)
BUILT MACHINES)
FIGURE 1-3. AXLE INSTALLATION - OSCILLATING (WITHOUT TOW PACKAGE) (CHINA BUILT MACHINES)
FIGURE 1-4. AXLE INSTALLATION - OSCILLATING (WITH TOW PACKAGE) (USA BUILT MACHINES)
FIGURE 1-5. AXLE INSTALLATION - OSCILLATING (WITH TOW PACKAGE) (CHINA BUILT MACHINES)
MACHINES)
FIGURE 1-7. STEERING INSTALLATION - WITHOUT TOW PACKAGE (CHINA BUILT MACHINES)
FIGURE 1-8. STEERING INSTALLATION - WITH TOW PACKAGE (USA BUILT MACHINES)
FIGURE 1-9. STEERING INSTALLATION - WITH TOW PACKAGE (CHINA BUILT MACHINES)
FIGURE 1-10. WHEEL DRIVE AND FRAME VALVES INSTALLATION - 2WD
FIGURE 1-11. WHEEL DRIVE AND FRAME VALVES INSTALLATION – 4WD
FIGURE 1-12. HUB ASSEMBELY - 2WD FRONT
FIGURE 1-13. DRIVE HUB/BRAKE ASSEMBLY
FIGURE 1-14. DRIVE MOTOR ASSEMBLY - 2WD
FIGURE 1-15. DRIVE MOTOR ASSEMBLY - 4WD
FIGURE 1-16. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED
FIGURE 1-17. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED TIRE
FIGURE 1-18. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE
FIGURE 1-19. LP TANK BRACKETS INSTALLATIONS
FIGURE 1-20. FRAME SHIELDS INSTALLATION - 2WS
FIGURE 1-21. TOW PACKAGE INSTALLATION (ENGLISH DECALS)
FIGURE 1-22. TOW PACKAGE INSTALLATION (FRENCH/ENGLISH DECALS)
FIGURE 1-23. TOW BAR ASSEMBLY
SECTION 2 - TURNTABLE
FIGURE 2-1. CONTROL VALVES INSTALLATION - 800S
FIGURE 2-2. CONTROL VALVES INSTALLATION - 860SJ
FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY
FIGURE 2-4. SWING DRIVE INSTALLATION
FIGURE 2-5. SWING MOTOR/HUB ASSEMBLY
FIGURE 2-6. TURNTABLE BEARING INSTALLATION
FIGURE 2-7. REMOTE BEARING LUBE INSTALLATION
FIGURE 2-8. TURNTABLE LOCK INSTALLATION
FIGURE 2-9. ROTARY COUPLING INSTALLATION
FIGURE 2-10. TANK INSTALLATION - GAS ENGINES
FIGURE 2-11. TANK INSTALLATION - DIESEL ENGINES
FIGURE 2-12. TANK INSTALLATION - DIESEL ENGINES (MACHINES WITH HOSTILE ENVIRONMENT PACKAGE)
FIGURE 2-13. HYDRAULIC TANK ASSEMBLY
FIGURE 2-14. AUXILIARY PUMP WITH BATTERY WITHOUT BATTERY DISCONNECT SWITCH INSTALLATION
FIGURE 2-15. AUXILIARY PUMP WITH BATTERY WITH BATTERY DISCONNECT SWITCH INSTALLATION
SPECS)
FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY - 800S WITH DEUTZ D2011 (CE SPECS)
FIGURE 2-19. GROUND CONTROL BOX ASSEMBLY - 860SJ WITH DEUTZ D2011 (CE SPECS)
JAPANESE SPECS)
FIGURE 2-21. GROUND CONTROL BOX ASSEMBLY - 800S WITH DEUTZ TD2.9L4 (STAGE V) (CE SPECS)
JAPANESE AND CHINA SPECS)
FIGURE 2-23. GROUND CONTROL BOX ASSEMBLY - 860SJ WITH DEUTZ TD2.9L4 (STAGE V) (CE SPECS)
EXPORT (HRC) AND CSA SPECS)
EXPORT (HRC), AUSTRALIAN AND CSA SPECS)
FIGURE 2-26. LIGHT PANEL INSTALLATION (USA BUILT MACHINES AND ROMANIA BUILT MACHINES)
FIGURE 2-27. LIGHT PANEL INSTALLATION (CHINA BUILT MACHINES)
FIGURE 2-28. ALARM INSTALLATION
FIGURE 2-29. WHITE NOISE ALARM INSTALLATION
FIGURE 2-30. STROBE LIGHT INSTALLATION (AMBER)

