JLG 800S HC3, 860SJ HC3 Boom Lift Parts Manual
728 pages · Publication 31215891
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- Models
- 800S HC3, 860SJ HC3
- Manual type
- Parts Manual
- Pages
- 728
- Publication
- 31215891
- Condition
- Brand new

What's inside
From the manual's own table of contents: 92 sections, 271 entries. See sample pages (PDF, 648 KB)
General56 topics
- SECTION 1 - FRAME
- FIGURE 1-1. AXLE INSTALLATION - OSCILLATING (WITHOUT TOW PACKAGE)
- FIGURE 1-2. AXLE INSTALLATION - OSCILLATING (WITH TOW PACKAGE)
- FIGURE 1-3. STEERING INSTALLATION - WITHOUT TOW PACKAGE
- FIGURE 1-4. STEERING INSTALLATION - WITH TOW PACKAGE
- FIGURE 1-5. WHEEL DRIVE AND FRAME VALVES INSTALLATION – 4WD
- FIGURE 1-6. DRIVE HUB/BRAKE ASSEMBLY
- FIGURE 1-7. DRIVE MOTOR ASSEMBLY - 4WD
- FIGURE 1-8. TIRE & WHEEL INSTALLATION - 15-625 NHS FOAM-FILLED
- FIGURE 1-9. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED TIRE
- FIGURE 1-10. TIRE AND WHEEL INSTALLATION 18-625 NHS FOAM-FILLED NON-MARKING TIRE
- FIGURE 1-11. LP TANK BRACKETS INSTALLATIONS
- FIGURE 1-12. TOW PACKAGE INSTALLATION (ENGLISH DECALS)
- FIGURE 1-13. TOW PACKAGE INSTALLATION (FRENCH/ENGLISH DECALS)
- FIGURE 1-14. TOW BAR ASSEMBLY
- FIGURE 1-15. FRAME SHIELDS INSTALLATION
- SECTION 2 - TURNTABLE
- FIGURE 2-1. CONTROL VALVES INSTALLATION - 860SJ HC3
- FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY
- FIGURE 2-3. SWING DRIVE INSTALLATION
- FIGURE 2-4. SWING MOTOR/HUB ASSEMBLY
- FIGURE 2-5. TURNTABLE BEARING INSTALLATION
- FIGURE 2-6. REMOTE BEARING LUBE INSTALLATION
- FIGURE 2-7. TURNTABLE LOCK INSTALLATION
- FIGURE 2-8. ROTARY COUPLING INSTALLATION
- FIGURE 2-9. TANK INSTALLATION - GAS ENGINES
- FIGURE 2-10. TANK INSTALLATION - DIESEL ENGINES
- FIGURE 2-11. HYDRAULIC TANK ASSEMBLY
- FIGURE 2-12. AUXILIARY PUMP WITH BATTERY WITHOUT BATTERY DISCONNECT SWITCH INSTALLATION
- FIGURE 2-13. AUXILIARY PUMP WITH BATTERY WITH BATTERY DISCONNECT SWITCH INSTALLATION
- AUSTRALIAN SPECS)
- FIGURE 2-15. GROUND CONTROL BOX ASSEMBLY - 860SJ HC3 WITH DEUTZ D2011 (CE SPECS)
- JAPANESE AND CHINA SPECS)
- FIGURE 2-17. GROUND CONTROL BOX ASSEMBLY - 860SJ HC3 WITH DEUTZ TD2.9L4 (STAGE V) (CE SPECS)
- EXPORT (HRC), AUSTRALIAN AND CSA SPECS)
- FIGURE 2-19. LIGHT PANEL INSTALLATION
- FIGURE 2-20. ALARM INSTALLATION
- FIGURE 2-21. WHITE NOISE ALARM INSTALLATION
- FIGURE 2-22. STROBE LIGHT INSTALLATION (AMBER)
- FIGURE 2-23. STROBE LIGHT INSTALLATION (BLUE)
- FIGURE 2-24. STROBE LIGHT INSTALLATION (RED)
- FIGURE 2-25. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ D2011 ENGINES)
- D2011 ENGINES)
- FIGURE 2-27. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 ENGINES)
- FIGURE 2-28. EXHAUST STACK INSTALLATION - STEEL HOOD (DEUTZ TD2.9L4 (STAGE V) ENGINES)
- ENGINES)
- FIGURE 2-30. EXHAUST STACK INSTALLATION - STEEL HOOD (FORD DF 2.5L ENGINES)
