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The JLG 800S is a popular and versatile boom lift known for its ability to provide significant lift height, reach, and maneuverability in a variety of applications, including construction, maintenance, and industrial work. However, as with any complex piece of machinery, issues can arise that may prevent the boom lift from starting, operating, or functioning properly, particularly if you are unable to drive the lift from the manbasket or experience a no-start condition.
In this article, we will explore potential causes of these common issues, walk through troubleshooting steps, and discuss how to resolve these problems to get your JLG 800S back in action. We will also include practical maintenance tips to avoid similar problems in the future.
Understanding the JLG 800S Boom Lift System
The JLG 800S is a 4WD, self-propelled boom lift designed to reach heights of up to 80 feet, with a horizontal outreach of 50 feet. The lift is powered by a diesel engine, typically the Deutz 2.9L engine, and it utilizes hydraulic systems to control the lift's boom, steering, and other essential functions. The manbasket, or platform, where the operator controls the machine, is connected to the hydraulic systems, which allow for precise movements in the air.
To ensure smooth operation, the 800S features sophisticated electronics, control systems, and safety features. Issues with any of these components, including the hydraulic, electrical, or engine systems, can result in the lift being inoperable.
Common Symptoms of JLG 800S Lift Issues
To resolve these common problems, you first need to identify the root cause. Here’s how to proceed with diagnosing the issues on your JLG 800S:
If the diagnostic process reveals a specific faulty component, you may need to replace or repair it. Here are the common components that may require attention:
Preventative maintenance is essential to avoid many of the problems discussed above. Here are some maintenance tips to keep your JLG 800S operating smoothly:
When your 2015 JLG 800S boom lift experiences issues such as failing to start or operate properly, it can be frustrating. However, by following a systematic approach to troubleshooting—starting with the battery and moving through to the hydraulic and control systems—you can identify the root cause and resolve the issue. Regular maintenance is key to preventing future problems and ensuring that your lift continues to perform efficiently for years.
By staying on top of maintenance, inspecting key components regularly, and addressing issues promptly, you can ensure that your JLG 800S continues to serve as a reliable and efficient piece of equipment for your lifting and construction needs.
In this article, we will explore potential causes of these common issues, walk through troubleshooting steps, and discuss how to resolve these problems to get your JLG 800S back in action. We will also include practical maintenance tips to avoid similar problems in the future.
Understanding the JLG 800S Boom Lift System
The JLG 800S is a 4WD, self-propelled boom lift designed to reach heights of up to 80 feet, with a horizontal outreach of 50 feet. The lift is powered by a diesel engine, typically the Deutz 2.9L engine, and it utilizes hydraulic systems to control the lift's boom, steering, and other essential functions. The manbasket, or platform, where the operator controls the machine, is connected to the hydraulic systems, which allow for precise movements in the air.
To ensure smooth operation, the 800S features sophisticated electronics, control systems, and safety features. Issues with any of these components, including the hydraulic, electrical, or engine systems, can result in the lift being inoperable.
Common Symptoms of JLG 800S Lift Issues
- No Start Condition: The engine fails to start when turning the key or pressing the start button. This may occur due to electrical issues, fuel problems, or even a malfunction in the ignition system.
- Inoperable Boom or Drive Function: The boom does not raise, extend, or rotate, or the lift cannot drive from the platform. This could be caused by hydraulic system failure, electrical faults, or malfunctioning sensors.
- Unable to Drive from the Manbasket: One of the key issues is when the operator cannot drive the lift from the manbasket. The platform’s controls typically allow the operator to drive the lift when needed, but if the control system is compromised, this function may not work.
To resolve these common problems, you first need to identify the root cause. Here’s how to proceed with diagnosing the issues on your JLG 800S:
- Check Battery Voltage and Connections:
- Problem: A low or dead battery can prevent the lift from starting. Corroded or loose battery terminals can also interrupt the electrical flow.
- Solution: Check the battery voltage using a multimeter. It should read at least 12.5 volts for a 12-volt system. If it’s low, charge the battery or replace it if necessary. Clean and tighten the battery connections to ensure proper contact.
- Problem: A low or dead battery can prevent the lift from starting. Corroded or loose battery terminals can also interrupt the electrical flow.
- Inspect Fuses and Circuit Breakers:
- Problem: Blown fuses or tripped circuit breakers can cause electrical malfunctions, preventing the lift from starting or operating.
- Solution: Locate the fuse panel and check for any blown fuses. Replace any fuses that appear damaged. Reset any circuit breakers that may have tripped, and verify that the lift’s power system is fully functional.
- Problem: Blown fuses or tripped circuit breakers can cause electrical malfunctions, preventing the lift from starting or operating.
- Examine the Fuel System:
- Problem: If the engine doesn’t start or runs poorly, the issue may be related to the fuel system, such as a clogged fuel filter or fuel supply issue.
- Solution: Check the fuel tank for adequate fuel levels. If the fuel is old or contaminated, drain the tank and refill it with fresh diesel fuel. Inspect the fuel filter and fuel lines for clogs or leaks, and replace the filter if necessary.
