JLG 800S, 860SJ Boom Lift Service Manual
516 pages · Publication 3121139
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What's inside
From the manual's own table of contents: 459 sections, 524 entries. See sample pages (PDF, 585 KB)
General
Hydraulic System Safety
Maintenance4 topics
- Operating Specifications
- Specifications and Performance Data
- Capacities
- Component Data
Engine Data
Battery4 topics
- Tires
- Torque Requirements
- Major Component Weights
- Lubrication
Hydraulic Oil1 topic
- Operator Maintenance
Draining Oil Build Up From The Propane Regulator (Prior to S/N 0300134626)
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief2 topics
- Serial Number Location
- 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 459 sections
Lubrication
Lubrication and Servicing1 topic
- Lubrication and Information
Changing Hydraulic Oil
Lubrication Specifications1 topic
- Cylinder Drift
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 Inflation
Tire Damage
Tire Replacement
Wheel Replacement
Wheel Installation3 topics
- Lockout Cylinder Bleeding
- Oscillating Axle Lockout Test
- Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
To Engage Drive Motors and Brakes (Normal Operation)1 topic
- Wheel Drive Assembly, 2WD (Prior to SN 0300083331)
Removal
Installation1 topic
- Wheel Drive Assembly, 4WD (Prior to SN 0300083331)
Disassembly
Cleaning and Inspection
Repair
Assembly
Bleeding
Inspection
Spare Parts Kits
Replacing the Drive Shaft Seal
Testing and Setup
Drive Motor Adjustment Procedure1 topic
- Drive Motor
Description
Shaft Seal Replacement
Loop Flushing Valve
Troubleshooting
Initial Start-up Procedures1 topic
- TABLE OF CONTENTS Drive Hub (4WD Machines W/ Integral Brake) (Prior to SN 0300083331)
Roll, Leak and Brake Testing
Tightening and Torquing Bolts
Main Disassembly
Input Carrier Disassembly
Output Carrier Disassembly
Housing-Spindle Disassembly
Spindle-Brake Disassembly
Input Carrier Sub-Assembly
Output Carrier Sub-Assembly
Spindle Brake Sub-Assembly
Housing-Spindle Sub-Assembly
DW2B Integral Brake Check
Main Assembly1 topic
- Re-Aligning Drive Hub Input Coupling
Equipment Required
Procedure
Main Assembly Procedure
Hub Shaft Sub-Assembly
Carrier Sub-Assembly1 topic
- Swing Drive Brake - Mico (Prior to SN 0300066417)
Inspection and Cleaning
Timing Procedure
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 Assembly
Disassembly and inspection
One Piece Stator Construction2 topics
- Swing Hub Removal
- Swing Bearing
Turntable Bearing Mounting Bolt Condition Check
Wear Tolerance
Swing Bearing Removal
Swing Bearing Installation
Swing Bearing Torque Values1 topic
- Procedure For Setting Gear Backlash
Swing Drive Lubrication2 topics
- Rotary Coupling (Prior to SN 0300083331)
- Generator
Maintenance Schedule
Overload Protection
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings1 topic
- Ford EFI Engine
Performing Diagnostics
EFI Diagnostics
ECM and Sensors
Fuel System2 topics
- Deutz EMR 2
- GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure - Dual Fuel Engine1 topic
- GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Injector Rail
Fuel Injector1 topic
- GM Engine Fuel System Repair
Propane Fuel System Leak Test
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
Mixer Replacement
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement1 topic
- GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids1 topic
- Main Boom Assembly
Boom Disassembly
Telescope Cylinder/Boom Cable Removal
Telescope Cylinder/Boom Cable Installation
Lift Cylinder Removal
Lift Cylinder Installation1 topic
- Platform
Platform Valve Removal
Platform Valve Installation
Support Removal
Support Installation3 topics
- Rotator and Slave Cylinder
- Main Boom Powertrack
- Powertrack Maintenance
One Piece Bracket Maintenance
Two Piece Bracket Maintenance
Snap Rings and Screws2 topics
- Boom Cleanliness Guidelines
- Wire Rope
Three Month Inspection
Year or 7000 Hour Replacement
Replacement Criteria1 topic
- Boom Rope Torquing Procedures
Torque Procedures3 topics
- Elevation & Capacity Switches - 800S
- Elevation, Dual Capacity, & Transport Switch - 860SJ
- Electronic Platform Leveling
Normal Operation
Platform Leveling Fault
CAN Errors
Replacing the Level Sensors
Additional Platform and Jib Valves
Platform Leveling Calibration Procedure1 topic
- Helac Rotary actuator
Theory of Operation
Tools Required for Assembly/Disassembly