- FIGURE 2-31. HOODS INSTALLATION - ABS (DEUTZ D2011 ENGINES)
- FIGURE 2-32. HOODS INSTALLATION - STEEL (DEUTZ D2011 ENGINES)
- FIGURE 2-33. HOODS INSTALLATION - STEEL WITH HOSTILE ENVIRONMENT MACHINES (DEUTZ D2011 ENGINES)
- FIGURE 2-35. HOODS INSTALLATION – STEEL (DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES)
- FIGURE 2-37. HOODS INSTALLATION – STEEL (FORD DF 2.5L ENGINES)
- FIGURE 2-38. HOOD ASSEMBLY - ENGINE SIDE REAR (DEUTZ TD2.9L4 ENGINES)
- FIGURE 2-39. HOOD ASSEMBLY - TANK SIDE REAR (DEUTZ TD2.9L4 AND DEUTZ TD2.9L4 (STAGE V) ENGINES)
- FIGURE 2-40. LIFTING PLATE INSTALLATION
- FIGURE 2-41. SKYAIR AIR COMPRESSOR INSTALLATION (DEUTZ D2011 AND FORD DF 2.5L ENGINES)
Show all 93 sections
FIGURE 3-57. 7500W/60HZ SKYPOWER GENERATOR INSTALLATION – FORD DF 2.5L ENGINES62 topics
- SECTION 4 - BOOM
- FIGURE 4-1. BOOM AND CYLINDERS INSTALLATION - 860SJ HC3
- FIGURE 4-2. MAIN BOOM ASSEMBLY - 860SJ HC3
- FIGURE 4-3. JIB ASSEMBLY - 860SJ HC3
- FIGURE 4-4. ROTATOR ASSEMBLY - 860SJ HC3
- FIGURE 4-5. PLATFORM SUPPORT INSTALLATION
- FIGURE 4-6. POWER TRACK INSTALLATION - MAIN BOOM - 860SJ HC3
- FIGURE 4-7. CONTROL VALVE INSTALLATION - 860SJ HC3
- FIGURE 4-8. PLATFORM VALVE ASSEMBLY - 860SJ HC3
- FIGURE 4-9. LIMIT SWITCHES AND COVERS INSTALLATION
- FIGURE 4-10. SENSOR ASSEMBLY - LOWER
- 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 8FT (91.5CM X 2.44M)
- FIGURE 5-6. PLATFORM ASSEMBLY WITH GATE - 30IN X 4FT (76CM X 1.22M)
- FIGURE 5-7. PLATFORM ASSEMBLY WITH GATE - 30IN X 5FT (76CM X 1.52M) (USA BUILT MACHINES
- FIGURE 5-8. PLATFORM ASSEMBLY WITH GATE- 36IN X 6FT (91.5CM X 1.83M)
- FIGURE 5-9. PLATFORM ASSEMBLY WITH GATE - 36IN X 8FT (91.5CM X 2.44M)
- FIGURE 5-10. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)
- FIGURE 5-11. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 6FT (91.5CM X 1.83M)
- FIGURE 5-12. PLATFORM ASSEMBLY WITH 1 GATE / 2 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)
- FIGURE 5-13. PLATFORM ASSEMBLY WITH 3 DROP BARS (TRI-ENTRY) - 36IN X 8FT (91.5CM X 2.44M)
- FIGURE 5-14. PLATFORM ASSEMBLY WITH FALL ARREST (6FT)
- FIGURE 5-15. PLATFORM ASSEMBLY WITH FALL ARREST (8FT)
- FIGURE 5-16. PLATFORM CONSOLE AND FOOTSWITCH INSTALLATION
- FIGURE 5-17. PLATFORM CONSOLE ASSEMBLY
- FIGURE 5-18. FOOTSWITCH ASSEMBLY
- FIGURE 5-19. CONTROLLER ASSEMBLY - LIFT/SWING
- FIGURE 5-20. CONTROLLER ASSEMBLY- DRIVE/STEER
- FIGURE 5-21. LIGHT PANEL INSTALLATION
- FIGURE 5-22. JIB SWITCH INSTALLATION - 860SJ
- FIGURE 5-23. SKYEYE INSTALLATION
- FIGURE 5-24. SKYGUARD BAR INSTALLATION
- FIGURE 5-25. SKYLINE INSTALLATION
- FIGURE 5-26. STORAGE TRAY INSTALLATION - CENTER
- FIGURE 5-27. SKYCUTTER INSTALLATION
- FIGURE 5-28. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)
- FIGURE 5-29. PLASMA CUTTER ASSEMBLY
- FIGURE 5-30. SKYWELDER INSTALLATION (50HZ)
- FIGURE 5-31. SKYWELDER INSTALLATION (60HZ)