FIGURE 2-31. STROBE LIGHT INSTALLATION (BLUE)

FIGURE 2-32. STROBE LIGHT INSTALLATION (RED)

FIGURE 2-33. DUAL CAPACITY INSTALLATION - ELEVATION AND TRANSPORTATION (800S)

FIGURE 2-34. DUAL CAPACITY INSTALLATION - ELEVATION AND TRANSPORTATION (860SJ)

FIGURE 2-35. LOWER SENSOR ASSEMBLY

FIGURE 2-36. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ D2011 ENGINES)

D2011 ENGINES) (USA BUILT MACHINES)

ENGINES) (CHINA BUILT MACHINES)

FIGURE 2-39. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 ENGINES) (USA BUILT MACHINES)

MACHINES)

ENGINES)

FIGURE 2-44. EXHAUST STACK INSTALLATION - STEEL HOOD (FORD DF 2.5L ENGINES)

FIGURE 2-45. HOODS INSTALLATION - ABS (DEUTZ D2011 ENGINES)

ONLY)

FIGURE 2-47. HOODS INSTALLATION - STEEL (DEUTZ D2011 ENGINES)

BUILT MACHINES)

(CHINA BUILT MACHINES)

MACHINE)

FIGURE 2-51. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 ENGINES) (CHINA BUILT MACHINE)

FIGURE 2-52. HOODS INSTALLATION - STEEL (DEUTZ TD2.9L4 (STAGE V) ENGINES) (CHINA BUILT MACHINE)

FIGURE 2-54. HOODS INSTALLATION – STEEL (FORD DF 2.5L ENGINES)

FIGURE 2-55. HOOD ASSEMBLY - ENGINE SIDE REAR (DEUTZ TD2.9L4 ENGINES) (CHINA BUILT MACHINES)

FIGURE 2-58. LIFTING PLATE INSTALLATION

Show all 165 sections

FIGURE 2-59. SKYAIR AIR COMPRESSOR INSTALLATION (DEUTZ D2011 AND FORD DF 2.5L ENGINES)

FIGURE 2-60. SKYAIR AIR COMPRESSOR INSTALLATION (DEUTZ TD2.9L4 ENGINES)

FIGURE 2-61. AIR COMPRESSOR ASSEMBLY

SECTION 3 - ENGINE

FIGURE 3-1. DEUTZ D2011 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-2. DEUTZ D2011 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)

FIGURE 3-3. DEUTZ D2011 ENGINE INSTALLATION (HIGH TEMP MARKETS)

FIGURE 3-4. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-5. DEUTZ D2011 ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-6. DEUTZ D2011 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-7. DEUTZ D2011 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-8. DEUTZ D2011 ENGINE COMPONENTS

FIGURE 3-9. DEUTZ TD2.9L4 ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)

FIGURE 3-10. DEUTZ TD2.9L4 ENGINE INSTALLATION (WITH ARCTIC PACKAGE)

FIGURE 3-11. DEUTZ TD2.9L4 (STAGE V) ENGINE INSTALLATION

FIGURE 3-12. DEUTZ TD2.9L4 ENGINE INSTALLATION (CHINA III ENGINES)

FIGURE 3-13. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-14. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-15. DEUTZ TD2.9L4 (STAGE V) ENGINE AND PUMP SUB-ASSEMBLY