Installing Counterbalance Valve
Testing the Actuator
Installation and Bleeding1 topic
- Load Sensing device
Calibrating the Load Sensor1 topic
- Lubricating O-Rings in the Hydraulic System
Cup and Brush
Dip Method
Spray Method
Brush-on Method1 topic
- Cylinder Repair
Axle Lockout Cylinder
Jib Lift Cylinder (860SJ Only)
Main Boom Lift Cylinder
Platform Level Cylinder
Steer Cylinder (Prior to SN 0300142665)
Telescope Cylinder1 topic
- Pressure Setting Procedure
Set Up of the Function Pump
Adjustments Made at the Main Valve Block
Adjustments Made at the Platform Valve Assembly1 topic
- Start Up Procedures
Start Up After Overhaul or Replacement of Components1 topic
- 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 Configuration Using the Hand Held Analyzer
Machine Setup
Level Vehicle Description2 topics
- Machine Personality Settings and Function Speeds
- Machine Orientation When Doing Speed Tests
Test Notes1 topic
- CANBUS Communications
Analyzer Diagnostics Menu Structure2 topics
- General
- Multimeter Basics
Grounding
Backprobing
Min/Max
Polarity
Scale
Voltage Measurement
Resistance Measurement
Continuity Measurement
Current Measurement1 topic
- Checking Switches
Basic Check
Limit Switches
Automatic Switches
Switch Wiring - Low Side, High Side1 topic
- TABLE OF CONTENTS Applying Silicone Dielectric Compound to Electrical Connections
Installation of Dielectric Grease
Deutsch HD, DT, DTM, DRC Series
AWP Seal
AMP Mate-N-Lok
DIN Connectors
Exclusions1 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 Disassembly1 topic
- Electrical Schematics
Operator Maintenance and Lubrication Diagram
Deutz Engine Dipstick
Filter Lock Assembly
Serial Number Locations
Torque Chart (SAE Fasteners)- Sheet 1 of 5
Torque Chart (SAE Fasteners)- Sheet 2 of 5
Torque Chart (SAE Fasteners)- Sheet 3 of 5
Torque Chart (METRIC Fasteners) - Sheet 4 of 5
Torque Chart (METRIC Fasteners) - Sheet 5 of 5
Engine Operating Temperature Specifications - Deutz
Engine Operating Temperature Specifications - Ford
Engine Operating Temperature Specifications - Caterpillar
Engine Operating Temperature Specifications - GM
Axle and Steering Installation without Tow Package - Sheet 1 of 2
Axle and Steering Installation without Tow Package - Sheet 2 of 2
Axle and Steering Installation with Tow Package- Sheet 1 of 2
Axle and Steering Installation with Tow Package - Sheet 2 of 2
Drive Hub Installation - 2WD (Prior to SN 0300083331)
Drive Hub Installation - 4WD (Prior to SN 0300083331)
Drive Motor Cutaway
Bearing Tension
Flow Control Pilot Valves
Drive Motor Adjustment
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
Swashplate & 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
Main Disassembly - Sheet 1 of 2
Main Disassembly- Sheet 2 of 2
Output Carrier Assembly
Spindle Brake Disassembly
Housing-Spindle Assembly
Main Assembly - Sheet 1
Main Assembly - Sheet 2
Assembly Drawing - Without Integral Input Brake - Sheet 1 of 2
Assembly Drawing - Without Integral Input Brake - Sheet 2 of 2
Assembly Drawing - With Integral Input Brake - Sheet 1 of 2
Assembly Drawing - With Integral Input Brake - Sheet 2 of 2
Assembly Tools - Bearing Cone Pressing - “B” Bearing
Assembly Tools - Bearing Cone Pressing - “A” Bearing
Assembly Tools - Bearing Cup Pressing - “A” & “B” Bearings
Assembly Tools - Seal Pressing
Assembly Tools - Spacer - Brake Disc Installation
Assembly Tools - Brake Retaining Ring Installation
Swing Drive and Turntable Bearing
Swing Drive Brake - Mico (Prior to SN 0300066417)
Motor Control Valve
Motor and Brake
Hub-Shaft
Carrier
Swing Drive Assembly
Swing Motor and Brake Assembly
Swing Bearing Torque Sequence
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 - 800S
Swing Bearing Removal - 860SJ
Rotary Coupling Seal Installation (Prior to SN 0300083331)
Rotary Coupling Cutaway (Prior to SN 0300083331)
Rotary Coupling Port Location (7 Port) (Prior to SN 0300083331)
Rotary Coupling Installation (Prior to SN 0300083331)
Inspecting Generator Brushes, Replacing Brushes, and Cleaning Slip Rings
EFI Component Location
Typical Fuel System
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
Engine Oil Dip Stick
Electric Fuel Lock Off
Low Pressure Regulators
ETC throttle control device
LPG Engine Control Unit (ECM)
ECM Assembly
Heated Exhaust Gas Oxygen Sensor (HEGO)
Gasoline Fuel Pressure and Temperature Manifold Assembly
Pressure Regulator Section
