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JLG Models 800A 800AJ Workshop Service and Maintenance Manual P/N – 3120740

Download JLG Models 800A 800AJ Workshop Service and Maintenance Manual P/N – 3120740 Manual.pdf

JLG Models 800A 800AJ Workshop Service and Maintenance Manual

This is the Most Practical Service Repair Manual for the JLG 800A, 800AJ Workshop Service Repair Manual Download ever compiled by mankind. This DOWNLOAD contains of high quality diagrams and instructions on how to service and repair your JLG.

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SECTION A. INTRODUCTION – MAINTENANCE SAFETY PRECAUTIONS

This section contains the general safety precautions
which must be observed during maintenance of the aerial
platform. It is of utmost importance that maintenance personnel
pay strict attention to these warnings and precautions
to avoid possible injury to themselves or others, or
damage to the equipment. A maintenance program must
be followed to ensure that the machine is safe to operate.

SECTION 1 – SPECIFICATIONS

– SPECIFICATIONS
1.1 Operating specifications
Capacities
1.2 Component Data
Engine Data
Tires
Drive System
Swing System
Hydraulic Drive Pump
Variable Displacement Pump
Hydraulic Load Sense Pump
Auxiliary Power Pump
Hydraulic Filter – In-line
1.3 Performance Data
Function Speeds
1.4 Torque Requirements
1.5 Lubrication
Hydraulic Oil
1.6 Pressure Settings
1.7 Cylinder Specifications
1.8 Major Component Weights
Critical Stability Weights
1.9 Lubrication and Operator Maintenance
Draining Oil Build Up From The Propane Regulator
Propane Fuel Filter Replacement
Propane Fuel System Pressure Relief

SECTION 2 – GENERAL

2.1 Machine Preparation, Inspection, and Maintenance
General
Preparation, Inspection, and Maintenance
Pre-Start Inspection
Pre-Delivery Inspection and Frequent Inspection
Annual Machine Inspection
Preventative Maintenance
2.2 Service and Guidelines
General
Safety and Workmanship
Cleanliness
Components Removal and Installation
Component Disassembly and Reassembly
Pressure-Fit Parts
Bearings
Gaskets
Bolt Usage and Torque Application
Hydraulic Lines and Electrical Wiring
Hydraulic System
Lubrication
Battery
Lubrication and Servicing
2.3 Lubrication and Information
Hydraulic System
Hydraulic Oil
Changing Hydraulic Oil
Lubrication Specifications
2.4 Cylinder Drift Test
Platform Drift
Cylinder Drift
2.5 Pins and Composite Bearing Repair Guidelines
2.6 Welding on JLG Equipment
Do the Following When Welding on JLG Equipment
Do NOT Do the Following When Welding on JLG Equipment