FIGURE 3-16. DEUTZ TD2.9L4 ENGINE AND PUMP SUB-ASSEMBLY (CHINA III SPECS)

FIGURE 3-17. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 3-18. DEUTZ TD2.9L4 ENGINE ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 3-19. DEUTZ TD2.9L4 ENGINE ASSEMBLY (STAGE V)

FIGURE 3-20. DEUTZ TD2.9L4 ENGINE ASSEMBLY (CHINA III SPECS)

FIGURE 3-21. DEUTZ TD2.9L4 ENGINE COMPONENTS53 topics

FIGURE 3-22. DEUTZ TD2.9L4 ENGINE COMPONENTS (CHINA III SPECS)
FIGURE 3-23. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES)
FIGURE 3-24. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 (STAGE V) ENGINES)
FIGURE 3-25. FUEL PUMP/FILTER BRACKET ASSEMBLY (DEUTZ TD2.9L4 ENGINES) (CHINA III SPECS)
FIGURE 3-26. BREATHER HEATER INST (DEUTZ TD2.9L4 ENGINES)
FIGURE 3-27. FORD ENGINE INSTALLATION (WITHOUT ARCTIC PACKAGE)
FIGURE 3-28. FORD ENGINE AND PUMP SUB-ASSEMBLY (WITHOUT ARCTIC PACKAGE)
FIGURE 3-29. FORD ENGINE ASSEMBLY (WITHOUT ARCTIC PACKAGE)
FIGURE 3-30. FORD ENGINE PREP ASSEMBLY
FIGURE 3-31. FORD ENGINE BRACKETS AND EXHAUST MANIFOLD INSTALLATION
FIGURE 3-32. FORD ENGINE DRIVE BELT INSTALLATION (MACHINES WITHOUT GENERATOR)
FIGURE 3-33. FORD ENGINE COMPONENTS
FIGURE 3-34. PUMP COUPING KIT (DEUTZ ENGINES)
FIGURE 3-35. HYDROSTATIC PUMP ASSEMBLY
FIGURE 3-36. VARIABLE PUMP ASSEMBLY
FIGURE 3-37. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 ENGINES
FIGURE 3-38. EXHAUST PIPE INSTALLATION - DEUTZ TD2.9L4 (STAGE V) ENGINES
FIGURE 3-39. EXHAUST PIPE INSTALLATION - FORD DF 2.5L ENGINES
FIGURE 3-40. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES (PVC 2001)
FIGURE 3-41. SPARK ARRESTOR MUFFLER INSTALLATION - DEUTZ D2011 ENGINES (PVC 2007)
FIGURE 3-42. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ D2011
FIGURE 3-43. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2.9L4 (PCV 2001)
FIGURE 3-44. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2.9L4 (PCV 2007)
FIGURE 3-45. FUEL FILTER ASSEMBLY (DEUTZ TD2.9L4 ENGINES)
FIGURE 3-47. RIGHT ENGINE SUPPORT INSTALLATION (DEUTZ D2011 ENGINES MACHINES WITH GENERATORS)
ABS HOODS
STEEL HOODS
FIGURE 3-50. ENGINE TRAY JACK INSTALLATION - DEUTZ ENGINES
FIGURE 3-51. ENGINE TRAY JACK INSTALLATION - FORD ENGINES
FIGURE 3-52. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
FIGURE 3-53. 2500W/110V/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES
FIGURE 3-54. 2500W/110V/60HZ GENERATOR INSTALLATION - FORD ENGINES
FIGURE 3-55. 2500W/220V/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
FIGURE 3-56. 4000W/50HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
FIGURE 3-57. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
FIGURE 3-59. 4000W/60HZ GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES
FIGURE 3-60. 7500W/50HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
FIGURE 3-61. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - DEUTZ D2011 ENGINES
ENGINES
FIGURE 3-64. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION - FORD DF 2.5L ENGINES (PVC 2001)
FIGURE 3-65. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – FORD DF 2.5L ENGINES (PVC 2007)
SECTION 4 - BOOM
FIGURE 4-1. BOOMS AND CYLINDERS INSTALLATION - 800S
FIGURE 4-3. BOOMS AND CYLINDERS INSTALLATION - 860SJ (CHINA BUILT MACHINES)
FIGURE 4-4. MAIN BOOM ASSEMBLY - 800S
FIGURE 4-5. MAIN BOOM ASSEMBLY - 860SJ
FIGURE 4-6. JIB ASSEMBLY (USA BUILT MACHINES AND ROMANIA BUILT MACHINES)
FIGURE 4-7. JIB ASSEMBLY (CHINA BUILT MACHINES)
FIGURE 4-8. ROTATOR ASSEMBLY - 800S
FIGURE 4-9. ROTATOR ASSEMBLY - 860SJ
FIGURE 4-10. PLATFORM SUPPORT INSTALLATION
FIGURE 4-11. POWER TRACK INSTALLATION - MAIN BOOM - 800S
FIGURE 4-12. POWER TRACK INSTALLATION - MAIN BOOM - 860SJ

