JLG Boom Lift 800A 800AJ Parts Catalog 3121629

[Hyundai]

Download this document, you need 2725 Gallons

JLG Boom Lift 800A 800AJ Parts Catalog 3121629
Size: 35.01 MB
Format: PDF
Language: English
Brand: JLG
Type of Machine: Boom Lift
Type of Manual: Parts Catalog
Model: JLG 800A 800AJ Boom Lift
Part Number: 3121629
Publication Date: 2025
Number of Pages: 488 Pages

Contents:
SECTION 1 - FRAME

FIGURE 1-1. AXLE AND STEERING INSTALLATION WITHOUT TOW PACKAGE​

FIGURE 1-2. AXLE AND STEERING INSTALLATION WITH TOW PACKAGE​

FIGURE 1-3. TIRE AND WHEEL DRIVE INSTALLATIONS​

FIGURE 1-4. DRIVE HUB/BRAKE ASSEMBLY (SN 0300183034 through 0300244579)​

FIGURE 1-5. DRIVE HUB/BRAKE ASSEMBLY (SN 0300244580 through 0300272376)​

FIGURE 1-6. DRIVE MOTOR ASSEMBLY​

FIGURE 1-7. FRAME VALVES AND SHIELDS INSTALLATIONS​

FIGURE 1-8. TOW PACKAGE INSTALLATION​

SECTION 2 - TURNTABLE

FIGURE 2-1. CONTROL VALVES AND AUXILIARY PUMP INSTALLATIONS​

FIGURE 2-2. MAIN CONTROL VALVE ASSEMBLY (SN 0300183034 through 0300194139)​

FIGURE 2-3. MAIN CONTROL VALVE ASSEMBLY (SN 0300194140 through 0300238223)​

FIGURE 2-4. MAIN VALVE ASSEMBLY (SN 0300238224 through 0300272376)​

FIGURE 2-5. MAIN VALVE ASSEMBLY (SN 0300238224 through 0300272376)​

FIGURE 2-6. ACCESSORY VALVE ASSEMBLY​

FIGURE 2-7. AUXILIARY PUMP ASSEMBLY​

FIGURE 2-8. TURNTABLE BEARING AND SWING DRIVE INSTALLATION​

FIGURE 2-9. SWING MOTOR/HUB ASSEMBLY (Prior to SN 0300270085)​

FIGURE 2-10. SWING MOTOR/HUB ASSEMBLY (SN 0300270085 through 0300272376)​

FIGURE 2-11. DEUTZ D2011 ENGINE INSTALLATION​

FIGURE 2-12. DEUTZ TD2.9L4 ENGINE INSTALLATION​

FIGURE 2-13. FORD ENGINE INSTALLATION​

FIGURE 2-14. GM ENGINE INSTALLATION​

FIGURE 2-15. HYDROSTATIC PUMP ASSEMBLY (SN 0300183034 through 0300207789)​

FIGURE 2-16. HYDROSTATIC PUMP ASSEMBLY (SN 0300207790 through 0300272376)​

FIGURE 2-17. VARIABLE PUMP ASSEMBLY​

FIGURE 2-18. BREATHER HEATER INSTALLATION - DEUTZ D2.9L4 ENGINES WITH ARCTIC PACKAGE​

FIGURE 2-19. FUEL-WATER SEPARATOR INSTALLATION - DEUTZ TD2011 (OPTIONAL)​

FIGURE 2-20. FUEL-WATER SEPARATOR INSTALLATION (CHINA SPECS) (SN 0300238788 through 0300246968)​

FIGURE 2-21. FUEL-WATER SEPARATOR INSTALLATION (CHINA SPECS) (SN 0300246969 through 0300272376)​

FIGURE 2-22. TANK INSTALLATIONS​

FIGURE 2-23. LP TANK INSTALLATIONS (FORD AND GM ENGINE MACHINES ONLY)​

FIGURE 2-24. ROTARY COUPLING INSTALLATION​

FIGURE 2-25. GROUND CONTROL BOX ASSEMBLY​

FIGURE 2-26. ELECTRICAL OPTIONS INSTALLATION (TURNTABLE MOUNTED)​

FIGURE 2-27. HOODS INSTALLATION (ABS)​

FIGURE 2-28. HOODS INSTALLATION (STEEL)​

FIGURE 2-29. ENGINE TRAY JACK INSTALLATION (OPTIONAL)​

FIGURE 2-30. 2500W GENERATOR INSTALLATION - DEUTZ D2011 MACHINES (OPTIONAL)​

FIGURE 2-31. 2500W GENERATOR INSTALLATION - DEUTZ TD2.9L4 MACHINES (OPTIONAL)​

FIGURE 2-32. 2500W GENERATOR INSTALLATION - FORD MACHINES (OPTIONAL)​

FIGURE 2-33. 2500W GENERATOR INSTALLATION - GM MACHINES (OPTIONAL)​

FIGURE 2-34. 4000W GENERATOR INSTALLATION - DEUTZ TD2.9L4 ENGINES​