SECTION 3 – CHASSIS & TURNTABLE

Tire Inflation The air pressure for pneumatic tires must be equal to the air pressure that is stenciled on the side of the JLG product or rim decal for safe and proper operational characteristics. Tire Damage For pneumatic tires, JLG Industries, Inc. recommends that when any cut, rip, or tear is discovered that exposes sidewall or tread area cords in the tire, measures must be taken to remove the JLG product from service immediately. Arrangements must be made for replacement of the tire or tire assembly. For polyurethane foam filled tires, JLG Industries, Inc. recommends that when any of the following are discovered, measures must be taken to remove the JLG product from service immediately and arrangements must be made for replacement of the tire or tire assembly. • a smooth, even cut through the cord plies which exceeds 3 inches (7.5 cm) in total length • any tears or rips (ragged edges) in the cord plies which exceeds 1 inch (2.5 cm) in any direction • any punctures which exceed 1 inch in diameter • any damage to the bead area cords of the tire If a tire is damaged but is within the above noted criteria, the tire must be inspected on a daily basis to insure the damage has not propagated beyond the allowable criteria. Tire Replacement JLG recommends a replacement tire be the same size, ply and brand as originally installed on the machine. Please refer to the JLG Parts Manual for the part number of the approved tires for a particular machine model. If not using a JLG approved replacement tire, we recommend that replacement tires have the following characteristics: • Equal or greater ply/load rating and size of original • Tire tread contact width equal or greater than original •Wheel diameter, width, and offset dimensions equal to the original Unless specifically approved by JLG Industries Inc. do not replace a foam filled or ballast filled tire assembly with a pneumatic tire. When selecting and installing a replacement tire, ensure that all tires are inflated to the pressure recommended by JLG. Due to size variations between tire brands, both tires on the same axle should be the same. Wheel Replacement The rims installed on each product model have been designed for stability requirements which consist of track width, tire pressure, and load capacity. Size changes such as rim width, center piece location, larger or smaller diameter, etc., without written factory recommendations, may result in an unsafe condition regarding stability. Wheel Installation It is extremely important to apply and maintain proper wheel mounting torque.
3.1 Tires & Wheels.
Tire Inflation
Tire Damage
Tire Replacement. .
Wheel Replacement.
Wheel Installation. .
3.2 Oscillating Axle Bleeding Procedure And Lockout Test.
Lockout Cylinder Bleeding .
Oscillating Axle Lockout Test
3.3 Free Wheeling Option
To Disengage Drive Motors and Brakes (Free Wheel) for Emergency Towing
To Engage Drive Motors and Brakes (Normal Operation)
3.4 Torque Hub, Drive
Disassembly.
Repair.
Assembly
3.5 Drive Brake – Ausco (Prior to S/N 56875) .
Disassembly.
Inspection
Assembly . 3-12
3.6 Drive Brake – Mico (S/N 56875 to 83332) .3-14
Disassembly. . . 3-14
Assembly . 3-14
Bleeding. . 3-16
3.7 Drive Brake (S/N 83332 to Present) .3-17
Disassembly. . . 3-17
Inspection 3-17
Assembly . 3-17
3.8 Drive Motor . . . .3-19
Description. . . . 3-19
Shaft Seal Replacement . 3-19
Loop Flushing Valve 3-20
Troubleshooting. . . . 3-21
Disassembly. . . 3-22
Inspection 3-26
Assembly . 3-28
Initial Start-up Procedures 3-33
SECTION NO. TITLE PAGE NO.
3.9 Swing Bearing . .3-34
Turntable Bearing Mounting Bolt Condition Check . . . 3-34
Wear Tolerance 3-37
Swing Bearing Replacement . . 3-37
Swing Bearing Torque Values . 3-39
3.10 Swing Hub installation. . . .3-40
3.11 Swing Hub (Prior to S/N 0300068040) . . .3-41
Disassembly. . . 3-41
Assembly . 3-41
Hub Shaft Sub-Assembly 3-44
Carrier Sub-Assembly . . . 3-47
3.12 Swing Brake – Ausco (Prior to S/N 0300068040) . .3-50
Disassembly. . . 3-50
Inspection 3-50
Assembly . 3-50
3.13 Swing Motor (Eaton) (Prior to S/N 0300068040) . .3-52
Disassembly. . . 3-52
Reassembly . . . 3-53
Motor Timing . . 3-54
3.14 Swing Hub (S/N 0300068040 to Present). . . . .3-56
Disassembly. . . 3-56
Main Assembly Procedure. . . . 3-56
Hub Shaft Sub-Assembly 3-59
Carrier Sub-Assembly . . . 3-61
3.15 Swing Brake (S/N 0300068040 to Present) . . .3-64
Disassembly. . . 3-64
Assembly . 3-64
3.16 Swing Motor (S/N 0300068040 to Present) . . .3-66
Disassembly. . . 3-66
Inspection and Cleaning . 3-68
Assembly . 3-68
Timing Procedure . . 3-70
3.17 Rotary Coupling. . . . .3-73
3.18 Tilt Alarm Switch (Prior to S/N 0300065534). . .3-77
Manual Adjustment . 3-77
3.19 Spark Arrester Cleaning Instructions . . . .3-77
3.20 Generator. .3-80
Every 250 hours 3-80
Every 500 hours 3-80
Overload Protection. 3-80
Inspecting Brushes, Replacing Brushes, and Cleaning Slip Rings . . . 3-80
3.21 Dual Fuel System . . .3-82
Changing from Gasoline to LP Gas. 3-82
Changing from LP Gas to Gasoline. 3-82
3.22 EFI Engine .3-82
Performing Diagnostics . . 3-82
EFI Diagnostics (Prior to S/N 0300065534). . 3-83
ECM and Sensors . . 3-83
Fuel System . . . 3-89SECTION NO. TITLE PAGE NO.
3.23 Ford LPG System (S/N 0300077500 To Present). .3-93
Description. . . . 3-93
Regulator . 3-93
Megajector 3-93
Mixer. 3-93
Lockoff Solenoid
Megajector Diagnostic Code Descriptions
3.24 Electric Governor Installation And Adjustments – Ford LRG425 Engine
(Prior to S/N 0300065534)
General
Quick-start Installations
Mounting-Actuator
Wiring .
Power Distribution
Check-Out and Initial Start-Up Procedures.
Troubleshooting
Automatic Choke Adjustment Procedure
3.25 Throttle Checks And Adjustments – Deutz Engine (Prior to S/N 0300065534)
General
Procedure .
Controller Status
Failure Modes .
3.26 Deutz EMR 2 (S/N 85331 to Present)
3.27 GM Engine General Maintenance
Maintenance of the Drive Belt
Engine Electrical System Maintenance
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.28 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module .
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI) .
Gasoline Fuel Pump .
Gasoline Pressure And Temperature Sensor Manifold.
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.23 Ford LPG System (S/N 0300077500 To Present)
Description
Regulator
Megajector
Mixer.
Lockoff Solenoid
Megajector Diagnostic Code Descriptions
3.24 Electric Governor Installation And Adjustments – Ford LRG425 Engine
(Prior to S/N 0300065534)
General
Quick-start Installations
Mounting-Actuator
Linkage
Mounting-Controller
Wiring
Power Distribution
Check-Out and Initial Start-Up Procedures
Troubleshooting
Automatic Choke Adjustment Procedure
3.25 Throttle Checks And Adjustments – Deutz Engine (Prior to S/N 0300065534)
General
Procedure
Controller Status
Failure Modes
3.26 Deutz EMR 2 (S/N 85331 to Present)
3.27 GM Engine General Maintenance.
Maintenance of the Drive Belt
Engine Electrical System Maintenance.
Checking/Filling Engine Oil Level
Changing The Engine Oil
Coolant Fill Procedure – Dual Fuel Engine
3.28 GM Engine Dual Fuel System
Fuel Filter
Electric Lock Off.
EPR Assembly
Low Pressure Regulator (LPR)
Air Fuel Mixer
Electronic Throttle Control (ETC)
Engine Control Module
Heated Exhaust Gas Oxygen Sensor
Gasoline Multi Point Fuel Injection System (MPFI)
Gasoline Fuel Pump
Gasoline Pressure And Temperature Sensor Manifold
Fuel Filter
Fuel Injector Rail
Fuel Injector
3.29 GM Engine Fuel System Repair
Propane Fuel System Pressure Relief
Propane Fuel System Leak Test
Propane Fuel Filter Replacement
Electronic Pressure Regulator (EPR) Assembly Replacement
Temperature Manifold Absolute Pressure (TMAP) Sensor
Electronic Throttle Control Replacement
MIXER REPLACEMENT
Coolant Hose Replacement
Vapor Hose Replacement
Engine Control Module Replacement
Heated Exhaust Gas Oxygen Sensor Replacement
3.30 GM Engine LPG Fuel System Diagnosis
Fuel System Description
Diagnostic Aids

