Medium Duty Piston Pump

Supplemental Repair Manual

Models
H800AJ
800A/S

JLG - 3128858

Component Manufacturer
Eaton

March 3, 2018

An Oshkosh Corporation Company

78462 = Single Piston Pump with Gear
Pump
78463 = Tandem Piston Pumps with
Gear Pump
 34
36
47 14

48 26 8
10
61
7 51 53
16
12 28-3 28-4-3
28-3-1 52
28-6 38
38-1 28-4
18
11 28-4-1 28-5
28-4-2

40
40-1
39-1
39
Serial Code and
Product Number 28-6
Location
41-1 9
28-2 41
28-1 12
17
30 61
7
31

4 31 6
19
20 Shaft assembly for 60 2
19 rear pump of tandem.
4
37
43
3
4
19
20
19
4
45
3
 K1

21 K1-3
29
21-1

K1-4
23 K1-1 K1-2
29-2
K3
57
35
29-1 57-1 25
22-1 62
46 32
27 44
22

K2
24
21 35
49 K2-1
29
21-1 62 32

50 42
42
29-2
33 49 Inner Gerotor
and
57 56 11 tooth Coupler

55
56
29-1 57-1
22-1
27
22
 Numbered End

2,29 mm 4,39 mm
[.09 in.] [.173 in.]
 Flange End of Housing
Numbered End 12,7 mm
[.5 in.]
1,78 mm
[.07 in.]

Adjust to center piston

Install servo piston
in this direction.
 Bearing

46-2
46-1

Gerotor Ring
Pocket
Bushing
Numbered End
Flange

46-6

Charge Pump
2,41 mm 46-5 Suction Port
[.095 in.]

46-4
46-3-1
Gerotor Pocket
46-3
 48-2
48-3
48-5
48-6
48-5
48-16
48-4 48-7

48-15
Metering Notches

48-14
48-1

Wide Band Neutral Spool

Identification Mark

48-8

48-12
48-10

48-9
48-13
48-11 48-17
 48-21

48-20

48-28
48-19-2A 48-26
48-19-2 48-19-2B
48-19-2C 48-25
48-24
48-19-1 48-23
48-19 48-18
48-22

48-27

48-30
48-29
"A"

"B"

"B"

"A"
 8-9
8-7
8-8
8-7
8-6
8-5

8-4

8-2 8-3

8-1
 Symptom:
Action
Step

Comment
Number Inspect
?
1

Decision
Defective

Solution Repair
or
Replace
 Symptom: Neutral Difficult or Impossible to Find
Inspect
External Inspect Inspect Replace
Ok Control Valve Ok Servo piston Ok
Control Linkage Pump
1 2 4

Defective Defective Defective

Repair Repair Repair

or or or
Replace Replace Replace

Symptom: System Operating Hot

Check Inspect Inspect Heat
Exchanger Check
Oil Level in Ok Heat Ok Ok Charge
Reservoir Exchanger Bypass Valve
(If used) Pressure
5 6 7 11

Below Level Defective Defective

Ok
Fill to Repair Repair Low
Proper or or
Level Replace Replace

Inspect Inspect Inspect Charge

Charge Ok Inlet Ok Relief Valve
Pump Screen or Filter
14 9 12

Defective Clogged Defective

Ok
Repair Repair
or Replace or
Replace Replace

Inspect Check
Replace Ok Inspect Motor Ok Bypass Valve Ok System
Pump & Motor (If used) Pressure
13 8 10

Defective Defective High

Repair Repair Reduce

or or System
Replace Replace Load
 Symptom: Operates in One Direction Only
Inspect Inspect
External Ok Inspect Ok System Replace
Control Valve Ok
Control Linkage Relief Valves Pump
1 2 3

Defective Defective Defective

Repair Repair Repair

or or or
Replace Replace Replace

Symptom: System Response Sluggish

Check Inspect Inspect Inspect
Charge Ok Control Ok Bypass Valve Ok Servo
Pressure Valve (If used) Piston
11 2 8 4

Defective Defective Defective

Ok
Repair Repair Repair
Low or or or
Replace Replace Replace

Replace Inspect
Ok Motor
Pump & Motor
13

Defective

Inspect Inspect Inspect

Charge Relief Ok Inlet Ok Charge Ok Repair
Valve Screen or Filter Pump or
12 9 14 Replace

Defective Clogged Defective

Repair Repair
or Replace or
Replace Replace
 Symptom: System Will Not Operate in Either Direction
Check Check External Inspect Check
Oil Level in Ok Control Ok Bypass Valve Ok Charge
Reservoir Linkage (If used) Pressure
5 1 8 11

