JLG 800S 860SJ Service and Maintenance Manual – 3121139 PDF

JLG 800S 860SJ Service and Maintenance Manual

This JLG 800S 860SJ Service and Maintenance Manual is the full PDF workshop documentation for the JLG 800S and 860SJ telescopic boom lifts, published under part number 3121139 with the most recent revision dated November 16, 2012. It is the same manual a JLG-trained technician uses to diagnose, repair, service and maintain these machines, and it covers every major assembly on the lift: chassis, turntable, boom, platform, hydraulics, engines and the JLG Control System.

File Details

• Manual Type: Service and Maintenance Manual
• Brand: JLG Industries, Inc.
• Models Covered: 800S, 860SJ
• Part Number: 3121139
• Publication Date: November 16, 2012
• Language: English
• File Format: PDF
• Page Count: 372 pages
• Revision History: First issue October 31, 2001, through final revision November 16, 2012

Chapters Covered

• Section A – Introduction: Maintenance safety precautions, hydraulic system safety, general maintenance warnings
• Section 1 – General: Operating specifications, performance data, capacities, engine data, battery, tires, function speeds, torque requirements, hydraulic oil, pressure settings, component weights, operator maintenance, propane regulator service, serial number location
• Section 2 – General: Machine preparation, inspection and maintenance, service guidelines, lubrication and information, cylinder drift test, pins and composite bearing repair, welding on JLG equipment
• Section 3 – Chassis & Turntable: Tires and wheels, 2WD and 4WD wheel drive assemblies, drive motors (prior to and after S/N 83331), torque hubs, integral brake torque hubs, drive brake (Mico), oscillating axle bleeding and lockout test, swing drive hub, swing brake, swing motor, gear backlash setting, swing bearing, rotary coupling, generator service, Ford EFI engine diagnostics, Deutz EMR 2 troubleshooting, GM engine general maintenance, GM dual fuel system, GM fuel system repair, GM LPG fuel system diagnosis
• Section 4 – Boom & Platform: Boom removal, disassembly, inspection, assembly and installation, wire rope inspection and replacement, boom rope torquing procedures, elevation and capacity switches, electronic platform leveling, powertrack maintenance, Helac rotary actuator, load sensing device
• Section 5 – Hydraulics: Lubricating O-rings, cylinder repair, pressure setting procedure, start-up procedures
• Section 6 – JLG Control System: Analyzer connection, access levels, machine setup, personality settings, diagnostics menu structure
• Section 7 – Basic Electrical Information & Schematics: Multimeter basics, silicone dielectric compound application, AMP and Deutsch connectors, electrical component installation, full electrical schematics, full hydraulic schematics

Between the covers, this JLG 800S 860SJ service manual walks through every system that keeps these telescopic boom lifts running. The chassis and turntable section alone spans more than 160 pages, covering the wheel drive assembly on both 2WD and 4WD machines, the Fairfield and Mico torque hub rebuilds, drive and swing brake service, swing bearing replacement with torque sequencing, rotary coupling seal kit installation, and full step-by-step teardown of the swing drive hub and swing motor. Engine coverage is split by manufacturer and serial number, with dedicated Ford EFI diagnostics, Deutz EMR 2 fault code lookup and vehicle/engine pin identification, and complete GM dual fuel system repair covering the EPR, LPR, mixer, ETC, TMAP and HEGO sensors.

Engines and Serial Number Coverage

The engine chapters are separated so you can match the exact procedure to the machine on the bench. Ford LRG-425 gasoline and dual fuel diagnostics run through DTC tables, ECM and sensor theory (CKP, CMP, ECT, IAT, MAP, TP, HO2S), fuel metering, open/closed loop operation and electronic ignition. Deutz EMR 2 coverage (S/N 85332 to present) includes the full troubleshooting flow chart, engine-side and vehicle-side connection diagrams, engine and vehicle plug pin identification, and a five-sheet fault code table cross-referencing fault numbers, SPN and FMI codes. GM 3.0L engines get general maintenance, drive belt tensioning, oil change procedure, dual fuel component layout, coolant fill procedure specific to dual fuel engines, and full LPG fuel system diagnosis with symptom tables covering no-start, hard start, cut-out, hesitation, backfire, lack of power, poor fuel economy and rough idle.

Diagnostics, Schematics and Control System Coverage

The JLG Control System section explains how to connect the hand-held analyzer, change access levels using the 33271 password, adjust personality parameters, navigate the machine setup menu, and read the diagnostics menu structure. It also walks through the EPBCS block diagram, analyzer connecting points and control module locations. The back of the book is filled with the schematic set: six sheets of electrical schematic covering Deutz EMR2, GM and CAT variants, plus eight sheets of hydraulic schematic. Whether you need to trace a throttle actuator signal, identify a boom capacity switch, or check a platform level valve circuit, the diagrams are printed alongside the procedures that reference them.

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Who This Manual Is For

Independent mechanics, fleet maintenance departments, rental companies and owner-operators of JLG 800S and 860SJ lifts will all find this JLG 800S 860SJ maintenance manual directly usable. Torque values, hydraulic pressure settings, bearing tolerance limits, wire rope replacement criteria, cylinder drift limits and diagnostic fault code tables are all in one place. Because it covers multiple serial number ranges and multiple engine options, one PDF works across a whole fleet of 800S and 860SJ machines rather than just a single unit.

Get the JLG 800S 860SJ Manual Today

With this JLG 800S 860SJ service and maintenance manual at hand you can carry out scheduled maintenance, rebuild a torque hub or swing drive, replace swing bearing bolts to correct torque, set gear backlash, troubleshoot a Ford EFI or Deutz EMR 2 fault, diagnose a GM LPG fuel system complaint, trace an electrical fault from the schematic, and rebuild a hydraulic cylinder – all using the manufacturer’s own procedures and specifications instead of guesswork. Getting a torque value or pressure setting wrong on a boom lift is not a small thing; the manual is what makes sure the job is done right the first time. The file is delivered instantly as a PDF download, no shipping or waiting, and can be opened on a laptop, tablet or phone in the workshop or printed and kept in the service truck. Order the JLG 800S 860SJ Service and Maintenance Manual – 3121139 now and have the full manual in your hands in minutes.