SECTION 4 – BOOM & PLATFORM
4 1 Platform 4-1
Support Removal 4-1
Support Installation 4-2
Platform Sections Replacement 4-2
4 2 Rotator and Slave Cylinder 4-3
Removal 4-3
4 3 Upper Boom Powertrack 4-4
Removal 4-4
4 4 Upper Boom 4-4
Removal 4-4
Disassembly 4-6
Inspection 4-6
Assembly 4-6
Installation 4-7
4 5 Upright 4-8
Removal 4-8
Installation 4-9
4 6 Tower Boom Assembly 4-9
Removal 4-9
Inspection 4-10
Assembly 4-10
Installation 4-11
Tower Out of Sync 4-12
4 7 Articulating Jib 4-14
Removal 4-14
Disassembly 4-14
Inspection 4-14
Assembly 4-15
4 8 Sequence For Hose Replacement In The Tower Boom 4-15
4 9 Limit Switches Adjustment 4-15
Upper Boom Horizontal Limit Switch 4-15
Tower Boom Horizontal Limit Switch 4-15
Dual Capacity Angle Limit Switch (800A only) 4-23
Upper Boom Length Switch (800 A only) 4-23
4 10 Boom Valve Adjustment 4-23
4 11 Wear Pads 4-24
Tower Boom 4-24
Upper Boom 4-24
4 12 Rotator (prior to S/N 0300067538) 4-24
Disassembly 4-24
Inspection 4-25
Assembly 4-26
4 13 Rotator Assembly (S/N 0300067538 to Present) 4-28
Theory of Operation 4-28
Required Tools 4-28
Disassembly 4-31
Inspection 4-35
Assembly 4-35
4 14 Drive Card Setup Procedures 4-40
Lift, Swing, and Drive Cards 4-40
Flow Control Card 4-40
4 15 Foot Switch Adjustment 4-41
4 16 Upright Monitoring System 4-41
Re-Synchronizing Upright 4-41
Calibration – Pre ADE Machines 4-43
Calibration – ADE Equipped Machines 4-47
Calibration Faults 4-51
Function Check 4-52
Service Mode/Tower Boom Retrieval 4-53
4 17 UMS Troubleshooting and Fault Messages – Non-ADE Machines 4-59
Tower Lift Down Permanently closed 4-59
Backward Stability Concern Message 4-59
Forward Stability Concern Message 4-59
UMS Out of Usable Range Message 4-59
Battery voltage < 9 0 Volts 4-59
Battery voltage > 16 0 Volts 4-59
UMS Sensor Not Calibrated Message 4-60
UMS Sensor Faulted 4-60
Tower Lift Down Output Short to Ground or Open Circuit 4-60
Tower Lift Down Output Short to Battery 4-60
Platform Indicator Output Short to Ground or Open Circuit 4-60
Platform Indicator Output Short to Battery 4-60
Ground Indicator Output Short to Ground 4-60
Ground Indicator Output Short to Battery 4-60
Turntable Sensor Not Calibrated Message 4-60
Turntable Sensor Faulted 4-61
EEPROM checksums failure 4-61
4 18 UMS Troubleshooting and Fault Messages – ADE Machines 4-61
Backward Stability Concern Message 4-61
Forward Stability Concern Message 4-61
Auto Detection Input Low Message 4-61
UMS Sensor Communications lost 4-61
Out of Usable Range Message 4-62
UMS Sensor Not Calibrated Message 4-62
UMS Sensor Faulted Message 4-62
Incompatible Software Detected Message 4-62
Calibration Faults 4-62