FIGURE 4-14. CONTROL VALVE INSTALLATION - 800S

FIGURE 4-15. CONTROL VALVE INSTALLATION - 860SJ

FIGURE 4-16. PLATFORM VALVE ASSEMBLY - 800S

FIGURE 4-17. PLATFORM VALVE ASSEMBLY - 860SJ

FIGURE 4-18. LEVEL SENSOR SWITCH INSTALLATION

SECTION 5 - PLATFORM

FIGURE 5-1. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 3FT (76CM X 1M)

FIGURE 5-2. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 4FT (76CM X 1.22M)

FIGURE 5-3. PLATFORM ASSEMBLY WITH DROP-BAR - 30IN X 5FT (76CM X 1.52M)

FIGURE 5-4. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-5. PLATFORM ASSEMBLY WITH DROP BAR - 36IN X 6FT (91.5CM X 1.83M) (SHIPYARD MACHINES)

PLATFORM BUMPERS REQIRED)

FIGURE 5-7. PLATFORM ASSEMBLY WITH DROP-BAR - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-8. PLATFORM ASSEMBLY WITH GATE - 30IN X 4FT (76CM X 1.22M)

FIGURE 5-9. PLATFORM ASSEMBLY WITH GATE - 30IN X 5FT (76CM X 1.52M) (USA BUILT MACHINES

FIGURE 5-10. PLATFORM ASSEMBLY WITH GATE- 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-11. PLATFORM ASSEMBLY WITH GATE - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-12. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-13. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)

FIGURE 5-14. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-15. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)

FIGURE 5-16. PLATFORM ASSEMBLY WITH FALL ARREST (6FT)

FIGURE 5-17. PLATFORM ASSEMBLY WITH FALL ARREST (8FT)

FIGURE 5-18. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION

FIGURE 5-19. PLATFORM CONSOLE ASSEMBLY

FIGURE 5-20. FOOTSWITCH ASSEMBLY

FIGURE 5-21. CONTROLLER ASSEMBLY - LIFT/SWING

FIGURE 5-22. CONTROLLER ASSEMBLY- DRIVE/STEER

FIGURE 5-23. LIGHT PANEL INSTALLATION (USA BUILT MACHINES AND ROMANIA BUILT MACHINES)

FIGURE 5-24. LIGHT PANEL INSTALLATION (CHINA BUILT MACHINES)

FIGURE 5-25. JIB SWITCH INSTALLATION - 860SJ

FIGURE 5-26. SKYEYE INSTALLATION

FIGURE 5-27. SKYGUARD BAR INSTALLATION

FIGURE 5-28. SKYLINE INSTALLATION

FIGURE 5-29. STORAGE TRAY INSTALLATION - CENTER

FIGURE 5-30. SKYCUTTER INSTALLATION

FIGURE 5-31. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)