Below Level Defective Defective

Ok
Fill to Repair Repair
Proper or or Low
Level Replace Replace

Inspect Inspect
Charge Inlet Ok Inspect Charge
Ok Relief Valve
Pump Screen or Filter
14 9 12

Defective Clogged Defective

Ok
Repair Repair
or Replace or
Replace Replace

Inspect Check
Replace Inspect Ok System
Pump & Motor Ok Ok Control
Motor Valve Pressure
13 2 11

Defective Defective High

Repair Repair Reduce

or or System
Replace Replace Load
 Corporate Office
JLG Industries, Inc.
1 JLG Drive
McConnellsburg PA. 17233-9533
USA
(717) 485-5161(Corporate)
(877) 554-5438(Service)
(717) 485-6417

JLG Worldwide Locations

JLG Industries JLG Ground Support Oude JLG Latino Americana LTDA Oshkosh-JLG (Tianjin)
358 Park Road Bunders 1034 Rua Antonia Martins Luiz, 580 Equipment Technology LTD
Regents Park Breitwaterstraat 12A Distrito Industrial Joao Narezzi Shanghai Branch
NSW 2143 3630 Maasmechelen Indiaatuba-SP 13347-404 No 465 Xiao Nan Road
Sydney 2143 Belgium Brasil Feng Xian District
Australia +32 (0) 89 84 82 26 +55 (19) 3936 7664 (Parts) Shanghai 201204
+6 (12) 87186300 Email: emeaservice@jlg.com +55(19)3936 9049 (Service) China
+6 (12) 65813058 Email: comercialpecas@jlg.com +86 (21) 800 819 0050
Email: techservicesauc@jlg.com Email: servicos@jlg.com

JLG Industries Dubai
Jafza View
PO Box 262728, LB 19
20th Floor, Office 05
Jebel Ali, Dubai
+971 (0) 4 884 1131
+971 (0) 4 884 7683
Email: emeaservice@jlg.com
JLG France SAS
Z.I. Guillaume Mon Amy
30204 Fauillet
47400 Tonniens
France
+33 (0) 553 84 85 86
+33 (0) 553 84 85 74
Email: pieces@jlg.com
JLG Deutschland GmbH JLG Equipment Services Ltd.
Max Planck Str. 21 Rm 1107 Landmark North
27721 Ritterhude - Ihlpohl 39 Lung Sum Avenue
Germany Sheung Shui N. T.
+49 (0) 421 69350-0 Hong Kong
+49 (0) 421 69350-45 +(852) 2639 5783
Email:german-parts@jlg.com +(852) 2639 5797

JLG Industries (Italia) S.R.L.
Via Po. 22
20010 Pregnana Milanese (MI)
Italy
+39 (0) 2 9359 5210
+39 (0) 2 9359 5211
Email: ricambi@jlg.com
JLG EMEA B.V.
Polaris Avenue 63
2132 JH Hoofdorf
The Netherlands
+31 (0) 23 565 5665
Email: emeaservice@jlg.com
JLG NZ Access Equipment &
Services
2B Fisher Cresent
Mt Wellington 1060
Auckland, New Zealand
+6 (12) 87186300
+6 (12) 65813058
Email:techservicesaus@jlg.com
JLG Industries
Vahutinskoe shosse 24b.
Khimki
Moscow Region 141400
Russia Federation
+7 (499) 922 06 99
+7 (499) 922 06 99

Oshkosh-JLG Singapore
Technology Equipment Pte Ltd.
35 Tuas Avenue 2
Jurong Industrial Estate
Singapore 639454
+65 6591 9030
+65 6591 9045
Email: SEA@jlg.com
JLG Iberica S.L.
Trapadella, 2
Pol. Ind. Castellbisbal Sur
08755 Castellbisbal
Barcelona
Spain
+34 (0) 93 772 47 00
+34 (0) 93 771 1762
Email:parts_iberica@jlg.com
JLG Sverige AB
Enkopingsvagen 150
176 27 Jarfalla
Sweden
+46 (0) 8 506 595 00
+46 (0) 8 506 595 27
Email: nordicsupport@jlg.com
JLG Industries (UK) Ltd.
Bentley House
Bentley Avenue
Middleton, Greater Manchester
M24 2GP
United Kingdom
+44 (0) 161 654 1000
+44 (0) 161 654 1003
Email: ukparts@jlg.com

www.jlg.com