JLG 800A 800AJ Service and Maintenance Manual 3121628 Rev F PDF Download

Description

JLG 800A 800AJ Service and Maintenance Manual 3121628 Rev F PDF Download

This JLG 800A 800AJ Service and Maintenance Manual 3121628 Rev F PDF Download provides detailed service, repair, adjustment, inspection and troubleshooting information for JLG 800A and 800AJ machines from S/N 0300183034 to Present. At 642 pages, the manual goes well beyond routine maintenance and includes component disassembly and assembly procedures, hydraulic pressure-setting information, boom and chassis repairs, engine-related service information, control-system diagnostics, fault-code references, hydraulic schematics and electrical schematics.

The manual is identified as publication 3121628, Revision F, dated February 08, 2019. Its coverage includes procedures and data for different engine installations shown in the manual, including Deutz D2011L04, Deutz TD 2.9, Deutz TD 2.9 L4 China III, GM 3.0L and Ford 2.5L DF MSG-425 configurations. Where components changed during production, the manual distinguishes applicable serial-number breakpoints within individual procedures and illustrations.

File Details

• Manual Type: Service and Maintenance Manual
• Brand: JLG
• Models: 800A, 800AJ
• Serial Number Coverage: S/N 0300183034 to Present
• Language: English
• Page Count: 642 pages
• File Format: PDF
• Publication Number: 3121628
• Revision: Rev F
• Date: February 08, 2019

Specifications, Capacities and Service Data

The opening technical section gives the technician a concentrated reference for operating specifications, capacities, tires, engine data, component specifications, torque requirements, hydraulic oil and major component weights. The manual includes separate engine specification data for the engine configurations it covers rather than treating every machine as mechanically identical.

Operating data includes travel speed, gradeability, turning radius, overall dimensions, ground clearance, stowed dimensions, platform heights, tire loading and machine weight. Capacity information covers the fuel tank, hydraulic tank and hydraulic system as well as drive components and engine-specific crankcase capacities. Dedicated tables provide drive-system, swing-system and auxiliary-power-pump information, while torque data covers critical items such as wheel bolts, support-to-rotator bolts, the rotator center bolt and swing-bearing bolts.

Hydraulic oil information includes viscosity ranges and fluid specifications for different operating temperatures. The service section also contains lubrication points and intervals, filter replacement intervals, engine-specific oil service information and maintenance diagrams. Major component and critical stability weights are included for components such as the platform, booms, cylinders, upright, counterweight, turntable and chassis.

Chapters Covered

• Section A – Introduction – Maintenance Safety Precautions
  • General maintenance precautions
  • Hydraulic system safety
  • Maintenance safety requirements

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• Section 1 – Specifications
  • Operating specifications and capacities
  • Tires and engine data
  • Drive, swing and auxiliary power component data
  • Torque requirements and hydraulic oil
  • Major component and critical stability weights
  • Operator maintenance and lubrication information
• Section 2 – General
  • Machine preparation, inspection and maintenance
  • Pre-start, pre-delivery, frequent and annual inspections
  • Service guidelines, removal, installation, disassembly and reassembly
  • Lubrication and hydraulic-system information
  • Cylinder drift and leakage testing
  • Pins and composite bearing repair guidelines
  • Welding on JLG equipment
• Section 3 – Chassis & Turntable
  • Tires, wheels and lockout-cylinder bleeding
  • Oscillating axle lockout testing
  • Drive hub, drive brake and drive motor
  • Swing drive, swing motor, swing hub and swing bearing
  • Tilt indicator and rotary coupling
  • Generator and auxiliary power system
  • Deutz engine service and Deutz EMR 2 diagnostics
  • GM engine maintenance, dual-fuel system, fuel-system repair and LPG diagnosis
  • Ford engine information and counterweight
• Section 4 – Boom & Platform
  • Platform, rotator and platform cylinder
  • Boom systems and main boom powertrack
  • Powertrack maintenance and boom cleanliness
  • Main boom, upright and tower boom assemblies
  • Upright Monitoring System calibration, troubleshooting and fault messages
  • Articulating jib and tower-boom hose replacement
  • Limit-switch and boom-valve adjustments
  • Rotator assembly and foot-switch adjustment
  • SkyGuard diagnostics and bolt-on external fall arrest
• Section 5 – Basic Hydraulics Information & Schematics
  • Hydraulic O-ring lubrication and fitting assembly
  • Hydraulic connection and torque specifications
  • Hydraulic cylinder disassembly, inspection and assembly
  • Cylinder removal and installation
  • Hydraulic pressure-setting procedures
  • Hydraulic component start-up and drive-pump pre-fill
  • Function pump and drive pump service
  • Hydraulic troubleshooting and multi-sheet hydraulic schematics
• Section 6 – JLG Control System
  • JLG Control System Analyzer instructions
  • Machine configuration and personality settings
  • Function-speed settings and machine orientation
  • CANbus communications and analyzer diagnostics
  • LSS calibration, testing and troubleshooting
  • MSSO reset information and diagnostic trouble codes
• Section 7 – Basic Electrical Information & Schematics
  • Multimeter and electrical troubleshooting fundamentals
  • Electrical connector servicing and dielectric compound application
  • AMP and Deutsch connector assembly and service
  • Telematics Gateway information
  • Electrical component installations and electrical schematics