FIGURE 2-35. 4000W GENERATOR INSTALLATION - DEUTZ D2011 ENGINES​

FIGURE 2-36. 4000W GENERATOR INSTALLATION - GM ENGINES​

FIGURE 2-37. 7500W SKYPOWER GENERATOR INSTALLATION - DEUTZ ENGINE MACHINES​

FIGURE 2-38. 7500W SKYPOWER GENERATOR INSTALLATION - FORD ENGINES​

FIGURE 2-39. 7500W SKYPOWER GENERATOR INSTALLATION - GM MACHINES​

FIGURE 2-40. SKYAIR AIR COMPRESSOR INSTALLATION​

FIGURE 2-41. AIR COMPRESSOR ASSEMBLY​

FIGURE 2-42. AUXILIARY PUMP WITHOUT BATTERY DISCONNECT (SN 0300259889 through 0300272376)​

FIGURE 2-43. AUXILIARY PUMP WITH BATTERY DISCONNECT (SN 0300259889 through 0300272376)​

SECTION 3 - BOOM

FIGURE 3-1. BOOM AND CYLINDER INSTALLATION (800A)​

FIGURE 3-2. BOOM AND CYLINDER INSTALLATION (800AJ)​

FIGURE 3-3. TOWER BOOM ASSEMBLY​

FIGURE 3-4. MAIN BOOM ASSEMBLY​

FIGURE 3-5. ROTATOR ASSEMBLY​

FIGURE 3-6. PLATFORM SUPPORT INSTALLATION - WITHOUT LSS​

FIGURE 3-7. PLATFORM SUPPORT INSTALLATION - WITH 4 CELL LSS​

FIGURE 3-8. PLATFORM SUPPORT INSTALLATION - WITH 1 CELL LSS​

FIGURE 3-9. VALVE AND LIMIT SWITCH INSTALLATIONS (BOOM MOUNTED)​

SECTION 4 - PLATFORM

FIGURE 4-1. PLATFORM COMPONENTS INSTALLATION​

FIGURE 4-2. PLATFORM COMPONENTS INSTALLATION (FALL ARREST FOR PLATFORM)​

FIGURE 4-3. PLATFORM CONSOLE ASSEMBLY (WITHOUT SKYGUARD)​

FIGURE 4-4. PLATFORM CONSOLE ASSEMBLY - WITH SKYGUARD​

FIGURE 4-5. CONTROLLER ASSEMBLY - SWING AND LIFT (SN 0300183034 through 0300188905)​

FIGURE 4-6. CONTROLLER ASSEMBLY - SWING AND LIFT (SN 0300188906 through 0300272376)​

FIGURE 4-7. CONTROLLER ASSEMBLY - DRIVE AND STEER (SN 0300183034 through 0300188905)​

FIGURE 4-8. CONTROLLER ASSEMBLY - DRIVE AND STEER (SN 0300188906 through 0300272376)​

FIGURE 4-9. SOFT TOUCH SYSTEM INSTALLATION (OPTIONAL)​

FIGURE 4-10. SKYGUARD SYSTEM INSTALLATION (SN 0300183034 through 0300259888)​

FIGURE 4-11. SKYGUARD SYSTEM INSTALLATION (SN 0300259889 through 0300272376)​

FIGURE 4-12. CROSS RAIL INSTALLATION​

FIGURE 4-13. SKYEYE INSTALLATION​

FIGURE 4-14. SKYGLAZIER INSTALLATION​

FIGURE 4-15. SKYLINE INSTALLATION​

FIGURE 4-16. SKYWELDER/SKYCUTTER COMBO INSTALLATION (60HZ)​

FIGURE 4-17. SKYWELDER INSTALLATION (50HZ)​

FIGURE 4-18. SKYWELDER INSTALLATION (60HZ)​

FIGURE 4-19. SKYWELDER PREP PACKAGE (60HZ)​

FIGURE 4-20. WELDER ASSEMBLY​

FIGURE 4-21. SKYWELDER LOCKING BRACKET INSTALLATION​

FIGURE 4-22. SKYCUTTER INSTALLATION​

FIGURE 4-23. PLASMA CUTTER ASSEMBLY​

FIGURE 4-24. PIPE RACKS INSTALLATION​

FIGURE 4-25. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M PLATFORM)​

FIGURE 4-26. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (6FT/1.82M TRI-ENTRY PLATFORM)​

FIGURE 4-27. FALL ARREST INSTALLATION (BOLT-ON EXTERNAL) (8FT/2.4M PLATFORM)​

FIGURE 4-28. BATTERY DISCONNECT (SN 0300240507 through 0300272376)​

SECTION 5 - CYLINDER

FIGURE 5-1. AXLE LOCKOUT CYLINDER ASSEMBLY​

FIGURE 5-2. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB (800AJ) (SN 0300183034 through 0300240878)​

