JLG 800A 800AJ Service & Maintenance Manual Prior to S/N 0300183033 – P/N 3120858 (2016)

Description

JLG 800A 800AJ Service & Maintenance Manual Prior to S/N 0300183033 – P/N 3120858 (2016)

This 494-page service and maintenance reference covers the JLG 800A and JLG 800AJ aerial platforms prior to S/N 0300183033. Revised January 15, 2016 under publication number 3120858, it brings together operating specifications, scheduled maintenance information, component repair procedures, hydraulic service data, JLG control-system diagnostics, and electrical and hydraulic schematics in one detailed document. The JLG 800A 800AJ Service & Maintenance Manual Prior to S/N 0300183033 – P/N 3120858 (2016) is especially useful when work goes beyond routine checks and requires serial-number-specific procedures, settings, troubleshooting information, or component disassembly and reassembly guidance.

File Details

• Manual type: Service and Maintenance Manual
• Brand: JLG
• Models: 800A and 800AJ
• Serial coverage: Prior to S/N 0300183033
• Publication number: 3120858
• Revision date: January 15, 2016
• Original issue: August 1998
• Language: English
• Pages: 494
• File format: PDF

Service Data and Maintenance Reference

The opening specification material gives technicians a working baseline before repair work begins. It includes operating specifications, fluid capacities, tire data, drive and swing system information, pump specifications, torque requirements, hydraulic-oil guidance, cylinder dimensions, major component weights, critical stability weights, and a maintenance and lubrication program. Engine data is provided for Deutz F4M2011F, Deutz D2011L04, Caterpillar 3044C/3.4 and Isuzu 4JB1 configurations, while later service sections also include Ford LRG425-related adjustment information. The manual also supplies SAE and metric fastener torque charts and lubrication intervals for items such as swing bearings, wheel bearings, drive hubs, filters, hydraulic tank, engine oil, fuel filters and air filter.

Inspection guidance extends from pre-start and pre-delivery checks through frequent inspections, annual machine inspection and preventive maintenance. Service guidelines address cleanliness, bearings, gaskets, bolt usage, hydraulic lines, electrical wiring, hydraulic-system contamination, lubrication and battery care. Cylinder drift testing, pin and composite-bearing repair guidance, and welding precautions are also included. This makes the JLG 800A 800AJ service manual useful not only for a major repair but also for establishing the checks and service practices that surround that repair.

Chapters Covered

• Introduction – Maintenance Safety Precautions
  • General maintenance safety
  • Hydraulic system safety
  • Maintenance precautions
• Section 1 – Specifications
  • Operating specifications and capacities
  • Component and engine data
  • Tires, drive system and swing system
  • Hydraulic drive, variable-displacement, load-sense and auxiliary pumps
  • Torque requirements and hydraulic-oil information
  • Cylinder specifications, component weights and critical stability weights
  • Maintenance and lubrication
• Section 2 – General
  • Machine preparation, inspection and maintenance
  • Service guidelines and workmanship
  • Lubrication and hydraulic-system information
  • Cylinder drift test
  • Pins and composite-bearing repair guidelines
  • Welding on JLG equipment
• Section 3 – Chassis & Turntable
  • Tires and wheels; oscillating axle bleeding and lockout testing
  • Free wheeling and emergency towing preparation
  • Drive torque hub, drive brakes and drive motors
  • Swing bearing, swing gear backlash, swing hubs, brakes and motors
  • Rotary coupling and tilt alarm switch
  • Generator and dual-fuel system service
  • EFI diagnostics, ECM and sensor information
  • Ford LPG system and Ford LRG425 governor adjustments
  • Deutz throttle checks and Deutz EMR 2 diagnostics
• Section 4 – Boom & Platform
  • Platform, rotator and slave cylinder
  • Upper boom powertrack and powertrack maintenance
  • Upper boom, upright and tower boom assembly
  • Upright Monitoring System calibration and troubleshooting
  • Articulating jib and tower-boom hose replacement
  • Limit-switch and boom-valve adjustments
  • Wear pads and rotator service
  • Drive-card setup and load-sensing system calibration
  • Foot switch adjustment
• Section 5 – Basic Hydraulic Information and Schematics
  • O-ring lubrication and hydraulic valve theory
  • Holding-valve checks and cylinder theory
  • Cylinder checking, repair, removal and installation
  • Hydraulic pump-drive coupling lubrication
  • Pressure setting procedures and hydraulic oil change-out
  • Hydraulic component start-up procedures
  • Rexroth variable-displacement pump service
  • Sauer piston pump troubleshooting and service
  • Hydraulic schematics for applicable drive and serial configurations
• Section 6 – JLG Control System
  • Control-system introduction and CANbus communications
  • Hand-held analyzer connection and use
  • Analyzer access levels and parameter adjustment
  • Machine setup and level-vehicle configuration
  • Machine personality settings and function speeds
  • Fault-code and diagnostic menu information
• Section 7 – Electrical Information & Schematics
  • Multimeter basics and electrical measurement techniques
  • Dielectric compound application and connector servicing
  • AMP connector assembly and disassembly
  • Deutsch DT/DTP and HD30/HDP20 connector service
  • Electrical component installation drawings and engine-specific schematics