- Problem: If the engine doesn’t start or runs poorly, the issue may be related to the fuel system, such as a clogged fuel filter or fuel supply issue.
- Inspect the Hydraulic System:
- Problem: The hydraulic system controls both the boom and the drive system. Low hydraulic fluid levels, leaks, or faulty components can prevent the boom lift from operating.
- Solution: Check the hydraulic fluid levels and top off if necessary. Inspect the hydraulic lines for any visible leaks or damage. Look for signs of air in the system, as this can disrupt hydraulic performance. If any hydraulic components seem damaged, they may need to be repaired or replaced.
- Problem: The hydraulic system controls both the boom and the drive system. Low hydraulic fluid levels, leaks, or faulty components can prevent the boom lift from operating.
- Examine the Control Systems:
- Problem: Issues with the electronic control systems may prevent the boom from operating or the lift from moving. If the control box in the manbasket isn’t responding or the lift isn’t responding to joystick movements, the problem may be in the electrical connections or sensors.
- Solution: Inspect the wiring and connections to the control box and the platform joystick. Check for any loose or damaged wires. If the lift will not drive from the manbasket, ensure that the emergency stop is not engaged and that the drive control settings are correct.
- Problem: Issues with the electronic control systems may prevent the boom from operating or the lift from moving. If the control box in the manbasket isn’t responding or the lift isn’t responding to joystick movements, the problem may be in the electrical connections or sensors.
- Check the Safety Systems:
- Problem: JLG lifts are equipped with multiple safety systems to prevent operation if certain conditions are not met (such as an obstruction in the path or a tilt sensor issue).
- Solution: Review the lift’s safety system indicators to ensure there are no active warnings or alarms. Check if the machine is level, as many boom lifts will not operate if they are on uneven ground. Make sure the outriggers (if applicable) are fully deployed and the tilt sensor is functioning.
- Problem: JLG lifts are equipped with multiple safety systems to prevent operation if certain conditions are not met (such as an obstruction in the path or a tilt sensor issue).
- Verify the Drive System:
- Problem: If the lift doesn’t move from the manbasket or exhibits sluggish movement, it could be an issue with the drive system. This could stem from mechanical failure, hydraulic issues, or a malfunction in the drivetrain.
- Solution: Inspect the drive motors and the drive pump. Ensure that the pump is not clogged, and verify that the hydraulic drive system is operating at the correct pressure. If you suspect the mechanical drive is malfunctioning, consult the machine’s service manual for diagnostic procedures.
- Problem: If the lift doesn’t move from the manbasket or exhibits sluggish movement, it could be an issue with the drive system. This could stem from mechanical failure, hydraulic issues, or a malfunction in the drivetrain.
If the diagnostic process reveals a specific faulty component, you may need to replace or repair it. Here are the common components that may require attention:
- Battery: If the battery is old or damaged, replace it with a new, high-quality battery designed for your JLG 800S.
- Fuel Filter: Replace the fuel filter if it is clogged, and make sure to clean the fuel lines before reassembling the system.
- Hydraulic Pump: If the hydraulic pump is malfunctioning, it may need to be replaced. You can consult the manufacturer’s specifications for the correct part.
- Control Box: If the control box or joystick is faulty, the wiring may need to be repaired or the unit replaced entirely. Ensure all connections are secure and undamaged.
- Solenoid or Sensors: In some cases, faulty sensors or solenoids may cause operational issues. These parts should be tested for proper operation and replaced if defective.
Preventative maintenance is essential to avoid many of the problems discussed above. Here are some maintenance tips to keep your JLG 800S operating smoothly:
- Regularly Check and Maintain Fluid Levels: Ensure the hydraulic fluid and engine oil are changed regularly to prevent clogging and breakdowns. Keeping these fluids at optimal levels will ensure that all components are well-lubricated.
- Clean and Inspect Filters: Regularly replace air, fuel, and hydraulic filters to prevent clogs and maintain proper function.
- Inspect the Battery and Electrical System: Clean the battery terminals periodically and check the battery voltage to prevent electrical issues. Also, inspect the wiring for any signs of wear or corrosion.
- Monitor Tire and Drive System Health: Regularly inspect the tires and drive systems for wear and tear, especially if the lift is used frequently on rough terrain.
- Calibrate Control Systems: Periodically check the control systems and sensors to ensure they are calibrated properly. This will help avoid malfunctions and keep the system responsive.
When your 2015 JLG 800S boom lift experiences issues such as failing to start or operate properly, it can be frustrating. However, by following a systematic approach to troubleshooting—starting with the battery and moving through to the hydraulic and control systems—you can identify the root cause and resolve the issue. Regular maintenance is key to preventing future problems and ensuring that your lift continues to perform efficiently for years.
By staying on top of maintenance, inspecting key components regularly, and addressing issues promptly, you can ensure that your JLG 800S continues to serve as a reliable and efficient piece of equipment for your lifting and construction needs.