FIGURE 5-32. PLASMA CUTTER ASSEMBLY

FIGURE 5-33. SKYWELDER INSTALLATION (50HZ)

FIGURE 5-34. SKYWELDER INSTALLATION (60HZ)

FIGURE 5-35. WELDER ASSEMBLY

FIGURE 5-36. SKYWELDER PREP PACKAGE (60HZ)

FIGURE 5-37. SKYGLAZIER INSTALLATION (ENGLISH LANGUAGE DECALS)

FIGURE 5-38. SKYGLAZIER INSTALLATION (SPANISH LANGUAGE DECALS)

FIGURE 5-39. SKYGLAZIER INSTALLATION (PORTUGUESE LANGUAGE DECALS)

FIGURE 5-40. PIPE RACKS INSTALLATION (ANSI AND CSA SPECS)

FIGURE 5-41. PIPE RACKS INSTALLATION (AUSTRALIAN SPECS)

FIGURE 5-42. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M PLATFORM

FIGURE 5-43. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM

FIGURE 5-44. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM

FIGURE 5-45. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM

FIGURE 5-46. PLATFORM BUMPER PADDING INSTALLATION (OPTIONAL)

FIGURE 5-47. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)

FIGURE 5-48. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M PLATFORM)

FIGURE 5-49. FALL ARREST INSTALLATION (BOLT-ON) (8FT/2.4M PLATFORM)

FIGURE 5-50. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M TRI-ENTRY PLATFORM)

SECTION 6 - CYLINDER

FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 6-2. AXLE LOCKOUT CYLINDER ASSEMBLY

FIGURE 6-3. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (800S)

FIGURE 6-4. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (860SJ)

FIGURE 6-5. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (860SJ)33 topics

FIGURE 6-6. LEVEL CYLINDER ASSEMBLY - JIB (860SJ ONLY)
FIGURE 6-7. LEVEL CYLINDER ASSEMBLY - JIB (860SJ)
FIGURE 6-8. LIFT CYLINDER ASSEMBLY - MAIN BOOM (800S)
FIGURE 6-9. LIFT CYLINDER ASSEMBLY - MAIN BOOM (860SJ)
FIGURE 6-10. LIFT CYLINDER ASSEMBLY - MAIN BOOM (860SJ)
FIGURE 6-11. STEER CYLINDER ASSEMBLY
FIGURE 6-12. STEER CYLINDER ASSEMBLY
FIGURE 6-13. TELESCOPE CYLINDER ASSEMBLY (800S)
FIGURE 6-14. TELESCOPE CYLINDER ASSEMBLY (860SJ)
SECTION 7 - HYDRAULIC
FIGURE 7-1. HYDRAULIC DIAGRAM - AXLE (OSCILLATING)
FIGURE 7-2. HYDRAULIC DIAGRAM - DRIVE (2WD)
FIGURE 7-3. HYDRAULIC DIAGRAM - DRIVE (4WD WITHOUT ARCTIC PACKAGE)
FIGURE 7-4. HYDRAULIC DIAGRAM - DRIVE (4WD WITH ARCTIC PACKAGE)
FIGURE 7-5. HYDRAULIC DIAGRAM - STANDARD (800S WITHOUT TOW BAR PACKAGE)
FIGURE 7-6. HYDRAULIC DIAGRAM - STANDARD (800S WITH TOW BAR PACKAGE)
FIGURE 7-7. HYDRAULIC DIAGRAM - STANDARD (860SJ WITHOUT TOW BAR PACKAGE)
FIGURE 7-8. HYDRAULIC DIAGRAM - STANDARD (860SJ WITH TOW BAR PACKAGE)
SECTION 8 - ELECTRICAL
FIGURE 8-2. AC BOX AT PLATFORM INSTALLATION - 220V (ANSI, CSA & JAPANESE SPECS)
(ANSI EXPORT, AUSTRALIAN & CE SPECS)
FIGURE 8-4. AC BOX AT PLATFORM MID-BOOM PLUG INSTALLATION (WITHOUT GENERATOR) (CHINA SPECS)
GENERATOR)
OR NO GENERATOR OPTION)
FIGURE 8-9. AC BOX AT PLATFORM INSTALLATION - 220V IEC 60309 BLUE WITH 2500W GENERATOR (CE SPECS)
GENERATOR OR NO GENERATOR OPTION)
(CE SPECS)
2500W GENERATOR OR NO GENERATOR OPTION)
GENERATOR (CE SPECS)
4000W GENERATOR)
RECEPTACLE) (4000W GENERATOR)
WITH 4000W SKYPOWER GENERATOR)
SKYPOWER GENERATOR)