(TMAP) Sensor & Electronic Throttle Control (ETC)
Mixer Assembly
Boom Assembly Cutaway - Sheet 1 of 2
Boom Assembly Cutaway - Sheet 2 of 2
Boom Components - Sheet 1 of 2
Boom Components - Sheet 2 of 2
Disassembly of Sheave Assembly
Disassembly Wire Rope Routing Procedure
Dimension of Sheaves When New
Proximity Switch Adjustment
Routing Installation of Retract Wire Ropes
Location of Components Platform Support
Platform Support Torque Values
Reassembly of Components-Rotator and Leveling Cylinder
Main Boom Powertrack Components
Powertrack Installation Main Boom - (Sheet 1 of 2)
Powertrack Installation Main Boom - (Sheet 2 of 2)
Clamping Wire Ropes
Elevation, Dual Capacity and Transport Switch Information - 800S
Elevation, Dual Capacity and Transport Switch Installation - 800S
Elevation, Dual Capacity, and Transport Switch Information - 860SJ
Elevation, Dual Capacity, and Transport Switch Installation - 860SJ
Level Switches - 800S
Level Switches - 860SJ
Rotary Actuator (Exploded View)
Rotary Actuator (Cutaway View)
Rotator Counterbalance Valve
Load Sensing Device
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 Bushing
Piston Seal Kit Installation
Rod Assembly Installation
Seating the Tapered Bearing
Hydrolock Piston Seal Installation
Spanner Nut Support
Spanner Nut Removal
Piston Seal Kit Installation (Prior to SN 0300142664)
Telescopic Cylinder
Control Valve Installation
Main Valve Identification
Platform Valve Identification
Main Valve Cartridge Torque Values
Platform Valve Cartridge Torque Values
Hydraulic Schematic - Sheet 1of 8
Hydraulic Schematic - Sheet 2 of 8
Hydraulic Schematic - Sheet 3 of 8
Hydraulic Schematic - Sheet 4 of 8
Hydraulic Schematic - Sheet 5 of 8
Hydraulic Schematic - Sheet 6 of 8
Hydraulic Schematic - Sheet 7 of 8
Hydraulic Schematic - Sheet 8 of 8
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
Fault Code Light and module 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)
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 (WITHOUT UGM) (Prior to SN 0300085332) - Sheet 1 of 2
Electrical Components Installation (WITHOUT UGM) (Prior to SN 0300085332) - Sheet 2 of 2
Electrical Components Installation (WITH UGM) (Prior to SN 0300140000) - Sheet 2 of 2
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 1 of 6
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 2 of 6
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 3 of 6
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 4 of 6
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 5 of 6
Electrical Schematics Caterpillar, Deutz EMR2 and GM (Prior to SN 0300139080) - Sheet 6 of 6
Electrical Schematic GM - Sheet 1 of 2
Electrical Schematic GM - Sheet 2 of 2
Operating Specifications - Prior to S/N 0300143294
Specifications and Performance Data
Capacities
Ford LRG-425 Specifications
Deutz F4M2011 Specifications
Deutz D2011L04 Specifications
Caterpillar 3044C/ Caterpillar 3.4
Battery Specifications
Tire Specifications
Torque Requirements
Component Weights
Mobilfluid 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
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 (Prior to SN 0300083331)
ECM Diagnostic Trouble Codes
LPF Fuel System Diagnosis
Symptom Diagnosis
DTC to SPN/FMI Cross Reference Chart
Cartridge Torque Values
Coil Torque Values
Analyzer Abbreviations
Machine Configuration Programming Information Prior to Software Version P5.3
Machine Configuration Programming Information Software Version P5.3 to P6.1
Machine Configuration Programming Information Software Version P6.1 to Present
Machine Configuration Programming Information
800S Machine Configuration Programming Settings
860SJ Machine Configuration Programming Settings
Machine Personality Settings
Function Speeds (In Seconds)
ADJUSTMENTS - Personality Descriptions
Diagnostic Menu Descriptions
Diagnostic Trouble Code Chart (DTC)
Inside this manual
Real pages from this service manual (516 pages). Open the sample pages (PDF, 582 KB)
- Specifications, page 23: SECTION 1 - SPECIFICATIONS
- Troubleshooting, page 93: Troubleshooting
- Diagram, page 499: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page: SECTION 7 - BASIC ELECTRICAL INFORMATION & SCHEMATICS
- Color page: SECTION 7 - BASIC 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, 516 pages
Quantity one is the manual described above.
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