- FIGURE 5-32. WELDER ASSEMBLY
- FIGURE 5-33. SKYWELDER PREP PACKAGE (60HZ)
- FIGURE 5-34. PIPE RACKS INSTALLATION (ANSI AND CSA SPECS)
- FIGURE 5-35. PIPE RACKS INSTALLATION (AUSTRALIAN SPECS)
- FIGURE 5-36. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M PLATFORM
- FIGURE 5-37. SOFT TOUCH SYSTEM INSTALLATION - 6FT/1.83M FALL ARREST PLATFORM
- FIGURE 5-38. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M PLATFORM
- FIGURE 5-39. SOFT TOUCH SYSTEM INSTALLATION - 8FT/2.44M FALL ARREST PLATFORM
- FIGURE 5-40. SOFT TOUCH SYSTEM INSTALLATION - OVER HEAD (CHINESE/KOREAN SPECS)
- FIGURE 5-41. FALL ARREST INSTALLATION (BOLT-ON) (4FT/1.22M PLATFORM)
- FIGURE 5-42. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M PLATFORM)
- FIGURE 5-43. FALL ARREST INSTALLATION (BOLT-ON) (8FT/2.4M PLATFORM)
- FIGURE 5-44. FALL ARREST INSTALLATION (BOLT-ON) (6FT/1.82M TRI-ENTRY PLATFORM)
- SECTION 6 - CYLINDER
- FIGURE 6-1. AXLE LOCKOUT CYLINDER ASSEMBLY
- FIGURE 6-2. LEVEL CYLINDER ASSEMBLY - PLATFORM SLAVE (860SJ HC3)
- FIGURE 6-3. LIFT CYLINDER ASSEMBLY - JIB (860SJ HC3 ONLY)
- FIGURE 6-4. LIFT CYLINDER ASSEMBLY - JIB
- FIGURE 6-5. LIFT CYLINDER ASSEMBLY - JIB
(ANSI, ANSI EXPORT, CSA AND JAPANESE SPECS)61 topics
- (ALL SPECS)
- (ANSI, ANSI EXPOERT AND CSA SPECS)
- FIGURE 8-33. BOOM CABLES INSTALLATION - 860SJ HC3 WITHOUT AC CABLES (CHINA SPECS)
- FIGURE 8-34. BOOM HARNESS - 860SJ HC3 (MAIN BOOM) (WITHOUT ARCTIC PACKAGE)
- FIGURE 8-35. BOOM HARNESS - 860SJ (MAIN BOOM) (WITH ARCTIC PACKAGE)
- FIGURE 8-36. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)
- FIGURE 8-37. BOOM CABLE (TOWER BOOM) (WITHOUT ARCTIC PACKAGE)
- FIGURE 8-38. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (CE SPECS WITHOUT 7500W GENERATOR)
- FIGURE 8-39. BREAKER BOX KIT - ONE DOUBLE 16AMP BREAKER (WITH 4000W/50HZ GENERATOR)
- FIGURE 8-40. BREAKER BOX KIT - 10 AMP (CE SPECS WITHOUT 7500W GENERATOR)
- FIGURE 8-41. ENGINE HARNESS - DEUTZ D2011 ENGINES (ANSI EXPORT (LRC) AND AUSTRALIAN SPECS)
- FIGURE 8-42. ENGINE HARNESS - DEUTZ D2011 ENGINES (CE SPECS)
- FIGURE 8-43. ENGINE HARNESS - DEUTZ TD2.9L4 AND DEUTZ 2.9L4 (STAGE V) ENGINES
- FIGURE 8-44. ENGINE HARNESS - DEUTZ TD2.9L4 ENGINES
- FIGURE 8-45. ENGINE HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINES
- FIGURE 8-46. ENGINE HARNESS - FORD DF 2.5L ENGINES
- FIGURE 8-47. FUEL PUMP HARNESS - DEUTZ TD2.9L4 ENGINES
- FIGURE 8-48. FUEL HARNESS - DEUTZ TD2.9L4 (STAGE V) ENGINE
- FIGURE 8-49. GENERATOR TO ENGINE HARNESS - 2500W (FORD ENGINES)
- FIGURE 8-50. GENERATOR TO ENGINE HARNESS - 4000W/50HZ (DEUTZ D2011 ENGINES)
- FIGURE 8-51. GENERATOR TO ENGINE HARNESS - 4000W/60HZ (DEUTZ ENGINES)
- FIGURE 8-52. GENERATOR TO ENGINE HARNESS - 4000W/50HZ (DEUTZ TD2.9L4 ENGINES)
- FIGURE 8-53. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER GENERATOR (DEUTZ D2011 ENGINES)