Taken as a whole, the manual follows the machine from routine inspection and lubrication into major mechanical, hydraulic and electrical work. Chassis and turntable coverage includes serial-dependent drive brake, drive motor, swing hub, swing brake and swing motor procedures. Boom and platform coverage moves through structural assemblies, powertrack, upright monitoring, jib, limit switches, wear pads, rotator and load-sensing adjustments. The hydraulic section contains extensive cylinder repair procedures and system schematics, while the control-system section adds analyzer setup, configuration programming, function-speed information and fault-code references. Electrical pages then provide connector service guidance together with installation drawings and schematics for the engine and control configurations covered by the manual.

Detailed Repair, Diagnostics and Schematics

Many procedures are presented as step-by-step disassembly, inspection, repair, assembly, installation or adjustment sequences. Examples include the drive torque hub, multiple drive-brake versions, drive motors, swing bearing and swing components, upper and tower boom assemblies, rotator assemblies, hydraulic cylinders and hydraulic pumps. Exploded views and component illustrations support these procedures, and the manual repeatedly distinguishes between different serial-number ranges where hardware or procedures changed.

Troubleshooting is also a significant part of the coverage. The document includes drive-system troubleshooting, EFI diagnostic trouble codes, Deutz EMR 2 fault-code material, Upright Monitoring System fault messages for both non-ADE and ADE machines, hydraulic pump troubleshooting, JLG analyzer fault codes and diagnostic menu descriptions. Hydraulic schematics cover 2-wheel-drive, 4-wheel-drive and later serial configurations, while electrical schematics include Deutz, Isuzu, Caterpillar and other applicable system arrangements. For technicians tracing a fault rather than simply replacing a part, these diagnostic and schematic sections provide the relationships between controls, sensors, pumps, valves, wiring and machine functions.

Built Around Serial-Specific Service Work

The overall manual applies to 800A and 800AJ machines prior to S/N 0300183033, but many individual components are divided at earlier serial breaks. The contents identify different drive-brake, drive-motor, swing-hub, swing-brake, swing-motor, rotator, steering-cylinder, hydraulic-pump, electrical-installation and control-system configurations. Checking the machine serial number against the procedure heading is therefore an important part of using this manual correctly. That detail is valuable when the same model designation spans several component revisions.

Keep the Correct Service Information at Hand

The JLG 800A 800AJ Service & Maintenance Manual Prior to S/N 0300183033 – P/N 3120858 (2016) supports inspection, scheduled maintenance, hydraulic pressure checks, component removal and installation, cylinder rebuilding, drive and swing repairs, boom and platform service, control-system setup, fault diagnosis, and electrical or hydraulic troubleshooting. Having the specified procedures, torque information, capacities, adjustment data, fault references and schematics available helps technicians work from the values and sequences intended for the covered machine configuration instead of relying on memory or generic information.

After purchase, the manual is supplied as an instant PDF download – there is no shipping wait. Open it on a computer, tablet or phone, keep it available in the workshop, and print the pages needed for a particular service job.