SECTION 5 – HYDRAULICS
5 1 Lubricating O-Rings in the Hydraulic System 5-1
Cup and Brush 5-1
Dip Method 5-2
Spray Method 5-2
Brush-on Method 5-2
5 2 Valves – Theory Of Operation 5-3
Solenoid Control Valve – Rexroth 5-3
Relief Valves 5-3
5 3 Holding Valve Checks 5-3
5 4 Cylinders – Theory Of Operation 5-4
Systems Incorporating Double Acting Cylinders 5-4
Systems Incorporating Holding Valves 5-4
5 5 Cylinder Checking Procedure 5-5
Cylinders Without Counterbalance Valves – Master Cylinder and Steer Cylinders 5-5
Cylinders With Single Counterbalance Valve 5-5
Cylinders With Dual Counterbalance Valves 5-6
5 6 Cylinder Repair 5-7
Disassembly 5-7
Cleaning and Inspection 5-19
Assembly 5-20
5 7 Cylinder Removal And Installation 5-24
Upper Boom Telescope Cylinder Removal 5-24
Upper Boom Telescope Cylinder Installation 5-25
Upper Lift Cylinder Removal 5-25
Upper Boom Lift Cylinder Installation 5-26
Upright Level Cylinder Removal 5-26
Upright Level Cylinder Installation 5-27
Tower Boom Lift Cylinder Removal 5-27
Tower Lift Cylinder Installation 5-28
Tower Telescope Cylinder Removal 5-28
Tower Telescope Cylinder Installation 5-28
Slave Cylinder Removal 5-28
Slave Cylinder Installation 5-29
5 8 Hydraulic Pump W/hayes Pump drive Coupling Lubrication 5-29
5 9 Pressure Setting Procedures 5-29
FIRST: Set Up the Function Pump 5-29
SECOND: Adjustments Made at the Main Valve Block 5-36
5 10 Hydraulic oil change-out procedure 5-37
5 11 Hydraulic Component Start-Up Procedures and Recommendations 5-38
5 12 Rexroth Variable Displacement Pump Prior to S/N 0300121643 5-40
5 13 Sauer Piston Pump S/N 0300121643 to Present 5-42
Initial start-up procedures 5-43
Troubleshooting 5-43
Shaft Seal Replacement 5-47
Control Assembly 5-47
Plug and Fitting Sizes and Torques 5-49

SECTION 6 – JLG CONTROL SYSTEM (S/N 0300065534 TO PRESENT)
6 1 Introduction 6-1
6 2 CANbus Communications 6-14
6 3 To Connect the JLG Control System Analyzer 6-14
6 4 Using the Analyzer 6-14
6 5 Changing the Access Level of the Hand Held Analyzer 6-15
6 6 Adjusting Parameters Using the Hand Held Analyzer 6-16
6 7 Machine Setup 6-17
6 8 Level Vehicle Description 6-17
6 9 Machine Personality Settings 6-33
Analyzer Diagnostics Menu Structure 6-50
SECTION 7 – BASIC ELECTRICAL INFORMATION & SCHEMATICS
7 1 General 7-1
7 2 Multimeter Basics 7-1
Grounding 7-1
Backprobing 7-1
Min/Max 7-1
Polarity 7-1
Scale 7-1
Voltage Measurement 7-1
Resistance Measurement 7-2
Continuity Measurement 7-2
Current Measurement 7-3
7 3 Applying Silicone Dielectric Compound to Electrical Connections 7-3
7 4 AMP Connector 7-4
Applying Silicone Dielectric Compound to AMP Connectors 7-4
Assembly 7-4
Disassembly 7-6
Wedge Lock 7-6
Service – Voltage Reading 7-6
7 5 Deutsch Connectors 7-8
DT/DTP Series Assembly 7-8
DT/DTP Series Disassembly 7-8
HD30/HDP20 Series Assembly 7-9
HD30/HDP20 Series Disassembly 7-9

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