- FIGURE 8-54. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (DEUTZ TD2.9L4 T4F ENGINES)
- FIGURE 8-55. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES) (PVC 2001)
- FIGURE 8-56. GENERATOR TO ENGINE HARNESS - 7500W SKYPOWER (FORD DF 2.5L ENGINES) (PVC 2007)
- FIGURE 8-57. GENERATOR TO REAR OF BOOM HARNESS - 110V
- FIGURE 8-58. GENERATOR TO REAR OF BOOM HARNESS - 220V
- FIGURE 8-59. GROUND CONTROL BOX HARNESS
- FIGURE 8-60. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITHOUT ARCTIC PACKAGE)
- FIGURE 8-61. HOLDING VALVE/LIFT DUMP HARNESS ASSEMBLY (WITH ARCTIC PACKAGE)
- FIGURE 8-62. PLATFORM CONSOLE BOX HARNESS
- FIGURE 8-63. RECEPTACLE BOX KIT - 110V IEC YELLOW WITHOUT 2500W GENERATOR (CE SPECS)
- FIGURE 8-64. RECEPTACLE BOX KIT - 110V IEC YELLOW WITH 2500W GENERATOR (CE SPECS)
- FIGURE 8-65. RECEPTACLE BOX KIT - 220V IEC BLUE WITHOUT 2500W GENERATOR (CE SPECS)
- FIGURE 8-66. RECEPTACLE BOX KIT - 220V IEC BLUE WITH 2500W GENERATOR (CE SPECS)
- FIGURE 8-67. RECEPTACLE BOX KIT - 220V CEE7 POST GROUND 2X4 BOX (CE SPEC)
- FIGURE 8-68. RECEPTACLE BOX KIT - 220V CEE7 SIDE GROUND 2X4 BOX (CE SPEC)
- FIGURE 8-69. RECEPTACLE BOX KIT - 220V AFSINT107 KEYED GROUND (CE SPECS)
- FIGURE 8-70. SKYEYE INTERMEDIATE HARNESS
- FIGURE 8-71. SKYEYE RECEIVER HARNESS
- FIGURE 8-72. SKYEYE EMITTER HARNESS
- FIGURE 8-73. SKYLINE HARNESS
- FIGURE 8-74. SKYGUARD INERFACE HARNESS
- FIGURE 8-75. VALVE HARNESS
- SECTION 9 - DECALS
- FIGURE 9-1. DECAL INSTALLATION - 860SJ HC3 (ANSI SPECS)
- FIGURE 9-2. DECAL INSTALLATION - 860SJ HC3 (AUSTRALIAN SPECS)
- FIGURE 9-3. DECAL INSTALLATION - 860SJ HC3 (BRAZILIAN SPECS)
- FIGURE 9-4. DECAL INSTALLATION - 860SJ HC3 (CE SPECS)
- FIGURE 9-5. DECAL INSTALLATION - 860SJ HC3 (CHINESE SPECS)
- FIGURE 9-6. DECAL INSTALLATION - 860SJ HC3 (CSA SPECS)
- FIGURE 9-7. DECAL INSTALLATION - 860SJ HC3 (JAPANESE SPECS)
- FIGURE 9-8. DECAL INSTALLATION - 860SJ HC3 (KOREAN SPECS)
- FIGURE 9-9. DECAL INSTALLATION - 860SJ HC3 (LATIN AMERICAN SPECS)
- FIGURE 9-10. DECAL INSTALLATION - OPTIONS
- FIGURE 9-11. SKYCUTTER DECAL INSTALLATION (ANSI, ANSI EXPORT & CSA SPECS)
- FIGURE 9-12. SKYCUTTER DECAL INSTALLATION (JAPANESE SPECS)
- FIGURE 9-13. SKYWELDER DECAL INSTALLATION - 50HZ
- FIGURE 9-14. SKYWELDER DECAL INSTALLATION - 60HZ (PVC 2007)
- SECTION 10 - RECOMMENDED SERVICE PARTS STOCK
Inside this manual
Real pages from this parts manual (728 pages). Open the sample pages (PDF, 647 KB)
- Parts illustration, page 153: SECTION 2 - TURNTABLE
- Parts illustration, page 461: SECTION 6 - CYLINDER
- Parts illustration, page 670: SECTION 9 - DECALS
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.
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, 728 pages
Quantity one is the manual described above.
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Other editions and similar models
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