JLG 800A 800AJ Illustrated Parts Manual 3121854 Rev AJ PDF – SN 0300069000 through 0300140000

Description

JLG 800A 800AJ Illustrated Parts Manual 3121854 Rev AJ PDF – SN 0300069000 through 0300140000

The JLG 800A 800AJ Illustrated Parts Manual 3121854 Rev AJ PDF – SN 0300069000 through 0300140000 is a detailed component identification and parts-reference manual for 800A and 800AJ machines within the serial-number range printed on the cover. Its illustrated breakdowns connect numbered components to part numbers, quantities, descriptions, replacement information, and applicable serial ranges, making it useful when identifying the exact assembly or component fitted to a machine before ordering parts.

This manual is especially valuable where parts changed during production. Many figures are divided by serial number and distinguish original equipment from service-replacement assemblies. The document also separates configurations such as 2WD, 4WD, 2WS and 4WS where applicable, and identifies model-specific items for the 800A and 800AJ. Caterpillar and Deutz engine installations are covered, together with associated pumps, cooling, electrical, fuel, exhaust and mounting components.

File Details

• Manual type: Illustrated Parts Manual
• Brand: JLG
• Models: 800A, 800AJ
• Serial coverage: SN 0300069000 through 0300140000
• Part number: 3121854
• Revision: Rev AJ
• Date: August 31, 2018
• Language: English
• Pages: 376
• File format: PDF

How the Illustrated Parts Information Is Organized

The manual is arranged around machine sections and individual illustrated assemblies. A figure identifies the assembly visually, while the accompanying parts list provides item numbers, part numbers, quantities, descriptions and revision information. Serial-number breaks are shown directly in many assembly titles and component entries, which is important because the same general system can use different hubs, motors, valves, controls, engine components, rotary couplings or harnesses depending on when the machine was built.

The parts listings also document service replacements and superseded components. Examples include separate four-bolt original-equipment and five-bolt service-replacement drive motor assemblies, different swing motor/hub arrangements, several rotary coupling generations, ground control boxes with and without UGM, and multiple engine installation revisions. Notes within the listings tell the reader when a complete assembly must be purchased, when an individual part is no longer available, when a replacement part number applies, or when a component must be visually identified before parts are ordered.

Chapters Covered

• Section 1 – Frame
  • Axle and steering installation
  • Tire and wheel installations
  • Drive hub assemblies for earlier and later serial ranges
  • Drive motor assemblies, including original equipment and service replacement versions
  • Drive valves and shields installations
  • Tow package installation for 2WS machines
• Section 2 – Turntable
  • Control valves and horn installations
  • Main control valve and accessory valve assemblies
  • Auxiliary pump assembly
  • Turntable bearing and swing drive installation
  • Swing motor/hub assemblies for different serial ranges
  • Caterpillar engine installations
  • Caterpillar Tier IVi engine installation
  • Deutz engine installations
  • Optional 2500W generator installations for Caterpillar and Deutz machines
  • Piston pump assembly
  • Hydraulic and fuel tank installations
  • Rotary coupling installations for multiple serial ranges
  • Ground control box assemblies without and with UGM
  • Turntable-mounted electrical options
  • Hood installations
  • Optional engine tray jack installation
• Section 3 – Boom
  • Boom and cylinder installation – 800A
  • Boom and cylinder installation – 800AJ
  • Tower boom assembly
  • Main boom assemblies
  • Front-entry and side-entry platform rotator assemblies
  • Boom-mounted valve and limit switch installations
• Section 4 – Platform
  • Front-entry platform components
  • Side-entry platform components
  • Fall arrest platform components
  • Platform console assemblies by serial range
  • Lift and swing controller assemblies
  • Drive and steer controller assemblies
  • Optional Soft Touch system installation
• Section 5 – Cylinder
  • Axle lockout cylinder assembly
  • Platform slave and upright level cylinder assemblies
  • 800A and 800AJ service-replacement level cylinders
  • 800AJ jib lift cylinder assemblies
  • Main boom and tower boom lift cylinder assemblies
  • 800A and 800AJ master cylinder assemblies
  • Steer cylinder assembly
  • Main boom and tower boom telescope cylinder assemblies
• Section 6 – Hydraulic
  • Axle lockout hydraulic diagram
  • 2WD drive hydraulic diagrams by serial range
  • 4WD/2WS drive hydraulic diagrams by serial range
  • Standard hydraulic diagrams with Fenner and Haldex auxiliary pumps
  • Standard hydraulic diagram with Bucher auxiliary pump
  • Hydraulic diagram list
• Section 7 – Electrical
  • Electrical diagram list
  • Harness components installation without UGM
  • Harness components installation with UGM
• Section 8 – Decals
  • Decal installations divided across three serial-number ranges
• Section 9 – Recommended Service Parts Stock
  • Model 800A/800AJ standard parts
  • Model 800A/800AJ variable parts
• Section 10 – Special Options
  • Special options parts coverage
• Part Number Index
  • Index linking part numbers to their locations in the manual