SPECS)

FIGURE 8-25. ANALYZER CALBE HARNESS

FIGURE 8-26. BEACON CONTROL HARNESS (BLUE AND RED STROBE LIGHTS)

FIGURE 8-27. BATERY DISCONNECT SWITCH INSTALLATION

FIGURE 8-28. BOOM CABLES INSTALLATION - 800S WITHOUT ARCTIC PACKAGE (ALL SPECS)

ANSI EXPORT, CSA AND JAPANESE SPECS)

ANSI EXPORT AND CSA SPECS)

FIGURE 8-33. BOOM CABLES INSTALLATION - 860SJ WITHOUT ARCTIC PACKAGE (ALL SPECS)

(ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)

ANSI EXPOERT AND CSA SPECS)

FIGURE 8-38. BOOM CABLES INSTALLATION - 860SJ WITHOUT AC CABLES (CHINA SPECS)

FIGURE 8-39. BOOM HARNESS - 800S (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-40. BOOM HARNESS - 800S (MAIN BOOM) (WITH ARCTIC PACKAGE)

FIGURE 8-41. BOOM HARNESS - 860SJ (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-42. BOOM HARNESS - 860SJ (MAIN BOOM) (WITH ARCTIC PACKAGE)

FIGURE 8-43. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-44. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)

FIGURE 8-45. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (CE SPECS WITHOUT 7500W GENERATOR)

FIGURE 8-46. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (WITH 4000W/50HZ GENERATOR)

FIGURE 8-47. BREAKER BOX KIT - 10 AMP (CE SPECS WITHOUT 7500W GENERATOR)

FIGURE 8-48. ENGINE HARNESS - DEUTZ D2011 ENGINES (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS)

FIGURE 8-49. ENGINE HARNESS - DEUTZ D2011 ENGINES (CE SPECS)

FIGURE 8-50. ENGINE HARNESS - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES

FIGURE 8-51. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-52. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINES

FIGURE 8-53. ENGINE HARNESS - FORD DF 2.5L ENGINES

FIGURE 8-54. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ENGINES

FIGURE 8-55. FUEL HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE

FIGURE 8-56. GENERATOR TO ENGINE HARNESS - 2500W (FORD ENGINES)

FIGURE 8-57. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ D2011 ENGINES)

FIGURE 8-58. GENERATOR TO ENGINE HARNESS - 4000W (DEUTZ TD2.9L4 ENGINES)

FIGURE 8-59. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)

FIGURE 8-60. GENERATOR HARNESS - 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)

FIGURE 8-61. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES) (PVC 2001)

FIGURE 8-62. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES) (PVC 2007)

FIGURE 8-63. GENERATOR TO REAR OF BOOM HARNESS - 110V

FIGURE 8-64. GENERATOR TO REAR OF BOOM HARNESS - 220V

FIGURE 8-65. GROUND CONTROL BOX HARNESS

FIGURE 8-66. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITHOUT ARCTIC PACKAGE)

FIGURE 8-67. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITH ARCTIC PACKAGE)

FIGURE 8-68. PLATFORM CONSOLE BOX HARNESS

FIGURE 8-69. RECEPTACLE BOX KIT - 110V IEC YELLOW WITHOUT 2500W GENERATOR (CE SPECS)