FIGURE 5-3. LEVEL (SLAVE) CYLINDER ASSEMBLY - JIB (800AJ) (SN 0300240879 through 0300272376)​

FIGURE 5-4. LEVEL (SLAVE) CYLINDER ASSEMBLY - PLATFORM (800A) (SN 0300183034 through 0300245050)​

FIGURE 5-5. LEVEL (SLAVE) CYLINDER ASSEMBLY - PLATFORM (800A) (SN 0300245051 through 0300272376)​

FIGURE 5-6. LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT (SN 0300183034 through 0300239885)​

FIGURE 5-7. LEVEL (SLAVE) CYLINDER ASSEMBLY - UPRIGHT (SN 0300239886 through 0300272376)​

FIGURE 5-8. LIFT CYLINDER ASSEMBLY - JIB (800AJ) (SN 0300183034 through 0300245050)​

FIGURE 5-9. LIFT CYLINDER ASSEMBLY - JIB (USAGE MAY VARY) (800AJ) (SN 0300245051 through 0300245146)​

FIGURE 5-10. LIFT CYLINDER ASSEMBLY - JIB (USAGE MAY VARY) (800AJ) (SN 0300245051 through 0300245146)​

FIGURE 5-11. LIFT CYLINDER ASSEMBLY - JIB (800AJ) (SN 0300245147 through 0300272376)​

FIGURE 5-12. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 0300183034 through 0300239885)​

FIGURE 5-13. LIFT CYLINDER ASSEMBLY - MAIN BOOM (SN 0300239886 through 0300272376)​

FIGURE 5-14. LIFT CYLINDER ASSEMBLY - TOWER BOOM (SN 0300183034 through 0300239885)​

FIGURE 5-15. LIFT CYLINDER ASSEMBLY - TOWER BOOM (SN 0300239886 through 0300272376)​

FIGURE 5-16. MASTER CYLINDER ASSEMBLY (800A) (SN 0300183034 through 0300245050)​

FIGURE 5-17. MASTER CYLINDER ASSEMBLY (800A) (SN 0300245051 through 0300272376)​

FIGURE 5-18. MASTER CYLINDER ASSEMBLY (800AJ) (SN 0300183034 through 0300243317)​

FIGURE 5-19. MASTER CYLINDER ASSEMBLY (800AJ) (SN 0300243318 through 0300272376)​

FIGURE 5-20. STEER CYLINDER ASSEMBLY​

FIGURE 5-21. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM​

FIGURE 5-22. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (800A) (SN 0300245051 through 0300272376)​

FIGURE 5-23. TELESCOPE CYLINDER ASSEMBLY - MAIN BOOM (800AJ) (SN 0300243318 through 0300272376)​

FIGURE 5-24. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM​

FIGURE 5-25. TELESCOPE CYLINDER ASSEMBLY - TOWER BOOM (SN 0300243318 through 0300272376)​

SECTION 6 - HYDRAULIC

FIGURE 6-1. AXLE LOCKOUT HYDRAULIC DIAGRAM​

FIGURE 6-2. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300183034 through 0300196955)​

FIGURE 6-3. DRIVE HYDRAULIC DIAGRAM - 2WD (SN 0300196956 through 0300272376)​

FIGURE 6-4. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300183034 through 0300196955)​

FIGURE 6-5. DRIVE HYDRAULIC DIAGRAM - 4WD/2WS (SN 0300196956 through 0300272376)​

FIGURE 6-6. STANDARD HYDRAULIC DIAGRAM (SN 0300183034 through 0300194139)​

FIGURE 6-7. STANDARD HYDRAULIC DIAGRAM (SN 0300194140 through 0300196955)​

FIGURE 6-8. STANDARD HYDRAULIC DIAGRAM (SN 0300196956 through 0300272376)​

FIGURE 6-9. HYDRAULIC DIAGRAM LIST​

SECTION 7 - ELECTRICAL

FIGURE 7-1. ELECTRICAL DIAGRAM LIST​

FIGURE 7-2. HARNESS COMPONENTS INSTALLATION​

FIGURE 7-3. SKYEYE INTERMEDIATE HARNESS​

FIGURE 7-4. SKYEYE EMITTER HARNESS​

FIGURE 7-5. SKYEYE RECEIVER HARNESS​

FIGURE 7-6. SKYLINE HARNESS​

SECTION 8 - DECALS

FIGURE 8-1. DECAL INSTALLATION (ANSI SPEC)​

FIGURE 8-2. DECAL INSTALLATION (COUNTRY SPEC)​

FIGURE 8-3. DECAL INSTALLATION (AUSTRALIAN AND CE SPEC)​

SECTION 9 - RECOMMENDED SERVICE PARTS STOCK

FIGURE 9-1. STANDARD PARTS​

FIGURE 9-2. VARIABLE PARTS​

SECTION 10 - SPECIAL OPTIONS

FIGURE 10-1. SPECIAL OPTION​

PART NUMBER INDEX