Taken as a whole, the JLG 800A and 800AJ parts manual follows the machine from the frame and drive system through the turntable, engines, boom, platform, cylinders, hydraulics and electrical system. It then covers decals, recommended service-parts stock and special equipment before finishing with the part number index. This structure allows a technician or parts buyer to move from a physical assembly to its illustrated breakdown and then identify the corresponding component number and applicable machine configuration.

Serial-Number and Configuration-Specific Parts Identification

A major strength of this JLG 800A 800AJ Illustrated Parts Manual 3121854 Rev AJ is the amount of production-change information built into the figures and parts lists. Frame components include different drive hub and drive motor arrangements at SN 0300083332, while steering and drive installations distinguish 2WD/2WS, 4WD/2WS and 4WD/4WS configurations. The manual also identifies separate rotary coupling arrangements over several serial breaks and different platform console assemblies before and after SN 0300137975.

The engine section likewise separates applications carefully. Caterpillar installations are divided into serial ranges and include a later Caterpillar Tier IVi arrangement. Deutz installations include the Deutz F4M1011F Diesel in the earlier configuration and later engine-and-pump assemblies with their own serial-specific components. Optional generator systems, spark-arresting and catalytic muffler arrangements, pump configurations, battery cables, engine harnesses and control components are identified within these sections.

Exploded Assemblies and Component Breakdowns

The illustrated pages provide more than a general location view. Detailed breakdowns show the internal or subassembly relationships of drive hubs, drive motors, control valves, accessory valves, auxiliary pumps, swing motor/hubs, piston pumps, rotary couplings and hydraulic cylinders. Each numbered callout corresponds to the parts listing beside or following the illustration. This is useful when the required item is a seal kit, bearing, retaining ring, gear, cartridge, valve, shaft, piston, coil, bracket, harness or other component contained inside a larger assembly.

Service-replacement information is also integrated into these breakdowns. For example, the drive motor coverage distinguishes the original four-bolt assembly from the five-bolt service-replacement assembly and instructs the user to identify the component before ordering. Similar notes appear for auxiliary pump brands, swing drive assemblies and other components where production or replacement configurations changed.

Hydraulic, Electrical and Optional Equipment Coverage

The hydraulic section adds system diagrams for axle lockout and drive circuits, including separate 2WD and 4WD/2WS arrangements across applicable serial ranges. Standard hydraulic diagrams account for auxiliary pump variations using Fenner, Haldex and Bucher equipment. These diagrams complement the individual valve, pump, cylinder and rotary coupling parts breakdowns found elsewhere in the manual.

Electrical coverage includes diagram references, harness-component installations with and without UGM, ground control box assemblies, engine harness references and turntable-mounted electrical options. Optional equipment covered in the illustrated listings includes generator installations, alarms, amber strobe lights, work lights, Soft Touch equipment, tow-package components and other special options shown in the manual.

Parts Identification for the JLG 800A and 800AJ

For owners, workshops and parts departments working with machines inside SN 0300069000 through 0300140000, this manual provides the information needed to identify assemblies and select the correct listed components for the machine’s serial range and configuration. It is an illustrated parts reference rather than a step-by-step service-repair procedure manual, so its primary purpose is component identification, exploded-view reference, part-number lookup and configuration checking.

Get the Correct Parts Information Without Waiting for Shipping

The JLG 800A 800AJ Illustrated Parts Manual 3121854 Rev AJ PDF – SN 0300069000 through 0300140000 helps you trace machine assemblies, compare serial-number-specific configurations, identify individual parts from exploded illustrations, locate replacement and superseded components, and verify part numbers before ordering. That matters when seemingly similar 800A or 800AJ machines can use different components because of serial range, steering configuration, engine installation or service-replacement history.

After payment, the manual is delivered as an instant PDF download. There is no physical book and no shipping delay. You can open it on a computer, tablet or phone and print the pages you need for workshop, maintenance or parts-counter reference.