Taken together, these chapters make the JLG 800A 800AJ service manual useful from periodic inspection through major mechanical and hydraulic repair. Procedures are supported by component-location drawings, exploded views, assembly illustrations, test information, adjustment values and troubleshooting material. The document also provides extensive coverage of systems that require machine-specific setup or diagnosis rather than simple parts replacement.

Chassis, Drive and Swing Repairs

The chassis and turntable material covers work ranging from wheel installation and axle lockout checks to internal drive and swing components. Drive-hub procedures include disassembly, cleaning, inspection, repair and assembly. The drive motor section covers troubleshooting, shaft-seal work, disassembly, inspection, assembly and initial start-up procedures. Swing-system coverage extends through the swing drive, swing motor, hub installation and removal, bearing inspection, wear tolerance, replacement and specified torque procedures.

This part of the JLG 800A and 800AJ maintenance manual also contains engine and auxiliary-system information. Deutz sections include engine component and installation illustrations, maintenance procedures and EMR 2 diagnostic material with fault-code references. GM coverage includes general engine maintenance, gasoline/LP systems, fuel-system repairs and LPG diagnosis. Ford engine information is also included for the applicable configuration.

Boom, Platform and Hydraulic System Service

For boom and platform work, the manual addresses the platform assembly, platform valve, rotator and leveling components, main and tower boom assemblies, powertrack systems, articulating jib and limit switches. Procedures include removal, installation, disassembly, inspection, assembly, adjustment and testing where applicable. The Upright Monitoring System receives dedicated coverage for re-synchronizing, calibration, calibration faults, function checks, service mode and fault messages.

The hydraulic section is particularly extensive. It explains connection types and correct assembly methods for hydraulic fittings, then moves into individual cylinder service. Covered components include axle lockout, platform level, upright level, jib lift, main boom lift, tower boom lift, master, steer, main boom telescope and tower boom telescope cylinders. Numerous cylinder procedures contain detailed seal, bearing, bushing, piston and rod assembly illustrations, with serial-number distinctions where the hardware changed.

Pressure-setting procedures identify adjustments at the function pump, main valve block and platform valve block. Function-pump and drive-pump chapters include removal or installation, start-up information and troubleshooting. The hydraulic section concludes with multi-sheet system schematics that allow the technician to trace circuits while working through pressure, flow or component-related faults.

Control-System Diagnostics and Electrical Schematics

The JLG control-system section explains connection and use of the handheld analyzer, access levels, parameter adjustment, machine setup, personality settings and function speeds. It includes machine configuration programming information, CANbus communications, analyzer menu structures, LSS calibration and troubleshooting, and a detailed diagnostic trouble-code chart. This is important when a fault involves controls, sensors, setup or communications rather than a purely mechanical component.

Electrical coverage starts with practical multimeter procedures for voltage, resistance, continuity and current measurements, then deals with electrical connectors and correct service techniques. AMP and Deutsch connector procedures, dielectric compound application and telematics-related wiring are included before the manual moves into machine electrical schematics. The schematic material includes GM-specific sheets along with a larger multi-sheet electrical schematic set for tracing circuits and diagnosing operating problems.

Service the JLG 800A and 800AJ with the Correct Technical Reference

The JLG 800A 800AJ Service and Maintenance Manual 3121628 Rev F PDF Download supports routine maintenance, scheduled inspections, chassis and swing repairs, boom and platform work, hydraulic cylinder and pump service, pressure adjustments, engine-system diagnosis, control-system troubleshooting and electrical fault tracing. Having the correct procedures, torque information, specifications, serial-number distinctions and schematics available can make the difference between replacing parts by trial and performing the repair according to the documented service data.

This manual is supplied as an instant PDF download after purchase. There is no physical book and no shipping delay. You can open the PDF on a computer, tablet or phone and print the pages you need for workshop use.