FIGURE 8-70. RECEPTACLE BOX KIT - 110V IEC YELLOW WITH 2500W GENERATOR (CE SPECS)

FIGURE 8-71. RECEPTACLE BOX KIT - 220V IEC BLUE WITHOUT 2500W GENERATOR (CE SPECS)

FIGURE 8-72. RECEPTACLE BOX KIT - 220V IEC BLUE WITH 2500W GENERATOR (CE SPECS)

FIGURE 8-73. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE SPEC)

FIGURE 8-74. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE SPEC)

FIGURE 8-75. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE SPECS)

FIGURE 8-76. SKYEYE INTERMEDIATE HARNESS

FIGURE 8-77. SKYEYE RECEIVER HARNESS

FIGURE 8-78. SKYEYE EMITTER HARNESS

FIGURE 8-79. SKYLINE HARNESS

FIGURE 8-80. INTERFACE HARNESS - WITH 1 CELL LSS

FIGURE 8-81. VALVE HARNESS28 topics

SECTION 9 - DECALS
FIGURE 9-1. DECAL INSTALLATION - 800S (ANSI SPECS)
FIGURE 9-2. DECAL INSTALLATION - 800S (AUSTRALIAN SPECS)
FIGURE 9-3. DECAL INSTALLATION - 800S (BRAZILIAN SPECS)
FIGURE 9-4. DECAL INSTALLATION - 800S (CE SPECS)
FIGURE 9-5. DECAL INSTALLATION - 800S (CHINESE SPECS)
FIGURE 9-6. DECAL INSTALLATION - 800S (CSA SPECS)
FIGURE 9-7. DECAL INSTALLATION - 800S (JAPANESE SPECS)
FIGURE 9-8. DECAL INSTALLATION - 800S (KOREAN SPECS)
FIGURE 9-9. DECAL INSTALLATION - 800S (LATIN AMERICAN SPECS)
FIGURE 9-10. DECAL INSTALLATION - 860SJ (ANSI SPECS)
FIGURE 9-11. DECAL INSTALLATION - 860SJ (AUSTRALIAN SPECS)
FIGURE 9-12. DECAL INSTALLATION - 860SJ (BRAZILIAN SPECS)
FIGURE 9-13. DECAL INSTALLATION - 860SJ (CE SPECS)
FIGURE 9-14. DECAL INSTALLATION - 800S (CHINESE SPECS)
FIGURE 9-15. DECAL INSTALLATION - 860SJ (CSA SPECS)
FIGURE 9-16. DECAL INSTALLATION - 860SJ (JAPANESE SPECS)
FIGURE 9-17. DECAL INSTALLATION - 860SJ (KOREAN SPECS)
FIGURE 9-18. DECAL INSTALLATION - 860SJ (LATIN AMERICAN SPECS)
FIGURE 9-19. DECAL INSTALLATION - OPTIONS
FIGURE 9-20. SKYWELDER DECAL INSTALLATION - 50HZ
FIGURE 9-21. SKYWELDER DECAL INSTALLATION - 60HZ (PVC 2001)
FIGURE 9-22. SKYWELDER DECAL INSTALLATION - 60HZ (PVC 2007)
SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
FIGURE 10-1. MODEL 800S/860SJ STANDARD PARTS
SECTION 11 - SPECIAL OPTIONS
FIGURE 11-1. SPECIAL OPTIONS
PART NUMBER INDEX

Inside this manual

Real pages from this parts manual (926 pages). Open the sample pages (PDF, 677 KB)

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

Parts illustration, page 208: SECTION 2 - TURNTABLE
Parts illustration, page 320: SECTION 3 - ENGINE
Parts illustration, page 866: SECTION 9 - DECALS

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 31215050_Rev_B$99.63

Service manuals

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

Service Manual 3121631 · 576 pagesCovers 800S, 810SJ, 860SJSerial: 0300182743-0300272492, B300001328-B300005730, Exclude Serial Number Range: 0300272449-0300272454, B300005568$69.93Details

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, 926 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).