JLG 800A_AJ Service Manual User Manual
Service and maintenance manual
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Table of contents
Document Outline
- Section A. INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires & Wheels
- 3.2 Oscillating Axle Bleeding Procedure And Lockout Test
- 3.3 Free Wheeling Option
- 3.4 Torque Hub, Drive
- 3.5 Drive Brake - Ausco (Prior to S/N 56875)
- 3.6 Drive Brake - Mico (S/N 56875 to 83332)
- 3.7 Drive Brake (S/N 83332 to Present)
- 3.8 Drive Motor (Prior to S/N 83332)
- 3.9 Drive Motor Adjustment Procedure (Prior to S/N 83332)
- 3.10 Drive Motor (S/N 83332 to Present)
- 3.11 Swing Bearing
- 3.12 Swing Hub installation
- 3.13 Swing Hub (Prior to S/N 0300068040)
- 3.14 Swing Brake - Ausco (Prior to S/N 0300068040)
- 3.15 Swing Motor (Eaton) (Prior to S/N 0300068040)
- 3.16 Swing Hub (S/N 0300068040 to Present)
- 3.17 Swing Brake (S/N 0300068040 to Present)
- 3.18 Swing Motor (S/N 0300068040 to Present)
- 3.19 Rotary Coupling
- 3.20 Tilt Alarm Switch (Prior to S/N 0300065534)
- 3.21 Spark Arrester Cleaning Instructions
- 3.22 Generator
- 3.23 Dual Fuel System
- 3.24 EFI Engine
- 3.25 Ford LPG System (S/N 0300077500 To Present)
- 3.26 Electric Governor Installation And Adjustments - Ford LRG425 Engine (Prior to S/N 0300065534)
- 3.27 Throttle Checks And Adjustments - Deutz Engine (Prior to S/N 0300065534)
- 3.28 Deutz EMR 2 (S/N 85331 to Present)
- 3.29 GM Engine General Maintenance
- 3.30 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
- 3.31 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
- 3.32 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- 4.1 Platform
- 4.2 Rotator and Slave Cylinder
- 4.3 Upper Boom Powertrack
- 4.4 Upper Boom
- 4.5 Upright
- 4.6 Tower Boom Assembly
- 4.7 Articulating Jib
- 4.8 Sequence For Hose Replacement In The Tower Boom
- 4.9 Limit Switches Adjustment
- 4.10 Boom Valve Adjustment
- 4.11 Wear Pads
- 4.12 Rotator (prior to S/N 0300067538)
- 4.13 Rotator Assembly (S/N 0300067538 to Present)
- 4.14 Drive Card Setup Procedures
- 4.15 Load Sensing System machines built to s/n 0300062045
- 4.16 Load Sensing System machines built s/n 62045 to 67883
- 4.17 Foot Switch Adjustment
- 4.18 Upright Monitoring System
- 4.19 UMS Troubleshooting and Fault Messages - Non-ADE Machines
- Tower Lift Down Permanently closed
- Backward Stability Concern Message
- Forward Stability Concern Message
- Auto Detection Input Low Message
- UMS Sensor Communications lost
- UMS Sensor Not Calibrated Message
- UMS Sensor Faulted
- Tower Lift Down Output Short to Ground or Open Circuit
- Tower Lift Down Output Short to Battery
- Platform Indicator Output Short to Ground or Open Circuit
- Platform Indicator Output Short to Battery
- Ground Indicator Output Short to Ground
- Ground Indicator Output Short to Battery
- Turntable Sensor Not Calibrated Message
- Turntable Sensor Faulted
- EEPROM checksums failure
- 4.20 UMS Troubleshooting and Fault Messages - ADE Machines
- Section 5. Hydraulics
- 5.1 Lubricating O-Rings in the Hydraulic System
- 5.2 Valves - Theory Of Operation
- 5.3 Holding Valve Checks
- 5.4 Cylinders - Theory Of Operation
- 5.5 Cylinder Checking Procedure
- 5.6 Cylinder Repair
- 5.7 Cylinder Removal And Installation
- Upper Boom Telescope Cylinder Removal
- Upper Boom Telescope Cylinder Installation
- Upper Lift Cylinder Removal
- Upper Boom Lift Cylinder Installation
- Upright Level Cylinder Removal
- Upright Level Cylinder Installation
- Tower Boom Lift Cylinder Removal
- Tower Lift Cylinder Installation
- Tower Telescope Cylinder Removal
- Tower Telescope Cylinder Installation
- Slave Cylinder Removal
- Slave Cylinder Installation
- 5.8 Hydraulic Pump W/hayes Pump drive Coupling Lubrication
- 5.9 Pressure Setting Procedures
- 5.10 Hydraulic oil change-out procedure
- 5.11 Hydraulic Component Start-Up Procedures and Recommendations
- 5.12 Rexroth Variable Displacement Pump Prior to S/N 0300121643
- 5.13 Sauer Piston Pump S/N 0300121643 to Present
- Section 6. JLG Control System (S/N 0300065534 to Present)
- 6.1 Introduction
- 6.2 CANbus Communications
- 6.3 To Connect the JLG Control System Analyzer
- 6.4 Using the Analyzer
- 6.5 Changing the Access Level of the Hand Held Analyzer
- 6.6 Adjusting Parameters Using the Hand Held Analyzer
- 6.7 Machine Setup
- 6.8 Level Vehicle Description
- 6.9 Machine Personality Settings
- Section 7. Basic Electrical information & schematics