Service Manual Owner's manual
Table Of Contents
- Section 1. Specifications
- Section 2. General
- Section 3. Chassis & Turntable
- 3.1 Tires & Wheels
- 3.2 Wheel Drive Assembly, 2WD
- 3.3 Drive Motor - 2WD (Prior to S/N 83331)
- 3.4 Drive Motor (S/N 83331 to Present)
- 3.5 Torque Hub
- 3.6 Wheel Drive Assembly, 4WD
- 3.7 Torque Hub (4WD Machines W/ Integral Brake)
- Roll, Leak and Brake Testing
- Tightening and Torquing Bolts
- Main Disassembly
- Input Carrier Disassembly
- Output Carrier Disassembly
- Housing-Spindle Disassembly
- Spindle-Brake Disassembly
- Input Carrier Sub-Assembly
- Output Carrier Sub-Assembly
- Spindle-Brake Sub-Assembly
- Housing-Spindle Sub-Assembly
- DW2B Integral Brake Check
- Main Assembly
- 3.8 Drive Brake, 2WD - Mico (Prior to S/N 83331)
- 3.9 Re-Aligning torque hub input coupling
- 3.10 Oscillating Axle Bleeding Procedure and Lockout Test
- 3.11 Swing Drive Hub
- 3.12 Swing Brake - Mico (Prior to S/N 66417)
- 3.13 Swing Motor (Prior to S/N 66417)
- 3.14 Swing Motor (S/N 66417 to Present)
- 3.15 Procedure For Setting Gear Backlash
- 3.16 Swing Bearing
- 3.17 Rotary Coupling
- 3.18 Generator
- 3.19 Ford EFI Engine
- 3.20 Deutz EMR 2 (S/N 85332 to Present)
- 3.21 GM Engine General Maintenance
- 3.22 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 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
- 3.24 GM Engine LPG Fuel System Diagnosis
- Section 4. Boom & Platform
- Section 5. Hydraulics
- Section 6. JLG Control System
- Section 7. Basic Electrical information & schematics
SECTION 1 - SPECIFICATIONS
3121139 – JLG Lift – 1-1
SECTION 1. SPECIFICATIONS
1.1 OPERATING SPECIFICATIONS 1.2 SPECIFICATIONS AND PERFORMANCE
DATA
Table 1-1. Operating Specifications
Maximum Work Load (Capacity)
U nre stricted:
Restricted
500 lb (230 kg)
Refer to Capacity Decals on
machine for restricted platform
capacities
Maximum Capacity - Dual Rating
8 00S
8 60SJ
1000 lb. (450 kg)
750 lb. (340 kg)
Maximum Travel Grade (Gradeability)*
2 WD
4 WD
30%
45%
Maximum Travel Grade (Side Slope)* 5°
Maximum Vertical Platform Height: 800S - 80 ft. (24.3 m)
860SJ - 86 ft. (26.2 m)
Maximum Horizontal Platform Reach
800S
860SJ
71 ft. (21.6 m)
75 ft. (22.9 m)
Turning Radius (outside) 22 ft. 6 in. (6.8 m)
Turning Radius (inside) 12 ft. (3.6 m)
Maximum Drive Speed: 3.5 mph (1.5 m/s)
Max. Hydraulic System Pressure 4500 psi (310 Bar)
Maximum Wind Speed 28 mph (12.5 m/s)
Maximum Manual Force 400 N
Electrical System Voltage 12 Volts
Gross Machine Weight
(Platform Empty)
8 00S
8 60S J
34,700 lbs. (15,740 kg)
37,900 lbs. (17,191 kg)
* With boom in stowed position
Table 1-2. Specifications and Performance Data
Swing 360°
Tail Swing 4’8" (1.42 m)
Platforms 36" x 72" (0.91m x 1.83m)
36" x 96" (0.91m x 2.44m)
Overall Width 8’ 2" (2.5 m)
Stowed Height
800S
860SJ
9’ 10.6" (3.01 m)
10’ (3.04 m)
Stowed Length
800S
860SJ
37’ 3.25" (11.4 m)
40’ (12.2 m)
Wheel base 10’ (3.04 m)
Ground Clearance 15.625" (0.4 m)
Drive Speed
S tow ed 2 WD
S tow ed 4 WD
E lev ated
3.0 mph (5.5 kph)
3.5 mph (5.6 kph)
0.75 mph (1.2 kph)
Ground Bearing Pressure - 800S
15-625
15-625FF
41/18LLx22.5
72 psi (5.0 kgm/cm
2
)
79 psi (5.5 kgm/cm
2
)
68 psi (4.8 kgm/cm
2
)
Ground Bearing Pressure - 860SJ
15-625
15-625FF
41/18LLx22.5
81 psi (5.7 kgm/cm
2
)
92 psi (6.5 kgm/cm
2
)
79 psi (5.5 kgm/cm
2
)
Max. Tire Load - 800S
15-625
15-625FF
41/18LLx22.5
16,900 lbs. (7665 kg)
17,200 lbs. (7802 kg)
17,300 lbs. (7850 kg)
Max. Tire Load - 860SJ
15-625
15-625FF
41/18LLx22.5
19,800 lbs. (8981 kg)
20,100 lbs. (9117 kg)
20,200 lbs. (9163 kg)